Snorkel 600S Service Maintenance Manual
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Snorkel 600S Service Maintenance Manual

Snorkel 600S Service Maintenance Manual

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SERVICE & MAINTENANCE
MANUAL
Part Number 1435378-000
January 2024

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  • Page 1 SERVICE & MAINTENANCE MANUAL Part Number 1435378-000 January 2024...
  • Page 2 The aerial platform is not electrically insulated. Death or serious injury will result from contact with, or inadequate clearance from, an energized conductor. Do not go closer than the minimum safe approach distance as defined by the Minimum Safe Approach Distance sections in Chapter 3–Safety of the machine Operator’s Manual. Regard all conductors as energized.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Section 1 General Information Component Identification ....................12 600S ......................... 12 660SJ ........................13 Chassis Component Location..................14 Chassis Ballast ......................15 600SJ ........................15 Dual Capacity ....................15 660SJ ........................16 Single Capacity ....................16 Dual Capacity ....................17 Turntable Component Location ..................
  • Page 4 Dual Capacity Sensors ..................... 78 Emergency Power Unit ....................79 Horn Installation......................80 Lower Control Box ......................81 Rear Panel Components ..................81 600S ........................82 Single Capacity ....................82 Front View ....................... 82 Bottom View ....................83 Internal Wiring ....................84 Dual Capacity T4F ....................
  • Page 5 Booms Electrical Component Location................. 108 Boom Angle Sensor ...................... 109 Foot Switch ........................110 Selector Valve Harness ....................111 Upper Control Box ......................112 600S ........................112 Dual Capacity ..................... 112 660SJ ........................113 Single Capacity ....................113 Inside View ......................114 Wire Chart ......................
  • Page 6 Intermediate and Tip Boom Assembly ................173 Jib Boom........................174 Section 8 Platform Platform Components ....................176 Rotator .......................... 177 Snorkel Guard ......................178 Section 9 Options Tow Kit .......................... 180 2KW Belt Driven Generator ..................181 Specifications ......................181 Installation ......................
  • Page 7 Engine Codes ....................... 223 Kubota Engine ......................223 Deutz Engine ......................227 Cummins Engine ....................253 Oscillating Axle Lock Cylinder Operation..............261 Swing Drive Adjustment Procedure ................262 Boom Elevation and Limit Switch Adjustment .............. 263 600S/660SJ – 1435378-000 January 2024...
  • Page 8 Internal Wiring ....................299 Turntable Electrical Installation ..................302 Deutz Stage V ......................302 Dual Capacity ..................... 302 Upper Control Box ......................304 600S ........................304 Dual Capacity ..................... 304 Top and Bottom View ..................304 Harness ......................305 Pinouts ......................309 Top and Bottom View ..................
  • Page 9 Board Pin Outs ....................... 358 GP400 ........................ 358 GP440 ........................ 362 12V TBM ......................366 VCCM ......................... 367 Lower Control Box ....................368 Upper Control Box ....................369 Section 14 Appendix Appendix A - Glossary ....................372 600S/660SJ – 1435378-000 January 2024...

  • Page 11: Section 1 General Information

    SECTION 1 General Information...

  • Page 12: Component Identification

    Serial Number Placard On Side of Chassis Fall Protection Platform Serial Number • Model Number Anchors Tie-Down/Lifting Lugs Rear of Chassis Platform Steer Wheels Foot Switch Front Rear Left Side Tie-Down/Lifting Lugs Front of Chassis January 2024 600S/660SJ – 1435378-000...

  • Page 13: 660Sj

    Fall Protection Anchors Platform Serial Number Placard On Side of Chassis Serial Number • Model Number Tie-Down/Lifting Lugs Platform Front of Chassis Steer Wheels Foot Switch Front Rear Tie-Down/Lifting Lugs Left Side Rear of Chassis 600S/660SJ – 1435378-000 January 2024...

  • Page 14: Chassis Component Location

    1....................Tires 4 Each (Directional) 2..........................Chassis 3....................... Rotation Bearing 4........................Steer Cylinders 5....................Articulating Axle Cylinders 6........................Hose Guides 7......................Front Axle Assembly 8......................Articulating Axle Pin 9.......................Traction Manifold 10............Drive Motors and Power Hubs 4 Each (Not Shown) TCB20.006 January 2024 600S/660SJ – 1435378-000...

  • Page 15: Chassis Ballast

    Section 1 General Information CHASSIS COMPONENT LOCATION Chassis Ballast 600SJ Dual Capacity TORQUE M24 FASTENERS TO 200 FT-LBS Rear of Chassis (Drive End) Note: Torque to 200 ft/lbs (271 Nm) 1................Ballast Mounting Hardware (See Note) 2........................Chassis Ballast 600S/660SJ – 1435378-000 January 2024...

  • Page 16: 660Sj

    Section 1 General Information CHASSIS COMPONENT LOCATION Chassis Ballast 660SJ Single Capacity TORQUE M24 FASTENERS TO 200 FT-LBS Note: Torque to 200 ft/lbs (271 Nm) Rear of Chassis (Drive End) 1........................Chassis Ballast 2................Ballast Mounting Hardware (See Note) January 2024 600S/660SJ – 1435378-000...

  • Page 17: Dual Capacity

    Note: Torque to 200 ft/lbs (271 Nm) TORQUE M24 HARDWARE TO 200 FT-LBS Chassis Side Plate Hidden for Clarity CHASSIS SIDE PLATE HIDDEN FOR CLARITY 1....................Chassis Steer End Ballast 2................Ballast Mounting Hardware (See Note) 3....................Chassis Drive End Ballast 600S/660SJ – 1435378-000 January 2024...

  • Page 18: Turntable Component Location

    Section 1 General Information TURNTABLE COMPONENT LOCATION Left Side 12 11 Note 2 Note 1 For Reference Only Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 19 11....................Hydraulic Oil Return Filter 12..........................Vent 13......................Boom Pin Bosses Note 1: Items 3 and 4 are not used in Cummins or Kubota engines. Note 2: Swing Drive and rotary manifold inside of turntable see page 18 for installation. 600S/660SJ – 1435378-000 January 2024...

  • Page 20: Swing Drive Installation

    3....................Swing Drive Eccentric Ring 4....................Eccentric Adjustment Ring 5........................Eccentric Lock 6......................Eccentric Hold Down 7........................Swing Drive 8................Swing Drive Bolts and Washers (Note 1) 9................Rotation Bearing Upper Bolts (Note 2) Refer to page 262 for Swing Drive Adjustment. January 2024 600S/660SJ – 1435378-000...

  • Page 21: Turntable Counterweight

    Note 1: Torque to 200 ft/lbs (271 Nm) Note 2: Torque to 580 ft/lbs (786 Nm) 1..............Jib Adder Counterweight Hardware (Note 1) 2..................Counterweight Hardware (Note 2) 3................Jib Adder Counterweight (660SJ Only) 4..........................Shims 5........................Counterweight TCB20.026 600S/660SJ – 1435378-000 January 2024...

  • Page 22: Serial Number Locations

    Section 1 General Information SERIAL NUMBER LOCATIONS 600S and 660SJ Serial Number Stamped on Turntable Inside Door Serial Number Placard On Side of Chassis Serial Number • Model Number Serial Number Stamped on Right Rear of Chassis Front Rear Left Side...

  • Page 23: Working Envelope

    1,000 lb Maximum (15.2) Platform Capacity (13.7) (12.2) (10.7) 600 lb Maximum (9.1) Platform Capacity (7.6) (6.1) (4.6) (3.0) (1.5) (1.5) (3.0) (18.3) (16.8) (15.2) (13.7) (12.2) (10.7) (9.1) (7.6) (6.1) (4.6) (3.0) (1.5) (1.5) (3.0) 600S/660SJ – 1435378-000 January 2024...

  • Page 24: 660Sj

    Section 1 General Information WORKING ENVELOPE 660SJ Single Capacity Feet (Meters) (21.3) (18.3) (15.2) (12.2) Maximum Platform (9.1) Capacity 600 lb (272 kg) (6.1) (3.0) (3.0) (15.2) (18.3) (3.0) (3.0) (6.1) (9.1) (12.2) January 2024 600S/660SJ – 1435378-000...

  • Page 25: Dual Capacity

    1,000 lb (453.5 kg) (15.2) (13.7) (12.2) Maximum (10.7) Platform Capacity (9.1) 600 lb (272 kg) (7.6) (6.1) (4.6) (3.0) (1.5) (1.5) (3.0) (19.9) (18.3) (16.8) (15.2) (13.7) (12.2) (10.7) (9.1) (7.6) (6.1) (4.6) (3.0) (1.5) (1.5) (3.0) 600S/660SJ – 1435378-000 January 2024...

  • Page 26: Safety Precautions

    Hydraulic Fluid Under Pressure • Hydraulic Fluid can penetrate the skin, which can result in possible blood poisoning. • Always shut down primary engine driving hydraulic pump before loosening or tightening any fittings or components. January 2024 600S/660SJ – 1435378-000...

  • Page 27: Operator's Manual Procedures

    Winching, Towing, Emergency Lowering / Operation, etc. TECHNICAL BULLETINS This symbol throughout the manual means that there is a Technical Bulletin that is relevant to that part or procedure. Visit www.snorkellifts.com to search for the applicable bulletin. 600S/660SJ – 1435378-000 January 2024...

  • Page 28: Abbreviations List

    Turret Right, Clockwise lb / lbs Pounds Underwriters Laboratory Liters VCCM Valve Current Control Module Left Front Drive Motor A Port Volt Left Front Drive Motor B Port Watt Left Rear Drive Motor A Port January 2024 600S/660SJ – 1435378-000...

  • Page 29: Section 2 Specifications

    SECTION 2 Specifications...

  • Page 30: General Specifications

    Optional AC generator .... 208 V, 3-phase, 7.5 kw Fuel Tank Capacity Optional AC generator ..... 208 V, 3-phase, 10 kw Diesel..........35 US gal (132 l) Optional AC generator ..208-230 V, 3-phase, 20 kw January 2024 600S/660SJ – 1435378-000...
  • Page 31 Sound Power Level ......97.5 dB LWAd Fahrenheit ..........0°F to 110°F Celsius ...........-18°C to 43°C Group Classification Heavy Duty – intended life..100,000 load cycles Vibration Hand/arm ........less than 2.5 m/sec² Body ..........less than 0.5 m/sec² 600S/660SJ – 1435378-000 January 2024...

  • Page 32: 660Sj

    Transport height ........10′ 1″ (3.1 m) Vertical wheel travel....... 9″ (22.8 cm) All Terrain ........10′ 5.5″ (3.18 m) Maximum drive height ......66′ 7″ (20.3 m) All Terrain ........66′ 11″ (20.4 m) January 2024 600S/660SJ – 1435378-000...
  • Page 33 Below -12°C (10°F) ......... ISO VG15 Group Classification Heavy Duty – intended life..100,000 load cycles Engine Diesel .............Cummins QSF Output ..........65 hp (48.4kW) Diesel ..........Deutz TCD 2.9 L4 Output ..........75 hp (55.9kW) 600S/660SJ – 1435378-000 January 2024...

  • Page 34: Drive Motor Specifications

    Minimum Displacement ........Rated rpm 4,650 rpm (5,200 max rpm) Minimum Pressure at Outlet ..............45.5 psi (0.3 MPa) Case Drain Pressure Normal ....................29 psi (0.2 MPa) Peak ....................87 psi (0.6 MPa) Control Pressure Lowest ....................203 psi (1.4 MPa) Highest ..................1,000 psi (6.9 MPa) January 2024 600S/660SJ – 1435378-000...

  • Page 35: Engine Specifications

    Bore and Stroke............3.7 in x 3.94 in (94 mm x 100 mm) Displacement ..................171 cu in (2.8 Liters) Firing Order ......................1-3-4-2 Horsepower .................... 210 @ 3,600 rpm Torque....................385 ft/lbs @1,800 rpm Weight (Approximate) ................475 lbs (215 kg) 600S/660SJ – 1435378-000 January 2024...

  • Page 36: Variable Displacement Hydraulic Pump Specifications

    Theoretical Displacement Max ................32 gpm at 2,700 rpm (45 cc/r 32) Minimum ................23 gpm at 1,000 rpm (2.5 cc/r) Revolution Speed Minimum ......................1,000 rpm Rated ........................2,700 rpm Case Drain Pressure Maximum.............14.5 psi (0.1 MPa) January 2024 600S/660SJ – 1435378-000...

  • Page 37: Swing Drive Specifications

    Minimum Opening Pressure ............175-200 psi (12-14 bar) Maximum Opening Pressure ..............3,625 psi (250 bar) GEAR HUB SPECIFICATIONS Oil Quantity .................... 17 oz (.0.6 Liters) Maximum Input Speed..................3,500 rpm Maximum Torque ..................568 ft/lbs (770 Nm) Ratio ..........................56.2 600S/660SJ – 1435378-000 January 2024...

  • Page 38: Fastener Torque Chart

    The chart may be used with both coarse and fine thread fasteners lightly lubricated. • Increase torque by 20% when multiple tapered tooth (shake proof) lock washers are used. • The torque values are given in foot/pounds. • Inch/pound equivalent may be obtained by multiplying by 12. January 2024 600S/660SJ – 1435378-000...

  • Page 39: Metric System

    Foot/pound equivalent may be obtained by dividing by 12. • Inch/pound equivalent may be obtained by multiplying by 12. • Newton/meter equivalent may be obtained by multiplying inch/pound by 0.1130. • Newton/meter equivalent may be obtained by multiplying foot/pound by 1.3558. 600S/660SJ – 1435378-000 January 2024...

  • Page 41: Section 3 Hydraulic Components

    SECTION 3 Hydraulic Components...

