ST597 - 400-450-600 Boom Combo Participant Manual PDF

JLG University JLGU.JLG.
com
400S/460SJ/450AJ/520AJ/600S/660SJ
Boom Lifts
Service Training Program
Manual Number ST597
Release Date:November 6, 2018

Table of Contents
Table of Contents
MODULE 1: MACHINE OVERVIEW............................................................................... 1
INTRODUCTION ............................................................................................................. 1
OBJECTIVES .................................................................................................................. 1
MACHINE ORIENTATION .............................................................................................. 2
MODEL NOMENCLATURE ............................................................................................ 3
400S.......................................................................................................................................................... 3
450AJ ........................................................................................................................................................ 3
MAJOR COMPONENTS ................................................................................................. 4
400S.......................................................................................................................................................... 4
460SJ ........................................................................................................................................................ 5
450AJ ........................................................................................................................................................ 6
520AJ ........................................................................................................................................................ 7
600S.......................................................................................................................................................... 8
GROUND CONTROLS AND INDICATORS .................................................................... 9
660SJ Ground Controls ............................................................................................................................ 9
450AJ Ground Controls .......................................................................................................................... 10
Indicator Panel ........................................................................................................................................ 11
GROUND CONTROL CONSOLE ................................................................................. 12
Display Gauge ........................................................................................................................................ 12
Display Screens.................................................................................................................................. 12
MACHINE SAFETY SYSTEM OVERRIDE (MSSO)...................................................... 14
PLATFORM CONTROLS AND INDICATORS .............................................................. 15
600SJ/400SJ Platform Controls.............................................................................................................. 15
600SJ/400SJ Indicator Panel ................................................................................................................. 16
MACHINE SPECIFICATIONS ....................................................................................... 17
MACHINE IDENTIFICATION ........................................................................................ 18
INSPECTION AND MAINTENANCE REQUIREMENTS ............................................... 19
MODULE 2: POWER DISTRIBUTION.......................................................................... 21

INTRODUCTION ........................................................................................................... 21
OBJECTIVES ................................................................................................................ 21
HYDRAULIC SYSTEM ................................................................................................. 22
400S/600S Hydraulic Drive System........................................................................................................ 22
400S/600S Hydraulic Drive Circuit Description .................................................................................. 23
Practice: 400S/600/ Hydraulic Drive Circuit ...................................................................................... 24
450AJ/520AJ Hydraulic Drive System .................................................................................................... 25
Hydraulic System Major Components (DRIVE) ...................................................................................... 26
Hydraulic Reservoir ............................................................................................................................ 26
Charge Filter ....................................................................................................................................... 26
Drive Pump Assembly ........................................................................................................................ 27
Drive Direction Spools- ....................................................................................................................... 27
Axle Control Valve (400S/600S)......................................................................................................... 28
Brake Spool (400S/600S) ................................................................................................................... 28
2 Speed Spool (400S/600S)............................................................................................................... 29
Swivel ................................................................................................................................................. 29
Traction Valve (600S) ......................................................................................................................... 30
Traction Valve (450AJ/520AJ)............................................................................................................ 31
i
Table of Contents
Drive Motor ......................................................................................................................................... 32

Torque Hubs-...................................................................................................................................... 32
600S/660SJ Hydraulic FunctionsSystem ............................................................................................... 33
600S/660SJ Hydraulic Function Circuit Description........................................................................... 34
Practice: Hydraulic Functions System ............................................................................................... 34
Hydraulic System (450AJ/520AJ Functions) .......................................................................................... 35
Hydraulic System (400SJ Functions) ..................................................................................................... 36
HYDRAULIC SYSTEM MAJOR COMPONENTS (FUNCTIONS) .......................................................... 37
Function Pump (450AJ/400S/600S .................................................................................................... 37
Main Control Valve ............................................................................................................................. 37
Platform Valve (600S) ........................................................................................................................ 38
Upright Valve (450AJ/520AJ) ............................................................................................................. 38
Fly Boom Valve (450AJ/520AJ) ......................................................................................................... 39
ELECTRICAL SYSTEM ................................................................................................ 40
Power Up System Overview ................................................................................................................... 41
Battery ................................................................................................................................................ 41
Auxiliary Power Pump Relay .............................................................................................................. 42
Auxiliary Power Pump ........................................................................................................................ 43
Start Relay (Solenoid) ........................................................................................................................ 44
Starter ................................................................................................................................................. 45
Glow Plug Relay and Glow Plugs....................................................................................................... 46
Alternator ............................................................................................................................................ 47
Ground Emergency Stop Switch ........................................................................................................ 48
Ground/Platform Select Keyswitch ..................................................................................................... 49
Fuse Box ............................................................................................................................................ 50
Ground Control Module ...................................................................................................................... 51
Yellow Power Module ......................................................................................................................... 52
Fuel Pump .......................................................................................................................................... 53
Platform Emergency Stop Switch ....................................................................................................... 54
Platform Control Module ..................................................................................................................... 55
MODULE 3: CANBUS NETWORK ............................................................................... 57

INTRODUCTION ........................................................................................................... 57
OBJECTIVES ................................................................................................................ 57
CANBUS ................................................................................................................................................. 58
Typical Circuit ..................................................................................................................................... 58
CANbus Components ......................................................................................................................... 59
Basic CANbus Circuit Layouts ........................................................................................................... 60
Troubleshooting CANbus Circuits........................................................................................................... 62
Closed Circuit ..................................................................................................................................... 62
Open Circuit........................................................................................................................................ 62
Understanding CANbus Circuits ............................................................................................................. 63
JLG CANbus ........................................................................................................................................... 64
CANBUS CAN 1 ..................................................................................................................................... 65
Basic Circuit........................................................................................................................................ 65
Detailed Circuit ................................................................................................................................... 66
CANbus CAN 2 ....................................................................................................................................... 67
CANbus CAN2: Deutz Tier 4 Final (T4F) Engine ............................................................................... 68
CANbus CAN2: Deutz Tier 4 Interim (T4I) Engine ............................................................................. 70
CANbus CAN2: Ford Engine .............................................................................................................. 71
MODULE 4: BOOM ...................................................................................................... 73

INTRODUCTION ........................................................................................................... 73
ii
Table of Contents
OBJECTIVES ................................................................................................................ 73
BOOM CYLINDERS ...................................................................................................... 74
400S........................................................................................................................................................ 74
460SJ ...................................................................................................................................................... 74
450AJ ...................................................................................................................................................... 75
520AJ ...................................................................................................................................................... 75
600S Boom Cylinders ............................................................................................................................. 76
400S/460SJ BOOM SENSORS .................................................................................... 77
Transport Position Sensing System ....................................................................................................... 78
400S/450AJ/520AJ Boom Angle Sensor ................................................................................................ 79
Boom Angle Sensor Circuit ................................................................................................................ 80
400S/460SJ Boom Length Sensors ....................................................................................................... 81
Boom Length Sensors Circuit............................................................................................................. 82
400S Dual Capacity Sensors .................................................................................................................. 83
Dual Capacity Sensor Circuit ............................................................................................................. 84
400S/460SJ Chassis Tilt Sensor ............................................................................................................ 85
Tilt Sensor Electrical Circuit ............................................................................................................... 86
450AJ/520AJ BOOM SWITCHES AND SENSORS ...................................................... 87
450AJ/520AJ Tower Boom Angle Switch ............................................................................................... 88
Tower Boom Angle Switch Circuit ...................................................................................................... 89
450AJ/520AJ Main Boom Angle Sensor ................................................................................................ 90
Main Boom Angle Sensor Circuit ....................................................................................................... 91
450AJ/520AJ Chassis Tilt Sensor .......................................................................................................... 92
Tilt Sensor Electrical Circuit ............................................................................................................... 93
450AJ/520AJ Drive Orientation Switches ............................................................................................... 94
450AJ/520AJ Drive Orientation Electrical Circuit ............................................................................... 95
400S/450S Platform Load Sensing System (LSS) ................................................................................. 96
LSS Module ........................................................................................................................................ 97
Load Cells........................................................................................................................................... 98
LSS Electrical Circuit .......................................................................................................................... 99
600S/660SJ BOOM SENSORS .................................................................................. 100
600S/66SJ Transport Position Sensing System ................................................................................... 100
600S/66SJ Boom Angle Sensors ..................................................................................................... 101
600S/66SJ Boom Angle Sensor Circuit............................................................................................ 103
600S/66SJ Telescope Retracted Sensors ....................................................................................... 104
600S/66SJ Telescope Retracted Sensor Circuit .............................................................................. 106
600S/66SJ Dual Capacity Sensors....................................................................................................... 107
600S/66SJ Dual Capacity Length Proximity Sensor ........................................................................ 108
600S/660SJ Dual Capacity Sensor Circuit ....................................................................................... 109
600S/66SJ Main Boom Angle Sensor .................................................................................................. 110
600S/66SJ Main Boom Angle Sensor Circuit................................................................................... 111
600S/66SJ Chassis Tilt Sensor ............................................................................................................ 112
600S/66SJ Platform Angle Sensors ................................................................................................. 114
600S/66SJ Platform Angle Sensor Circuit ....................................................................................... 115
600S/66SJ Broken Cable Proximity Sensor ..................................................................................... 117
600S/66SJ Broken Cable Proximity Sensor Circuit ......................................................................... 118
600S/66SJ Platform Load Sensing System (LSS) ............................................................................... 120
600S/66SJ Load Sensing Gauge ..................................................................................................... 120
DRIVE ORIENTATION SYSTEM (DOS) ..................................................................... 122
400S/600S/660SJ Drive Orientation Sensor .................................................................................... 123
400S/600S/660SJ Drive Orientation Electrical Circuit ..................................................................... 124
450AJ/520AJ Drive Orientation Switches......................................................................................... 126
450AJ/520AJ Drive Orientation Electrical Circuit ............................................................................. 127
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Table of Contents
MODULE 5: DRIVE TRAIN ......................................................................................... 129

INTRODUCTION ......................................................................................................... 129
OBJECTIVES .............................................................................................................. 129
DRIVE TRAIN COMPONENTS ................................................................................... 130
Engine ................................................................................................................................................... 130
Deutz Tier 4 Final D 2.9 L4 .............................................................................................................. 131
Deutz Tier 4 Interim D 2.3 L3 ........................................................................................................... 132
Ford .................................................................................................................................................. 133
Drive System Hydraulics....................................................................................................................... 134
Practice: Drive Train ......................................................................................................................... 136
Drive Pump Components and Ports ................................................................................................. 137
Drive Pump ........................................................................................................................................... 138
Hydraulic Swivel.................................................................................................................................... 139
Traction Valve ....................................................................................................................................... 140
Traction Valve Components and Ports ............................................................................................ 141
Drive Motors.......................................................................................................................................... 142
Axle Valve ............................................................................................................................................. 143
Axle Valve Two Speed and Brakes .................................................................................................. 145
Drive System (Electrical) .................................................................................................................. 151
Drive Joystick ........................................................................................................................................ 152
Drive Solenoids ..................................................................................................................................... 155
Oscillating Axle ..................................................................................................................................... 156
450AJ/520AJ Oscillating Axle Electrical Circuit (Locked) ................................................................ 160
MODULE 6: FUNCTIONS........................................................................................... 165

INTRODUCTION ......................................................................................................... 165
OBJECTIVES .............................................................................................................. 165
FUNCTION PUMP ...................................................................................................... 168
AUXILIARY POWER PUMP ........................................................................................ 169
400S/460SJ BOOM VALVE LOCATIONS................................................................... 170
450AJ/520AJ BOOM VALVE LOCATIONS ................................................................. 171
MAIN CONTROL VALVE IDENTIFICATION ............................................................... 172
400S Illustration .................................................................................................................................... 172
400S Manifold Schematic ..................................................................................................................... 173
460SJ Illustration .................................................................................................................................. 174
460SJ Manifold Schematic ................................................................................................................... 175
450AJ/520AJ Illustration ....................................................................................................................... 176
450AJ/520AJ Manifold Schematic ........................................................................................................ 177
450AJ/520AJ UPRIGHT VALVE ................................................................................. 178
Coils and Ports...................................................................................................................................... 178
450AJ/520AJ FLY BOOM VALVE ............................................................................... 179
Coils and Ports...................................................................................................................................... 179
400S/450AJ ACTUATORS.......................................................................................... 180
400S/450AJ Main Lift Cylinder ............................................................................................................. 180
400S Main Lift Up Hydraulic Circuit ...................................................................................................... 181
400S Main Lift Up Electrical Circuit ...................................................................................................... 182
450AJ/520AJ Tower Lift Cylinder ......................................................................................................... 183
450AJ Tower Lift Down Hydraulic Circuit ............................................................................................. 184
450AJ Tower Lift Down Electrical Circuit .............................................................................................. 185
400S/450AJ Master and Platform Level Cylinders ............................................................................... 186
Master and Platform Level Cylinders Hydraulic Circuit ........................................................................ 187
400S Platform Level Down Override Hydraulic Circuit ......................................................................... 188
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Table of Contents
400S Platform Level Down Override Electrical Circuit ......................................................................... 189

400S/450AJ Telescope Cylinder .......................................................................................................... 190
400S Telescope In Hydraulic Circuit .................................................................................................... 191
400S Telescope In Electrical Circuit ..................................................................................................... 192
400S/450AJ Jib Cylinder ...................................................................................................................... 193
450AJ Jib Lift Down Hydraulic Circuit ................................................................................................... 194
400S Jib Lift Down Electrical Circuit ..................................................................................................... 195
400S/45AJ Platform Rotator ................................................................................................................. 196
400S Platform Rotate Right Hydraulic Circuit....................................................................................... 197
400S Platform Rotate Right Electrical Circuit ....................................................................................... 198
400S/450AJ Swing Motor ..................................................................................................................... 199
400S/460SJ Swing Motor Ports ....................................................................................................... 200
450AJ/520AJ Swing Motor Ports...................................................................................................... 200
400S Swing Left Hydraulic Circuit ........................................................................................................ 201
400S Swing Left Electrical Circuit ......................................................................................................... 202
450AJ Swing Left Hydraulic Circuit ...................................................................................................... 203
450AJ Swing Left Electrical Circuit................................................................................................... 204
600S FUNCTION SYSTEM ......................................................................................... 205
Function Pump When Cranking the Engine for Start ....................................................................... 206
Function Pump with No Function Activated (Idle)- ........................................................................... 209
Function Pump with Enable (Footswitch) Activated - ....................................................................... 212
600S Function Pump ............................................................................................................................ 216
600S Auxiliary Power Pump ................................................................................................................. 217
600S Main Valve ................................................................................................................................... 218
600S Main Valve (Valve Locations) ................................................................................................. 219
600S Main Valve (Schematic) .......................................................................................................... 220
600S Platform Valve ............................................................................................................................. 221
600S Platform Valve (Schematic) .................................................................................................... 222
600S Main Lift Up Function (Hydraulic) ................................................................................................ 223
Lift Up Function- ............................................................................................................................... 223
600S Main Dump .............................................................................................................................. 224
600S Priority Flow Control ................................................................................................................ 225
600S Main Lift Up Valve ................................................................................................................... 226
600S Lift Cylinder ............................................................................................................................. 227
600S Main Lift Up Hydraulic Schematic ........................................................................................... 228
600S Main Lift Up (Hydraulic) .......................................................................................................... 229
600S Main Lift Function (Electrical) ...................................................................................................... 230
600S Main Lift Up (Electrical) ........................................................................................................... 231
600S Main Lift Up (Electrical) ........................................................................................................... 232
600S Main Lift Down Function (Hydraulic) ........................................................................................... 233
Lift Down Function (Normal Operation) ............................................................................................ 233
Lift Down Function (Auxiliary Operation) .......................................................................................... 233
600S Main Lift Down Hydraulic Schematic ...................................................................................... 235
600S Main Lift Down (Hydraulic) ...................................................................................................... 235
600S Main Aux Lift Up Hydraulic Schematic .................................................................................... 236
600S Main Aux Lift Down (Hydraulic)............................................................................................... 236
600S Main Lift Down (Electrical) ...................................................................................................... 237
600S Main Lift Down (Electrical) ...................................................................................................... 238
600S Platform Level (Hydraulic) ........................................................................................................... 239
600S Platform Valve ......................................................................................................................... 240
600S Platform Valve (Schematic) .................................................................................................... 242
600S Platform Level Cylinder ........................................................................................................... 243
600S Platform Level (Hydraulic)....................................................................................................... 244
600S Platform Level Up Hydraulic Circuit ........................................................................................ 245
High/Low Dump Logic ...................................................................................................................... 245
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Table of Contents
Practice: Platform Level Down Hydraulic ......................................................................................... 246

Practice: Platform Level Down Hydraulic ......................................................................................... 247
600S Platform Level (Electrical) ........................................................................................................... 248
600S Platform Level (Electrical) ....................................................................................................... 249
600S Platform Level Up (Manual) .................................................................................................... 250
Practice: Platform Level Down Electrical ......................................................................................... 251
Practice: Platform Level Down Electrical ......................................................................................... 252
Platform Level Up Auto (Electrical) .................................................................................................. 253
600S Platform Level Up (Auto)......................................................................................................... 254
600S Telescope Out (Hydraulic)........................................................................................................... 255
600S Main Valve .............................................................................................................................. 256
600S Telescope Cylinder ................................................................................................................. 257
600S Telescope Out (Hydraulic) ...................................................................................................... 258
600S Telescope Out Hydraulic Circuit ............................................................................................. 259
Practice: Telescope In Hydraulic Schematic .................................................................................... 260
Practice: Telescope In Hydraulic (Description) ................................................................................ 261
600S Telescope (Electrical) .................................................................................................................. 262
Telescope Out (Electrical) ................................................................................................................ 263
600S Telescope Out Electrical Circuit .............................................................................................. 264
Practice: Telescope In ...................................................................................................................... 265
600S Platform Rotate (Hydraulic) ......................................................................................................... 266
600S Platform Rotator ...................................................................................................................... 267
600S Platform Rotate Right (Hydraulic) ........................................................................................... 268
600S Platform Rotate Right Hydraulic Circuit .................................................................................. 269
600S Platform Rotate (Electrical) ......................................................................................................... 270
600S Platform Rotate Right (Electrical)............................................................................................ 271
600S Platform Rotate Right Electrical Circuit................................................................................... 272
600S Swing Right (Hydraulic) ............................................................................................................... 273
600S Swing Right Hydraulic Schematic ........................................................................................... 274
600S Swing Right Hydraulic Circuit.................................................................................................. 275
Practice: Swing Left and Lift Down Hydraulic .................................................................................. 276
600S Swing Motor ............................................................................................................................ 278
600S Swing Motor Ports .................................................................................................................. 279
600S/660SJ Swing Right (Electrical)................................................................................................ 280
Practice: Swing Left Electrical ......................................................................................................... 281
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Table of Contents
vii
Module 1
MODULE 1: MACHINE OVERVIEW

INTRODUCTION
This module describes the model nomenclature, major component identification, and
model specifications. The models covered in this manual are the
400S/450AJ/520AJ/600S/660SJ// boom lifts.
OBJECTIVES
Upon completion of this module, participants will be able to:
• Describe the nomenclature for each model
• Identify the major components for each model
• List the model specifications for each model
1
Machine Overview
MACHINE ORIENTATION
This manual will reference the front, rear, right, and left of the boom lift using the
perspective of the operator standing in the platform, facing the platform control console.
The directional arrow on the frame must be showing the black side pointing forward.
Front/Forward
LEFT
FRONT
Rear/Reverse
REAR
RIGHT
Figure 1-1 Machine Orientation
2
Module 1
MODEL NOMENCLATURE
400S
• 40 - Indicates the maximum vertical platform height in feet
• 0 - Indicates 100 Series
• S - Indicates straight boom
450AJ
• 45 - Indicates the maximum vertical platform height in feet
• 0 - Indicates 100 Series
• A - Indicates articulating boom
• J - Indicates machine is equipped with a jib
3
Machine Overview
MAJOR COMPONENTS
400S Platform
Controls
Rotator
Main Fly
Boom
Platform
Main Base
Boom Platform
Level
Cylinder
Telescope Cylinder
(located internally)
Lift Cylinder
Turntable
Drive/Steer Frame Drive Tires

Tires
Figure 1-2 400S Major Components
4
Module 1
460SJ
Platform Main Fly

Controls Jib Boom
Telescope Cylinder
Main Base
Platform
Boom
Level
Cylinder
Jib Lift
Platform Cylinder
Rotator Lift
Cylinder
Ground Control
Console
Turntable
Drive Tires Frame Drive/Steer

Tires
Figure 1-3 460SJ Major Components
5
Machine Overview
450AJ
Platform
Controls Jib
Main Fly
Boom
Telescope Cylinder
Platform
Level Main Base
Cylinder Boom
Jib Lift
Cylinder Master
Platform Cylinder
Rotator Main Lift
Cylinder
Upper
Upper Tower
Upright
Boom
Ground Control
Tower Lift
Console
Cylinder
Lower
Upright
Drive/Steer
Lower Tower Tires
Boom
Turntable
Drive Tires
Frame
Figure 1-4 450AJ Major Components
6
Module 1
520AJ
Platform
Controls
Platform
Jib Level
Cylinder
Main Fly
Boom
Jib Lift
Platform Cylinder
Telescope Cylinder
Rotator (located internally)
Main Base
Boom
Master
Cylinder
Main Lift
Cylinder Upper
Upright
Upper Tower
Boom
Tower Lift
Lower Cylinder
Upright
Ground Control
Console
Lower Tower
Boom
Drive/Steer
Tires
Turntable
Drive Tires
Frame
Figure 1-5 520AJ Major Components
7
Machine Overview
600S
Figure 1-6 600S Major Components
8
Module 1
GROUND CONTROLS AND INDICATORS
660SJ Ground Controls
1. Indicator Panel
2. Display Gauge
3. Engine Start/Auxiliary Power/Function Enable
4. Platform/Ground Select Keyswitch
5. Platform Level
6. Platform Rotate
7. Jib Lift (600SJ only)
8. Telescope
9. Power/Emergency Stop
10. Main Boom Lift
11. Swing
12. Machine Safety System Override (MSSO)
Figure 1-7a 660SJ Ground Control Console
9
Machine Overview
450AJ Ground Controls
1. Indicator Panel
2. Display Gauge
4. Platform/Ground Select Keyswitch
5. Platform Level
6. Platform Rotate
7. Jib Lift
8. Telescope
9. Main Boom Lift
10. Tower Boom Lift
11. Swing
12. Engine Start/Auxiliary Power/Function Enable
13. Machine Safety System Override (MSSO)
Figure 1-7b 450AJ Ground Control Console
10
Module 1
Indicator Panel
1. Battery Malfunction
2. Low Engine Oil Pressure
3. High Engine Coolant Temperature
4. Engine Oil Temperature
5. System Distress
6. Low Fuel
7. Glow Plug
8. Platform Overload (if equipped)
9. Drive and Steer Disable (if equipped)
Figure 1-7c 660SJ/450AJ Ground Control Console
11
Machine Overview
GROUND CONTROL CONSOLE
Display Gauge
The display gauge shows engine hours, fuel level, and diagnostic trouble codes (DTCs)
from both the JLG Control System and the engine control system.
Display Screens
Main Screen
1. Indicator Lamp
2. Fuel Level
3. Navigate Forward Arrow
4. Navigation Arrows
5. Navigate Back Arrow
6. Engine Hours
12
Module 1
Splash Screen
During machine start up with no active DTCs in
the control system, the splash screen will show
for 3 seconds and then switch to the main
screen. If there is an active DTC while powering
up the machine, the splash screen will show for
3 seconds and then launch the Diagnostic
Screen. The indicator lamp will light when there
is an active DTC in the fault log.
Diagnostic Screen
The Diagnostic Screen will show active and

inactive faults from the JLG Control System. An
asterisk (*) will be displayed to show active
faults.
Engine Diagnostic Screen
The Engine Diagnostic Screen will show

Suspect Parameter Number (SPN), Failure
Mode Identifier (FMI), and Occurrence count
information.
Figure 1- 8 Ground Control Display Screens
13
Machine Overview
MACHINE SAFETY SYSTEM OVERRIDE (MSSO)

Note: CE Machines Only
The (MSSO) is required to conform to the latest EN280:2013 requirements. It is fitted to

the ground control console and is standard on all CE boom lifts. The MSSO is only to be
used to retrieve an operator that is pinned, trapped, or unable to operate the machine.
All function controls are locked out from the platform due to a platform overload
situation. Figure 1- shows examples of the MSSO switch and decal.
A platform overload fault is logged like any other fault. It remains active and is displayed
until it is removed using the JLG Analyzer. No functional checks of the MSSO system
are necessary. The JLG Control System will set a diagnostic code if the MSSO enable
switch is faulty. For proper operation of the MSSO system, refer to the machine’s
Operation and Safety Manual.
Figure 1- 9 Machine Safety System Override
14
Module 1
PLATFORM CONTROLS AND INDICATORS
600SJ/400SJ Platform Controls
1. Drive Speed/Torque Select

2. Platform Leveling Override
3. Fuel Select (if equipped)
4. Horn
6. Start/Auxiliary Power
7. Capacity Select
8. Drive Orientation Override
9. Drive/Steer Controller
10. Telescope
11. Lights (if equipped)
12. Jib Lift (600SJ only)
13. Soft Touch/Sky Guard Override (if equipped)
14. Soft Touch/Sky Guard Indicator (if equipped)
15. Platform Rotate
16. Function Speed Control
17. Main Lift/Swing Controller
Figure 1-10a Platform Control Console
15
Machine Overview
600SJ/400SJ Indicator Panel
1. AC Generator (if equipped)

2. Platform Overload (if equipped)
3. Capacity Indicator
4. Tilt
5. Glow Plug/Wait to Start
6. Enable/Footswitch
7. Fuel Level
8. Creep
9. System Distress
10. Drive Orientation
Figure 1-10b Platfrom Indicator Panel
16
Module 1
MACHINE SPECIFICATIONS
The table below provides a list of the basic specifications for the boom lifts covered in
this manual. For a complete listing of the machine specifications, go to the JLG website
(www.jlg.com).
450AJ 400S 600S
550 lb 600 lb 600 lb

Capacity Unrestricted
(250 kg) (272 kg) (272 kg)
1000 lb 1000 lb
Capacity Restricted N/A
(454 kg) (454 kg)
Gradeability (4WD) 45% 45% 45%
5 mph 5 mph 4 mph

Drive Speed
(7.2 kph) (7.2 kph) (6.1 kph)
24 ft 6 in 34 ft 7 in 50 ft.
Horizontal Outreach
(7.47 m) (10.54 m) (15 m)
24 ft 10 in
Up and Over Height N/A N/A
(7.57 m)
7 ft 8 in 7 ft 9 in
Overall Width
(2.34 m) (2.36 m)
7 ft 6 in 7 ft 10 in 8 ft 2 in
Stowed Height
(2.29 m) (2.39 m) (2.5 m)
22 ft 24 ft 9 in 28 ft 7 in
Stowed Length
(6.71 m) (7.54 m) (8.71 m)
360°
360° 360°
Swing Non-
Continuous Continuous
Continuous
13,250 lb 12,650 lb 21,461 lb
Weight
(6,010 kg) (5,738 kg) (9,735 kg)
17
Machine Overview
MACHINE IDENTIFICATION
The serial number placard provides important information that is used when servicing
the machine. The serial number plate is located on the left side of the machine’s frame,
between the front and rear tires.
Figure 1- 11 Serial Number Plate
The serial number is stamped on the left side of the frame.
Figure 1- 12 Serial Number Stamp
18
Module 1
INSPECTION AND MAINTENANCE REQUIREMENTS

The following table covers the periodic machine inspections and maintenance required
by JLG Industries. Consult local regulations for further requirements for aerial work
platforms.
The inspection and maintenance requirements are published in the Service and
Maintenance Manual.
PRIMARY SERVICE
TYPE FREQUENCY REFERENCES
RESPONSIBILITY QUALIFICATIONS
Prior to the use

Pre-Start Operation and
each day or at each User or Operator User or Operator
Inspection Safety Manual
operator change
Service and
Prior to each sale, Maintenance
Pre-Delivery Owner, Dealer, or Qualified JLG
lease, or rental Manual and
Inspection User Mechanic
delivery applicable JLG
inspection form
In service for 3
months or 150
Service and
hours (whichever
Maintenance
Frequent comes first), out of Owner, Dealer, or Qualified JLG
Manual and
Inspection service for a period User Mechanic
applicable JLG
of more than 3
inspection form
months or
purchased used
Service and
Annually, no later
Annual Factory Certified Maintenance
than 13 months Owner, Dealer, or
Machine Service Technician Manual and
from the date of the User
Inspection (recommended) applicable JLG
prior inspection
inspection form
At intervals as
specified in the Service and
Preventative Owner, Dealer, or Qualified JLG
Service and Maintenance
Maintenance User Mechanic
Maintenance Manual
Manual
19
Power Distribution
20
Module 2
MODULE 2: POWER DISTRIBUTION

INTRODUCTION
This module describes the various power up systems of the
400S/450AJ/520AJ/600S/660SJ booms. This includes the electrical and hydraulic
systems.
OBJECTIVES
• Examine the hydraulic and electrical systems
• Identify the components of the hydraulic and electrical systems
21
Power Distribution
Drive Pump Flow

HYDRAULIC SYSTEM Charge Pump Flow
Suction
Return
400S/600S Hydraulic Drive System
Figure 2-1 400S/600S Hydraulic Drive Overview
22
Module 2
400S/600S Hydraulic Drive Circuit Description

• When the engine is started and running, the charge pump will suction fluid
(green) from the hydraulic reservoir and create flow (orange) through the charge
filter to the brake spool, 2 speed spool, and the axle spools.
• The drive direction spools will also receive the charge pump pressure (orange)
• If the drive function is activated, charge pump pressure (orange) will travel across
the drive direction spools to the drive pump
• The drive pump will then suction fluid (green) from the hydraulic reservoir and
create drive pressure (red)
• In addition, if the drive function is activated, charge pump pressure (orange) will
travel across the brake spool to the brakes, across the 2 speed spool to the
swash plate of the drive motor, and across the axle spools to the oscillating axle
• The drive pressure will then travel to the flow dividers and continue to the drive
motors, forcing the drive motors to rotate
• From the drive motors, a case drain (blue) allows fluid to return to the hydraulic
reservoir
23
Power Distribution
Practice: 400S/600/ Hydraulic Drive Circuit
Using Figure 2-1, conclude how the system would react if the direction spools are
failing. Explain how to check for this failure.
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
If there is a problem with the brakes, 2 speed spool, and oscillating axle, what are the
common components that could be the source of this issue?
1. _____________________________
2. _____________________________
3. _____________________________
4. _____________________________
24
Module 2
450AJ/520AJ Hydraulic Drive System
Figure 2-1b 450/520 Hydraulic Drive Overview
25
Power Distribution
Hydraulic System Major Components (DRIVE)

Hydraulic Reservoir -The hydraulic reservoir is located at the turntable next to the
counter weight. Depending on the model, it will be located under the right or left
hood opposite the engine side.
Figure 2-2 Hydraulic Reservoir
Charge Filter-The charge filter is located near the drive pump mounted to the
turntable. It is a pressure type cartridge and should be changed every 6 months or
300 hours.
Figure 2-3 Charge Filter
26
Module 2
Drive Pump Assembly-The drive pump is attached to the rear of the engine. It is the
only pump for the drive system.
Figure 2-4 Drive Pump
Drive Direction Spools-The drive direction spools are located at the bottom or the top
of the drive pump. These are electrically controlled and direct charge pump
pressure to the swash plate of the drive pump. When the swash plate is moved, the
pump will create flow.
Figure 2-5 Drive Direction Spools
27
Power Distribution
Axle Control Valve (400S/600S)-The axle control valve is located on the right or left
side of the turntable under the hood. It houses the brake valve, 2 speed valve,
oscillating axle valve 1, and oscillating axle valve 2.
Figure 2-6 Axle Control Valve
Brake Spool (400S/600S)-The brake spool is located in the axle control valve. When
drive is activated, this spool is electrically moved to allow charge pump flow to travel to
the brake assemblies and release the brakes.
Figure 2-7 Brake Spool
28
Module 2
2 Speed Spool (400S/600S)-The 2 speed spool is located in the axle control valve.
This valve is electrically controlled by the drive speed/torque select switch located at
the platform control panel. In the hi speed position, the 2 speed spool is moved,
allowing charge pump pressure to be sent to the drive motors. This charge pump
pressure will destroke the drive motor to create hi speed and low torque.
Figure 2-8 2Speed Spool
Swivel-The swivel is located in the center of the chassis/turntable. This creates a

connection point from the turntable to the chassis and permits 360 degree
continuous rotation.
Note: The 450/520 does not use a swivel. These models use hoses and swivel type fittings.
Figure 2-9 Swivel
29
Power Distribution
Traction Valve (600S)-The traction valve is located near the swivel in the center of
the chassis or attached to the side of the chassis. Its purpose is to direct equal flow
to each drive motor.
Figure 2-10 Traction Valve
30
Module 2
Traction Valve (450AJ/520AJ)-The traction valve is located at the rear axle

accessible through an access cover on the top of the chassis Its purpose is to direct
equal flow to each drive motor. The additional purpose on the 450AJ and 520AJ is
to control the 2 speed spools, brakes, and oscillating axle.
Figure 2-10b Traction Valve
31
Power Distribution
Drive Motor-The drive motors are located at each wheel. The purpose of drive
motors is to receive hydraulic flow and create torque in the torque hub. Drive motors
are spring biased to maximum displacement and hydraulically shifted to minimum.
Maximum is required for torque and minimum is required for speed.
Figure 2-11 Drive Motor
Torque Hubs-The torque hubs receive the torque from the drive motor and transmit
this into mechanical rotation through a sun and planetary gears.
Check fluid level when plugs

are at 12 and 3 o’clock or 12
and 9 o’clock.
Disengage cap is to release

gears internally for towing.
Note: Always chock tires
when this is used.
Disengage Cap
Figure 2-12 Torque Hub
32
Module 2
600S/660SJ Hydraulic FunctionsSystem
Gear Pump Flow

Suction
Return
Figure 2-13 600S/660SJ Hydraulic Functions Overview
33
Power Distribution
600S/660SJ Hydraulic Function Circuit Description

• When the engine is started and running, the gear pump will suction fluid (green)
from the hydraulic reservoir and create flow (red) through the charge filter to the
main control valve and to the steer, swing, lift, and tele spools
• Flow from the gear pump (red) will also travel through the filter at the platform
valve, to the platform valve, though the high/low dump, and to the rotate and
level, and jib spools
• If a function is activated, the spool will move allowing hydraulic flow (red) to travel
to the actuator
• The main control valve and platform valves each have a return (blue) to the
hydraulic reservoir
Practice: Hydraulic Functions System
Using Figure 2-13 on page 32, what is the only function that requires flow through the
swivel?
______________________________________________________________________
Using figure 2-13 on page 32, list the components that receive hydraulic flow from the
platform valve.
1. _________________________________
2. _________________________________
3. _________________________________
Using figure 2-13 on page 32, list the components that receive hydraulic flow from the
main control valve.
1. _________________________________
2. _________________________________
3. _________________________________
4. _________________________________
34
Module 2
Gear Pump Flow

Hydraulic System (450AJ/520AJ Functions) Suction
Return
Figure 2-14 450AJ/520AJ Hydraulic Functions
35
Power Distribution
Gear Pump Flow

Hydraulic System (400SJ Functions) Suction
Return
Figure 2-15 400SJ Hydraulic Functions
36
Module 2
HYDRAULIC SYSTEM MAJOR COMPONENTS (FUNCTIONS)