  • Page 42: Chassis Hydraulic Component Location

    1....................Gear Hub x 4 (page 45) 2....................Drive Motor x 4 (page 44) 3................Oscillating Axle Cylinder x 2 (page 51) 4..................Front Axle Assembly (page 43) 5..............Traction Manifold (Deutz Engine Only, page 53) January 2024 600S/660SJ – 1435378-000...

  • Page 43: Front Axle Assembly

    Shown 1........................Steer Cylinders 2......................Right Hand Steer Yoke 3...........................Gear Hub 4....................King Pins and Retainers 5........................Axle Weldment 6........................Drive Motor 7......................Left Hand Steer Yoke 8..................Steer Cylinder Pins and Retainers 9......................... Axle Center Pin TCB20.004 TCB17.014 600S/660SJ – 1435378-000 January 2024...

  • Page 44: Drive Motor

    Section 3 Hydraulic Components DRIVE MOTOR 1....................... A Port Clockwise 2....................B Port Counterclockwise 3......................... Brake Port 4..........................Shaft January 2024 600S/660SJ – 1435378-000...

  • Page 45: Gear Hub

    Section 3 Hydraulic Components GEAR HUB 17 16 Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 46 Section 3 Hydraulic Components GEAR HUB See section B-B Detail B-B Detail C-C Detail D-D Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 47 43...........O-Ring 20...........O-Ring 44..........Backup Ring 21..........Cap Screw 22..........Nyloc Nut Detail D-D 23....Bearing Retaining Washer 45............Spring 24......Needle Bearing X84 46........Retaining Plug 25........Bearing Spacer 47..........Snap Ring 26........Planetary Gear 27..........Roll Pin 28..........Snap Ring 600S/660SJ – 1435378-000 January 2024...

  • Page 48: Chassis Hydraulic Hoses

    Section 3 Hydraulic Components CHASSIS HYDRAULIC HOSES Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 49 15...........Shift port on Right Rear Motor to Port 1 on Rotary Manifold 16......Case Drain on Right Rear Drive Motor to Port 5 on Rotary Manifold 17..........Drain on Traction Manifold to Port 7 on Rotary Manifold Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 50 28........Port B on Left Steer Cylinder to Port A on Right Steer Cylinder 29.... Extend Port on Left Oscillating Axle Cylinder to GBR Port on Traction Manifold 30..........CB on Left Oscillating Axle to Port 4 on Rotary Manifold January 2024 600S/660SJ – 1435378-000...

  • Page 51: Oscillating Axle Cylinder

    Section 3 Hydraulic Components OSCILLATING AXLE CYLINDER 1........................Retract Port 2..........................Test Port 3........................Extend Port 4............Counterbalance Valve Pre-set by Supplier to 5,000 psi 5......................Bushing Base End 6......................Bushing Rod End 600S/660SJ – 1435378-000 January 2024...

  • Page 52: Steer Cylinder

    Section 3 Hydraulic Components STEER CYLINDER 1......................Bushing Base End 2........................Extend Port 3........................Retract Port 4......................Bushing Rod End January 2024 600S/660SJ – 1435378-000...

  • Page 53: Traction Manifold

    Section 3 Hydraulic Components TRACTION MANIFOLD Deutz Engine Right Side Left Side 600S/660SJ – 1435378-000 January 2024...
  • Page 54 5...................... Shuttle Valve and Plug 5a........................Port Plug x 20 6............Pressure Reducing Valve (Preset by Manufacturer) 7a........................Check Valve 7b........................Check Valve 8a........................Cavity Plug 8b........................Cavity Plug Note: Schematic for valve is on page 349. January 2024 600S/660SJ – 1435378-000...

  • Page 55: Turntable Hydraulic Installation

    Section 3 Hydraulic Components TURNTABLE HYDRAULIC INSTALLATION R = Retract E = Extend D = Drain 600S/660SJ – 1435378-000 January 2024...

  • Page 56: Hydraulic Oil Cooler

    14..................40 Amp Fuse And Fuse Holder 15.............. Return Hose From Main Manifold to Oil Cooler 16....................... Hose to Return Filter 17................ Hydraulic Cooler Electric Fan and Motor 18..................Fitting Toe Going to Return Filter 19..........................Fan Plug January 2024 600S/660SJ – 1435378-000...

  • Page 57: Hydraulic Tank Return Filter

    1........................Defuser Seal 2........................Filter Housing 3......................Filter Element Seal 4........................Defuser Seal 5........................Filter Element 6........................External Seal 7...................Insert Assembly, Internal Seal 8........................Cover Seal 9..........................Cover 10......................Plug Anti-Splash Seal 11 ....................Air Breather Screw Seal 12..........................O-Ring 13.......................... Breather 600S/660SJ – 1435378-000 January 2024...

  • Page 58: Hydraulic And Fuel Tank Tray

    8......................Hydraulic Oil Tank 9....................Hydraulic Oil Level Gauge 10....................Hydraulic Oil Tank Cap 11 ......................Hydraulic Oil Cooler 11A ....................Top Oil Cooler Mount 11B ....................Lower Oil Cooler Mount 12....................Hydraulic Oil Cooler Fan January 2024 600S/660SJ – 1435378-000...

  • Page 59: Hydraulic Pump

    5....................... Load Sense Port 6..................System Pressure Adjustment Port 7..............Stand By Pressure Adjustment Pressure Port 8........................... Tank Port 9......Torque Limit Control Valve – Preset by Manufacturer No Adjustment 10....................Hydraulic Fluid Inlet Port TCB20.010 TCB21.014 600S/660SJ – 1435378-000 January 2024...

  • Page 60: Coupler Installation

    ASSEMBLED PUMP VIEW 1......................Flywheel Coupling 2..............Flywheel Coupling Bolts 10mm x8 (Note 1) 3......................Pump Mount Plate 4..............Pump Mount Plate Bolts 10mm x12 (Note 2) 5..................Hydraulic Pump Bolts (Note 3) 6................Hydraulic Pump-Shown For Clarification 7........................Engine Flywheel January 2024 600S/660SJ – 1435378-000...

  • Page 61: Swing Drive

    18.........Roller Bearing Set 6........... Oil Seal 19........Worm Gear 44:1 7...........Housing 20........Roller Bearing 8........... Oil Seal 21........Bronze Bushing 9..........Hex Plug 22..........Oil Seal 10..........Bushing 23........... Pinion Gear 11............Vent 12..........Dowel Pin 13........Grease Fitting 600S/660SJ – 1435378-000 January 2024...

  • Page 62: Function Manifold

    Section 3 Hydraulic Components FUNCTION MANIFOLD 11B 11 9B 9 Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 63 11a................Platform Level Down Relief 2,900 psi 11b..................Platform Up Relief 2,900 psi 12..................Oscillating Axle Pressure Switch 13......................Three-Way Valve 14....................Pressure Reducing Valve 15..............Intermediate Plate and Double Check Valves 16......................Pressure Test Port See Procedures and Adjustments section for pressure adjustments. 600S/660SJ – 1435378-000 January 2024...

  • Page 64: Rotary Manifold

    3A ........... Port 6 4............Port 7 4A ........... Port 7 5............Port 5 5A ........... Port 5 6............Port 4 6A ........... Port 4 7............Port 3 7A ........... Port 3 8.......Rotary Manifold Stop (Reference Only) January 2024 600S/660SJ – 1435378-000...

  • Page 65: Pressure Filter

    Section 3 Hydraulic Components PRESSURE FILTER 1....................Pressure Filter Assembly 2....................Replacement Filter Element 3a....................O-Ring for Filter Element 3b....................O-Ring for Filter Housing 3c......................Anti Extrusion Ring 3d..........................Gasket 3e..........................O-Ring 3f........................Protector Seal 4........................... Plug 5.....................Pressure Filter Housing 600S/660SJ – 1435378-000 January 2024...

  • Page 66: Boom Lift Cylinder

    5........................... Tank Port 6........................Extend Port 7........................Retract Port 8......................Extend Bleed Port 9......................Retract Bleed Port 10....................... Oil Return Tube 11 ......................Rod End of Cylinder 12........................Bushings x2 13........................ Cylinder Barrel 14......................... Rod End Boss January 2024 600S/660SJ – 1435378-000...

  • Page 67: Master Level Cylinder

    Section 3 Hydraulic Components MASTER LEVEL CYLINDER 1........................Base End Boss 2........................Bushings x2 3........................Extend Port 4........................Cylinder Body 5........................Retract Port 6........................End Gland Nut 7........................Cylinder Rod 8......................Rod End Bushing 9........................Rod End Boss 600S/660SJ – 1435378-000 January 2024...

  • Page 68: Extend Cylinder

    2................Rod End of Extend Cylinder and Fittings 3.....................Extend Cylinder Pin Boss x2 4....................Sheave Mount Weldment 5..................Sheave Mount Lower Slide Pad 6........................Cable Sheave 7..................Cable Sheave Pin and Retainers 8..................Sheave Mount Upper Slide Pad TCB20.012 January 2024 600S/660SJ – 1435378-000...

  • Page 69: Jib Boom Cylinder

    6....................Counterbalance Cartridge 7................Retract Port (at Base of Hydraulic Block) 8................Extend Port (at Base of Hydraulic Block) 9......................Cylinder Base Boss 10....................Base End Bushings x2 11..........................Plug 12..........................Plug 13..........................Plug 14....................... Hydraulic Block 600S/660SJ – 1435378-000 January 2024...

  • Page 70: Slave Level Cylinder

    Section 3 Hydraulic Components SLAVE LEVEL CYLINDER 1........................Bushings x2 2......................Cylinder Base Boss 3........................Transfer Tube 4....................... Counterbalance Valve 5........................Cylinder Rod 6..................... Cylinder Rod End Boss 7........................Bushings x2 8.......................... Gland Nut January 2024 600S/660SJ – 1435378-000...

  • Page 71: Section 4 Electrical Components

    SECTION 4 Electrical Components...

  • Page 72: Turntable Electrical Components

    5....................Emergency Power Pump 6........................Power Bus Bar 7........................40 Amp Fuse 8..................Circuit Breaker 15 Amp (Throttle) 9................Circuit Breaker 40 Amp (Glow Plugs) 10....................Kubota Engine (For Ref) 11.......................Engine Harness 12......................Engine Tray (For Ref) January 2024 600S/660SJ – 1435378-000...

  • Page 73: Deutz Engine

    Section 4 Electrical Components TURNTABLE ELECTRICAL COMPONENTS Right Side Deutz Engine To Master Disconnect Switch To Glow Plug Relay To Engine Harness Power Bus Bar Located Near Engine TCB23.005 Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 74 2..................ECU Location (ECU Not Shown) 3........................Ground Lugs 4.................Approximate Location of Power Buss Bar 5.....................Engine Tray (For Reference) 6..................Deutz Engine (For Reference) 7....................Emergency Power Pump 8....................Emergency Power Relay 9........................Fuse Block 10....................Master Disconnect Switch January 2024 600S/660SJ – 1435378-000...

  • Page 75: Cummins Engine

    RelayPower Emergency Stud Pump Relay 86 Emergency Pump Relay 85 1..........................Batteries 2....................Master Disconnect Switch 3....................Emergency Power Relay 4...........................ECU 5.....................Engine (For Reference) 6.....................Engine Tray (For Reference) 7....................Emergency Power Pump TCB19.005 Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 76 Black Post Start Grid Heater Relay 85 Relay 28 Start Grid Heater Relay 86 Relay 85 Grid Heater Relay 86 Grid Heater Start Relay 87 Relay 87 Ref Starter Detail D Detail C Lockout Relay January 2024 600S/660SJ – 1435378-000...

  • Page 77: Engine Tray Latch With Sensor

    Section 4 Electrical Components TURNTABLE ELECTRICAL COMPONENTS Engine Tray Latch with Sensor All Engines 1....................Proximity Sensor to J-20 2................. 6 Pin Connector to Proximity Connectors 3..............Engine Latch Tray Assembly (Reference Only) 600S/660SJ – 1435378-000 January 2024...

  • Page 78: Dual Capacity Sensors

    Section 4 Electrical Components TURNTABLE ELECTRICAL COMPONENTS Dual Capacity Sensors All Engines 2x sensors - only one visible in drawing. Adjust both sensors to be no more than 0.28 inches (7mm) from target plate. January 2024 600S/660SJ – 1435378-000...

  • Page 79: Emergency Power Unit

    3............... Relief Setting: 2500 psi +/-50 psi (Bypass) 4......................Typical Performance: 1.8 gpm at 2,000 psi With 230 amp Current Draw @ 10.5 VDC 3.3 gpm at 500 psi With 120 amp Current Draw @ 11.7 VDC 600S/660SJ – 1435378-000 January 2024...

  • Page 80: Horn Installation

    Section 4 Electrical Components HORN INSTALLATION Wiring Schematic From Wire Color P1-1 H1-1 P1-2 H1-2 January 2024 600S/660SJ – 1435378-000...

  • Page 81: Lower Control Box

    3...... VCCM = Valve Current Control Module (Used for Proportional Functions) 4........LCD = Liquid Crystal Display (Used to Navigate Control Board) 5..................TBM = Terminal Board Module (Used as a Junction Point for Positive and Negative Battery Connections) TCB20.024 TCB19.003 600S/660SJ – 1435378-000 January 2024...

  • Page 82: Single Capacity

    Section 4 Electrical Components LOWER CONTROL BOX 600S Single Capacity Front View LCD Screen Control Selector Overload Lamp Switch Platform Rotate 25 AMP CB Platform Level Boom Extend/Retract Emergency Stop Boom Up/ E-Power Rotation Down Enable Down Start January 2024 600S/660SJ – 1435378-000...

  • Page 83: Bottom View

    Alarm Mini Spare J20 (Rotation Sensor) Spare J12 (Drive Lights) J11 (Running Lights) J13 (Generator) J14 (Cold Weather Package) J16 (Limit Switch) J15 (Hyd. Oil Cooler) J17 (Axle Switch) J18 (Boom Length) J19 (Boom Angle) 600S/660SJ – 1435378-000 January 2024...

  • Page 84: Internal Wiring

    Section 4 Electrical Components LOWER CONTROL BOX 600S Single Capacity Internal Wiring Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 85 Section 4 Electrical Components LOWER CONTROL BOX 600S Single Capacity Internal Wiring Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 86 Section 4 Electrical Components LOWER CONTROL BOX 600S Single Capacity Internal Wiring January 2024 600S/660SJ – 1435378-000...

  • Page 87: Dual Capacity T4F

    Engine Oil Lamp 600 lbs (272 kg) Capacity Control Selector Switch Platform Rotate Overload Lamp Platform Level 25 AMP CB Wait to Start Lamp Emergency Stop E-Power Enable Down Boom Extend/Retract Start Rotation Boom Up/Down 600S/660SJ – 1435378-000 January 2024...

  • Page 88: Bottom View

    Alarm Mini Spare Spare J17 (Axle Switch) J12 (Drive Lights) J11 (Running Lights) J14 (Cold Weather Package) J13 (Generator) J15 (Hyd. Oil Cooler) J16 (Limit Switch) J18 (Boom Length) J20 (Rotation Sensor) J19 (Boom Angle) January 2024 600S/660SJ – 1435378-000...

  • Page 89: Internal Wiring

    Section 4 Electrical Components LOWER CONTROL BOX 600S Dual Capacity T4F Internal Wiring Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 90 Section 4 Electrical Components LOWER CONTROL BOX 600S Dual Capacity T4F Internal Wiring Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 91 Section 4 Electrical Components LOWER CONTROL BOX 600S Dual Capacity T4F Internal Wiring 600S/660SJ – 1435378-000 January 2024...

  • Page 92: 660Sj

    Engine Stop Lamp Engine Warning LCD Screen Lamp Control Selector Switch Platform Rotate Overload Lamp Platform Level 25 AMP CB Wait to Start Lamp Emergency Stop E-Power Enable Down Start Rotation Boom Up/Down Boom Extend/Retract January 2024 600S/660SJ – 1435378-000...

  • Page 93: Bottom View

    Alarm Mini Spare J18 (Boom Length) Spare J12 (Drive Lights) J11 (Running Lights) J13 (Generator) J14 (Cold Weather Package) J16 (Limit Switch) J15 (Hyd. Oil Cooler) J17 (Axle Switch) J19 (Boom Angle) J20 (Rotation Sensor) 600S/660SJ – 1435378-000 January 2024...

  • Page 94: Internal Wiring

    Section 4 Electrical Components LOWER CONTROL BOX 660SJ Single Capacity T4F Internal Wiring Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 95 Section 4 Electrical Components LOWER CONTROL BOX 660SJ Single Capacity T4F Internal Wiring Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 96 2 P - J12-P1 J16-P4 J14 COLD WEATHER J15 HYD. OIL COOLER J16 LIMIT SWITCH J19 BOOM ANGLE J13 GENERATOR J11 RUNNING LIGHTS J17 AXLE SWITCH PACKAGE J20 SLEW SENSOR J12 DRIVE LIGHTS J18 BOOM LENGTH January 2024 600S/660SJ – 1435378-000...

  • Page 97: Dual Capacity T4F

    Engine Warning Lamp 600 lbs (272 kg) Capacity Control Selector Switch Platform Rotate Overload Lamp Platform Level 25 AMP CB Wait to Start Lamp Emergency Stop E-Power Enable Down Start Rotation Boom Up/Down Boom Extend/Retract 600S/660SJ – 1435378-000 January 2024...

  • Page 98: Bottom View

    Alarm Mini Spare Spare J17 (Axle Switch) J11 (Running Lights) J12 (Drive Lights) J14 (Cold Weather Package) J13 (Generator) J16 (Limit Switch) J15 (Hyd. Oil Cooler) J18 (Boom Length) J20 (Rotation Sensor) J19 (Boom Angle) January 2024 600S/660SJ – 1435378-000...

  • Page 99: Internal Wiring

    Section 4 Electrical Components LOWER CONTROL BOX 660SJ Dual Capacity T4F Internal Wiring Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 100 Section 4 Electrical Components LOWER CONTROL BOX 660SJ Dual Capacity T4F Internal Wiring Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 101 Section 4 Electrical Components LOWER CONTROL BOX 660SJ Dual Capacity T4F Internal Wiring 600S/660SJ – 1435378-000 January 2024...

  • Page 102: Valve Current Control Module

    P11-1 J5-10 1 Volt Power Supply P11-2 TBM B-Neg B- Battery Ground P12-1 GP400 -P1-1 Can High P12-2 GP400-P1-2 Can Low P12-3 TBM-B-Neg Ground P13-1 J5-1 Can High P13-2 J5-2 Can lOW P13-3 J5-3 Ground January 2024 600S/660SJ – 1435378-000...

  • Page 103: Display

    Section 4 Electrical Components LOWER CONTROL BOX Display 1..........................Escape 2............................ Left 3..........................Right 4..........................Enter 5..........................Down 6............................Up 600S/660SJ – 1435378-000 January 2024...

  • Page 104: Gp400 Controller

    High Side PWM P5-5 Ignition High Side 2a P4-8 Boom Down High Side PWM P5-6 Overload Tilt Light High Side 2a P5-7 Boom Retract High Side PWM P5-8 Boom Extend High Side PWM Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 105 Digital Input P14-6 Riser Boom Up Digital Input P7-9 Platform Level Up Digital Input P14-7 Riser Boom Down Digital Input P7-10 Platform Level Down Digital Input Riser Limit Switch P14-8 Digital Input Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 106 Engine rpm Countable Input P15-8 Jib Down Digital Input Riser Limit Switch P15-9 Digital Input P15-1 Boom Extend Digital Input P15-2 Boom Retract Digital Input Switch P15-10 Battery Positive Commons P15-3 Swing Clockwise Digital Input January 2024 600S/660SJ – 1435378-000...

  • Page 107: Terminal Board Module

    1...........Power to P7-4 on GP400 Board and Platform Switches 2..........Power to Ground Enable and Emergency Power Switches 3....................To P8-9 at GP400 Board 4...................Option for Telematic Keypad Relay 5................. To P15-10 on GP400 - Switch Commons 600S/660SJ – 1435378-000 January 2024...

  • Page 108: Booms Electrical Component Location

    BOOMS ELECTRICAL COMPONENT LOCATION 1......................Extend Limit Switch 2................Lower Controls (For Reference Only) 3....................Power to Platform Cable 4................Selector Valve Harness (660SJ Only) 5................Upper Controls (For Reference Only) 6................Selector Valve Harness (660SJ Only) 7......................Hose Carrier Track January 2024 600S/660SJ – 1435378-000...

  • Page 109: Boom Angle Sensor

    Section 4 Electrical Components BOOM ANGLE SENSOR PIN # Color Function Battery Voltage Output from Sensor White 2.3 Volts Boom Fully Lowered 1.5 Volts Boom Fully Elevated Black Ground 600S/660SJ – 1435378-000 January 2024...

  • Page 110: Foot Switch

    Section 4 Electrical Components FOOT SWITCH TCB22.014 January 2024 600S/660SJ – 1435378-000...

  • Page 111: Selector Valve Harness

    Section 4 Electrical Components SELECTOR VALVE HARNESS 660SJ SELECTOR VALVE SELECTOR VALVE HARNESS J6 HARNESS J6 WIRE# SELECTOR VALVE WIRE# SELECTOR VALVE HARNESS J6 HARNESS J6 WIRE# WIRE# 600S/660SJ – 1435378-000 January 2024...

  • Page 112: Upper Control Box

    Drive Lights Bottom View Switch Note: Use J7 to route load cell wiring through J6 Layout Cords Description Snorkel Guard Beacon Light Platform Rotate See Table for J6 Cold Weather Routing Platform Lights Switch TCB22.019 January 2024 600S/660SJ – 1435378-000...

  • Page 113: 660Sj

    Bottom View Drive Lights Note: Use J7 to Switch route load cell wiring through J6 Layout Cords Description Snorkel Guard Beacon Light Platform Rotate See Table for J6 Cold Weather Routing Platform Lights Switch TCB22.019 600S/660SJ – 1435378-000 January 2024...

  • Page 114: Inside View

    Section 4 Electrical Components UPPER CONTROL BOX Inside View 1..............GP440 Controller (GP442 can also be used) 2.................... J6 Foot Switch Harness Plug 3................J4 Ground to Platform Harness Plug 4....................Snorkel Guard Lamp Plug January 2024 600S/660SJ – 1435378-000...

  • Page 115: Wire Chart

    12 Volt Supply from TBM Battery Positive+ GP440/443 P5-3 White Platform Rotate Enable Valve GP440/443 P5-4 White Battery Ground Supply GP440/443 P5-7 Black Snorkel Guard Blue Flashing Light GP440/443 P5-8 Boom Extend/Retract GP440/443 P6-1 White Steer GP440/443 P6-2 White Ground...
  • Page 116 J5=1 Black Ground J6-1 Black B+Power J68-1 White B+ Power J9-1 White B+ Power J10-1 White Ground J10-3 Black Ground J11-2 Black Ground Terminal B- Terminal B-Terminal Black Ground J2-6 Black B+ Power J2-8 White January 2024 600S/660SJ – 1435378-000...

  • Page 117: Gp440 Controller

    Digital Input P5-3 TBM Battery Positive Supply P10-12 Joystick Battery Positive P5-7 TBM Battery Ground Negative P11-1 Canbus To GP400 Can High P5-8 Snorkel Guard Light 2 Amp Output P11-2 Canbus To GP400 Can Low 600S/660SJ – 1435378-000 January 2024...
  • Page 118 Digital Input Clockwise P14-14 Bump Guard 2 Digital Input P15-12 Platform Rotate Digital Input Counterclockwise P14-15 Bump Guard Over Digital Input Ride P15-13 Horn Digital Input P15-14 Emergency Power Digital Input P15-15 Drive Lights Digital Input January 2024 600S/660SJ – 1435378-000...

  • Page 119: Joystick

    PCB and Handle Wires (12 POS. Connector) Position Color Function P1-1 Blue Y Axis Output P1-4 Power (5V) P1-6 Black Ground P1-9 White/Yellow Handle Left (N.O.) P1-10 White/Green Handle Right (N.O.) P1-12 White/Red Handle Common P1-2,3,5,7,8,11 None No Connection 600S/660SJ – 1435378-000 January 2024...
  • Page 120 D Direction Full ................... 4.50V (±0.10V) C DIR FULL 0.50V (±0.10V) PWM Frequency.....................DCOUT D DIR FULL 4.50V (±0.10V) Pot Operation .....................Hall Effect DCOUT PWM FREQ. Electrical Output .................Proportional Voltage HALL EFFECT POT OPERATION ELECT. OUTPUT PROPORTIONAL VOLTAGE January 2024 600S/660SJ – 1435378-000...

  • Page 121: Harnesses

    Section 4 Electrical Components HARNESSES Kubota Engine Harness and Routing - Right Side To Glow Plug To Throttle TO GLOW PLUG TO THROTTLE FUEL SHUTOFF Fuel Shutoff TO CONTROL TO CONTROL Engine Harness 600S/660SJ – 1435378-000 January 2024...

  • Page 122: Engine Harness

    Section 4 Electrical Components HARNESSES Kubota Engine Engine Harness Wiring January 2024 600S/660SJ – 1435378-000...
  • Page 123 Section 4 Electrical Components HARNESSES Kubota Engine Engine Harness Wiring 600S/660SJ – 1435378-000 January 2024...

  • Page 124: Wire And Connector Legend

    Can Bus (Hi) To Telematic Telematic White J8 Alternator Exciter Alternator 3 Pin Plug Black J8 Ground, B- Splice 3 S3 J8 Power, B+ Splice 2 S2 Power To Fuse Fuse Holder Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 125 Connector 1 Termination Number Color Description Description Ignition Signal To Telematic Splice 7 S7 White Power To Telematic Telematic White Hour Meter To Telematic Telematic Black Ground To Telematic Telematic White Ignition Signal To Telematic Telematic 600S/660SJ – 1435378-000 January 2024...

  • Page 126: Deutz 2.9 L4 Engine

    Section 4 Electrical Components HARNESSES Deutz 2.9 L4 Engine Harness and Routing - Right Side Front Engine Tray Latch With Sensor Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 127 8..Positive Battery Cable from Battery Disconnect Switch to Emergency Power Relay 9............Positive Battery Cable to Battery Disconnect Switch 10....................Proximity Sensor to J-20 11............... 6 Pin Connector to Proximity Connectors 12.............. Engine Latch Tray Assembly (Reference Only) 600S/660SJ – 1435378-000 January 2024...

  • Page 128: Engine Harness

    Section 4 Electrical Components HARNESSES Deutz 2.9 L4 Engine Engine Harness Wiring January 2024 600S/660SJ – 1435378-000...
  • Page 129 Section 4 Electrical Components HARNESSES Deutz 2.9 L4 Engine Engine Harness Wiring 600S/660SJ – 1435378-000 January 2024...