Function Pump (450AJ/400S/600S) -The function gear pump is attached to the drive
pump. The purpose of the gear pump is to supply hydraulic flow for all the boom and
platform functions and steering. This type of pump is a fixed displacement style.
Figure 2-16 Gear Pump
Main Control Valve (600S)-The main control valve is located at the turntable on
either the right or left side depending on model. This valve controls various functions
depending on the model. It houses various relief valves, spools, test ports, and
solenoids.
Figure 2-17 Main Control Valve
37
Power Distribution
Platform Valve (600S)-The platform valve is located at the end of the fly boom This
valve controls platform level, platform rotate, and jib lift. It houses various relief
valves, spools, test ports, and solenoids.
Figure 2-18 Platform Valve
Upright Valve (450AJ/520AJ)-The upright valve is located inside the upper tower
boom. This valve controls platform level and main telescope. It houses various
relief valves, spools, test ports, and solenoids.
Figure 2-19 Upright Valve
38
Module 2
Fly Boom Valve (450AJ/520AJ)-The fly boom valve is located at the end of the fly
boom. This valve controls platform rotate and jib lift. It houses various relief valves,
spools, test ports, and solenoids.
Figure 2-20 Fly Boom Valve
39
Power Distribution
ELECTRICAL SYSTEM
Battery
Ground
Module
MTB MTB
EMS Select Fuse Box
Switch
Platform
Module
Aux Pump
Relay
12 VDC Battery Supply

12 VDC Switched Supply
Aux Pump
Engine
Starter
Glow Plug
Relay
Glow
Plugs
Alternator
Figure 2-21 Electrical System
40
Module 2
Power Up System Overview
Battery
The 600S/660SJ Boom Lifts use a single 12 volt battery to power all electrical systems.
The battery is located under the right side hood.
Figure 2-22 Battery
41
Power Distribution
Auxiliary Power Pump Relay
The auxiliary power pump relay receives 12 volts from the battery. When either the
ground or platform auxiliary power switch is activated, the relay energizes, sending 12
volts to the auxiliary power pump. The auxiliary power pump relay is located beside the
auxiliary power pump and battery.
Power from
Ground
Battery
To Start Signal from
Relay Ground Module
To
Plug J1 Pin 13
Auxiliary
Power
Pump
Figure 2-23 Auxiliary Power Pump Relay
42
Module 2
Auxiliary Power Pump
The auxiliary power pump provides sufficient oil flow to operate the basic machine
functions if the main pump or engine fails. The auxiliary power pump operates on 12
volts supplied from the battery through the auxiliary power relay. The auxiliary power
pump is located near the battery.
Auxiliary Power Pump Relay Auxiliary Power Pump
Power from Ground

Battery
Signal from Ground
To Start Ground Module
Relay Plug J1 Pin 13
Figure 2-24 Auxiliary Power Pump
43
Power Distribution
Start Relay (Solenoid)
The start relay receives 12 volts from the battery. When either the ground or platform
engine start switch is activated, the relay energizes and sends 12 volts to the starter.
The starter then engages the engine, allowing it to begin rotation. The start relay is
located beside the starter, on the backside of the engine.
Start Relay
Ground
Signal from
Ground Module
Plug J1 Pin 11
Power from
Start Signal to
Battery
Starter
To Glow Plug
Relay
Figure 2-25 Start Relay
44
Module 2
Starter
The starter is used to initiate the rotation of the engine. The starter is activated when
the starter relay is energized, sending 12 volts from the battery to the starter motor. The
starter is located on the backside of the engine, on the left side (engine side) of the
machine.
Starter
Start Relay
Ground
Power from
Ground Battery
Signal from
Ground Module
Plug J1 Pin 11
Power from
Battery
To Glow Plug
Relay
Figure 2-26 Starter
45
Power Distribution
Glow Plug Relay and Glow Plugs
The glow plugs are heating devices used to aid in starting a diesel engine. The control
system monitors the engine coolant (oil) and ambient temperature to determine cylinder
pre-heating requirements.
If the coolant temperature is below 50°, the glow plugs will be automatically fired for a
period of time that depends on ambient temperature. The glow plug indicator will flash
when the plugs are energized.
Glow Plugs
Glow Plugs
Indicator Lamp
Ground
Signal from Glow Sense
Ground Module Signal
Plug J1 Pin 10
Power from
Battery
To
Alternator
Figure 2-27 Glow Plug Relay and Glow Plugs
46
Module 2
Alternator
An alternator is an electrical device that converts mechanical energy to electrical energy

in the form of alternating current. The alternator is turned by the engine and charges the
battery. The alternator is located under the left side (engine side) hood.
Power from Signal from

Battery Ground Module
Plug J1 Pin 32
Figure 2-28 Alternator
47
Power Distribution
Ground Emergency Stop Switch
The ground emergency stop switch is a two-position, red, push-pull switch that supplies
power to the ground/platform select keyswitch. The ground emergency stop switch is
the main power switch. It must be on to power up the platform. The ground emergency
stop switch is located on the ground control console on the right side of the machine.
Switch positions:
• ON- pulled out, closed position, power is supplied to the ground/platform select
keyswitch
• OFF- pushed in, open position, power is shut off to the ground/platform select
keyswitch
ON Position (Pulled out) OFF Position (Pushed in)
Battery + Battery +
Power
To EMS
Figure 2-29 Ground Emergency Stop Switch
48
Module 2
Ground/Platform Select Keyswitch
The ground/platform select keyswitch is a three-position, key operated switch that

supplies power to either the ground or platform controls. The ground/platform select
keyswitch is located on the ground control console on the right side of the machine.
Ground Platform
Mode Power Mode
From EMS
Switch Positions:
• Ground Mode - horizontal position, power is supplied to the ground controls
• OFF- middle position, power is shut off to all controls
• Platform Mode - vertical position, power is supplied to the platform controls
Figure 2-30 Ground/Platform Select Keyswitch
49
Power Distribution
Fuse Box
The fuse box distributes electrical power to different circuits and provides a protective
fuse for each circuit. The fuse box receives power through the ground emergency stop
switch and the ground/platform select keyswitch. The fuse box is located under the
right side (hydraulic side) hood of the machine, behind the ground control console.
Refer to the appropriate Service and Maintenance Manual for fuse, relay, and pin
information.
Figure 2-31 Fuse Box
50
Module 2
Ground Control Module
The ground control module is the main module that receives inputs from and supplies
outputs to various components. The CANbus outputs typically supply voltage or ground
to components, control valves, and LEDs. The inputs are typically voltage from ground
control switches and platform mode inputs. The ground control module is located behind
the ground control console.
Refer to the appropiate Service and Maintenance Manual for pin inputs and outputs.
Figure 2-32 Ground Control Module
51
Power Distribution
Yellow Power Module
The yellow power module acts as a relay for the fuel pump. It contains two fuses: one
for the fuel pump and one for the ECM. The yellow power module is located on the back
side of the engine.
Yellow Power Module
Power from To ECM

Battery
Ground
Fuel Pump
Signal from
Ground Module
Plug J1 Pin 10
Ground
Figure 2-33 Yellow Power Module
52
Module 2
Fuel Pump
The fuel pump is an electrical device in the fuel system which draws fuel from the fuel
tank and supplies it to the fuel injection system. The fuel pump on the 600S/660SJ
boom lifts is located under the left side hood, beside the fuel tank.
Signal from
Ground Module
Plug J1 Pin 10
Ground
Figure 2-34 Fuel Pump
53
Power Distribution
Platform Emergency Stop Switch
The platform emergency stop switch is a two-position, red, push-pull switch that
supplies power to the platform control module. The ground emergency stop switch must
be on to power the platform console. The platform emergency stop switch is located on
the platform control console.
Switch positions:
• ON- pulled out, closed position, power is supplied to the platform controls
• OFF- pushed in, open position, power is shut off to the platform controls
ON Position (Pulled out) OFF Position (Pushed in)
Figure 2-35 Platform Emergency Stop Switch
54
Module 2
Platform Control Module
The platform control module receives inputs and supplies outputs to various
components. CANbus is used as the main communication between the ground control
and platform control modules. The platform module is located inside the platform control
console.
Refer to the appropiate Service and Maintenance Manual for pin inputs and outputs.
Figure 2-36 Platform Control Module
55
Power Distribution
56
Module 3
MODULE 3: CANBUS NETWORK

INTRODUCTION
This module describes the controller area network bus (CANbus) network used on the
400S/460SJ/450AJ/520AJ/600S/660SJ boom lifts.
OBJECTIVES
• Demonstrate general knowledge of a CANbus circuit

• Identify the components in a CANbus circuit
• Calculate the resistance in a CANbus circuit
• Trace a CANbus circuit using the exercise manual and electrical schematic
57
CANbus Network
CANBUS
CANbus is a digital communication system that connects electronic control units
(ECUs). These ECUs are called nodes in CANbus terminology. The CANbus network
requires two or more nodes along with termination resistors to communicate. The nodes
are connected using two wires (one high and one low). The wires are twisted together in
a pair. Each CANbus circuit contains a resistor at each end of the circuit.
Typical Circuit
CAN High
120Ω CAN Low 120Ω

Resistor Resistor
Node Node Node
Figure 3-1 CANbus Circuit
58
Module 3
CANbus Components
Node
Node
o Each node contains a host processor
o The host processor receives and
transmits data
CAN High
Two Wires
1. CAN High (Dark Blue)
2. CAN Low (Light Blue)
CAN Low
Twisted Wires
o Wires are twisted to reduce outside
interference and prevent
communication errors
o The wires are twisted the entire length
of the circuit but are usually only
shown on the schematic twisted at the Represents twisted wires
ends
120Ω Termination Resistors

o Two resistors are required to complete 120Ω
the CANbus circuit and help reduce Resistor
communication errors
Figure 3-2 CANbus Components
59
CANbus Network
Basic CANbus Circuit Layouts
The circuit below shows a basic CANbus circuit with three nodes and two resistors. The
nodes communicate with each other using the CAN High and CAN Low twisted wire
pair. The circuit below shows the termination resistors placed outside of the nodes at
each end of the circuit.
120Ω 120Ω
Resistor Resistor
Node Node Node
The circuit below shows a basic CANbus circuit with two nodes and two resistors. The
pair. The circuit below shows the termination resistors inside of the nodes at the ends of
the circuit.
Node Node
120Ω 120Ω
Resistor Resistor
60
Module 3
The circuit below shows a basic CANbus circuit with two nodes and two resistors. The
pair. The circuit below shows one termination resistor inside of the node and the other
at the end of the circuit.
120Ω
Resistor
Node Node
120Ω
Resistor
Figure 3-3 Basic CANbus Circuit Layouts
61
CANbus Network
Troubleshooting CANbus Circuits

To take a resistance reading in the CANbus circuit, power down the machine. The
reading must be taken between a CAN High and CAN Low wire. A closed CANbus
circuit will read 60Ω. An open CANbus circuit will read 120Ω.
Closed Circuit
When a resistance reading is taken on Node 1 between pins 1 and 2, the reading will be
60Ω. Likewise, any reading between any CAN High or CAN Low wire will read 60Ω.
120Ω 120Ω
Resistor Resistor
Node 1 Node 2 Node 3
Open Circuit
When a resistance reading is taken on Node 1 between pins 1 and 2, the reading will be
120Ω because the ohmmeter is measuring the resistor on the left. A resistance reading
on Nodes 2 or 3 between a CAN High or CAN Low wire will also read 120Ω, but the
ohmmeter is now measuring the resistor on the right.
120Ω 120Ω
Resistor Resistor
Figure 3-4 Troubleshooting CANbus Open Circuit
62
Module 3
Understanding CANbus Circuits

Why 60Ω or 120Ω?
The formula shown below is used to calculate the resistance of two resistors when
connected in parallel.
1 1 1 1 1 1
= + … 𝑂𝑂𝑂𝑂 = + …
𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 1 𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 2 𝑅𝑅𝑅𝑅 𝑅𝑅1 𝑅𝑅2
The following CANbus circuit is using two, 120Ω resistors, in parallel. Use the formula to
solve for Resistance Total or RT.
120Ω 120Ω
Resistor Resistor
(R1) (R2)
Figure 3-5 Understanding CANbus Circuits
1 1 1
= +
𝑅𝑅𝑅𝑅 𝑅𝑅1 𝑅𝑅2
1 1 1
= +
𝑅𝑅𝑅𝑅
1
= 𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 𝑡𝑡𝑡𝑡
𝑅𝑅𝑅𝑅
𝑅𝑅𝑅𝑅 = _______ 𝑂𝑂ℎ𝑚𝑚𝑚𝑚
63
CANbus Network
JLG CANbus
JLG refers to nodes as modules but the layout of the CANbus circuits are the same as
the previous pages. JLG machines use all the examples of the basic CANbus circuits.
Some circuits have resistors that start and end inside the modules, while others are
external to the modules. All JLG machines use two resistors placed in parallel for each
CANbus circuit.
64
Module 3
CANBUS CAN 1
CANbus CAN 1 is the circuit that communicates between the platform and ground
modules and a few other CANbus components. The resistors are located inside the
platform and ground modules.
Basic Circuit
The basic circuit shows just the CANbus components linked together.
CAN1 LSS Tilt

Option Sensor
Platform Ground
Module Buss MS131 Module
(Resistor) Bar Connector (Resistor)
MS16
Platform Control Box

Ground Control Box
Figure 3-6 CANbus CAN 1: Basic Circuit
65
CANbus Network
Detailed Circuit
This is the schematic drawing of the CANbus CAN 1 circuit from the platform module to
the ground module.
Figure 3-7 CANbus CAN 1: Detailed Circuit
66
Module 3
CANbus CAN 2
The second CANbus circuit is the communication between the machine and the engine.
The circuit starts with a resistor in the ground module. Based on which engine
application is equipped in the machine, the end resistor location may vary. The circuit
below shows the circuit from the ground module to the engine connector where the
engine’s harness connects.
The CANbus circuits for the available engine options are shown on the following pages.
CAN2
Ground MS325
Module Connector
(Resistor)
Ground Control Box
Engine Diagnostic
Module Connector MDI
(Resistor)
Figure 3-8 CAN 2: Basic Circuit
67
CANbus Network
CANbus CAN2: Deutz Tier 4 Final (T4F) Engine
Boom lifts equipped with the Deutz Tier 4 Final engines use two CANbus circuits. They
use Circuit 2 (Figure 3-8) and the two circuits shown below in Figure 3-9.
Figure 3-9 CANbus Deutz Tier 4 Final Engine
68
Module 3
Figure 3-10 CANbus Deutz Tier 4 Final Engine(continued)
69
CANbus Network
CANbus CAN2: Deutz Tier 4 Interim (T4I) Engine
Boom lifts equipped with the Deutz Tier 4 Interim engines use two CANbus circuits.
They use Circuit 2 (Figure 3-8) and the circuit shown below (Figure 3-11). This circuit
allows the machine to communicate with the engine.
Figure 3-11 CANbus Deutz Tier 4 Interim Engine
70
Module 3
CANbus CAN2: Ford Engine
Boom lifts equipped with the Ford engines use two CANbus circuits. They use CAN2
shown in (Figure 3-8) and the circuit shown below (Figure 3-12). This circuit allows the
machine to communicate with the engine.
Figure 3-12 CANbus Ford Engine
71
CANbus Network
72
Module 4
MODULE 4: BOOM
INTRODUCTION
This module covers the boom assembly, the mechanical aspects of the boom, and the
limit switches and sensors associated with the boom system on the
OBJECTIVES
• Identify the components of the boom assembly
• Identify the location of the boom limit switches and sensors
• Describe how the boom assembly operates
73
Boom
BOOM CYLINDERS
Platform
400S Rotator
Master
Cylinder
Platform Level
Cylinder
Telescope (not visible)
Cylinder
(not visible)
Lift
Cylinder
460SJ Platform
Rotator
Master
Cylinder
Jib
Cylinder
Platform Level
Cylinder
Telescope
(not visible)
Cylinder
(not visible)
Lift
Cylinder
Figure 4-1 400S/460SJ Boom Cylinders
74
Module 4
450AJ
Telescope
Cylinder
(not visible)
Main Lift
Master Cylinder
Cylinder Platform
Rotator
Jib
Cylinder
Platform Level
Tower Lift Cylinder
Cylinder (not visible)
520AJ
Telescope
Cylinder
(not visible)
Main Lift
Master Cylinder
Platform
Cylinder Rotator
Jib
Cylinder
Platform Level
Tower Lift Cylinder
Cylinder (not visible)
Figure 4-2 450AJ/520AJ Boom Cylinders
75
Boom
600S Boom Cylinders
Platform Level
Cylinder
Main Lift
Cylinder Telescope
Cylinder
(not visible)
Figure 4-3 600S Boom Cylinders
76
Module 4
400S/460SJ BOOM SENSORS

The 400S/460SJ Boom Lifts use a system of boom sensors to track boom position.
These sensors communicate together to keep the boom in safe operating conditions.
Both machines use a boom angle sensor and boom length sensors. The 400S has an
additional set of boom capacity sensors. Sensor locations for the 400S/460SJ are
shown below in Figure 4-4Error! No bookmark name given..
Boom Angle Sensor Boom Length Sensors
Dual Capacity Sensors (400S only)
Figure 4-4 400S/460SJ Boom Sensors
77
Boom
Transport Position Sensing System

The transport position sensing system consists of the boom angle sensors mounted on
the pivot end of the lift cylinder and two telescope retracted proximity sensors near the
pivot end of the base boom. The system uses these sensors to detect if the boom is in
the position associated with high speed drive.
This system is used to control the following systems:
• Above elevation (above horizontal)
• Drive/Steer – Boom Function Interlock System (CE only)
• Oscillating axle system
• Lift cylinder end of stroke damping stop
The transport position sensing system uses the following components:
• Boom angle sensors
• Telescope retracted sensors
78
Module 4
400S/450AJ/520AJ Boom Angle Sensor

The boom angle sensors measure boom position to control drive speed and the
oscillating axle. The redundant sensor reading is used as a safety redundancy in case
one sensor fails. The boom angle sensors are mounted on the pivot end of the lift
cylinder as shown previously in Figure 4-4. Figure 4-5 shows the boom angle sensors
and linkage.
In transport:
• When the boom angle sensor reads the main boom is less than 3° below
horizontal with respect to the turntable, drive speed and oscillating axle are not
affected
Out of transport:
• When the boom angle sensor reads the main boom is more than 5° above
horizontal with respect to the turntable, drive speed is cut back and the oscillating
axle locks
Dual capacity (400S only):
• When the boom angle sensor reads more than 51° above horizontal with respect
to the turntable, capacity is unrestricted
Boom Angle
Sensor
Sensor Linkage
6.5 in (166mm)
Figure 4-5 Boom Angle Sensor
79
Boom
Boom Angle Sensor Circuit
The boom angle sensor circuit uses a redundant reading to ensure the sensor is
operating properly and the machine stays within safe operating conditions.
With the main boom completely lowered on the rest, activate the lift up function and the
sensor will read the following:
Ground Module: Plug J7 Pin 4
• Voltage starts at 4.5 volts when the boom is on the boom rest
• As the boom is raised, the voltage decreases to 0.5 volts
• As the boom is lowered, the voltage increases to 4.5 volts
• As the boom is raised, the voltage increases to 4.5 volts
• As the boom is lowered, the voltage decreases to 0.5 volts
Ground Control
Module
Boom Angle
Sensor
4.5 – 0.5V
5V Power
Ground
0.5 – 4.5V
Figure 4-6 Boom Angle Sensor Circuit
80
Module 4
400S/460SJ Boom Length Sensors