  • Page 130: Wire And Connector Legend

    EGR Actuator (TW W31) White EGR Actuator (TW W30) White EGR Sensor White EGR Sensor White EGR Ground Battery Positive J1939 Black Battery Negative J1939 White CAN BUSS communication (LO) J1939 Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 131 White Coolant Level Sensor Power D3-2 White Fuel Pump Relay Signal D2-2 White Fuel PUMP Relay Return Signal D2-2 Black Engine Harness B- Ground D2-2 Black Engine Harness B- Ground D2-2 Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 132 Can Buss (HI) to Telematic Splice 13 Black Ground to Telematic Splice 14 Power To Fuse Splice 15 Power To Telematic Telematic W100 White Hour Meter To Telematic Splice 16 W101 White Ignition Signal To Telematic Splice 16 January 2024 600S/660SJ – 1435378-000...

  • Page 133: Glo-Plug Relay Harness

    Section 4 Electrical Components HARNESSES Deutz 2.9 L4 Engine Glo-Plug Relay Harness Glo-Plug Relay P6-56R To Glo-Plug 600S/660SJ – 1435378-000 January 2024...

  • Page 134: Cummins Engine

    Section 4 Electrical Components HARNESSES Cummins Engine Harness and Routing - Right Side Alternator Alt. to Battery Side of Disconnect Starter J2 (Engine Harness) Emergency Pump Relay 86 Emergency Pump Relay 85 January 2024 600S/660SJ – 1435378-000...

  • Page 135: Wiring

    Section 4 Electrical Components HARNESSES Cummins Engine Engine Harness Wiring 600S/660SJ – 1435378-000 January 2024...
  • Page 136 Section 4 Electrical Components HARNESSES Cummins Engine Engine Harness Wiring January 2024 600S/660SJ – 1435378-000...

  • Page 137: All Engines

    2c..................Boom Extend and Retract Coils 2d..................... Turntable Swing Coils 2e..................Jib Boom /Platform Rotate Coils 2f........................Steer Coils 2g......................Platform Level Coils 3............. Oscillating Axle Pressure Switch Connection P-1 3a......................Axle Unlock Coil 3b.....................High Speed Drive Coil 4.........................Engine Harness 600S/660SJ – 1435378-000 January 2024...

  • Page 138: Lower Control Box To Amber Light Harness

    Section 4 Electrical Components HARNESSES All Engines Lower Control Box to Amber Light Harness Wiring Schematic From Wire Color P1-1 S1-1 P1-2 S1-2 P2-1 S1-1 (Splice) P2-2 S1-2 (Splice) January 2024 600S/660SJ – 1435378-000...

  • Page 139: Lower Control Box To Limit Switch Harness

    Section 4 Electrical Components HARNESSES All Engines Lower Control Box to Limit Switch Harness Wiring Schematic From Designation Wire Color P1-1 P2-1 Pink P1-2 P2-2 Brown P1-3 P2-3 White P1-4 P2-4 Yellow 600S/660SJ – 1435378-000 January 2024...

  • Page 140: Function Manifold Harness

    Section 4 Electrical Components HARNESSES All Engines Function Manifold Harness January 2024 600S/660SJ – 1435378-000...

  • Page 141: Hydraulic Oil Cooler Harness

    LABEL "TEMP SENSOR" in Harness 40A FUSE SUPPLIED IN HARNESS Sensor 12V 20/40A Relay 12V 20/40A RELAY CAVITY DESCRIPTION TBM B- to Sensor Ground P8-12 Analog to Temp Sensor P6-8 Output to Relay Relay Ground 600S/660SJ – 1435378-000 January 2024...

  • Page 142: Upper Control Box To Lower Control Box Harness

    J2-5 J5-5 E-Stop J2-6 J5-6 Empty Blue J2-7 J5-7 Battery Negative Terminal Orange J2-8 J5-8 Empty Yellow J2-9 J5-9 E-Stop Red/Black J2-10 J5-10 Battery+ Terminal Blue/Black J2-11 J5-11 Battery+ Terminal Orange/Black J2-12 J5-12 Battery- Terminal January 2024 600S/660SJ – 1435378-000...

  • Page 143: Angle Sensor Harness

    Section 4 Electrical Components HARNESSES All Engines Angle Sensor Harness 1 – Red 2 – White 3 – White 4 – Black 600S/660SJ – 1435378-000 January 2024...

  • Page 144: Boom Elevation Limit Switch Harness

    Boom Elevation Limit Switch Harness Single Capacity Elevation Limit Switch J-16 See Below for Pinouts ELEVATION SWITCH WIRING PINOUT CONNECTOR P1 WIRING SWITCH WIRING COLOR P1 LOCATION COLOR LOCATION BROWN P1-2 BROWN YELLOW P1-4 YELLOW PINK P1-1 PINK WHITE January 2024 600S/660SJ – 1435378-000...

  • Page 145: Dual Capacity

    All Engines Boom Elevation Limit Switch Harness Dual Capacity Elevation Limit Switch See Below for Pinouts Switch P1 J-18 DUAL CAPACITY HARNESS AND LIMIT SWITCH PINOUTS HARNESS FROM P1-1 J18-1 P1-2 J18-2 P1-3 J18-3 P1-4 J18-4 600S/660SJ – 1435378-000 January 2024...

  • Page 146: Proximity Switch / Angle Sensor Harness

    Section 4 Electrical Components HARNESSES All Engines Proximity Switch / Angle Sensor Harness Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 147 3..... Dual Capacity Proximity Switch Number One (NO, on When Retracted) to J-18 4................. Boom Angle Sensor Number Two to J-19 5.................Boom Angle Sensor Number One to J-19 6..............Boom Angle Sensor to Controller and TBM 600S/660SJ – 1435378-000 January 2024...

  • Page 148: Upper Controls Internal Harness

    Section 4 Electrical Components HARNESSES All Engines Upper Controls Internal Harness Refer to page 149 Refer to page 150 Refer to page 151 January 2024 600S/660SJ – 1435378-000...
  • Page 149 CONNECTOR 1 CONNECTOR 2 B- TERM POSITION POSITION B+ TERM E-STOP 2-1 P14-14 B+ TERM B+ TERM B- TERM SNORKEL GUARD SENSOR J10 CONNECTOR 1 CONNECTOR 2 POSITION POSITION FOOT SWITCH J3 B+ TERM CONNECTOR 1 CONNECTOR 2 POSITION POSITION...
  • Page 150 Section 4 Electrical Components HARNESSES All Engines Upper Controls Internal Harness January 2024 600S/660SJ – 1435378-000...
  • Page 151 CONNECTOR 1 CONNECTOR 2 LEVEL UP P14-1 POSITION POSITION HIGH SPD DRIVE 2 B+ TERM LEVEL DOWN P14-2 P8-6 P8-2 SNORKEL GUARD OVERRIDE SWITCH P8-1 CONNECTOR 1 CONNECTOR 2 POSITION POSITION JS-C TELESCOPE JOYSTICK P14-12 CONNECTOR 1 CONNECTOR 2 PLATFORM LEVEL 2...

  • Page 153: Section 5 Engine Components

    SECTION 5 Engine Components...

  • Page 154: Kubota V2403 Turbo Diesel Engine

    3......................Engine Oil Dipstick 4......................Mechanical Fuel Pump 5.........................Engine Oil Filter 6.................Lower V-Belt Pulley (For Reference) 7........................Throttle Body 8......................Engine Cooling Fan 9......................Fuel Injection Pump 10....................Thermostat and Housing 11....................Fuel Lines to Injectors x4 12.......................... Flywheel January 2024 600S/660SJ – 1435378-000...

  • Page 155: Left View

    5..........................Starter 6....................Engine Oil Pressure Switch 7.......................Exhaust Manifold 8..................Turbo Charger and Waste Gate 9......................Engine Oil Fill Cap 10....................Thermostat and Housing 11..........................V-Belt 12......................Engine Cooling Fan 13..........Lower V-Belt Pulley (For Reference for Front of Engine) 600S/660SJ – 1435378-000 January 2024...

  • Page 156: Section 5 Engine Components

    5.................... Lower Serpentine Belt Pulley 6......................Lower Radiator Hose 7......................Radiator Assembly 8................. Turbocharger and Waste Gate Assembly 9........................Air Intake Tube 10......................Engine Air Cleaner 11....................Diesel Particulate Filter 12..........................Starter 13........................Engine Tray TCB23.005 January 2024 600S/660SJ – 1435378-000...

  • Page 157: Left View

    7......................Fuel Injection Pump 8........................Engine Flywheel 9................Diesel Particulate Filter (For Reference) 10.....................Fuel Shut-off Solenoid 11..................Fuel Injectors and Fuel Lines x4 12.......................Engine Air Filter 13................Thermostat Housing and Thermostat 14...................... Upper Radiator Hose 15......................Engine Cooling Fan TCB23.005 600S/660SJ – 1435378-000 January 2024...

  • Page 158: Cummins Qsf 2.8 Liter T4F Diesel Engine

    5....................Lower Coolant Belt Pulley 6........................Idler Pulley 7......................Radiator Assembly 8......................Upper Radiator Hose 9................... Engine Coolant Sight Level Gauge 10......................Air Cleaner Assembly 11 .........................Alternator 12..................Turbocharger And Waste Gate 13......................Exhaust Manifold 14..........................Doc 15........................Exhaust Pipe TCB19.017 January 2024 600S/660SJ – 1435378-000...

  • Page 159: Left View

    8......................Fuel Injection Pump 9........................Engine Oil Fill 10........................Starter Relay 11..........................DOC 12..................... Fuel Injectors and Lines x4 13........................Intake Manifold 14......................Grid Heater Relay 15......................Air Cleaner Assembly 16........................Intake Tube 17................... Coolant Thermostat and Housing TCB19.017 600S/660SJ – 1435378-000 January 2024...

  • Page 160: Bell Housing

    3....................Coupler to Flywheel Bolts Note: Apply Blue Loctite 242 and torque A – M10: 51 ft/lbs Apply Blue Loctite 242 and torque B – M10: 33 ft/lbs Apply Blue Loctite 242 and torque C – M8: 18 ft/lbs January 2024 600S/660SJ – 1435378-000...

  • Page 161: Section 6 Drive System Components

    SECTION 6 Drive System Components...

  • Page 162: Drive Motor

    14........... Back Cover 34........Circlip for Hole 15........... Name Plate 35..........Oil Seal 16......Stainless Steel Rivet 36.......Spacer For Oil Seal 17......Hexagon Socket Screw 37........Bearing Bushing 18...........O-Ring 38..........Elastic Pin 19............Plug 39............Plug 20..........Elastic Pin 40...........O-Ring January 2024 600S/660SJ – 1435378-000...

  • Page 163: Section 6 Drive System Components

    Section 6 Drive System Components FRONT AXLE 1......................Front Axle Assembly 2....................... Pin and Retainer 3..........................Shim 4........................Thrust Washer 5..................... Axle Centerpin and Retainer 6................Oscillating Cylinder Pin and Retainer 7..........................Chassis 600S/660SJ – 1435378-000 January 2024...

  • Page 165: Section 7 Booms

    SECTION 7 Booms...

  • Page 166: Main Boom Assembly

    5..................Retract Cables Adjustment Point 6....................... Base Boom Assembly 7..................Lift Cylinder Rod End Pin Boss 8....................Boom To Turntable Boss 9..................Extend Cylinder Inspection Hole 10......................Interactive Link Arm 11................. Extend Cable Adjustment Location January 2024 600S/660SJ – 1435378-000...

  • Page 167: Tip Boom Assembly

    4......................Cable Sheave Pin 5........................Cable Sheave 6....................Cable Sheave Weldment 7..................Top and Bottom Slide Pads x2 8..........Side Slide Pads and Shims x4 (Shims are as Required) 9.........................Extend Cylinder 10.........................Extend Cables 11........................Cable Anchor 600S/660SJ – 1435378-000 January 2024...

  • Page 168: Tip Boom Base

    4......................Cable Retainer x2 5..................Boom Cable Retainer Mount x2 6......................Boom Retract Cables 7....................Boom Cable Anchors x2 8................Boom Side Slide Pads and Shims x4 9......................Extend Cylinder Pin 10....................Extend Cylinder C-Clip x2 11......................Upper Slide Pad January 2024 600S/660SJ – 1435378-000...

  • Page 169: Main Boom

    8..... Boom Lift Cylinder Rod End Pin 16........Interlink Base Pin 8a.........Boom Lift Cylinder Bearings x4 – 2 Per Side Rod Pin and Retainer 17........ Interlink Weldment 9....... Slave Level Cylinder 10......Slave Level Cylinder Bushings x4 Rod and Base End 600S/660SJ – 1435378-000 January 2024...

  • Page 170: Boom Lift And Master Level Cylinders

    3................. Boom Lift Cylinder Pin Retainers x2 4....................Boom Lift Cylinder Rod End 5..................... Boom Lift Cylinder Base Pin 6..................Master Level Cylinder Base Pin 7..............Master Level Cylinder Pin Retainer and Bolt 8..................Master Level Cylinder Rod End 9......................Boom Lift Cylinder January 2024 600S/660SJ – 1435378-000...

  • Page 171: Hose Carrier Track

    HOSE CARRIER TRACK 1....................Cable Track Guide Fingers 2....................Fixed End Track Bracket 3....................Moving End Track Bracket 4............Cable Track Links (600S and 660SJ Use 63 Links) Location Of Guide Fingers Guide Finger Number Link Number From Fixed End 600S/660SJ – 1435378-000...

  • Page 172: Intermediate Boom Assembly

    3....................Extend Wire Rope Retainer 4................... Extend Wire Rope Retainer Mount 5......................Extend Wire Rope x2 6........................ Upper Slide Pad 7.................Inner Side Slide Pads and Shims x4 8................Inner Lower Mid Slide Pad and Shims January 2024 600S/660SJ – 1435378-000...