The boom length sensors measure boom length to control drive speed and the
oscillating axle based on that measurement. The two proximity sensor system is used
as a safety redundancy in case one sensor fails. The boom length sensors are
mounted on the left side of the base boom, near the pivot end, as shown previously in
Figure 4-4. Figure 4-6 shows the two boom length sensors.
In transport:
• When the two length switches read less than 12 in (30.5 cm) of extension of the
fly boom, drive speed and oscillating axle are not affected
Out of transport:
• When the two length switches read more than 12 in (30.5 cm) of extension of the
fly boom, drive speed is cut back and the oscillating axle locks
Proximity
Sensors
Figure 4-7 Boom Length Sensors
81
Boom
Boom Length Sensors Circuit
In transport:
Boom Length
Ground Control Module Sensor 1
Retracted Switch
12V Power
Ground
Retracted Switch
Boom Length
Sensor 2
Out of transport:
Boom Length
Ground Module Control Sensor 1
Retracted Switch
12V Power
Ground
Retracted Switch
Boom Length
Sensor 2
Figure 4-8 Boom Length Sensors Circuit
82
Module 4
400S Dual Capacity Sensors

The dual capacity selection and indicator system consists of a capacity mode toggle
switch on the platform control console, a set of fly boom proximity sensors, and a main
boom angle sensor. The system prevents the platform from entering the unrestricted
600 lb (272 kg) zone if the restricted 1000 lb (454 kg) mode is selected.
Unrestricted capacity 600 lb (272 kg)
• The machine control system will allow the platform to go anywhere inside the
entire working envelope. The unrestricted capacity envelope is shown below in
both yellow and green.
Restricted capacity 1000 lb (454 kg)
• The machine control system will not allow the platform to go beyond the
restricted boundaries. The machine only allows the retraction of the fly boom or
lifting up of the main boom since these movements place the platform further
away from the unrestricted zone. The restricted capacity envelope is shown
below in green.
Proximity
Sensors
Figure 4-9 Dual Capacity Sensors
83
Boom
Dual Capacity Sensor Circuit
Unrestricted capacity 600 lb (272 kg)
Dual Capacity
Capacity Switch
12V Power
Ground
Capacity Switch
Dual Capacity
Sensor 2
Restricted capacity 1000 lb (454 kg)
Dual Capacity
Capacity Switch
12V Power
Ground
Capacity Switch
Dual Capacity
Sensor 2
Figure 4-10 Dual Capacity Sensor Circuit
84
Module 4
400S/460SJ Chassis Tilt Sensor

The tilt sensor on the 400S/460SJ boom lifts has been removed from the ground control
module and is now a stand-alone part. The tilt sensor uses a CANbus signal to
communicate the tilt value. The tilt sensor is located under the right side (hydraulic side)
hood on the machine. The sensor is mounted on a bracket behind the ground module.
The Chassis Tilt Indicator Sensor measures the turntable angle with respect to level
ground.
• When the machine is in transport position, it can drive up to maximum speed until
it tilts more than 8.0°. Then the system will limit the drive speed to minimum.
• When the machine is in the out of transport position and the turntable tilts more
than the pre-set value, the boom functions can only operate in creep speed and
the drive function is disabled.
• The operator has to return the machine to the in transport mode in order to
continue to drive the machine.
Figure 4-11 400S/460SJ Chassis Tilt Sensor
85
Boom
Tilt Sensor Electrical Circuit
The 400S/460SJ/450AJ/520AJ boom lifts use the same tilt sensor and the circuit is the
same on all models.Locations of the tilt sensor vary from model to model.
The platform module communicates with the ground control module using CANbus
• The platform module uses signals from the tilt sensor to light indicators and
sound the tilt warning alarm.
• The ground control module communicates with the tilt sensor using CANbus and
also supplies a power and ground to the sensor.
• The ground control module uses signals from the tilt sensor to control machine
cutbacks such as: drive speed, drive cutout, and function speed.
Platform Module
CAN Low
CAN High
Tilt Sensor
Power 12V
Ground
Ground Module
Figure 4-12 Tilt Sensor Electrical Circuit
86
Module 4
450AJ/520AJ BOOM SWITCHES AND SENSORS

Tower Boom Angle Switch Main Boom Angle Sensor
Figure 4-13 450AJ/520AJ Boom Switches and Sensors
87
Boom
450AJ/520AJ Tower Boom Angle Switch

The tower boom angle switch is used to sense if the boom is in a position where drive
speed will be affected. The system uses a roller-style limit switch that rides along a cam
until the roller is pulled away, causing the switch to open. The tower boom angle switch
is mounted in the top of the lower upright as shown previously in Figure 4-.
In transport:
• When the tower boom angle switch reads the tower boom is less than 5° below
horizontal with respect to the turntable,switch is closed and drive speed is not cut
back.
Out of transport:
• When the tower boom angle switch reads the tower boom is more than 5° above
horizontal with respect to the turntable, switch is open and drive speed is cut
back.
Tower Boom
Angle Switch
Figure 4-14 Tower Boom Angle Switch
88
Module 4
Tower Boom Angle Switch Circuit
The tower boom angle is read using a roller-style limit switch that communicates with
the ground control module to determine if drive speed should be cut back or not.
In transport:
• Switch closed, drive speed is not cut back
Ground Module
Tower Boom
Angle Switch
Tower Elevation 12V

Transport Elevation 12V
Out of transport:
• Switch open, drive speed is cut back

Ground Module
Tower Boom
Angle Switch
Tower Elevation 8.5V (ref)

Transport Elevation 12V
Figure 4-15 Tower Boom Angle Switch Circuit
89
Boom
450AJ/520AJ Main Boom Angle Sensor

The main boom angle sensor measures boom position to control drive speed and the
oscillating axle. The redundant sensor reading is used as a safety redundancy in case
one sensor fails. The main boom angle sensor is mounted in the upper upright and is
attached to the pivot end of the main lift cylinder as shown previously in Figure 4-13.
Figure 4-16 shows the main boom angle sensor and linkage.
In transport:
• When the main boom angle sensor reads the main boom is less than 3° below
affected
Out of transport:
• When the main boom angle sensor reads the main boom is more than 5° above
axle locks
Boom Angle
Sensor
Sensor Linkage
6.5 in (166 mm)
Figure 4-16 Main Boom Angle Sensor
90
Module 4
Main Boom Angle Sensor Circuit
The main boom angle sensor circuit uses a redundant reading to ensure the sensor is
• As the boom is raised, the voltage decreases to 0.5 volts
• As the boom is raised, the voltage increases to 4.5 volts
Ground Control
Module
Main Boom
Angle Sensor
4.5 – 0.5V
5V Power
Ground
0.5 – 4.5V
Figure 4-17 Main Boom Angle Sensor Circuit
91
Boom
450AJ/520AJ Chassis Tilt Sensor

The tilt sensor on the 450AJ/520AJ boom lift has been removed from the ground control
module and is now a stand-alone part. The tilt sensor uses a CANbus signal to
communicate the tilt value. The sensor is mounted to the turntable base plate.
ground.
• The 5.0° angle is used for the purpose of warning the operator by means of the
chassis tilt light in the platform display panel. The tilt sensor will cause an alarm
to sound, and automatically put all functions in the creep speed mode.
• The 8° angle is used exclusively for the purpose of automatically slowing drive
speed when this angle is reached and the boom is in the in transport position.
When the boom is in the in transport position and the chassis is at or above 8°,
the drive system will automatically switch into max torque mode.
The operator is responsible for preventing the machine from attaining an unstable
position.
Figure 4-18 450AJ/520AJ Chassis Tilt Sensor
92
Module 4
Tilt Sensor Electrical Circuit
The 400S/460SJ/450AJ/520AJ boom lifts use the same tilt sensor and the circuit is the
same on all models.
The platform module communicates with the ground control module using CANbus
• The platform module uses signals from the tilt sensor to light indicators and
sound the tilt warning alarm.
• The ground control module communicates with the tilt sensor using CANbus and
also supplies a power and ground to the sensor.
• The ground control module uses signals from the tilt sensor to control machine
cutbacks such as: drive speed, drive cutout, and function speed.
Platform Module
CAN Low
CAN High
Tilt Sensor
Power 12V
Ground
Ground Module
93
Boom
450AJ/520AJ Drive Orientation Switches

The drive orientation system on the 450AJ/520AJ boom lifts use a redundant limit
switch system to read when the boom is between the rear tires or swung past either
rear tire. The switches will always read opposite of each other, one open and one
closed, due to how they are mounted to the machine. One switch rides along an
elevated cam while the other rides inside a groove.
The limit switches are activated when the turntable is swung +/- 41° off center. This
occurs roughly when the boom is swung past a rear tire.
The drive orientation switches are mounted under the turntable, beside the turntable
gear. Note: On the 450AJ/520AJ, these switches also control the oscillating axle.
Figure 4-20 450AJ/520AJ Drive Orientation Switches
94
Module 4
450AJ/520AJ Drive Orientation Electrical Circuit
Machine Configuration: Boom swung past rear tire
• Power is sent from the platform module to the DOS override switch on plug J1
pin 18
• Power is sent from the platform module to the footswitch on plug J7 pin 4
• Platform and ground control module communicate using CANbus
• Power is sent from the ground control module to the drive orientation switches
Drive Orientation Override
Toggle Switch Footswitch
Platform Module
CAN High
CAN Low
Switch Power 12V
Footswitch Disengaged
Footswitch 12V
CAN Low
CAN High
Footswitch Engaged
Transport Switch 12V

Osc Switch 1, 12V
Osc Switch 2 Drive
Orientation
Switches
Ground Module
Figure 4-21 450AJ/520AJ Drive Orientation Electrical Circuit
95
Boom
400S/450S Platform Load Sensing System (LSS)

Note: This is standard on CE and AUS machines only. It is optional on ANSI Export
machines.
The Platform Load Sensing System consists of the following components:
• Four load cells
• Load Sensing System (LSS) Module
The LSS uses load cells to measure the weight in the platform. When the capacity is
exceeded or when there is a fault in the system, the platform overload indicator will
flash, the platform alarm will sound, and all platform controls (except auxiliary
power/emergency descent) will be disabled.
LSS Module
Load Cells
Figure 4-22 Platform Load Sensing System
96
Module 4
LSS Module
The LSS module distributes power to the four load cells under the platform. The LSS
module reads inputs from the load cells and provides the outputs required to lock out
machine functions if the platform is overloaded. The LSS module is located on the
backside of the platform, under the platform control box, as previously shown in Error!
Reference source not found.Figure 4-22.
Refer to the appropriate Service and Maintenance Manual for pin inputs and outputs.
J1 Gray
12 Pin
J5, J6, J7, J8

6 Pin
J2 Black
12 Pin
Figure 4-23 LSS Module
97
Boom
Load Cells
The LSS uses four load cells mounted between the platform and the platform support.
These load cells are positioned to support the load of the platform so they can measure
the weight in the platform and send inputs and outputs back to the LSS module. If the
load cells sense that the platform is overloaded, all machine functions (except auxiliary
power/emergency decent) will be disabled.
CE Machines: Ground personnel will be able to retrieve occupants in the platform using
the ground control’s Machine Safety System Override (MSSO) button.
ANSI Export Machines: Ground personnel will be able to retrieve occupants in the
platform using the ground controls but there is not a Machine Safety System Override
(MSSO) button.
Refer to the JLG Load Sensing Supplement Manual for detailed troubleshooting,
calibrating, and general information on the LSS system.
Figure 4-24 Load Cells
98
Module 4
LSS Electrical Circuit
Machine Configuration: 450AJ with the platform overloaded.
• Power is sent from the platform module to the LSS module on plug J2 pin 32
• Platform and LSS modules communicate using CANbus
• Power is sent to the platform overload indicator lamp and the alarm
• Power is sent from the ground control module to the MSSO button
Platform Overload
LSS Module
Indicator Lamp
+ Signal
Left
- Excite Front
+ Excite
CAN High - Signal
Load
Cell
Platform Module + Signal

CAN Low
Right
- Excite
CAN High + Excite
Front
CAN Low - Signal Load
Cell
Platform Overload 12V + Signal

LSS Module 12V LSS Module 12V Left
MSSO Ground - Excite Rear
+ Excite Load
MSSO Ground - Signal
Alarm 12V Cell
Alarm Ground
+ Signal
Right
- Excite Rear
CAN Low + Excite
- Signal
Load
CAN High Cell
Alarm
MSSO
Button
MSSO Button 12V
MSSO Ground
Ground Module
Figure 4- 25 LSS Electrical Circuit
99
Boom
600S/660SJ BOOM SENSORS

The 600S/660SJ boom lifts use a system of boom sensors to track boom and platform
position. These sensors communicate together to keep the boom and platform in safe
operating conditions. This model uses a boom angle sensor, boom length sensors, and
platform angle sensors. The 600S has an additional set of boom capacity sensors.
600S/66SJ Transport Position Sensing System

The transport position sensing system consists of the boom angle sensors mounted on
the pivot end of the lift cylinder and two telescope retracted proximity sensors near the
pivot end of the base boom. The system uses these sensors to allow the oscillating
axle to float and allow hi speed drive, also control the end of stroke speed.
This system is used to control the following systems:
• Above elevation (above horizontal)
• Drive/Steer – Boom Function Interlock System (CE only)
• Oscillating axle system
• Lift cylinder end of stroke damping stop
The transport position sensing system uses the following components:
• Boom angle sensor
• Telescope retracted sensors
100
Module 4
600S/66SJ Boom Angle Sensors
Boom Angle Sensors
Figure 4-26 600S/660SJ Boom Angle Sensors
101
Boom
The boom angle sensor measures boom position to control drive speed, oscillating axle,
and end of stroke speed The redundant sensor reading is used as a safety redundancy
in case one sensor fails. The boom angle sensor is mounted on the pivot end of the lift
cylinder as shown previously in Figure 4-26.
In transport:
• When the boom angle sensor reads the main boom is less than 3° below
affected
Out of transport:
• When the boom angle sensor reads the main boom is more than 5° above
axle locks
• When the boom angle sensor reads the main boom is 5° from the max angle, the
lift up function is slowed to cushion the end of stroke of the lift cylinder
Figure 4-27 Boom Angle Sensor
102
Module 4
600S/66SJ Boom Angle Sensor Circuit
The boom angle sensor circuit uses a redundant reading to ensure the sensor is
• Voltage is 4.5 volts when the boom is in the stowed position
• As the boom is raised, the voltage will decrease from 4.5 volts to 0.7 volts at full
boom angle
• As the boom is lowered from full boom angle, the voltage will increase to 4.5
volts at stowed position
• Voltage is .7 volts when the boom is in the stowed position
• As the boom is raised, the voltage will increase from .7 volts to 4.5 volts at full
boom angle
• As the boom is lowered from full boom angle, the voltage will decrease from 4.5
volts to 0.7 volts at stowed position
Figure 4-28 Boom Angle Sensor Circuit
103
Boom
600S/66SJ Telescope Retracted Sensors
Telescope Retracted
Proximity Sensors
Figure 4-29 600S/660SJ Telescope Retracted Sensors
104
Module 4
The telescope retracted sensors measure boom length to control drive speed and the
oscillating axle based on that measurement. The two proximity sensor system is used
as a safety redundancy in case one sensor fails. The sensors are mounted on the right
side of the base boom, near the pivot end, as shown previously in Figure 4-29. Figure
4-30 shows the two boom length sensors.
In transport and analyzer shows both switches closed:
• When the two length switches read less than 22 in (30.5 cm) of extension of the
fly boom, drive speed and oscillating axle are not affected
Out of transport and analyzer shows both switches open:
• When the two length switches read more than 22 in (30.5 cm) of extension of the
fly boom, drive speed is cut back and the oscillating axle locks
Proximity
Sensors
Figure 4-30 Telescope Retracted Sensors
105
Boom
600S/66SJ Telescope Retracted Sensor Circuit
In transport:
With the main boom completely telescoped in, both proximity switches will be closed.
This will allow hi speed drive and the oscillating axle to operate.
Ground Module: Plug J1 Pin 34 will have 12 volts

Out of transport:
With the main boom telescoped out approximately 22 inches (30.5 cm), both proximity
switches will be open. This will reduce the drive speed and lock the oscillating axle.

Ground Module: Plug J7 Pin 21 will have 8.6 volts
Figure 4-31 Telescope Retracted Sensors Circuit
106
Module 4
600S/66SJ Dual Capacity Sensors

The dual capacity selection and indicator system consists of a capacity mode toggle
switch on the platform control console, a set of fly boom proximity sensors, and a main
boom angle sensor. The system prevents the platform from entering the unrestricted
zone if the restricted mode is selected.
600S Unrestricted capacity 600 lb (272 kg)

600SJ Unrestricted capacity 550 lb (249 kg)
• The machine control system will allow the platform to go anywhere inside the
entire working envelope. The unrestricted capacity envelope is shown below in
both yellow and green.
600S Restricted capacity 1000 lb (454 kg)

600SJ Restricted capacity 750 lb (340 kg)
• The machine control system will not allow the platform to go beyond the
restricted boundaries. The machine only allows the retraction of the fly boom or
lifting up of the main boom since these movements place the platform further
away from the unrestricted zone. The restricted capacity envelope is shown
below in green.
600S
107
Boom
600S/66SJ Dual Capacity Length Proximity Sensor
Dual Capacity Length

Proximity Sensors
Figure 4-32 Capacity Length Sensors
108
Module 4
600S/660SJ Dual Capacity Sensor Circuit
Unrestricted capacity of 600S is 600 lb (272 kg) and of 660SJ is 550 lb (250 kg)
With the main boom completely telescoped in, both proximity switches will be closed.