  • Page 173: Intermediate And Tip Boom Assembly

    5................Wire Rope and Sheave Inspection Hole 6......................Retract Cables x2 7...........................Tip Boom 8........................Level Cylinder 9................Outer Top Slide Pads (1 Top, 1 Bottom) 10.........Outer Side Slide Pads and Shims (2 Left Side, 2 Right Side) TCB21.020 600S/660SJ – 1435378-000 January 2024...

  • Page 174: Jib Boom

    11....................... Slave Level Cylinder 12................. Tip Boom to Quadrant Pin and Retainer 13..................Jib and Rotate Selector Valve 14........................Main Boom 15..........Upper Jib Boom Weldment to Quadrant Pin and Retainer 16........................Hose Cover January 2024 600S/660SJ – 1435378-000...

  • Page 175: Section 8 Platform

    SECTION 8 Platform...

  • Page 176: Platform Components

    4........................Overload Cell 4a..................Overload Cell Mounting Bolts 5....................Rotary Actuator Center Bolt 6...................... Platform Mount Frame 7......................... Footswitch 8.................... Snorkel Guard Warning Light 9........................Grab Rail x4 10....................Side Entry Gravity Gate 11..................Entry Gate Hinges and Stops x4 12......................Front Entry Gate 13.........................

  • Page 177: Rotator

    Section 8 Platform ROTATOR 1..................... Counterbalance Valves 2........................Valve Block 3....................Platform Rotary Actuator 4......................Mounting Brackets 5........................Bushings X4 Refer to Procedures & Adjustments section for adjustments. 600S/660SJ – 1435378-000 January 2024...

  • Page 178: Snorkel Guard

    3..................... Anti-entrapment Spring 4........................Activation Bar 5....................Snorkel Guard Weldment 6........................ Shields (2 each) 7..........................Cable Note 1: Air gap between proximity sensor and stop should be approximately 3/16″. See upper controls harness for wiring. TCB21.008 TCB19.010 January 2024 600S/660SJ – 1435378-000...

  • Page 179: Section 9 Options

    SECTION 9 Options...

  • Page 180: Tow Kit

    Section 9 Options TOW KIT 1..........................Tow Bar 2..........................Chain 3..........................Tie Road 4........................Float Valve 5........................ Tie Rod Storage 6........................Tow Bar Storage Refer to Operator’s Manual 600S 1433542 or 660SJ 1432633 for towing procedure. January 2024 600S/660SJ – 1435378-000...

  • Page 181: 2Kw Belt Driven Generator

    Section 9 Options 2KW BELT DRIVEN GENERATOR Specifications W001 Pin 4 is not used W002 W003 Specifications Voltage (VAC) Peak Current (A) Peak Power (W) 3500 Continuous Power (W) 2500 Specified Speed (rpm) 3600 600S/660SJ – 1435378-000 January 2024...

  • Page 182: Installation

    Section 9 Options 2KW BELT DRIVEN GENERATOR Installation Deutz Engine V-Belt To Lower Control Box J13 Connector To Generator Pigtail Generator Harness Connect to Power to 2KW Generator Platform Cable January 2024 600S/660SJ – 1435378-000...

  • Page 183: Cummings 2.8 Engine

    Section 9 Options 2KW BELT DRIVEN GENERATOR Installation Cummings 2.8 Engine To J-13 at Ground Control Box To Power Stud and Pos 1................2KW Generator Harness (See Page 184) 2......................... 2KW Generator 3........................Serpentine Belt TCB21.012 TCB22.007 600S/660SJ – 1435378-000 January 2024...

  • Page 184: Harness

    Section 9 Options 2KW BELT DRIVEN GENERATOR Harness To Generator Pigtail Relay 3 2 1 W001 W005 (JUMPER PINS 3 & 4) W006 W007 Lower Control Box J13 Connector Fuse 12V/30A W008 W009 Power To Platform January 2024 600S/660SJ – 1435378-000...

  • Page 185: Upper Control Box

    TOGGLE (B+) CONNECT TO P14-13 ON GP400 BOARD TIE INTO EXISTING TOGGLE (B+) CONNECT TO P14-13 ON GP400 BOARD 1................. Hole Location for 2KW Generator Switch 2..................2KW Generator Switch and Wires 3........................Upper Controls 600S/660SJ – 1435378-000 January 2024...

  • Page 186: Troubleshooting

    Defective Bearing Broken Fan Replace Fan Noisy Generator Belt Worn Replace Belt Broken Mount or Bolt Inspect or Replace Load exceeds Rating Reduce Load Will Not Hold Load Loose Or Worn Belt Tighten or Replace January 2024 600S/660SJ – 1435378-000...

  • Page 187: 7.5Kw Generator

    Section 9 Options 7.5KW GENERATOR Hydraulic Components Port P2 Port T Port P Port P1 19cc Gear Pump Hydrostatic Pump To Tank Side Generator Port P1 600S/660SJ – 1435378-000 January 2024...

  • Page 188: Electrical Components

    ROUTES TO LWR CTRL BOX TO 'J13' PLUG IN TO 110V POWER-TO-PLATFORM CABLE INTERNAL GENERATOR WIRING 1....................Generator Electrical Panel 2................220 Power Cable from Electrical Panel 3.................... 220 Power to Platform Cable 4......................7.5KW Generator 5......................220 Plug at Platform January 2024 600S/660SJ – 1435378-000...

  • Page 189: Electrical Panel

    C............... To Generator Wiring Block (Refer to page 190) D........................Green Wire 1..................63 amp 3 Phase Circuit Breaker 2........................Ground Lug 3..................30 amp 3 Phase Circuit Breaker 4................15 amp Single Phase Circuit Breaker 600S/660SJ – 1435378-000 January 2024...

  • Page 190: Generator Switch At Upper Control Box

    Section 9 Options 7.5KW GENERATOR Generator Switch at Upper Control Box Note: Install toggle such that key is facing downward while looking at the closed lid. To Battery+ Positive To P15-5 at Control Module January 2024 600S/660SJ – 1435378-000...

  • Page 191: Troubleshooting

    Unstable Voltage Check For Engine Surge And Even Pump Uneven Motor Rotation Motor Rotation Check Bearings And/Or Replace Broken Or Worn Bearings Bearings Noisy Generator Check Coupling And Insert For Wear And Bad Coupling Alignment 600S/660SJ – 1435378-000 January 2024...

  • Page 192: 10Kw Generator

    Torque to (7 ft/lbs) 86 in/lbs Torque to 41 ft/lbs (7 ft/lbs) 23 ft/lbs Torque to 41 ft/lbs Pocket cut-out must face turret Torque to Torque to 41 ft/lbs Note Alignment 41 ft/lbs See Note 2 January 2024 600S/660SJ – 1435378-000...

  • Page 193: Power To Platform

    Section 9 Options 10KW GENERATOR Power to Platform PLUG WIRING DIAGRAM 220V Power to Platform 220V Power to Platform Plug 220V Power from Inverter to 220V Power to Platform Plug 600S/660SJ – 1435378-000 January 2024...

  • Page 194: Generator To Inverter Installation

    8................. Generator to Inverter Input Harness 9......................Electrical Harness 10..................Generator Input from Harness 11............. Coolant Fill Point (Uses 50/50 Mix Anti-Freeze) 12....................Coolant Pump Pigtail Plug 13..............Coolant Pump Supply Hose from Radiator 14.......................Circuit Breakers January 2024 600S/660SJ – 1435378-000...

  • Page 195: Harness

    Section 9 Options 10KW GENERATOR Harness Plug Labeled Inverter Inverter Plug Battery- 12V 20/40A Negative Relay J13 Plug 20 AMP Fuse Battery+ Positive J13 Plug 600S/660SJ – 1435378-000 January 2024...

  • Page 196: Troubleshooting

    To eliminate the possibility of a malfunctioning generator: turn off the engine, remove the cover from the generator and remove the generator cable from the generator. Turn the control selector switch back to lower controls, start the engine, switch the control selector switch back January 2024 600S/660SJ – 1435378-000...
  • Page 197 NOTE: Pay close attention to the position of each wire before removing them as they will need to be later re-placed in the correct location. Figure 2 LINE NEUTRAL FROM GENERATOR L1, L2, L3 Figure 3 600S/660SJ – 1435378-000 January 2024...
  • Page 198 INTERNAL VOLTAGE REGULATOR AND/OR ARMATURE. b. If the generator does not measure 3,600 rpm but the pump pressure, pump flow, and engine rpm are correct; the generator flow control valve may need adjustment (figure 4). Figure 4 January 2024 600S/660SJ – 1435378-000...
  • Page 199 The bottom ELCI conducts 3-phase 208v AC to the platform 3-phase receptacle. If the green LED is not lit, try resetting the ELCI. If the ELCI does not reset, consult factory for further troubleshooting. 600S/660SJ – 1435378-000 January 2024...

  • Page 200: Cold Weather Package

    Section 9 Options COLD WEATHER PACKAGE Hose Installation January 2024 600S/660SJ – 1435378-000...
  • Page 201 Section 9 Options COLD WEATHER PACKAGE Hose Installation 600S/660SJ – 1435378-000 January 2024...

  • Page 202: Lower Control Box

    Section 9 Options COLD WEATHER PACKAGE Lower Control Box Toggle Switch Install toggle harness and position the toggle switch Up = On Down = Off Hydraulic Warm-up Decal January 2024 600S/660SJ – 1435378-000...

  • Page 203: Internal Wiring

    Section 9 Options COLD WEATHER PACKAGE Lower Control Box Internal Wiring 600S/660SJ – 1435378-000 January 2024...

  • Page 204: Switch And Harness

    Section 9 Options COLD WEATHER PACKAGE Upper Control Box Switch and Harness Form Wire Color T1-2 P1-1 T1-3 P1-2 January 2024 600S/660SJ – 1435378-000...

  • Page 205: Manifold Heater Valve

    Section 9 Options MANIFOLD HEATER VALVE 600S/660SJ – 1435378-000 January 2024...
  • Page 206 3................Proportional Valve Coil and Cartridge 4..............LS-OUT Port to LSX Port on Main Manifold 5...................R Port to T2 Port on Main Manifold 6...................P Port to P2 Port on Main Manifold 7................. LS-IN Port to GLS Port on Main Manifold January 2024 600S/660SJ – 1435378-000...

  • Page 207: Bellows Kit

    Section 9 Options BELLOWS KIT Front View 1.......................Steer Cylinder 2x 2..................Slave and Level Cylinder Bellow 3......................Boom Lift Cylinder 4....................Master Level Cylinder Bellow 600S/660SJ – 1435378-000 January 2024...

  • Page 208: Platform Ac Power

    GREEN GREEN PLATFORM OUTLET WIRING WHITE WHITE BLACK BLACK GREEN GREEN TANK TRAY INLET WIRING 1................... Male Connector Power to Platform 2....................... Platform Power Cable 3....................Platform Power Receptacle 4..............15 amp Platform Receptacle Circuit Breaker January 2024 600S/660SJ – 1435378-000...

  • Page 209: Bumpguard

    3..............Bumpguard Alignment Lanyard and Sleeve 4.....................Proximity Switch Target 5........................Proximity Switch 6..............Pipe Insulation and Yellow Cover Middle Rail 7................Pipe Insulation and Yellow Cover Top Rail 8..............Amber Bumpguard Light and Override Switch 9..............Platform Mount Frame (For Reference Only) 600S/660SJ – 1435378-000 January 2024...

  • Page 210: Upper Control Box

    WIRING (BANNER) (if manufactured (if manufactured by Pepperl) by Banner) 1......................Upper Control Box 2....................Amber Bump Guard LED 3..................... Bumpguard Override Switch 4....................Bumpguard Override Decal 5......................Photo Electric Sensor 6................Bumpguard Upper Control Box Harness 7........................Control Module January 2024 600S/660SJ – 1435378-000...

  • Page 211: Led Light Wire Harness

    Section 9 Options BUMPGUARD Upper Control Box LED Light Wire Harness To Ground Buss Bar To Position 1 on LED Light W01 (BLK) W02 (WHT) To Position 2 on LED Light To PP5-5 600S/660SJ – 1435378-000 January 2024...

  • Page 212: Harness

    Left Switch Post 3 PP 15-6 Black Left Switch Post 1 B+ Positive Buss Bar Right Switch Post 3 B-Negative Buss Bar White Right Switch Post 1 PP 15-7 Black Right Switch Post 2 B+ Positive Buss Bar January 2024 600S/660SJ – 1435378-000...

  • Page 213: Platform Lights

    Section 9 Options PLATFORM LIGHTS Installation 1.........................LED Lights 2....................Upper Control Box Light 3.....................Platform Light Switches 4......................Platform Light Harness 600S/660SJ – 1435378-000 January 2024...

  • Page 214: Harness

    Left Right Light Light Light Light J5 Plug J5 Plug SQUARE PLATFORM LIGHT HARNESS WIRE # COLOR DESCRIPTION CONNECTOR BLACK BLACK RIGHT LAMP RIGHT LAMP UTILITY LAMP BLACK UTILITY LAMP LEFT LAMP BLACK LEFT LAMP January 2024 600S/660SJ – 1435378-000...

  • Page 215: Section 10 Procedures & Adjustments

    SECTION 10 Procedures & Adjustments...

  • Page 216: Recommended Tools

    11. Two ton or larger hoist 12. Sling capable of lifting 6,000 pounds vertically 13. Sledgehammer 14. Ball peen hammer 15. 1 inch aluminum drift punch 16. 1/2 inch aluminum drift punch 17. Feeler gauge January 2024 600S/660SJ – 1435378-000...

  • Page 217: Torque Hubs

    Over filling the torque hub will damage the inner seals of the hub. Never fill the hub from a plug hole that is above the add line, as shown above. This will overfill the hub. 600S/660SJ – 1435378-000 January 2024...

  • Page 218: Gp400

    Help Screen will appear, scroll right to access level 3, press ENTER. Enter code 2222 using arrow up for access level 2 and Press ENTER. Access level 2 should appear. TCB22.014 Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 219 16. Press ENTER when finished. 17. The display should now show FINISHED. 18. Press ESC Button to exit load calibration. If this is not done machine will not operate. 600S/660SJ – 1435378-000 January 2024...

  • Page 220: Fault And Flash Codes

    Fault: Battery Voltage Too High ..................4/4 The battery voltage is too high-check alternator output. Fault: Can Bus-Load Cell ....................6/6 Fault: Can Bus-Matrix ....................6/6 Fault: Can Bus-P-440 ....................6/6 Check can bus wiring. Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 221 The enable or footswitch is activated at power up or wiring issue is causing input to be active or enable or footswitch has been activated too long with no function selected. Some Functions Must Be Used Alone ................2/2 Some functions cannot be used at the same time as another function. 600S/660SJ – 1435378-000 January 2024...

  • Page 222: Help Messages Without Flash Codes

    All of the above help messages indicate a function is active and the machine should be operating as requested. Vehicle Tilted The machine is tilted beyond the limits of the machine and some functions will be disabled. January 2024 600S/660SJ – 1435378-000...

  • Page 223: Engine Codes

    Crankshaft position sensor (NE sensor) abnormality P0336 P0340 Camshaft position sensor (G sensor) abnormality P0341 P0380 P0380 523544 Glow relay abnormality P0380 523544 P0381 P0403 523574 P0404 523574 EGR actuator abnormality P0409 523572 Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 224 Intake throttle feedback error P2122 Accelerator position sensor 1 abnormality P2123 P2127 Accelerator position sensor 2 abnormality P2128 P2131 523543 Accelerator position sensor error (CAN) P2135 Accelerator position sensor correlation error Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 225 P3023 523601 temperature OTC P3024 523602 High frequency of regeneration P3025 523603 Over heat pre-caution U0075 523547 CAN2 Bus off U0076 523578 No communication with EGR U0077 523604 CAN1 Bus off Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 226 Section 10 Procedures & Adjustments ENGINE CODES Kubota Engine J1939-73 14229 Name P-Code U0081 523548 U0082 523591 U0083 523592 CAN2 frame error U0086 523595 U0087 523596 U0089 523598 January 2024 600S/660SJ – 1435378-000...

  • Page 227: Deutz Engine

    Burner dosing valve (DV2); powerstage over temperature 523911 Burner dosing valve (DV2); short circuit to battery 523911 Burner dosing valve (DV2); short circuit to ground 523911 Burner dosing valve (DV2); short circuit high side powerstage Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 228 Sensor error coolant temperature; signal range check high Sensor error coolant temperature; signal range check low High coolant temperature; warning threshold exceeded Coolant temperature; system reaction initiated Coolant level too low Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 229 Engine shut off request through CAN 523741 No detail information! Timeout Error of CAN-Transmit-Frame ERC 523213 No detail information! Timeout Error of CAN-Transmit-Frame FlEco 523706 No detail information! 523240 Timeout CAN-message FunModCtl; Function Mode Control Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 230 Actuator EGR Valve; powerstage over temperature 523612 Internal software error ECU; injection cut off Engine speed above warning threshold Overspeed detection in component engine protection Engine speed above warning threshold (FOC-Level 1) Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 231 Physical range check high for exhaust gas temperature upstream (SCR-CAT) 523915 HCI dosing valve (DV1); overcurrent at the end of the injection phase 523915 HCI dosing valve (DV1); powerstage over temperature Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 232 Injector 3 (in firing order); interruption of electric connection Injector 4 (in firing order); interruption of electric connection Injector 5 (in firing order); interruption of electric connection Injector 6 (in firing order); interruption of electric connection Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 233 ECU reported internal software error 523612 ECU reported internal software error 523612 ECU reported internal software error 523612 ECU reported internal software error 523612 ECU reported internal software error 523612 Injection system,electrical error injectors Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 234 No detail information! Nox feed back fault detection 3226 No detail information! Plausibility error during Rich to Lean switch over 523752 No detail information! Monitoring of Nox signal readiness 523752 No detail information! Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 235 Learning valu too high 523699 No detail information! Over temperature of device driver of pressure control valve 523889 No detail information! Delta pressure across venturi in EGR line above physical high limit Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 236 Pressure sensor upstream turbine, signal range check (SRC) low 523613 Rail pressure metering unit, Positive governor deviation Rail pressure metering unit, Rail pressure disrupted. 523613 Maximum positive deviation of rail pressure exceeded Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 237 Sensor DEF supply module temperature; plausibility error (cold start condition) SCR plausibility, OBD and diagnosis; Stuck in range check of DEF tank temperature sensor 523981 DEF-tank without heating function (heating phase) Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 238 523580 Variant dataset switching error No detail information! Starter relay high side. Short circuit to battery Starter relay high side short circuit to ground Starter relay low side no load error Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 239 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8). Signal range check high 520521 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); Signal range check low 5763 Actuator position for EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8) not plausible Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 240 SCR main relay (secondary side); Shortcut to battery SCR main relay (secondary side), heat relay (secondary side), heating elements or heating 4366 valve short to ground 4341 SCR heater relay DEF supply line secondary side; open load Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 241 4334 Urea supply module pressure sensor; physical range check low (defect pressure sensor) 4334 Urea pump pressure sensor; high signal not plausible 4334 Urea pump pressure sensor; low signal not plausible Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 242 Physical range check high for battery voltage Physical range check low for battery voltage Air inlet filter sensor out of physical range check 1180 Physical range check high for exhaust gas temperature upstream turbine Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 243 Burner Shut Off Valve; blocked closed Burner Control; Fuel line Shut Off downstream - broken 524021 Burner fuel line pipe leak behind Shut Off Valve 523922 Burner Shut Off Valve; blocked open 523993 Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 244 524035 Injector diagnostics; time out error in the SPI communication 524036 Injector diagnostics Slave; time out error in the SPI communication Timeout Error of CAN-Receive-Frame MSMon_FidFCCTO; Master-Slave CAN 524069 communication faulty Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 245 524033 EGR actuator; due to overload in Save Mode 3711 Temperature during stand-still main phase too low or too high 523960 High exhaust gas temperature EGR cooler downstream; warning threshold exceeded Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 246 NOx sensor upstream SCR-CAT, lambda value above upper physical threshold 524081 NOx sensor upstream SCR-CAT, lambda value below lower physical threshold (Downstream NOx-Sensor) Diagnostic Fault Check for downstream NOx value over 524082 maximum limit (DFC set by Deutz-SW) Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 247 Urea Error Lamp; short circuit ground 524132 Fuel low pressure upstream fuel low pressure pump not plausible Fuel low pressure upstream fuel low pressure pump, pressure above maximum warning 524132 threshold Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 248 Timeout error of CAN-Receive-Frame ComRxCustSCR3 524102 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmpCtl 524103 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmp 524104 Timeout error of CAN-Receive-Frame ComRxDPFCt 524106 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw 524107 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw2 Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 249 1188 Turbocharger wastegate, current above maximum threshold 1188 Turbocharger wastegate, supply voltage above maximum threshold 1188 Turbocharger wastegate, supply voltage below minimum threshold 1188 Turbocharger wastegate, learning process out of range Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 250 DEF quality sensor, short circuit to battery or open load 3520 DEF quality sensor, short circuit to ground 3519 DEF quality sensor, internal temperature sensor short circuit to battery or open load Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 251 DEF dosing valve error in slave ECU 524251 DEF pressure problems in slave ECU 524252 Reverting valve error in slave ECU 524253 DEF back flow line heater error on slave ECU Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 252 Max. launch time for stand still exceeded (60min) 4171 Dynamic temperature check of temp before SCR Set together with DFC_SCRCoBldUpLoPres. 524147 DFC_SCRCoBldUpLoPresRst is only used for inducement purposes. It ensures that legal inducement is working correctly Continued on next page... January 2024 600S/660SJ – 1435378-000...

  • Page 253: Cummins Engine

    Intake Manifold 1 Temperature Sensor Circuit - Voltage below (Solid) normal, or shorted to low source Stop Intake Manifold 1 Temperature - Data valid but above normal (Solid) operational range - Most Severe Level Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 254 Warning SAE J1939 Multiplexing Configuration Error - Out of Calibration (Solid) Stop SAE J1939 Multiplexing Remote Accelerator Pedal or Lever (Solid) Position Sensor System - Received Network Data In Error Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 255 Battery 1 Voltage - Data Valid But Above Normal Operating (Solid) Range - Moderately Severe Level Stop Injector Metering Rail 1 Pressure - Data valid but above normal (Solid) operational range - Most Severe Level Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 256 Engine Speed / Position Camshaft and Crankshaft Misalignment (Solid) - Mechanical system not responding or out of adjustment Warning Engine Camshaft Speed / Position Sensor - Data erratic, (Solid) intermittent or incorrect Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 257 EGR Valve Position Circuit - Voltage above normal, or shorted to 2271 (Solid) high source Warning EGR Valve Position Circuit - Voltage below normal, or shorted to 2272 (Solid) low source Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 258 Auxiliary PWM Driver 1 Circuit - Voltage above normal, or 2557 (Solid) shorted to high source Warning Auxiliary PWM Driver 1 Circuit - Voltage below normal, or shorted 2558 (Solid) to low source Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 259 Coolant Level Sensor - Received Network Data In Error (Solid) Warning 3641 Transmission Output Retarder - Abnormal update rate (Solid) Stop Engine Control Module Calibration Memory - Bad intelligent 3697 (Solid) device or component Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 260 Fan Speed - Data Valid but Above Normal Operational Range - 4789 1639 (Solid) Most Severe Level Warning Fan Speed - Data Valid but Below Normal Operational Range - 4791 1639 (Solid) Most Severe Level January 2024 600S/660SJ – 1435378-000...

  • Page 261: Oscillating Axle Lock Cylinder Operation

    Drive machine onto block on left front or right front. Lift the boom approximately 2 feet (0.6096 m). With boom still raised drive off block carefully and see if axle is locked. Lower boom to stowed position and drive, the axle should unlock. 600S/660SJ – 1435378-000 January 2024...

  • Page 262: Swing Drive Adjustment Procedure

    Rotate adjustment ring to move swing drive as far away from rotation bearing as possible. Place shim (available from Snorkel) on green high point mark on rotation bearing. Rotate turntable until pinion bearing on swing drive is centered on the shim.

  • Page 263: Boom Elevation And Limit Switch Adjustment

    With boom raised check to verify there is continuity between Pin 1 (yellow wire) and Pin 2 (white wire). Reconnect the P1 plug and return the machine to the stowed position. Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 264 With boom extended P14-9 should show off and P14-10 should show off. Dual Capacity Limit Switch With boom retracted on to switch P14-9 should show on and P14-10 should show off. With boom extended past switch P14-9 should show off and P14-10 should show on. January 2024 600S/660SJ – 1435378-000...

  • Page 265: Boom Pressure Settings

    Section 10 Procedures & Adjustments BOOM PRESSURE SETTINGS Hydraulic Pressure Adjustments for Function Manifold Deutz Engine Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 266 6A..................Steer Right Relief – 2,900 psi 7.................Platform Level Up Relief – 2,900 psi 7A................. Platform Level Down Relief – 2,900 psi 8........Pressure Reducing Valve (Preset By Manufacturer at 400 psi) Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 267 Operate jib boom down fully and read gauge, pressure should be 2,500 psi, if adjustment is required adjust jib boom up relief (item 5) clockwise to increase pressure and counterclockwise to decrease pressure. Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 268 14. Operate platform level down fully and read gauge, pressure should be 2,900 psi, if adjustment is required adjust platform level down relief (item 7A) clockwise to increase pressure and counterclockwise to decrease pressure. Note: return machine to stowed position when finished. January 2024 600S/660SJ – 1435378-000...

  • Page 269: Turntable Lock Pin Location

    Section 10 Procedures & Adjustments BOOM PRESSURE SETTINGS Hydraulic Pressure Adjustments for Function Manifold Turntable Lock Pin Location Properly Stowed Position Turntable Lock Pin 600S/660SJ – 1435378-000 January 2024...

  • Page 270: Extend/Retract Boom Cable Inspection And Adjustment

    C. If there is still hesitation more adjustment is needed D. After cables are adjusted retighten the jam nuts. January 2024 600S/660SJ – 1435378-000...

  • Page 271: Booms Disassembly / Extend Cylinder Removal

    Using a 4 ton or greater hoist remove intermediate and tip boom along with extend cylinder. Paying attention to extend and retract cable wile removing tip boom. 10. Reverse the procedure to reassemble the extend cylinder and boom sections. 600S/660SJ – 1435378-000 January 2024...

  • Page 272: Cylinder Removal

    Remove retainers (item 3, page 169) and pin (item 5 page 169) and remove cylinder using a forklift or another hoist. 10. Reverse the procedure to reinstall main boom cylinder using anti-seize on pins. January 2024 600S/660SJ – 1435378-000...

  • Page 273: Jib Boom

    Secure the cylinder with a hoist, then remove 10mm bolt and lower pin (item 2) to remove the cylinder (item 6). Carefully remove cylinder (item 6). Note: Pay attention to shims used on cylinder pins. Reverse procedure for reinstalling the jib boom cylinder using anti-seize on pins. 600S/660SJ – 1435378-000 January 2024...

  • Page 274: Rotator

    All air should be purged from the opposite direction. actuator. With port P2 still open, apply pressure to port V2 allowing oil/air to be purged from the open port. TCB21.008 January 2024 600S/660SJ – 1435378-000...
  • Page 275 Section 10 Procedures & Adjustments ROTATOR Bleeding Procedure Platform Rotator with Platform Mounts Platform Mount 600S/660SJ – 1435378-000 January 2024...