Restricted capacity of 600S is1000 lb (454 kg) and of 660SJ is 750 lb (340 kg)
With the main boom telescoped out beyond the factory dimension, both proximity
switches will be open.

Figure 4-33 Dual Capacity Sensor Circuit
109
Boom
600S/66SJ Main Boom Angle Sensor

The main boom angle sensor measures boom position to control capacity boundaries.
This sensor works with the capacity length sensors.
Dual capacity:
• If main boom angle sensor reads more than 60° above horizontal with respect to
the turntable, the capacity will be unrestricted
• If the angle is below 60˚, the capacity will be restricted if the capacity length
sensors are open (boom is extended more than the factory spec)
Figure 4-34 Main Boom Angle Sensor
110
Module 4
600S/66SJ Main Boom Angle Sensor Circuit
The main boom angle sensor circuit uses a redundant reading to ensure the sensor is
• As the boom is raised, the voltage decreases to approximately 2.0 volts at 51˚
Figure 4-35 Main Boom Angle Sensor Circuit
111
Boom
600S/66SJ Chassis Tilt Sensor

The tilt sensor on the 600S/660SJ Boom Lifts is now a stand-alone part. The tilt sensor
uses a CANbus signal to communicate the tilt value. The tilt sensor is located on the left
side of the turntable beside the hydraulic reservoir.
ground.
• When the machine is in transport position, it can drive up to maximum speed until
it tilts more than 8.0°. Then the system will limit the drive speed to minimum by
forcing the drive motors to maximum displacement or slow drive speed.
• When the machine is in the out of transport position and the turntable tilts more
than the pre-set value, the boom functions can only operate in creep speed and
the drive function is disabled.
• The operator has to return the machine to the in transport mode in order to
continue to drive the machine.
Figure 4-36 600S/660SJ Chassis Tilt Sensor
112
Module 4
113
Boom
600S/66SJ Platform Angle Sensors
Platform Angle
Sensors
Figure 4-38 600S/660SJ Platform Angle Sensors
114
Module 4
600S/66SJ Platform Angle Sensor Circuit
The platform angle sensor circuit uses a redundant reading to ensure the sensor is
operating properly and the machine stays within safe operating conditions. The
platform angle sensor will detect changes in the boom angle and adjust the platform
level accordingly.
With the platform lowered to the ground position, activate the lift up function and the
Platform Module: Plug J1 Pin 25
Platform Module: Plug J1 Pin 26
115
Boom
Figure 4-39 600S/660SJ Platform Angle Sensor
116
Module 4
600S/66SJ Broken Cable Proximity Sensor
The boom cable sensor is a normally open switch located at the rear of the machine at
the end of the boom. It senses if the boom cable is out of adjustment or broken. If the
cable becomes out of adjustment or breaks, this switch will close and illuminate an LED
at the platform and ground controls. All boom functions are still operable.
Figure 4-40 Boom Cable Sensor
117
Boom
600S/66SJ Broken Cable Proximity Sensor Circuit
Figure 4-41 Boom Cable Sensor (Open)
118
Module 4
Figure 4-42 Boom Cable Sensor (Closed)
119
Boom
600S/66SJ Platform Load Sensing System (LSS)
600S/66SJ Load Sensing Gauge
The 600S/660SJ LSS system uses one shear load cell to measure the weight in the
platform. It is mounted in such a way to sense the load applied in the platform. As the
load increases, the electrical resistance increases and a signal is sent through CAN bus
to the platform module. If the platform is overloaded, all machine functions (except
auxiliary power/emergency decent) will be disabled. This system does not use a
separate LSS module.
CE Machines: Ground personnel will be able to retrieve occupants in the platform using
the ground control’s Machine Safety System Override (MSSO) button.
ANSI Export Machines: Ground personnel will be able to retrieve occupants in the
platform using the ground controls but there is not a Machine Safety System Override
(MSSO) button.
Refer to the JLG Load Sensing Supplement Manual for detailed troubleshooting,
calibrating, and general information on the LSS system.
Figure 4-43 Platform Load Cell
120
Module 4
Figure 4-44 Platform Load Cell
Figure 4-45 LSS Schematic
121
Boom
DRIVE ORIENTATION SYSTEM (DOS)

The drive orientation system (DOS) is intended to indicate to the operator conditions
that could make the direction of movement of the chassis different than the direction of
movement of the drive/steer controller. The system indicates to the operator the need to
match the black and white directional arrows on the platform control console to the
arrows on the chassis. The system uses switches or sensors, an indicator light, and an
override switch on the platform control console.
When the boom is between the rear tires, no indicators are lit and no DOS interlocks are
made.
When the boom is swung past a rear tire, the DOS indicator will flash and the
drive/steer function will be disabled. The operator must engage the DOS override switch
to enable drive/steer.
When the DOS is enabled:
• The DOS indicator will be on continuously
• A 3-second enable timer will be started and will continue for 3 seconds after the
end of the last drive/steer command
• If the timer expires, the DOS override switch must be re-engaged to enable
drive/steer
Drive Orientation Drive Orientation Indicator Drive Orientation Override Switch

Arrow on Platform Indicator on Platform Contol Console
Figure 4-46 Drive Orientation System
122
Module 4
400S/600S/660SJ Drive Orientation Sensor
The drive orientation system on the 400S/600S/660SJ boom lifts uses a proximity
sensor to read when the boom is centered between the rear tires or swung past either
rear tire.
The proximity sensor closes when the turntable is swung +/- 42° off center. This occurs
roughly when the boom is swung past a rear tire.
The drive orientation sensor is located under the turntable, mounted to the top of the
swivel.
Figure 4-47 Drive Orientation Sensor
123
Boom
400S/600S/660SJ Drive Orientation Electrical Circuit

Drive Orientation
Override Switch Footswitch
Platform Module
Drive Orientation
Proximity Switch
Ground Module
Figure 4-48 Drive Orientation Electrical Circuit
124
Module 4
Drive Orientation Description
• Voltage (12 vdc) is supplied from the ground control module at plug J7 pin 32 to
the drive orientation switch
• The boom is positioned past the rear tires, which closes the switch
• As the switch is closed, voltage will travel back to the ground control module at
J7 pin 35
• This voltage input will force the operator to activate the drive orientation switch at
the platform to allow the drive function
125
Boom
450AJ/520AJ Drive Orientation Switches
The drive orientation system on the 450AJ/520AJ Boom Lifts use a redundant limit
switch system to read when the boom is between the rear tires or swung past either
rear tire. The switches will always read opposite of each other, one open and one
closed, due to how they are mounted to the machine. One switch rides along an
elevated cam while the other rides inside a groove. Note: Only on the 450/520, these
switches control the oscillating axle in addition to the DOS system.
The limit switches energize when the turntable is swung +/- 41° off center. This occurs
roughly when the boom is swung past a rear tire.
The drive orientation switches are mounted under the turntable, beside the turntable
gear.
Figure 4-49 450AJ/520AJ Drive Orientation Switches
126
Module 4
450AJ/520AJ Drive Orientation Electrical Circuit
• Power is sent from the platform module to the DOS override switch on Plug J1
Pin 18
• Power is sent from the platform module to the footswitch on Plug J7 Pin 4
• Power is sent from the ground control module to the drive orientation switches
Toggle Switch Footswitch
Platform Module
CAN High
CAN Low
Switch Power 12V
Footswitch 12V
CAN Low
CAN High
Footswitch Engaged
Transport Switch 12V

Osc Switch 1, 12V
Osc Switch 2 Drive
Orientation
Switches
Ground Module
Figure 4-50 450AJ/520AJ Drive Orientation Electrical Circuit
127
Boom
128
Module 5
MODULE 5: DRIVE TRAIN

INTRODUCTION
This module describes the drive train components and drive circuits on the
OBJECTIVES
• Identify the components of the drive train
• Trace electrical and hydraulic circuits within the drive train and their respective
schematics
129
Drive Train
DRIVE TRAIN COMPONENTS
Engine
The boom lift’s engine is the power source for the machine. The engine turns the
hydraulic pumps, the alternator, and the optional AC generator.
JLG offers three engine options for the 400S/460SJ/450AJ/520AJ/600S/660SJ boom

lifts:
• Deutz Tier 4 Final D 2.9 L4
• Deutz Tier 4 Interim D 2.3 L3
• Ford 2.5L DF MSG425
130
Module 5
Deutz Tier 4 Final D 2.9 L4
Engine Specifications
Make and Model Deutz T4F D 2.9 L4

Number of Cylinders 4
Displacement 177 cu in
Engine Horsepower 49 hp
Maximum Engine RPM 2300 rpm
Engine Oil Capacity 8 quart (7.5 L)
Engine Components
Diesel Charge
Coolant ECM Oxidation Pressure Fuel
Tank Alternator Plug Catalyst Filter Filter
Fan Oil Generator Fuel Filter Drive and

Filter (optional) Function
Pumps
Figure 5-1 Deutz Tier 4 Final Engine
131
Drive Train
Deutz Tier 4 Interim D 2.3 L3
Make and Model Deutz T4I D 2.3 L3

Displacement 142 cu in
Engine Horsepower 48.9 hp
Engine Oil Capacity 6 quart (5.6 L)
Engine Components
Charge
Pressure
Muffler Filter
Auxiliary Drive
Fan Alternator Starter Function
Power Pump Pump
Pump
Figure 5-2 Deutz Tier 4 Interim Engine
132
Module 5
Ford
Make and Model Ford MSG425-DF

Displacement 2.5 L
Engine Horsepower 84 hp @ 3200 rpm
Engine Oil Capacity 7 quarts (6.6 L)
Engine Components
Figure 5-3 Ford Engine
133
Drive Train
Drive System Hydraulics

Idling with no function activated-As the engine is started, the charge pump, located
inside the drive pump, suctions hydraulic oil from the hydraulic tank through the “S” or
“suction” port. The charge pump keeps the drive hydraulic system fully charged with
hydraulic fluid, forming a closed loop.
Drive
Directional
Valves
Drive Pump
Swash
Plate
E
Motor
Charge
Pump
S D
Hydraulic Oil Cooler

Reservoir (option)
Charge
Filter
Axle
Control
Valve
Figure 5-4 Drive Pump Hydraulic Block Diagram
134
Module 5
Driving forward activated-As the drive function is activated, the drive directional valve is
energized, directing charge pump pressure to the swash plate of the drive pump. When
the swash plate is forced from the neutral position, the drive pump will produce flow to
the drive motors. The drive motors will use the flow for rotation and the flow will return to
the drive pump. The brakes are released with hydraulic pressure and the 2speed at
each drive motor is either pressurized or not.
Drive
Directional
Valves
Drive Pump
Drive Swash
Motor Plate
E
Motor
Charge
Pump
S D
Hydraulic Oil Cooler

Reservoir (option)
Brake
Charge
Filter
Axle
2 Control
Speed Valve
Figure 5-5 Drive Forward Hydraulic Block Diagram
135
Drive Train
Practice: Drive Train
Using Figure 5-5, what type of pressure do the drive directional valves use to move the
swash plate?
______________________________________________________________________
Using Figure 5-5, list the components that receive hydraulic flow from the charge pump.
1_____________________________________
2_____________________________________
3_____________________________________
4_____________________________________
5_____________________________________
Using Figure 5-5, identify the component that receives hydraulic flow from the swash
plate of the drive pump?
______________________________________________________________________
136
Module 5
Drive Pump Components and Ports

Port A Drive Direction (Outlet or Input)
Port B Drive Direction (Outlet or Input)
Port D Charge Pressure Outlet
Port E Charge Pressure Inlet
Port S Suction From Tank
Port L1 Case Drain
Port L2 Case Drain
Figure 5-6 Drive Pump Components and Ports
137
Drive Train
Drive Pump
The drive pump is a variable displacement piston pump. The pump is equipped with two
proportional solenoid valves, one for moving the machine forward and one for moving
machine in reverse. The drive pump is attached to the unit’s engine.
Manufacturer Danfoss
Displacement 28cc (1.71 cu in)
Maximum Pressure 6525 psi (450 bar)
High Pressure Relief 4060 psi (280 bar)
Maximum Speed 3750 rpm
Minimum Input Speed 500 rpm
Charge Pump Displacement 11cc (0.67 cu in)
Charge Pressure 348 psi (24 bar)
Figure 5-7 Drive Pump
138
Module 5
Hydraulic Swivel
The hydraulic swivel allows hydraulic oil to flow from the hydraulic tank and pumps to
the steer, drive, two speed, oscillating axle, and brake functions on units that have 360˚
continuous turntable rotation (swing). On dual fuel units, the middle of the swivel also
provides a passage for LP gas.
• 400S/460SJ/600S/660SJ: 360° Continuous Swing
Swivel
Port 1 Brake
Port 2 Two Speed
Port 3 Steer Right
Port 4 Steer Left
Port 5 Drive Reverse
Port 6 Drive Forward
Port 7 Oscillating Axle
Port 8 Drain
Figure 5-8 Swivel
139
Drive Train
Traction Valve
The traction valve is used as a hydraulic oil divider. The traction valve has three
internal flow dividers that guarantee an even distribution of flow and pressure to the four
drive motors. The traction valve also has a loop flush valve that dumps excess oil from
the traction valve to help cool the system. The traction valve is typically located under
the machine, near the swivel.
Figure 5-9 600S/660SJ Traction Valve
140
Module 5
Traction Valve Components and Ports
Port 1 Drive Forward

Port 2 Drive Reverse
Port 3 Left Front Drive Motor Reverse
Port 4 Left Rear Drive Motor Reverse
Port 5 Right Front Drive Motor Forward
Port 6 Right Rear Drive Motor Forward
Port 7 Left Front Drive Motor Forward
Port 8 Right Rear Drive Motor Reverse
Port 9 Right Front Drive Motor Reverse
Port 10 Left Rear Drive Motor Forward
Port 11 Oscillating Axle Return
Port 12 Drain
Port M11 Test Port
Figure 5-10 600S/660SJ Traction Valve Ports
141
Drive Train
Drive Motors
Each machine has four drive motors located at each end of the front and rear axles. The
drive motors are spring biased to maximum displacement and hydraulically shfted to
minumum. In maximum they create torque and in minimum they create speed. Drive
motors are hydraulically shifted with pressure from the 2 speed valve.
Bias spring Servo piston

Swashplate
Minimum
angle
stop
Output
Cylinder shaft
Block
Shaft
seal
End
cap Valve Piston Slipper Bearing
Plate
Figure 5-11 Drive Motors

.
142
Module 5
Axle Valve
The axle valve is located at the turntable, on the right or the left side, depending on
model. The 450/520 axle valve is part of the travIt houses hydraulic spools and
electrical solenoids that control 2 speed, brakes, and oscillating axle.
Figure 5-12 Axle Valve
143
Drive Train
Oscillating Oscillating
Axle Axle Release
8.8Ω 8.8Ω
Two
Speed
8.8Ω
Brake
Release
8.8Ω
144
Module 5
Axle Valve Two Speed and Brakes
Axle Valve Description (Hydraulic)
• The engine is running and charge pressure is sent to the axle valve at PII port
• When the drive joystick is activated, the 2 speed and brake valve are energized,
directing flow to the brake assemblies and 2 speed
• The brakes will release and the drive motors will be forced to minimum
displacement, which results in high drive speed and low torque
• If the speed select switch is positioned in torque, the 2 speed solenoid will be
deenergized, removing charge pressure from the drive motor, creating torque
and low speed
• If the machine is in a tilt condition when driving, the 2 speed solenoid will be
deenergized, removing charge pressure from the drive motor, creating torque
and low speed
145
Drive Train
Figure 5-15 Drive Pump Hydraulic Schematic (Idling)
146
Module 5
Figure 5-16 Drive Forward Hydraulic Schematic (Drive Pump)
147
Drive Train
Drive Forward Description (Hydraulic)-
Figure 5-16
• Engine is running creating flow (orange) from the charge pump out of the drive
pump at D port through the charge pump filter and return into the drive pump at E
port
• Flow will split to the charge pressure relief (350 PSI) and to the drive directional
control valves
• C1 is energized, allowing flow (orange) across the drive spool and onto the servo
piston
• As the servo piston moves from the pressure applied, the swashplate also moves
within the drive pump
• Changing the angle of the swashplate will create flow (purple) out of the drive
pump at the A port
148
Module 5
Figure 5-17 Drive Forward Hydraulic Schematic (Swivel)
149
Drive Train
Drive Forward Description (Hydraulic)-
Figure 5-17
• From the drive pump, flow (purple) will travel to the swivel at port #6 and onto the
traction valve at port 1
• Hydraulic flow will travel to flow divider 1 and split to ports 3, 4, 5, and 6
• From these ports at the traction valve, flow will travel to each drive motor
• The drive motors will rotate and create flow (brown) back to the traction valve at
ports 7, 8, 9, and 10
• Flow will then combine at flow divider 2 and 3 and leave the traction valve at port
2
• From port 2, flow (brown) will continue to port #5 of the swivel and return to the
drive pump at port B
150
Module 5
Drive System (Electrical)
As the drive joystick is activated, a voltage signal is sent into the platform module. The
platform module changes the voltage signal to a CAN signal and transmits this to the
ground module. The ground module energizes the brake, 2 speed, and drive forward
solenoids.
Figure 5-18 Drive Forward Electrical Block Diagram
151
Drive Train
Drive Joystick
Figure 5-19 Drive Forward Electrical Block Diagram
Drive Joystick Description
• Voltage (7 vdc) is supplied from the platform control module at plug J6 pin 1 to
the drive joystick and the steer switch
• A center tap signal is sent from the joystick to the platform module at J6 pin 2 (if
system is operating properly, this will be 3.5 vdc)
• As the joystick is moved, a variable voltage signal will travel into the platform
module at J6 pin 3
• The variable voltage signal will range from 3.5 vdc to 0.5 vdc (reverse) and 3.5
vdc to 6.5 vdc (forward)
152
Module 5
Figure 5-20 Drive Forward Electrical Schematic
153
Drive Train
Drive Forward Description (Electrical)
• As the joystick is moved, a voltage input (purple) is sent to J6 pin 3 (3.5-7vdc)

• The platform module will transmit a digital CAN signal (blue) out at J7 pins 31
and 30
• This signal enters the ground module at J7 pins 13 and 24
• The ground module will energize the brake solenoid from J1 pin 23 (red)
• The ground module will energize the 2 speed solenoid from J1 pin 23 (red)
• The ground module will energize the drive forward solenoid from J1 pin 3 (red)
154
Module 5
Drive Solenoids
Drive Solenoid Description
• Drive solenoids receive a variable voltage supply from the ground module
• Once energized, the drive spool will open, allowing charge pressure to be
directed to the swashplate of the drive pump
• The swashplate movement will create flow and direction of hydraulic oil from the
drive pump
Figure 5-21 Drive Solenoids
155
Drive Train
Oscillating Axle
The oscillating front axle is attached to the frame by a pivot pin, which allows all four
wheels to remain on the ground when traveling over rough terrain. The oscillating axle
also incorporates two lockout cylinders connected between the frame and the axle.
• The oscillating axle locks if the boom is raised 5° above horizontal
• The oscillating axle locks if the boom is telescoped out more than 22.4 in (51.8
cm)
• For 450AJ/520AJ, the oscillating axle locks if the boom is positioned past the rear
tires(+/- 41° off center)
Figure 5-22 Oscillating Axle
156
Module 5
Oscillating Axle Hydraulic Circuit (Locked)
Machine configuration: 400/600 modle with the main boom above horizontal or boom
extended more than 22 in (30.5 cm) or 450AJ/520AJ model with boom positioned
beyond the rear tires or main boom above horizontal
• When the drive pump is activated, flow from the traction valve will enter the V
ports of the lock out cylinders
• This 325 psi will force the rams to stay in contact with the axle when drive is
activated
• Oil is pumped from the charge pump located inside the drive pump to the PII port
of the axle control valve
• Oil flows to the osc axle 1 valve
• No hydraulic flow will travel to the holding valves at the ram cylinders, which
allows them to stay closed
• Oil is forced to stay inside the ram cylinders, locking the axle
Figure 5-23 Oscillating Axle Hydraulic Circuit (Locked)
157
Drive Train
400/600 Oscillating Axle Electrical Circuit (Locked)
Figure 5-24 Oscillating Axle Electrical Circuit (Locked)
158
Module 5
400/600 Oscillating Axle Electrical Circuit (Locked)
Machine configuration: Main boom above horizontal or boom extended more than 22 in
(30.5 cm)
• Power is supplied from the ground control module to the main boom angle
sensor and the right and left tele proximity switches
• The boom angle sensor applies a variable voltage proportional to boom position
to plug J7, pins 4 and 7, which reads the main boom is raised 5° above horizontal
• The tele proximity sensors apply a voltage at plug J7 pin 21 and plug J1 pin 34,
which reads the boom is telescoped out more than 22 inches (30.5 cm)
• No power is sent to the oscillating axle valves, causing them to stay closed and
locking the axle
159
Drive Train
450AJ/520AJ Oscillating Axle Electrical Circuit (Locked)
Machine configuration: Main boom above horizontal or the boom swung past the rear
wheels
• Power is supplied from the ground control module to the main boom angle
sensor and the two oscillating axle limit switches
• The boom angle sensor applies a variable voltage proportional to boom position
to plug J7, pins 4 and 7, which reads the main boom is above horizontal
• The oscillating axle switches send an opposite reading, one open/one closed, to
lug J7, ins 12 and 20, to read the boom is swung past the rear wheels
• No power is sent to the oscillating axle valves, causing them to stay closed and
locking the axle
Ground Module
DOS/Oscillating
Transport Switch 12 V Axle Switch 1
Osc Axle Switch 1
Osc Axle Switch 2, 12 V
Ground
4.5 – 0.5 V
5 V Power
0.5 – 4.5
DOS/Oscillating
Axle Switch 2
Main Boom
Angle Sensor
Oscillating Oscillating
Axle Valve 1 Axle Valve 2
Osc Axle 1
Osc Axle 2
Ground
Figure 5- 25 450AJ/520AJ Oscillating Axle Electrical Circuit (Locked)
160
Module 5
Oscillating Axle Hydraulic Circuit (Unlocked)
Machine configuration: 400/600 model with main boom below horizontal or boom
extended less than 22 in (30.5 cm) or 450AJ/520AJ model with boom positioned within
the rear tires or main boom below horizontal
• Oil is pumped from the charge pump located inside the drive pump
• Oil flows in the axle valve on port P11
• The osc axle 1 and osc axle 2 valves move, allowing flow out of port 27 to the P
ports of the lock out cylinders
• Pressure is sensed on the counter balance valves near the ram cylinders,
opening them
• Oil will now flow back and forth between the ram cylinders, allowing the axles to
float
Figure 5-26 Oscillating Axle Hydraulic Circuit (Unlocked)
161
Drive Train
400/600 Oscillating Axle Electrical Circuit (Unlocked)
Figure 5-27 Oscillating Axle Electrical Circuit (Unlocked)
162
Module 5
400/600 Oscillating Axle Electrical Circuit (Unlocked)
Machine configuration: Main boom below horizontal or boom extended less than 22 in
(30.5 cm)
• Power is supplied from the ground control module to the boom angle sensor and
the telescope proximity sensors
• The boom angle sensor applies a variable voltage (proportional to boom position)
to plug J7, pins 4 and 7, which reads the boom is below horizontal
• The tele proximity sensor removes the voltage at plug J7 pin 21 and plug J1 pin
34, which reads the boom is not telescoped out more than 22 inches (30.5 cm)
• Power is sent to the oscillating axle valves, causing them to open and allowing
the axle to oscillate
163
Functions
164
Module 6
MODULE 6: FUNCTIONS
INTRODUCTION
This module describes the boom components and function circuits.
OBJECTIVES
• Identify components of the function systems
• Analyze electrical and hydraulic circuits of the boom functions and their
respective schematics
165
Functions
400S/460SJ Boom Function Hydraulic Component Block Diagram
Platform
Level
Cylinder
Master Telescope Platform Lift Cylinder Jib Cylinder Swing

Cylinder Cylinder Rotator (460SJ Only) Motor
Main Control
Valve
Function Auxiliary
Pump OR Pump
Hydraulic
Tank
Figure 6-1 400S/460SJ Boom Function Hydraulic Component Block Diagram
166
Module 6
450AJ/520AJ Boom Function Hydraulic Component Block Diagram
Platform Jib Cylinder Platform

Level Rotator
Cylinder
Master Telescope Fly Boom

Cylinder Cylinder Valve
Upright Main Lift Tower Lift Swing

Valve Cylinder Cylinder Motor
Main Control
Valve
Function Auxiliary
Pump OR Pump
Hydraulic
Tank
Figure 6-2 450AJ/520AJ Boom Function Hydraulic Component Block Diagram
167
Functions
FUNCTION PUMP
The 400S/460SJ/450AJ/520AJ/600S/660SJ boom lifts use the same style function
pump. The function pump is a single section, gear pump. The function pump supplies
flow for all boom and steer functions. Flow enters the main control valve through the P1
port.
Figure 6-3 Function Pump
Main Control Valve

Main Dump Valve
P1 T1
Function Filter
Pump
Hydraulic
Tank
Figure 6-4 Function Pump Block Diagram
168
Module 6
AUXILIARY POWER PUMP

The auxiliary power pump functions to provide sufficient oil flow to operate the basic
machine functions should the main pump or engine fail. The auxiliary power pump
operates on 12 volts supplied from the battery through the auxiliary power relay. The
auxiliary power pump is located near the battery.
400S/460SJ Auxilary Power Pump 450AJ/520AJ Auxiliary Power Pump

Location Location
To Port P2 on
Main Control Valve
169
Functions
400S/460SJ BOOM VALVE LOCATIONS

All boom functions on the 400S/460SJ boom lifts are directed through the main control
valve.
Main
Control
Valve
Figure 6-6 400S/460SJ Boom Valves
170
Module 6
450AJ/520AJ BOOM VALVE LOCATIONS

All boom functions on the 450AJ/520AJ boom lifts are directed through the main control
valve. Unlike the 400S/460SJ, the 450AJ/520AJ boom lifts have two extra valves: the
upright valve and the fly boom valve. These valves direct oil to certain boom functions.
Upright
Valve
Fly Boom
Valve
Main
Control
Valve
Figure 6-7 450AJ/520AJ Boom Valves
171
Functions
MAIN CONTROL VALVE IDENTIFICATION

Telescope
400S Illustration 7.1Ω
Platform
Rotate
Platform 8.8Ω Lift Up
Level 7.1Ω
Swing
8.8Ω 8.8Ω
Steer
Flow
6.2Ω
Control
7.1Ω
Main
Dump
7.1Ω
Steer Right Steer Left

Relief Relief
2500 PSI 2500 PSI
Swing
Relief
1700 PSI
Load
Sense
230 PSI Main Relief
3000 PSI
Top Platform Level Up
Platform Level
Bottom Platform Level Down
Top Telescope Out
Telescope
Bottom Telescope In
Top Platform Rotate Right
Platform Rotate
Bottom Platform Rotate Left
Lift Up
Top Swing Right
Swing
Bottom Swing Left
Top Steer Right
Steer
Bottom Steer Left
Main Dump
Flow Control
Figure 6-8 400S Main Control Valve Identification
172
Module 6
400S Manifold Schematic
Platform Platform
Level Telescope Rotate Lift Up Swing
Main Load Main

Flow Relief
Dump Sense
Control
Port MP1 Test Port

Port P1 Pressure from Function Pump
Port P2 Pressure from Auxiliary Pump
Port T1 Tank
Port 15 Swing Left
Port 16 Swing Right
Port 17 Main Lift Up
Port 18 Main Lift Down
Port 23 Steer Left
Port 24 Steer Right
Port 31 Platform Rotate Left
Port 32 Platform Rotate Right
Port 35 Telescope Out
Port 36 Telescope In
Port 37 Platform Level Up
Port 38 Platform Level Down
Figure 6-9 400S Main Control Valve Identification
173
Functions
460SJ Illustration Jib Lift

Telescope
7.1Ω Jib Down
8.8Ω Relief
1200 PSI
Platform Platform
Level Lift Up
Rotate 7.1Ω
8.8Ω 8.8Ω
Swing
8.8Ω
Steer
6.2Ω
Flow Main
Control Dump
7.1Ω 7.1Ω
Steer Right
Relief
2500 PSI
Steer Left
Swing Relief
Relief 2500 PSI
1700 PSI
Load
Sense
230 PSI Main Relief
3000 PSI
Platform Level
Top Telescope Out
Telescope
Bottom Telescope In
Top Jib Lift Up
Jib
Bottom Jib Lift Down
Platform Rotate
Lift Up
Top Swing Right
Swing
Bottom Swing Left
Top Steer Right
Steer
Bottom Steer Left
Main Dump
Flow Control
Figure 6-10 460SJ Main Control Valve Identification
174
Module 6
460SJ Manifold Schematic
Telescope Jib Platform

Platform
Level Rotate Lift Up Swing
Flow Main Load Main

Control Dump Sense Relief
Port MP1 Test Port

Port T1 Tank
Port 15 Swing Left
Port 16 Swing Right
Port 18 Main Lift Down
Port 23 Steer Left
Port 24 Steer Right
Port 33 Jib Lift Up
Port 34 Jib Lift Down
Port M34 Test Port
Figure 6-11 460SJ Main Control Valve Identification
175
Functions
450AJ/520AJ Illustration
Main Lift Up Tower Lift Up
8.8Ω 7.1Ω
Swing
Flow 8.8Ω
Steer
Control 6.2Ω
7.1Ω
Main Dump
7.1Ω
Steer Right
Relief Steer Left
2750 PSI Relief
Swing 2750 PSI
Relief
1850 PSI
Load
Sense
230 PSI
Main Relief
3000 PSI
Flow Control
Main Lift Up
Tower Lift Up
Swing Top Swing Left
Bottom Swing Right
Steer Top Steer Left
Bottom Steer Right
Main Dump
Figure 6-12 450AJ/520AJ Main Control Valve Identification
176
Module 6
450AJ/520AJ Manifold Schematic
Flow Main Lift Tower Lift

Control Up Up Swing
Main Load Main

Dump Sense Relief
Port MP1 Test Port
Port P3 Pressure to Upright Valve
Port T1 Tank
Port T3 Tank from Upright Valve
Port 15 Swing Left
Port 16 Swing Right
Port 17 Tower Lift Up
Port 23 Steer Left
Port 24 Steer Right
Figure 6-12 450AJ/520AJ Main Control Valve Identification
177
Functions
450AJ/520AJ UPRIGHT VALVE
Coils and Ports

450AJ/520AJ Only
Telescope
8Ω
Level
Override
12.2Ω
Level Telescope
Override
Top Telescope Out

Telescope
Bottom Telescope In
Level Override
Port P4 Pressure
Port P5 Pressure to Fly Boom Valve
Port T4 Tank
Port T5 Tank from Fly Boom Valve
Figure 6-13 Upright Valve Coils and Ports
178
Module 6
450AJ/520AJ FLY BOOM VALVE
Coils and Ports

450AJ/520AJ Only
Platform
Rotate
12.2Ω
Jib Lift
12.2Ω
Port M34
Platform
Jib Lift Rotate

Platform Rotate
Top Jib Lift Up
Jib Lift
Bottom Jib Lift Down
Port P6 Pressure
Port T6 Tank
Port 33 Jib Lift Up
Port 34 Jib Lift Down
Port M34 Test Port
Figure 6-14 Fly Boom Valve Coils and Ports
179
Functions
400S/450AJ ACTUATORS
400S/450AJ Main Lift Cylinder

The main lift cylinder is used to raise and lower the main boom. The main lift cylinder is
attached to the main boom and the turntable on the 400S/460SJ boom lifts. The main lift
cylinder is attached to the main boom and the upper upright on the 450AJ/520AJ boom
lifts.
Figure 6-15 Main Lift Cylinders
180
Module 6
400S Main Lift Up Hydraulic Circuit

Machine Configuration: 400S, lift up activated
• Oil flows from the function pump into the main control valve on port P1
• The main dump valve closes, allowing oil to flow through the main control valve
• The lift up valve in the main control valve shifts allowing flow out of port 17 and
into port V1 (the barrel end of the main lift cylinder), lifting the main boom up
• Oil is returned to tank through the V2 port on the main lift cylinder to port 18 on
the main control valve and out port T1 on the main control valve and back to tank
Main Lift
Cylinder
Main
Control
Valve
Lift Up
Valve
Main Dump
Valve
Pressure from Return

Function Pump to Tank
Figure 6-16 Main Lift Up Hydraulic Circuit
181
Functions
400S Main Lift Up Electrical Circuit

Machine Configuration: 400S, lift up activated from platform controls
• Power is sent from the platform module to the lift/swing controller on plug J5 pin
1
• Power is sent from the platform module to the footswitch on plug J7 pin 4,
enabling all functions from the platform controls
• Plug J5 pin 3 will read a variable voltage between 3.5 to 7 since lift up was
activated
• The platform and ground modules communicate using CANbus to sound alarms,
light indicators, monitor safety systems, and open or close valves
• Power is sent from the ground control module to the main dump and main lift up
•
Lift/Swing
Platform Module Controller Footswitch
CAN High
CAN Low
7 V Power
Ground
0 – 7V
3.5V
Footswitch 12V
Main Lift Up Main Dump

CAN Low Valve Valve
CAN High
Main Lift Up 12V

Main Dump Ground
Main Dump 12V
Main Lift Up Ground
Footswitch Engaged
Ground Module
Figure 6-17 Main Lift Up Electrical Circuit
182
Module 6
450AJ/520AJ Tower Lift Cylinder

The tower lift cylinder on a 450AJ/520AJ is used to raise and lower the tower boom. The
tower lift cylinder uses a regeneration system to use oil from both ends of the cylinder,
resulting in faster function speed. The tower lift cylinder is located inside the lower
upright.
Figure 6-18 Tower Lift Cylinder
183
Functions
450AJ Tower Lift Down Hydraulic Circuit

Machine Configuration: 450AJ, tower lift down activated
• The valves in the tower lift cylinder open and allow oil to flow from the barrel end
of the cylinder to the rod end of the cylinder and also return back to tank
simultaneously
• Oil is returned to tank through the V2 port on the tower lift cylinder to port T3 on
the main control valve and out port T1 on the main control valve
Tower Lift
Cylinder
Main
Control
Valve

Figure 6-19 Tower Lift Down Hydraulic Circuit
184
Module 6
450AJ Tower Lift Down Electrical Circuit

Machine Configuration: 450AJ, tower lift down activated from platform controls
• Power is sent from the platform module to the tower lift toggle switch on plug J1
pin 18
• Power is sent from the platform module to the footswitch on plug J7 pin 4, which
enables all functions from the platform controls
• The platform and ground modules communicate using CANbus to sound alarms,
light indicators, monitor safety systems, and open or close valves
• Power is sent from the ground control module to the tower lift down valve
Tower Lift
Platform Module Toggle Switch Footswitch
CAN High
CAN Low
Tower Lift Down

Switch Power 12V
Tower Lift Up
Footswitch 12V
Tower Lift
CAN Low Down Valve
CAN High
Tower Lift Down 12V
Tower Lift Down Ground
Footswitch Engaged
Ground Module
Figure 6-20 Tower Lift Down Electrical Circuit
185
Functions
400S/450AJ Master and Platform Level Cylinders

The master and platform level cylinders work together to keep the platform at a set
angle during lift operations. The master cylinder is located at the lower end of the main
boom. The platform level cylinder is located at the upper end of the fly boom.
The master cylinder is attached to the machine and the main boom. It can only move
when the main boom is moved.
The platform level cylinder moves together with the master cylinder, but the platform
level cylinder can be manually used to move the position of the platform. Once a
position is selected, the machine will hold that angle of the platform. The machine does
not auto level. It only holds the position previously set.
Platform Level
Platform Level
Cylinder
Cylinder
Master
Cylinder
Master
Cylinder
Figure 6-21 Master and Platform Level Cylinders
186
Module 6
Master and Platform Level Cylinders Hydraulic Circuit

• As the main boom is lifted up the rod is forced out of the master cylinder. Oil is
pushed from the rod end of the master cylinder and into the rod end of the
platform level cylinder
• Pilot pressure from the V2 port opens the holding valve at the V1 port
• Oil is pushed from the barrel end of the platform level cylinder and refills the
barrel end of the master cylinder
• Excess oil can flow back to tank
Master Platform
Cylinder Level
Cylinder
Pressure from Excess oil