  • Page 276: Assembly And Disassembly

    17..................O-Ring (Piston & Endcap Inside) 18........................Stopper - RH 19..........................Endcap 20........................Dowel Pin Note 1: Torque to 106 in/lbs (12 Nm). Note 2: Torque to 120 in/lbs (13.5 Nm). Note 3: Torque to 350 in/lbs (40 Nm). January 2024 600S/660SJ – 1435378-000...

  • Page 277: Assembly And Disassembly Procedure

    Align piston (15) with marks on Tube (9) to insert in the correct orientation. 10. Install Rod (1) with marks on Piston (15) to insure correct orientation. 11. Reinstall Endcap (19). Torque it until the pin holes align. 12. Reinstall pins (20). 600S/660SJ – 1435378-000 January 2024...

  • Page 278: Troubleshooting Guide

    9. Port fittings are obstructing the piston during Check thread length of port fittings. Fittings stroke should not reach inside the housing bore. * Replacement parts may be needed. January 2024 600S/660SJ – 1435378-000...

  • Page 279: Overload Calibration

    19. When machine goes into overload observe the screen at lower controls lights at platform, and operate override switch at upper controls to make sure override switch functions correctly. 20. Actuate the emergency stop button and turn the battery disconnect switch to the off position. 600S/660SJ – 1435378-000 January 2024...

  • Page 281: Section 11 Stage

    SECTION 11 Stage V...

  • Page 282: Engine

    Right View 1..........................Flywheel 2......................Turbocharger Oil Line 3.........................EGR Valve 4........................Oil Separator 5......................Engine Oil Dipstick 6......................Fuel Primer Pump 7......................Engine Oil Filler Cap 8.........................Engine Oil Filter 9......................Fuel Injector Pump 10....................Fuel Pressure Requlator January 2024 600S/660SJ – 1435378-000...

  • Page 283: Left View

    9..........................Starter 10........................EGR Pipe 11 ....................Diesel Oxygen Catalyst 12..................Turbo Charger and Waste Gate 13......................Exhaust Manifold 14..................Air Cleaner Housing and Hoses 15........................Radiator Cap 16...................... Upper Radiator Hose 17............Thermostat Housing and Engine Temperature Switch 600S/660SJ – 1435378-000 January 2024...

  • Page 284: Deutz Stage V

    8.........................Engine Oil Filter 9......................Crankshaft Sensor 10...................... Lower Radiator Hose 11 ......................Radiator Assembly 12........................Idler Pulley 13...................... Coolant Overfill Hose 14........................Intake Tube 15..................... Air Cleaner Inlet Tube 16..................Turbo Charger And Waste Gate 17..........................DOC January 2024 600S/660SJ – 1435378-000...

  • Page 285: Left View

    7.......................... Fuel Filter 8......................Fuel Injector Pump 9......................Flywheel Location 10..........................DOC 11 ................Fuel Injection Lines and Injectors 4x 12........................Air Cleaner 13...................... Upper Radiator Hose 14........................Air Inlet Tube 15..............Thermostat Housing and Temperature Switch 600S/660SJ – 1435378-000 January 2024...

  • Page 286: Engine Harness

    Page 1 of 2 Refer to page 287 DIAG. CAN LO DIAG. CAN HI SNORKEL CAN LO SNORKEL CAN HI J1939 POWER J1939 GROUND W128 W127 W126 W125 W129 W124 W131 W130 Refer to page 288 January 2024 600S/660SJ – 1435378-000...
  • Page 287 B+ STUD W14 SHIELDED CABLE W17 SHIELDED CABLE F3.1 30A W109 W105 W23.2 W108 W21.2 W106 W110 F78 WATER IN FUEL SENSOR INTAKE TEMP SENSOR F80 W100 W101 W102 W103 W104 W107 W111 DEUTZ ENGINE ECM 600S/660SJ – 1435378-000 January 2024...
  • Page 288 INTAKE TEMP SENSOR F NEUTRAL START W119 IGNITION W120 J8 GROUND CONTROL CAN LO W121 CAN HI W122 POWER W123 GROUND E-PUMP B+ POWER STUD E-PUMP RELAY B A M F H G J1939 DIAGNOSTIC January 2024 600S/660SJ – 1435378-000...
  • Page 289 Section 11 Stage V ENGINE HARNESS Deutz Engine Page 2 of 2 Refer to page 290 Refer to page 291 600S/660SJ – 1435378-000 January 2024...
  • Page 290 Section 11 Stage V ENGINE HARNESS Deutz Engine Page 2 of 2 F3.1 ECU 30A FUSE GLOW PLUG RELAY B+ POWER STUD ALTERNATOR D2.2 DIODE SPLICES AMBIENT TEMP B- GROUND STUD COOLANT LEVEL SENSOR January 2024 600S/660SJ – 1435378-000...
  • Page 291 J1939 120 OHM B+ POWER F1.1 FUEL STUD 20A FUSE TELEMATIC SPLICES SPLICE D2.1 D2.2 1A FUSE SPLICES S12 S13 SPLICES SPLICES GRND FUEL PUMP POWER B- GROUND STUD WATER IN FUEL SENSOR E-PUMP RELAY 600S/660SJ – 1435378-000 January 2024...

  • Page 292: Lower Control Box

    Platform Rotate DPF Regen Lamp Overload Lamp Platform Level 25 AMP CB Wait to Start Emergency Stop Lamp Rotation E-Power Enable Down Boom Up/Down Start Boom Extend/Retract Refer to page 104 for 400 board pinouts. January 2024 600S/660SJ – 1435378-000...

  • Page 293: Bottom View

    J12 (Drive Lights) J11 (Running Lights) J14 (Cold Weather Package) J13 (Generator) J15 (Hyd. Oil Cooler) J16 (Limit Switch) J18 (Boom Length) J20 (Rotation Sensor) J19 (Boom Angle) Refer to page 104 for 400 board pinouts. 600S/660SJ – 1435378-000 January 2024...

  • Page 294: Internal Wiring

    Section 11 Stage V LOWER CONTROL BOX 600S Internal Wiring Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 295 Section 11 Stage V LOWER CONTROL BOX 600S Internal Wiring Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 296 Section 11 Stage V LOWER CONTROL BOX 600S Internal Wiring January 2024 600S/660SJ – 1435378-000...

  • Page 297: 660Sj

    Platform Rotate DPF Regen Lamp Platform Level Overload Lamp 25 AMP CB Wait to Start Emergency Stop Lamp Rotation E-Power Enable Down Boom Up/Down Start Boom Extend/Retract Refer to page 104 for 400 board pinouts. 600S/660SJ – 1435378-000 January 2024...

  • Page 298: Bottom View

    J12 (Drive Lights) J11 (Running Lights) J14 (Cold Weather Package) J13 (Generator) J15 (Hyd. Oil Cooler) J16 (Limit Switch) J17 (Axle Switch) J20 (Rotation Sensor) J19 (Boom Angle) Refer to page 104 for 400 board pinouts. January 2024 600S/660SJ – 1435378-000...

  • Page 299: Internal Wiring

    Section 11 Stage V LOWER CONTROL BOX 660S Internal Wiring Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 300 Section 11 Stage V LOWER CONTROL BOX 660S Internal Wiring Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 301 Section 11 Stage V LOWER CONTROL BOX 660S Internal Wiring 600S/660SJ – 1435378-000 January 2024...

  • Page 302: Turntable Electrical Installation

    Section 11 Stage V TURNTABLE ELECTRICAL INSTALLATION Deutz Stage V Dual Capacity January 2024 600S/660SJ – 1435378-000...
  • Page 303 Section 11 Stage V TURNTABLE ELECTRICAL INSTALLATION Deutz Stage V Dual Capacity 600S/660SJ – 1435378-000 January 2024...

  • Page 304: Upper Control Box

    Override Alarm Mini Platform Lights Output Bottom View Note: Drive Lights Use J7 to Route Switch Load Cell Wiring J6 Layout Through Cords Description Snorkel Guard Beacon Light Platform Rotate Cold Weather Platform Lights Switch January 2024 600S/660SJ – 1435378-000...

  • Page 305: Harness

    P14 14 B+ TERM START SWITCH 2 B+ TERM J3 1 B TERM HIGH SPEED SWITCH 600 lbs CAPACITY AMBER LAMP SNORKEL GUARD SENSOR J10 IGNITION P14 4 CONNECTOR 1 CONNECTOR 2 CONNECTOR 1 CONNECTOR 2 POSITION POSITION PLATFORM LEVEL...
  • Page 306 POSITION LEVEL UP P14 1 B+ TERM HIGH SPD DRIVE 2 P7 6 LEVEL DOWN P14 2 P7 2 P7 1 SNORKEL GUARD OVERRIDE SWITCH CONNECTOR 1 CONNECTOR 2 POSITION POSITION JS B JIB/PLATFORM ROTATE JOYSTICK P14 12 CONNECTOR 1...
  • Page 307 B TERM POSITION POSITION B+ TERM B+ TERM E STOP 2 1 P14 14 B+ TERM B+ TERM B TERM SNORKEL GUARD SENSOR J10 CONNECTOR 1 CONNECTOR 2 POSITION POSITION FOOT SWITCH J3 B+ TERM CONNECTOR 1 CONNECTOR 2 POSITION...
  • Page 308 Section 11 Stage V UPPER CONTROL BOX 600S Dual Capacity Harness January 2024 600S/660SJ – 1435378-000...

  • Page 309: Pinouts

    Start Switch (Mom) P14-5 Horn Switch White Horn Switch P14-6 J3-3 White Enable Foot Switch P14-7 Emergency Power Switch White Emergency Power Switch P14-8 J10-4 (Mom) Black Snorkel Guard Prox Switch P14-11 Snorkel Guard Proximity Switch 600S/660SJ – 1435378-000 January 2024...
  • Page 310 Jumper High Speed Drive Post 2 High Post2 Switch Speed Drive Switch White Jumper Platform Level Post 2 Post 2 Switch Platform Level Switch White Jumper Snorkel Guard Post 2 Snorkel Post 2 Override Switch Guard/Drive Switch January 2024 600S/660SJ – 1435378-000...
  • Page 311 Overload And Tilt Red Lamp Red Light Overload Tilt Red Light Black Ground Jumper 1000 Lbs 1000lbs 600 Lbs Capacity Amber Capacity Green Light Capacity Lamp Green Lamp Black Ground J2-6 B- Terminal White B+ Power J2-8 B+ Terminal 600S/660SJ – 1435378-000 January 2024...

  • Page 312: Top And Bottom View

    J6 Routing Platform Lights Output Drive Lights Note: Bottom View Switch Use J7 to Route J6 Layout Load Cell Wiring Through Cords Description Snorkel Guard Beacon Light Platform Rotate Cold Weather Platform Lights Switch January 2024 600S/660SJ – 1435378-000...

  • Page 313: Harness

    Section 11 Stage V UPPER CONTROL BOX 660SJ Single Capacity Harness Refer to page 315 Refer to page 316 Refer to page 314 600S/660SJ – 1435378-000 January 2024...
  • Page 314 CONNECTOR 1 CONNECTOR 2 LEVEL UP P14-1 POSITION POSITION HIGH SPD DRIVE 2 B+ TERM LEVEL DOWN P14-2 P8-6 P8-2 SNORKEL GUARD OVERRIDE SWITCH P8-1 CONNECTOR 1 CONNECTOR 2 POSITION POSITION JS-C TELESCOPE JOYSTICK P14-12 CONNECTOR 1 CONNECTOR 2 PLATFORM LEVEL 2...
  • Page 315 CONNECTOR 1 CONNECTOR 2 B- TERM POSITION POSITION B+ TERM E-STOP 2-1 P14-14 B+ TERM B+ TERM B- TERM SNORKEL GUARD SENSOR J10 CONNECTOR 1 CONNECTOR 2 POSITION POSITION FOOT SWITCH J3 B+ TERM CONNECTOR 1 CONNECTOR 2 POSITION POSITION...
  • Page 316 Section 11 Stage V UPPER CONTROL BOX 660SJ Single Capacity Harness January 2024 600S/660SJ – 1435378-000...

  • Page 317: Pinouts

    White 12V Supply From Tbm B+ P5-3 B+ Terminal White Platform Rotate Enable Valve P5-4 J6-1 Black Battery Ground Supply P5-7 Ground Terminal Snorkel Guard Flashing Light P5-8 J11-1 White Drive P6-1 JSD-4 Joystick White Steer P6-2 JSD-3 Joystick Black...
  • Page 318 Ground Jumper Glow Plugs Ring Terminal Post 2 Black Ground Jumper Amber Ring Terminal Post 2 Engine Warning Black Ground Jumper Red Engine Ring Terminal Post 2 Warning Black Ground B- Terminal Ring Terminal Post 2 January 2024 600S/660SJ – 1435378-000...

  • Page 319: Top And Bottom View

    J6 Routing Platform Lights Output Bottom View Drive Lights Note: Switch Use J7 to Route J6 Layout Load Cell Wiring Cords Description Through Snorkel Guard Beacon Light Platform Rotate Cold Weather Platform Lights Switch 600S/660SJ – 1435378-000 January 2024...