Function back to Tank
Pump
Figure 6-22 Master and Platform Level Cylinders Hydraulic Circuit
187
Functions
400S Platform Level Down Override Hydraulic Circuit

Machine Configuration: 400S, platform level down activated
• The main dump valve closes and the flow control valve opens, allowing oil to flow
through the main control valve
• The platform level override valve shifts, allowing oil to flow into the rod end of the
platform level cylinder
• No oil flows to or from the master cylinder since it is attached to the main boom
and is not moving
• Oil flows through the V1 port on the platform level cylinder to port 37 on the main
control valve, and out port T1 on the main control valve and back to tank
Master Platform
Cylinder Level
Cylinder
Main
Control
Valve
Platform Level
Override
Valve
Flow Control
Valve Main Dump
Valve

Figure 6-23 Platform Level Down Override Hydraulic Circuit
188
Module 6
400S Platform Level Down Override Electrical Circuit

Machine Configuration: 400S, platform level down activated from platform controls
• Power is sent from the platform module to the platform level toggle switch on
plug J1 pin 18
• Platform and ground modules communicate using CANbus to sound alarms, light
indicators, monitor safety systems, and open or close valves
• Power is sent from the ground control module to the main dump, flow control,
and platform level down valves
Platform Level
Platform Module Toggle Switch Footswitch
CAN High
CAN Low
Platform Level Down

Switch Power 12 V
Platform Level Up
Footswitch12V
Platform Level Main Dump Flow Control

CAN Low Down Valve Valve Valve
CAN High
Platform Level Ground
Platform Level Down 12V
Main Dump Ground
Main Dump 12V
Flow Control 12V
Ground Module
Flow Control Ground
Footswitch Engaged
Figure 6-24 Platform Level Down Override Electrical Circuit
189
Functions
400S/450AJ Telescope Cylinder

The telescope cylinder on the 400S/460SJ/450AJ/520AJ is used to extend and retract
the main boom. This cylinder is located inside the main boom assembly.
Figure 6-25 Telescope Cylinders
190
Module 6
400S Telescope In Hydraulic Circuit

Machine Configuration: 400S, telescope in activated
• The telescope valve shifts, allowing oil to flow from port 36 on the main control
valve into port V2 (the rod end of the telescope cylinder), causing the telescope
cylinder to retract
• Oil flows through the V1 port on the telescope cylinder, to port 35 on the main
control valve, and out port T1 on the main control valve and back to tank
Telescope
Cylinder
Main
Control
Valve
Telescope
Valve
Flow Control
Valve Main Dump
Valve

Figure 6-26 Telescope In Hydraulic Circuit
191
Functions
400S Telescope In Electrical Circuit

Machine Configuration: 400S, telescope in activated from platform controls
• Power is sent from the platform module to the telescope toggle switch on plug J1
pin 18
• Power is sent from the ground control module to the main dump, flow control,
and telescope in valves
Figure 6-27 Telescope In Electrical Circuit
192
Module 6
400S/450AJ Jib Cylinder

The jib cylinder is used to raise and lower the jib/platform. The jib cylinder is located
between the main boom and the platform.
Figure 6-228 Jib Cylinders
193
Functions
450AJ Jib Lift Down Hydraulic Circuit

Machine Configuration: 450AJ, jib lift down activated
• Oil flows to the upright valve from port P3
• Oil flows from the upright valve port P5 to the fly boom valve on port P6
• The jib valve shifts allowing oil to flow out of the fly boom valve port 34 and into
the jib cylinder on port V2
• Oil is returned from port V1 on the jib cylinder back through the fly boom and
upright valves on ports T6 and T5.
• Oil flows out of the upright valve on port T4, to port T3 on the main control valve,
and back to tank from port T1 on the main control valve
Jib
Cylinder
Upright Fly Boom

Valve Valve
Jib
Valve
Main
Control
Valve
Flow Control
Valve
Main Dump
Valve

Figure 6-29 Jib Lift Down Hydraulic Circuit
194
Module 6
400S Jib Lift Down Electrical Circuit

Machine Configuration: 400S, telescope in activated from platform controls
• Power is sent from the platform module to the jib toggle switch on plug J1 pin 18
• Power is sent from the platform module to the footswitch on plug J7 pin 4, to
enable all functions from the platform controls
• Power is sent from the platform module to the jib down valve on plug J7 pin 26
• Power is sent from the ground control module to the main dump and flow control
valves
Figure 6-30 Jib Lift Down Electrical Circuit
195
Functions
400S/45AJ Platform Rotator

The platform rotator is used to rotate the platform left or right. The platform rotator is
located behind the platform, attached to either the main boom or the jib (depending on
the model of the machine).
Figure 6-31 Platform Rotators
196
Module 6
400S Platform Rotate Right Hydraulic Circuit

Machine Configuration: 400S, platform rotate right activated
• The platform rotate valve shifts, allowing oil out of port 32
• Oil flows into the platform rotator, allowing it to turn
• Oil is returned from the platform rotator back into Port 31 on the main control
valve and back to tank from port T1
Rotator
Main
Control
Valve
Platform
Rotate Valve
Flow Control
Valve Main Dump
Valve

Figure 6-32 Platform Rotate Right Hydraulic Circuit
197
Functions
400S Platform Rotate Right Electrical Circuit

Machine Configuration: 400S, platform rotate right activated from platform controls
• Power is sent from the platform module to the platform rotate toggle switch on
plug J1 pin 18
• Platform and ground control module communicate using CANbus to sound

alarms, light indicators, monitor safety systemss and open or close valves
• Power is sent from the ground control module to the main dump, flow control, and
platform rotate right valves
Figure 6-33 Platform Rotate Right Electrical Circuit
198
Module 6
400S/450AJ Swing Motor

The swing motor is used to rotate (swing) the entire turntable. The swing motor on the
400S/460SJ boom lifts is located under the right side (hydraulic side) hood. The swing
motor for the 450AJ/520AJ boom lifts is located directly under the turntable.
Figure 6-34 Swing Motors
199
Functions
400S/460SJ Swing Motor Ports
Brake
Control
Port
Backlash
Adjustment
Gearbox
Drain Port
Port A Counter Clockwise Rotation Output

Port B Clockwise Rotation Output
Figure 6-36 400S/460SJ Swing Motor Ports
450AJ/520AJ Swing Motor Ports
Port A Clockwise Rotation Output

Port B Counter Clockwise Rotation Output
Figure 6-35 450AJ/520AJ Swing Motor Ports
200
Module 6
400S Swing Left Hydraulic Circuit

Machine Configuration: 400S, swing left activated
• Oil flows to the swing valve and the swing valve shifts, allowing flow out of port
15 on the main control valve
• Oil flows into the swing motor and the internal brake, releasing it and allowing it
to turn
• Oil is returned from the rotator back into the main control valve on port 16 and
back to tank from port T1 on the main control valve
Swing Motor
Main
Control
Valve
Swing
Valve
Main Dump
Valve

Figure 6-36 400S/460SJ Swing Left Hydraulic Circuit
201
Functions
400S Swing Left Electrical Circuit

Machine Configuration: 400S, swing left activated from platform controls
• Power is sent from the platform module to the lift/swing controller on Plug J5 Pin
1
• Power is sent from the platform module to the footswitch on Plug J7 Pin 4, to
• Plug J5 Pin 4 will read a variable voltage between 0 to 3.5 since swing left was
activated
• Power is sent from the ground control module to the main dump and swing left
valves
Lift/Swing
Platform Module Controller Footswitch
CAN High
CAN Low
3.5V
Power 7V
0 – 7V
Ground
Footswitch 12V
Swing Left Main Dump

Valve Valve
CAN Low
CAN High
Swing Left 12V
Main Dump Ground
Main Dump 12V
Ground Module
Swing Valves Ground
Footswitch Engaged
Figure 6-37 400S/460SJ Swing Left Electrical Circuit
202
Module 6
450AJ Swing Left Hydraulic Circuit

Machine Configuration: 450AJ, swing left activated
• Oil flows to the swing valve and the swing valve shifts, allowing flow out of port
15 on the main control valve
• Oil flows into the swing motor, allowing it to turn
• Oil is returned from the rotator back into the main control valve on port 16 and
back to tank from port T1 on the main control valve
Swing Motor
Main
Control
Valve
Swing
Valve
Main Dump
Valve

Figure 6-38 450AJ/520AJ Swing Left Hydraulic Circuit
203
Functions
450AJ Swing Left Electrical Circuit
Machine Configuration: 450AJ, swing left activated from platform controls
• Power is sent from the platform module to the lift/swing controller on plug J5 pin
1
• Power is sent from the platform module to the footswitch on plug J7 pin 4, to
• plug J5 pin 4 will read a variable voltage between 0 to 3.5 since swing left was
activated
• Power is sent from the ground control module to the main dump and swing left
valves
Figure 6-39 450AJ/520AJ Swing Left Electrical Circuit
204
Module 6
600S FUNCTION SYSTEM
Figure 6-42 600S
205
Functions
Function Pump When Cranking the Engine for Start-The start switch is activated from
ground or platform. The gear pump is creating flow as soon as the engine begins to
spin. The Bypass Dump Valve is energized directing flow back to the hydraulic tank.
This reduces the force on the starter and engine at start up. Once the engine starts, the
bypass dump valve deenergizes and blocks flow to tank.
Figure 6-43 Function Pump Block Diagram (Start)
206
Module 6
Function Pump Cranking Engine (Hydraulic)
Figure 6-44 Engine Start Hydraulic Schematic
207
Functions
Function Pump Cranking Engine (Electrical)
Figure 6-45 Engine Start Electrical Schematic
208
Module 6
Function Pump with No Function Activated (Idle)-The engine is idling with no function
activated from ground or platform. The gear pump is creating flow as soon as the
engine begins to spin. The Main Dump, LS Cartridge, and the High/Low pressure dump
are directing flow back to the hydraulic tank.
Figure 6-46 Function Pump Block Diagram (Idle)
209
Functions
Function Pump Idle (Hydraulic)
Figure 6-47 Function Pump (Idle)
210
Module 6
Function Pump Standby Circuit (Idle)
The function pump standby circuit is used to:
• Warm up the hydraulic system
• Provide a flow loop to flush debris
• Provide flow for immediate function response
Standby oil flow path allows:
• Oil to flow into the main control valve from the function pump on port P1
• Oil to flow through the LS cartridge inside the main control valve and back to tank
• Oil to flow to the platform valve across the high/low pressure dump and return to
tank
211
Functions
Function Pump with Enable (Footswitch) Activated -The footswitch or enable switch is
activated. The main dump energizes blocking flow to tank. The LS Cartridge and the
High/Low pressure dump are directing flow back to the hydraulic tank.
Figure 6-48 Function Pump Block Diagram (Enable)
212
Module 6
Function Pump Footswitch Activated (Hydraulic)
Figure 6-49 Function Pump with Footswitch/Enable Activated
213
Functions
Function Pump Enable Circuit
The function pump enable circuit is used to:
• Provide flow for immediate function response
• Provide oil to all boom functions and steering
When the operator presses the enable switch at the ground control panel or presses the
footswitch in the platform, the following occurs:
• The main dump valve closes
• If a boom or steering function is activated, the function pump sees the required
flow and pressure needed to activate that function through the LS cartridge and
automatically creates the flow and pressure needed to maintain that function or
functions
214
Module 6
Function Pump Enable Circuit (Electrical)
Figure 6-50 Function Pump with Footswitch/Enable Activated
215
Functions
600S Function Pump

The 600S/660SJ boom lifts use the same function pump. The function pump is a single
section, gear pump. The function pump supplies flow for all boom and steer functions.
Flow enters the main control valve through the P1 port.
Figure 6-51 Function Pump
216
Module 6
600S Auxiliary Power Pump

The auxiliary power pump functions to provide sufficient oil flow to operate the basic
machine functions should the main pump or engine fail. The auxiliary power pump
operates on 12 volts supplied from the battery through the auxiliary power relay. The
auxiliary power pump is located near the battery.
217
Functions
600S Main Valve

The main valve controls all boom functions and houses various valves and solenoids.
Its central purpose is to control boom lift, telescope, steer, and swing, but it also will
direct flow to the platform valve. This valve is located on the left side of the turntable.
Figure 6-53 Main Valve
218
Module 6
600S Main Valve (Valve Locations)
Figure 6-54 Main Valve
219
Functions
600S Main Valve (Schematic)
Figure 6-55 Main Valve Schematic
220
Module 6
600S Platform Valve

The platform valve controls all platform functions including jib and houses various
valves and solenoids. Its purpose is to control platform rotate, platform level, and jib. .
This valve is located at the end of the fly boom next to the platform rotator.
221
Functions
600S Platform Valve (Schematic)
Figure 6-57 Platform Control Valve Schematic
222
Module 6
600S Main Lift Up Function (Hydraulic)
Lift
Cylinder
Main Control Valve

Priority Flow Main
Lift
Control
Up
Main
Dump
P1 P2
Function
Pump
To
Platform
Valve
Hydraulic
Tank
Figure 6-58 Main Lift Up
Lift Up Function-The function pump creates flow to the main control valve and to the
priority flow control. The main dump valve blocks flow to the tank. When the main lift
up valve is energized, flow will travel to the lift cylinder. As the piston extends, the fluid
will travel out of the rod side and back to the tank.
223
Functions
600S Main Dump
Main
Dump
Figure 6-59 Main Dump
Main dump- The main dump valve is electrically energized which blocks fluid from
returning to tank. This allows fluid to be used for functions. When the main dump is
deenergized, it will allow flow to the tank.
224
Module 6
600S Priority Flow Control
Priority Flow
Control
Figure 6-60 Priority Flow Control
Priority Flow Control-The priority flow control is a hydraulically shifted proportional flow
valve that directs flow to the boom and platform functions. Depending on the need of
boom and platform functions, it will split the flow to allow multiple functions.
225
Functions
600S Main Lift Up Valve
Main Lift Up
Figure 6-61 Main Lift Up Valve
Main Lift Up Valve-The main lift up valve is electrically energized and controls flow to
the lift cylinder for the lift up function. As the valve is moved, a pilot pressure will force
the spool open, allowing flow to the lift up circuit.
226
Module 6
600S Lift Cylinder-The lift cylinder is located at the main boom and is used to lift and
lower the main boom. The cylinder has a valve block with various valves inside.
Figure 6-62 Lift Cylinder
227
Functions
600S Main Lift Up Hydraulic Schematic
228
Module 6
600S Main Lift Up (Hydraulic)
• Engine is running, creating flow (red) from the function pump to the P1 port of the
main manifold
• As the joystick or toggle switch is activated, main dump is energized, blocking LS
flow to tank
• Priority flow control is shifted from pilot pressure, allowing flow (red) from port 3
to 2
• Flow travels to the main lift up spool
• The main lift spool is energized, allowing flow across the spool and out of the
main manifold at port 7
• In addition, flow will travel across 2 shuttle valves and close the LS cartridge
• The main dump is energized, blocking the LS signal from traveling to tank
• Flow will travel into the lift cylinder block at port V1, across the check valve, and
into the lift cylinder
• The lift cylinder will begin to move and force the fluid (blue) on the rod side of the
cylinder out of the block at port V2
• From V2, fluid (blue) will travel through the return filter and into the hydraulic
reservoir
229
Functions
600S Main Lift Function (Electrical)
Lift
Joystick
Platform Module
OR Main
Dump
Solenoid
Ground
Lift Ground Module
Toggle
Main Lift
Up
Solenoid
From Platform-Joystick is moved, sending a signal into the platform module. The
platform module sends a CAN bus signal to the ground module. The ground module
then energizes the main dump valve and the main lift up valve.
From Ground-The lift toggle switch is moved, sending a signal into the ground module.
The ground module then energizes the main dump valve and the main lift up valve.
230
Module 6
600S Main Lift Up (Electrical)
Figure 6-65 Main Lift Up Electrical Circuit
231
Functions
600S Main Lift Up (Electrical)
Power (red) is sent from the platform module to the lift/swing controller on plug J5 pin 1
• Plug J5 pin 3 will read a variable voltage (purple) between 3.5 to 7 since lift up
was activated
Note: Lift down; voltage will be approximately 3.5 to 0.5 volts
• A digital signal (blue) is sent off the platform module at J7 pins 31 and 30 onto
the ground module at J7 pins 13 and 24
• The ground module will energize the main dump from J2 pin 13 (red)
• The ground module will energize the main lift up solenoid from J2 pin 11 (red)
232
Module 6
600S Main Lift Down Function (Hydraulic)
Figure 6-66 Main Lift Down
Lift Down Function (Normal Operation)-This is a gravity down function. The lift down
function is activated which will energize the main lift down solenoid. As the main lift
down down spool is opened, the fluid in the rod end of the cylinder will travel across the
lift ls down cartridge, through the main lift down spool, and return to tank.
Lift Down Function (Auxiliary Operation)-This is a gravity down function. The lift down
function is activated with the auxiliary system which will energize the main aux down
solenoid. As the main aux down spool is opened, the fluid in the rod end of the cylinder
will escape and return to tank.
233
Functions
Main Lift Down
Main Aux Down
Figure 6-67 Lift Cylinder (Valve Block)
234
Module 6
600S Main Lift Down Hydraulic Schematic
Figure 6-68 Main Lift Down
600S Main Lift Down (Hydraulic)
• As the joystick or toggle switch is activated, main lift down solenoid is energized
allowing fluid to leave the piston side of the cylinder
• Fluid (blue) travels across the lift down ls spool and across the main lift down
spool
• A small amount of fluid will be pulled into the rod end of the cylinder, while most
of the fluid will exit the lift cylinder block at V2 and return to the hydraulic
reservoir
235
Functions
600S Main Aux Lift Up Hydraulic Schematic
Figure 6-69 Main Aux Lift Down
600S Main Aux Lift Down (Hydraulic)
• As the auxiliary lift down is activated with the joystick or toggle switch, main aux
down solenoid is energized allowing fluid to leave the piston side of the cylinder
• Fluid (blue) travels across the main aux down spool
• A small amount of fluid will be pulled into the rod end of the cylinder, while most
of the fluid will exit the lift cylinder block at V2 and return to the hydraulic
reservoir
236
Module 6
600S Main Lift Down (Electrical)
Figure 6-70 Main Lift Down Electrical Circuit
237
Functions
600S Main Lift Down (Electrical)
Power (red) is sent from the platform module to the lift/swing controller on plug J5 pin 1
• Plug J5 pin 3 will read a variable voltage (purple) between 3.5 to 0 since lift down
was activated
• A digital signal (blue) is sent off the platform module at J7 pins 31 and 30 onto
the ground module at J7 pins 13 and 24
• The ground module will energize the main lift down valve from J2 pin 22 (red)
Note: Main aux lift down, J2 pin 21 of the ground module will send a
voltage signal to the main aux down valve
238
Module 6
600S Platform Level (Hydraulic)