  • Page 320: Harness

    Section 11 Stage V UPPER CONTROL BOX 660SJ Dual Capacity Harness Refer to page 323 Refer to page 322 Refer to page 321 January 2024 600S/660SJ – 1435378-000...
  • Page 321 POSITION LEVEL UP P14 1 B+ TERM HIGH SPD DRIVE 2 P7 6 LEVEL DOWN P14 2 P7 2 P7 1 SNORKEL GUARD OVERRIDE SWITCH CONNECTOR 1 CONNECTOR 2 POSITION POSITION JS B JIB/PLATFORM ROTATE JOYSTICK P14 12 CONNECTOR 1...
  • Page 322 B TERM POSITION POSITION B+ TERM B+ TERM E STOP 2 1 P14 14 B+ TERM B+ TERM B TERM SNORKEL GUARD SENSOR J10 CONNECTOR 1 CONNECTOR 2 POSITION POSITION FOOT SWITCH J3 B+ TERM CONNECTOR 1 CONNECTOR 2 POSITION...
  • Page 323 Section 11 Stage V UPPER CONTROL BOX 660SJ Dual Capacity Harness 600S/660SJ – 1435378-000 January 2024...

  • Page 324: Pinouts

    12 Volt Supply From TBM B+ P5-3 B Positive Terminal White Platform Rotate Selector P5-4 J6-1 Valve Black Battery Ground Supply P5-7 Ground Terminal Snorkel Guard Blue Flashing P5-8 J11-1 Light White Boom Extend /Retract P6-1 Joystick C-3 -Boom Extend/ Retract White Steer P6-2...
  • Page 325 Emergency Power Switch Stop 2 White Jumper High Speed Drive Emergency Switch Stop 2 White Jumper Platform Level Switch Emergency Stop2 White Jumper Snorkel Guard Emergency Override Switch Stop 2 White Horn Switch B+ Terminal 600S/660SJ – 1435378-000 January 2024...
  • Page 326 Pinouts Wire # Color Function Connection 1 Termination Point Black Ground Terminal Black Ground Jumper Black Ground Jumper Black Ground B- Terminal B- Terminal Black Ground J2-6 B- Terminal White B+ Power J2-8 B+ Terminal January 2024 600S/660SJ – 1435378-000...

  • Page 327: Section 12 Maintenance

    SECTION 12 Maintenance...

  • Page 328: General Maintenance

    When raising a portion of the machine, be sure that adequate blocking is properly positioned. Do not de- Snorkel recommends that you make additional copies of pend solely on the lifting device to hold and secure the preventative inspection and maintenance checklists weight.
  • Page 329 Shields, covers, seals and filters help to keep air and oil supplies clean. However, these items must be maintained Replace any guards and protective devices that have been on a scheduled basis in order to function properly. removed to carry out maintenance and repair work. 600S/660SJ – 1435378-000 January 2024...

  • Page 330: Lubrication Points

    LUBRICATION POINTS Lubrication Swing Drive Specific lubricants as recommended by Snorkel, should Swing drive – Item 4. To check oil level, remove check be used in maintaining the unit. If in doubt regarding the plug located on the side of the gear box. Unit is full if oil use of lubricants other than those listed, contact Snor- is level with bottom of fill hole or just starts to run out.
  • Page 331 Local oil suppliers can generally furnish this information. collect dirt or debris. If questions still remain, contact Snorkel Customer Ser- Slide Pads vice Department for further information. Slide pads – Item 11. Check slide pads for excessive wear and replace as required.

  • Page 332: Battery Care And Maintenance

    (higher amperage at the oversized charger will cause excess gassing and end of charge). Usually, older batteries need to be heat that could possibly result in a battery meltdown watered more often and their capacity decreases. and/or explosion. January 2024 600S/660SJ – 1435378-000...
  • Page 333 “thermal run away” which may lead to an explosion or fire. If extreme temperature is an unavoidable part of an application, consult a battery/charger specialist about ways to deal with the problem. 600S/660SJ – 1435378-000 January 2024...

  • Page 334: Maintenance Schedule

    No damage or deformation of trays, pins, and straps Platform Welder/Generator No damage or deformation, proper operation Placards and Decals In place and readable Maintenance Table Key: P = Pass, F = Fail, R = Repaired Performed by: Date: Model Number: Serial Number: January 2024 600S/660SJ – 1435378-000...

  • Page 335: Frequent Inspection And Maintenance - Every 90 Days Or 150 Hours

    Rotation backlash Check for wear and damage Operator’s Manual Proper manual in document holder System pressure Check maximum system pressure 4,900 – 5,000 psi Decals and placards Check for damage and readability Order replacements as necessary 600S/660SJ – 1435378-000 January 2024...
  • Page 336 Sheaves and wire rope anchors Check for wear and damage Wire ropes Check for wear and damage Cables Check for proper installation Cables Properly tensioned Whiffle bracket Check for proper installation Bracket should be straight January 2024 600S/660SJ – 1435378-000...
  • Page 337 Hydraulic fluid level Check for proper level Dexron III ATF Hydraulic filter Replace after the first 50 hours, every 90 days or 150 hours thereafter Inspect filter for foreign matter that could indicate component wear 600S/660SJ – 1435378-000 January 2024...
  • Page 338 Check condition and for proper operation Optional platform Verify that all fasteners are in place and are tight Maintenance Table Key: P = Pass, F = Fail, R = Repaired Performed by: Date: Model Number: Serial Number: January 2024 600S/660SJ – 1435378-000...

  • Page 339: Frequent Maintenance - Every 90 Days Or 150 Hours

    See engine owner’s manual Engine fuel filter Check condition Replace every 6 months or if dirty Maintenance Table Key: P = Pass, F = Fail, R = Repaired Performed by: Date: Model Number: Serial Number: 600S/660SJ – 1435378-000 January 2024...

  • Page 340: Annual Maintenance - Every 500 Hours

    SAE Grade 80W-90 Swing drive Replace fluid Sae Grade 80W-90 Engine coolant Check condition See engine owner’s manual Maintenance Table Key: P = Pass, F = Fail, R = Repaired Performed by: Date: Model Number: Serial Number: January 2024 600S/660SJ – 1435378-000...

  • Page 341: Major Repairs

    Section 12 Maintenance MAJOR REPAIRS Date Part Number Part Description Repair Performed 600S/660SJ – 1435378-000 January 2024...

  • Page 342: Filter Service Intervals

    Fuel Filter - Deutz 2.9 7631195 Fuel Water Separator - Deutz 2.9 7631190 Air Filter Element - Kubota 510378-001 Air Filter Element - Cummins Q 7631103 Air Filter Element - Deutz 2.9 5089690 Hydraulic Charge Filter Element 5089684 January 2024 600S/660SJ – 1435378-000...
  • Page 343 SECTION 13 Schematics...

  • Page 344: Section 13 Schematics

    Section 13 Schematics HYDRAULIC SCHEMATIC Dual Capacity Page 1 January 2024 600S/660SJ – 1435378-000...
  • Page 345 Section 13 Schematics HYDRAULIC SCHEMATIC Dual Capacity Page 2 600S/660SJ – 1435378-000 January 2024...

  • Page 346: Deutz Engine

    Section 13 Schematics HYDRAULIC SCHEMATIC Deutz Engine Turntable with Tow Package and Hydraulic Warm-up Valve January 2024 600S/660SJ – 1435378-000...

  • Page 347: Turntable With Oil Cooler

    Section 13 Schematics HYDRAULIC SCHEMATIC Deutz Engine Turntable with Oil Cooler Page 1 600S/660SJ – 1435378-000 January 2024...
  • Page 348 Section 13 Schematics HYDRAULIC SCHEMATIC Deutz Engine Turntable with Oil Cooler Page 2 January 2024 600S/660SJ – 1435378-000...

  • Page 349: Traction Manifold

    Section 13 Schematics HYDRAULIC SCHEMATIC Deutz Engine Traction Manifold 600S/660SJ – 1435378-000 January 2024...

  • Page 350: Kubota Engine

    Section 13 Schematics HYDRAULIC SCHEMATIC Kubota Engine Function Manifold January 2024 600S/660SJ – 1435378-000...

  • Page 351: Electrical Schematic

    Section 13 Schematics ELECTRICAL SCHEMATIC Dual Capacity Harness 600S/660SJ – 1435378-000 January 2024...
  • Page 352 Section 13 Schematics ELECTRICAL SCHEMATIC Dual Capacity Harness January 2024 600S/660SJ – 1435378-000...

  • Page 353: Engine Harness

    Section 13 Schematics ELECTRICAL SCHEMATIC Engine Harness Kubota T3/T4i 600S/660SJ – 1435378-000 January 2024...

  • Page 354: Deutz Tcd2.9L T4F

    Section 13 Schematics ELECTRICAL SCHEMATIC Engine Harness Deutz TCD2.9L T4F January 2024 600S/660SJ – 1435378-000...

  • Page 355: Deutz Tcd2.9L Stage V

    Section 13 Schematics ELECTRICAL SCHEMATIC Engine Harness Deutz TCD2.9L Stage V DIAG. CAN LO DIAG. CAN HI SNORKEL CAN LO SNORKEL CAN HI J1939 POWER J1939 GROUND W128 W127 W126 W125 W129 W124 W131 W130 600S/660SJ – 1435378-000 January 2024...

  • Page 356: Deutz D2.9 T4F

    Section 13 Schematics ELECTRICAL SCHEMATIC Engine Harness Deutz D2.9 T4F January 2024 600S/660SJ – 1435378-000...

  • Page 357: Cummins Qsf 2.8L T4F

    Section 13 Schematics ELECTRICAL SCHEMATIC Engine Harness Cummins QSF 2.8L T4F 600S/660SJ – 1435378-000 January 2024...

  • Page 358: Board Pin Outs

    High Side PWM Output Steer Right Steer Right P4-6 High Side 2A Output 1,000 lb Region Light 1,000 lb Region Light Snorkel Guard Blue Flashing Snorkel Guard Blue Flashing P4-7 High Side PWM Output Light Light P4-8 High Side PWM Output...
  • Page 359 Engine Start (Crank) SW P7-9 B+ Digital Input Platform Level Up Platform Level Up P7-10 B+ Digital Input Platform Level Down Platform Level Down DPF Regeneration Standstill P7-11 B+ Digital Input Switch Continued on next page... 600S/660SJ – 1435378-000 January 2024...
  • Page 360 P9-4 RS232 GND Display Ground Display Ground J1939 Throttle Actuator, Not P12-1 CAN2 H Engine ECU CAN H Used J1939 Throttle Actuator, Not P12-2 CAN2 L Engine ECU CAN L Used Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 361 On When Retracted On When Retracted Dual Capacity Limit SW (NC, Dual Capacity Limit SW (NC, P14-10 B+ Digital Input Off When Retracted) Off When Retracted) P14-11 B+ Countable Input Alternator Tach/Pulse P14-12 Negative (B-) Countable Input 600S/660SJ – 1435378-000 January 2024...

  • Page 362: Gp440

    High Side 2A Output DPF Regeneration Standstill Lamp High Side PWM P4-11 Output P4-12 High Side 2A Output Wait-to-Start Lamp Wait-to-Start Lamp P4-13 High Side 2A Output P4-14 High Side 2A Output High Side PWM P4-15 Output Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 363 (Jib Function When Disable) (Jib Function When Disable) P5-5 High Side 2A Output P5-6 Analog Input P5-7 Battery Ground Supply Battery Ground Supply Snorkel Guard Blue Flashing Snorkel Guard Blue Flashing P5-8 High Side 2A Output Light Light P5-9 Analog Input P6-1...
  • Page 364 Only If Elev. SW P15-9 Iis at P14-4 Digital Input P14-5 Digital Input Start SW Start SW P14-6 Digital Input Horn SW Horn SW P14-7 Digital Input P14-8 Digital Input Emergency Power Emergency Power Continued on next page... January 2024 600S/660SJ – 1435378-000...
  • Page 365 Left Turn Signal SW P14-10 Digital Input Right Turn Signal SW Right Turn Signal SW P14-11 Digital Input Snorkel Guard Proxi SW Snorkel Guard Proxi SW P14-12 Digital Input Snorkel Guard Override SW Snorkel Guard Override SW P14-13 Digital Input...

  • Page 366: 12V Tbm

    B+ supply to all I/O B- Battery B- supply to all I/O tp P8-14 of GP400 Platform select switch P7-4 of GP400 Ground Select Switch P7-2 of GP400 P8-9 of GP400 After EMS GND P15-10 January 2024 600S/660SJ – 1435378-000...

  • Page 367: Vccm

    Current Control PWM output Hydrostatic Pump Drive Release Valve 6 Minimum Current 0.0A Valve 6 Maximum Current 1.6A VP11-1 12/24V module supply VP11-2 GND module supply VP12-1 CANH VP12-2 CANL VP12-3 VP13-1 CANH VP13-2 CANL VP13-3 600S/660SJ – 1435378-000 January 2024...

  • Page 368: Lower Control Box

    Section 13 Schematics ELECTRICAL SCHEMATIC Lower Control Box January 2024 600S/660SJ – 1435378-000...

  • Page 369: Upper Control Box

    Section 13 Schematics ELECTRICAL SCHEMATIC Upper Control Box 600S/660SJ – 1435378-000 January 2024...

  • Page 371: Section 14 Appendix

    SECTION 14 Appendix...

  • Page 372: Appendix A - Glossary

    This system includes a harness or belt, lanyard, and a lanyard anchor. Federal OSHA, ANSI, and Snorkel require the use of qualified person – a person, who by reason of knowledge, experience,...
  • Page 374 Local Distributor / Lokaler Vertiebshändler / Distributeur local El Distribuidor local / ll Distributore locale EUROPE, MIDDLE EAST AFRICA & ASIA PHONE: +44 (0) 845 1550 058 FAX: +44 (0) 845 1557 756 NORTH & SOUTH AMERICA PHONE: +1 785 989 3000 TOLL FREE: +1 800 255 0317 FAX: +1 785 989 3070 AUSTRALIA...

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