The platform will automatically move when the boom is activated up or down. The
platform angle can be manually changed with a toggle switch at the ground and the
platform. The platform level cylinder is located at the end of the boom, near the
platform. The boom angle sensors are located at the end of the boom, near the
platform level cylinder.
Main Control Valve Platform Valve
Priority P2 P1
Flow Filter High/Low
Control Dump
P1
Relief Relief
3000 psi 2200 psi
T1
Level Valve
Function
Pump
Hydraulic
Level Cylinder
Tank
Figure 6-66 Platform Level Hydraulic Block Diagram
239
Functions
600S Platform Valve
240
Module 6
241
Functions
600S Platform Valve (Schematic)
Figure 6-69 Platform Control Valve Identification
242
Module 6
600S Platform Level Cylinder
Figure 6-70 Platform Level Cylinder
243
Functions
600S Platform Level (Hydraulic)
Figure 6-71 Platform Level (Hydraulic)
244
Module 6
600S Platform Level Up Hydraulic Circuit
• Oil flows from the function pump into the main control valve and continues to the
platform valve
• The high/low dump is energized, allowing flow to continue to the high dump
• If the pressure does not exceed 3000 psi, the high dump will remain closed
• If the pressure exceeds 3000 psi, the high dump will open to tank
• The platform level valve is energized, allowing flow off the valve at port 2
• From port 2, oil will flow into the piston side of the slave cylinder at port V1,
causing the cylinder to move
• Also, pressure will build at the rod side counterbalance valve, allowing it to open
• Fluid on the rod side of the cylinder will flow out of the cylinder block at port V2
• Fluid will flow into the platform valve at port 2, across the energized platform level
valve, and return to tank
Figure 6-72 High/low pressure dump circuit
High/Low Dump Logic
• When a platform function is activated, the high/low pressure dump will direct
flow to the high dump which is 3000psi
• When lift down is activated, the high/low pressure dump will direct flow to the
high dump which is 3000 psi
• When lift up is activated, the high/low pressure dump will direct flow to the low
dump which is 2200 psi
245
Functions
Practice: Platform Level Down Hydraulic
246
Module 6
Practice: Platform Level Down Hydraulic– Using the previous page schematic for
platform level down, highlight the level up circuit. In addition, using the numbers below,
note the components the hydraulic flow travels through to activate the function.
1._________________________________________________
2._________________________________________________
3._________________________________________________
4._________________________________________________
5._________________________________________________
6._________________________________________________
7._________________________________________________
8._________________________________________________
9._________________________________________________
10.________________________________________________
247
Functions
600S Platform Level (Electrical)

If platform level is activated from the ground, the input will travel into the ground module.
CAN bus signal will travel to the platform module and outputs from the platform module
will energize the high/low dump and level solenoids.
If platform level is activated from the platform, the input will travel into the platform
module. The platform module will energize the high/low dump and level solenoids.
High/Low
Dump
Platform Solenoid
Platform Module
Level Toggle
Level
Solenoid
OR
Ground
Level Toggle Ground Module
Figure 6-73 Platform Level
248
Module 6
600S Platform Level (Electrical)
Figure 6-74 Platform Level Up (Manual)
249
Functions
600S Platform Level Up (Manual)
Manual Electrical Circuit (Activated with the platform level switch at the platform)
• Power (red) is sent from the start switch to the center pole of the platform level
switch
• As the level up switch is activated, power (red) travels off the switch and into the
platform module at J1 pin 9
• The platform module will then send a voltage output (red) at J7 pin 15, across the
X652 connector and energizing the platform level up solenoid at the platform
valve
• The platform module also sends a CAN bus signal (blue) out at J7 pins 31 and
30 to the CAN buss in the platform box
• From the buss, the CAN signal will travel through the boom cable at pins 2 and 3
to the MS131 Buss Bar and onto the ground module at J7 pins 13 and 24
• The ground module sends a voltage output (red) at J2 pin 3, across the X701
connector, through the boom cable at pin 13, into the platform box at connector
X103, out of the platform box at connector X652, energizing the high press dump
solenoid at the platform valve
250
Module 6
Practice: Platform Level Down Electrical
251
Functions
Practice: Platform Level Down Electrical– Using the platform level down practice
schematic, highlight the level down circuit. In addition, using the numbers below, note
the components that are energized and the components that analog or digital signal
travels through.
1._________________________________________________
2._________________________________________________
3._________________________________________________
4._________________________________________________
5._________________________________________________
6._________________________________________________
7._________________________________________________
8._________________________________________________
9._________________________________________________
10.________________________________________________
252
Module 6
Platform Level Up Auto (Electrical)
Figure 6-75 Platform Level Up (Auto)
253
Functions
600S Platform Level Up (Auto)
Automatic Electrical Circuit (Activated by the angle sensors when boom or jib is
functioned)
• A 5 vdc supply (red) is sent off the platform module at J7 pin 11, across
connector X652 at pin 10, and into the angle sensors at pins F and B
• As the angle of the platform changes, through boom or jib functions, a variable
voltage (purple) signal is sent out from the platform angle sensors at pins D and
C
• This voltage (purple) travels across the X652 connector and onto the platform
module at J1 pins 25 and 26
• The platform module will then send a voltage output at J7 pin 15, across the
X652 connector and energizing the platform level up solenoid at the platform
valve
• The ground module sends a voltage output (red)at J2 pin 3, across the X701
X103, and out of the platform box at connector X652, energizing the high press
dump solenoid at the platform valve
254
Module 6
600S Telescope Out (Hydraulic)
Function Hydraulic
Pump Tank
P1 T1
Priority Tele
Flow Compensator
Control
Tele
Dump
Tele Valve
Main
Dump
Shuttle
Main Valve
Relief
5 6
Main Control Valve
Tele Cylinder
255
Functions
600S Main Valve
256
Module 6
600S Telescope Cylinder
The telescope cylinder on the 600S/660SJ is used to extend and retract the main boom.
This cylinder is located inside the main boom assembly.
Figure 6-78 Telescope Cylinder
257
Functions
600S Telescope Out (Hydraulic)
Figure 6-79 Telescope Out Hydraulic Circuit
258
Module 6
600S Telescope Out Hydraulic Circuit
• The main dump valve closes and blocks the LS signal from dumping to tank
• The priority flow control directs fluid to port #2 and to each function spool,
including the telescope compensator
• From the telescope compensator, fluid is directed to the telescope solenoid

which is energized
• This directs flow out of the main manifold at port #5 and into the telescope block
at port V1
• Fluid will travel across the check valve at the piston end counterbalance valve of
the telescope cylinder
• Pressure will begin to build and a pilot will be sent to the rod end counterbalance
valve and force it open
• A pilot pressure will also be sent to the regeneration valve, forcing the poppet to
close the V2 port
• The fluid on the rod end will flow out of the cylinder, across the open rod end
counterbalance and, through the regeneration valve, to combine with the flow
into the piston end of the cylinder
Note: The purpose of the regeneration valve is to increase telescope out speed
by increasing flow to the piston end of the telescope cylinder.
259
Functions
Practice: Telescope In Hydraulic Schematic
260
Module 6
Practice: Telescope In Hydraulic (Description) – Using the telescope in practice

schematic, highlight the tele in circuit. In addition, using the numbers below, note the
components that the hydraulic flow will travel through and the solenoids that are
energized.
1._________________________________________________
2._________________________________________________
3._________________________________________________
4._________________________________________________
5._________________________________________________
6._________________________________________________
7._________________________________________________
8._________________________________________________
9._________________________________________________
10.________________________________________________
261
Functions
600S Telescope (Electrical)

If telescope is activated from the ground, the input will travel into the ground module and
the ground module will energize the tele solenoid and main dump solenoid.
If telescope is activated from the platform, the input will travel into the platform module.
CAN bus signal will travel to the ground module and output from the ground module.
The ground module will energize the telescope and main dump valves.
Tele Toggle Platform Module
OR
Tele
Ground Tele Solenoid
Toggle
Ground Module
Main
Dump
Solenoid
Figure 6-80 Telescope
262
Module 6
Telescope Out (Electrical)
Figure 6-81 Telescope Out Electrical Circuit
263
Functions
600S Telescope Out Electrical Circuit
• In platform mode, power (red) is sent to the telescope toggle switch from the dual
capacity switch
• As the tele switch is moved to the out position, power (red) travels across the
switch and into the platform module at J1 pin 6
• The CAN bus signal (blue) travels off the platform module at J7 pins 31 and 31,
through the boom cable, and into the ground control box at X102A pins 2 and 3
• CAN bus signal travels from the X102A connector into the ground module at J7
pins 13 and 24
• The ground module will send power (red) out at J2 pin 13 to energize the main
dump solenoid
• The ground module will send power (red) out at J2 pin 20 to energize the tele out
solenoid
264
Module 6
Practice: Telescope In
The following is a scenario that may arise with the telescope function. Using the tele
out circuit, create a step by step process to solve the following issue. Record your
process below.
Telescope function does not operate from the ground or platform and all other
functions work normally.
1._________________________________________________
2._________________________________________________
3._________________________________________________
4._________________________________________________
5._________________________________________________
6._________________________________________________
7._________________________________________________
8._________________________________________________
9._________________________________________________
10.________________________________________________
265
Functions
600S Platform Rotate (Hydraulic)
Figure 6-82 Platform Rotate Circuit
266
Module 6
600S Platform Rotator
The platform rotator is used to rotate the platform left or right. The platform rotator is
located behind the platform attached to either the fly boom or the jib (depending on the
model of the machine).
Figure 6-83 Platform Rotator
267
Functions
600S Platform Rotate Right (Hydraulic)
Figure 6-84 Platform Rotate
268
Module 6
600S Platform Rotate Right Hydraulic Circuit
• Oil flows from the main control valve into the P1 port of the platform manifold
• The high/low pressure dump is energized, allowing pressure to be applied at the

high dump relief (3000 psi)
• The platform rotate valve is energized, allowing fluid to travel across the spool
and off the platform manifold at port #4
• Oil flows into the platform rotator at port V2, forcing the rotator to spin
• A pilot pressure will force the left counterbalance valve open, allowing fluid to
leave the rotator
• Oil flows off the platform rotator at port V1 and into the platform manifold at port
#3
• From port #3, fluid travels across the platform rotate valve and out of the platform
manifold at port T1
• Fluid travels from port T1 back to the hydraulic reservoir
Note: If the pressure reaches 3000 psi, the high dump relief will open, allowing
fluid to return to tank.
269
Functions
600S Platform Rotate (Electrical)

If platform rotate is activated from the ground, the input will travel into the ground
module. CAN bus signal will travel to the platform module. Outputs from the platform
module will energize the high/low dump and rotate valves.
If platform rotate is activated from the platform, the input will travel into the platform
module. The platform module will energize the high/low dump and rotate valves.
High/Low
Dump
Platform Solenoid
Platform Module
Level Toggle
Rotate
Solenoid
OR
Ground
Level Toggle Ground Module
Figure 6-85 Platform Rotate
270
Module 6
600S Platform Rotate Right (Electrical)
Figure 6-86 Platform Rotate Right Electrical Circuit
271
Functions
600S Platform Rotate Right Electrical Circuit
• Power (red) is sent from the level switch to the platform rotate toggle switch at
pin 2 of the SW03 connector
• As the rotate switch is moved to the right position, power (red) is sent from the
switch at pin 1 onto the platform module at connector J1 pin 7
• Power (red) is sent off the platform module at J7 pin 6, across the X652
connector, and into the platform rotate right solenoid at the platform valve bank
• The ground module sends a voltage output (red) at J2 pin 3, across the X701
X103, and out of the platform box at connector X652 energizing the high press
dump solenoid at the platform valve
272
Module 6
600S Swing Right (Hydraulic)
Swing
Brake
Swing
Motor
Main Control Valve

Pressure Swing
Compensator Solenoid
Main
Dump
P1 P2
Function
Pump
To
Platform
Valve
Hydraulic
Tank
Figure 6-87 Swing Right Hydraulic Schematic
273
Functions
600S Swing Right Hydraulic Schematic
Figure 6-88 Swing Right Hydraulic Schematic
274
Module 6
600S Swing Right Hydraulic Circuit
• Oil flows from the function pump into the main control valve on Port P1
• When the function is activated, the main dump valve closes, blocking LS fluid
from dumping to tank
• Fluid passes across the priority flow control and to the swing compensator
• Oil flows on to the swing solenoid, which was energized when the function was
activated
• The swing solenoid directs fluid off the main manifold at port #3 and also shifts
the LS shuttle valve
• LS signal is directed to the LS cartridge which closes blocking flow to tank
• From port #3, fluid travels in the swing motor assembly at port A
• Fluid travels to the shuttle valve, shifting and directing flow to the swing brake
which releases
• Fluid also travels across to the right counterbalance valve and this opens at 1000
PSI
• Also, oil will travel across the check valve at the left counterbalance valve and
out of the swing block and into the swing motor
• The swing motor will begin to rotate and fluid will flow from the swing motor and
into the swing block
• The right counterbalance is open allowing fluid to travel across and out of the
swing motor assembly at port B
• From port B, fluid travels into the main manifold at port 4 and back across the
energized swing solenoid and out of the main manifold at port T, returning to tank
275
Functions
Practice: Swing Left and Lift Down Hydraulic
276
Module 6
Practice Swing Left and Lift Down Hydraulic– Using the swing left and lift down practice
schematic on the previous page, highlight the swing left and lift down circuits. In
addition, using the numbers below, note the components that the hydraulic flow will
travel through and the solenoids that are energized.
1._________________________________________________
2._________________________________________________
3._________________________________________________
4._________________________________________________
5._________________________________________________
6._________________________________________________
7._________________________________________________
8._________________________________________________
9._________________________________________________
10.________________________________________________
277
Functions
600S Swing Motor
The swing motor is used to rotate (swing) the entire turntable. The swing motor on the
600S/660SJ boom lifts is located under the left side hood.
Figure 6-89 Swing Motor
278
Module 6
600S Swing Motor Ports
Brake
Control
Port
Backlash
Adjustment
Gearbox
Drain Port
Port A Counter Clockwise Rotation Output

Port B Clockwise Rotation Output
Figure 6-90 Swing Motor Ports
279
Functions
600S/660SJ Swing Right (Electrical)
Figure 6- 91 600S/660SJ Swing Right Electrical Schematic
280
Module 6
Practice: Swing Left Electrical
Troubleshoot a swing issue—The following is a scenario that may arise with the swing
function. Using the electrical swing circuit, create a step by step process to solve the
following issue. Record your process below.
Swing function does not operate from the platform and all other functions work
normally.
1._________________________________________________
2._________________________________________________
3._________________________________________________
4._________________________________________________
5._________________________________________________
6._________________________________________________
7._________________________________________________
8._________________________________________________
9._________________________________________________
10.________________________________________________
281
WWW.JLG.COM
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233
Telephone: 717-485-5161
Toll Free in US: 877-JLG-LIFT
Fax: 717-485-6417

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Release Date:November 6, 2018

MODULE 2: POWER DISTRIBUTION.......................................................................... 21

Drive Motor ......................................................................................................................................... 32

MODULE 3: CANBUS NETWORK ............................................................................... 57

MODULE 4: BOOM ...................................................................................................... 73

MODULE 5: DRIVE TRAIN ......................................................................................... 129

MODULE 6: FUNCTIONS........................................................................................... 165

400S Platform Level Down Override Electrical Circuit ......................................................................... 189

Practice: Platform Level Down Hydraulic ......................................................................................... 246

MODULE 1: MACHINE OVERVIEW

• Describe the nomenclature for each model

• Identify the major components for each model

• List the model specifications for each model

Figure 1-1 Machine Orientation

• 0 - Indicates 100 Series

• S - Indicates straight boom

• 0 - Indicates 100 Series

• A - Indicates articulating boom

• J - Indicates machine is equipped with a jib

Drive/Steer Frame Drive Tires

Figure 1-2 400S Major Components

Platform Main Fly

Drive Tires Frame Drive/Steer

Figure 1-4 450AJ Major Components

Figure 1-6 600S Major Components

GROUND CONTROLS AND INDICATORS

660SJ Ground Controls

3. Engine Start/Auxiliary Power/Function Enable

4. Platform/Ground Select Keyswitch

7. Jib Lift (600SJ only)

10. Main Boom Lift

12. Machine Safety System Override (MSSO)

Figure 1-7a 660SJ Ground Control Console

450AJ Ground Controls

4. Platform/Ground Select Keyswitch

9. Main Boom Lift

10. Tower Boom Lift

12. Engine Start/Auxiliary Power/Function Enable

13. Machine Safety System Override (MSSO)

Figure 1-7b 450AJ Ground Control Console

2. Low Engine Oil Pressure

3. High Engine Coolant Temperature

4. Engine Oil Temperature

8. Platform Overload (if equipped)

9. Drive and Steer Disable (if equipped)

Figure 1-7c 660SJ/450AJ Ground Control Console

GROUND CONTROL CONSOLE

The Diagnostic Screen will show active and

Engine Diagnostic Screen

The Engine Diagnostic Screen will show

Figure 1- 8 Ground Control Display Screens

MACHINE SAFETY SYSTEM OVERRIDE (MSSO)

The (MSSO) is required to conform to the latest EN280:2013 requirements. It is fitted to

Figure 1- 9 Machine Safety System Override

PLATFORM CONTROLS AND INDICATORS

600SJ/400SJ Platform Controls

1. Drive Speed/Torque Select

Figure 1-10a Platform Control Console

600SJ/400SJ Indicator Panel

1. AC Generator (if equipped)

Figure 1-10b Platfrom Indicator Panel

450AJ 400S 600S