JLG 600S 600SJ 660SJ Boom Lift Service and Maintenance Manual – P/N 3121202

Description

JLG 600S 600SJ 660SJ Boom Lift Service and Maintenance Manual

This is the complete JLG 600S 600SJ 660SJ Boom Lift Service and Maintenance Manual, document number 3121202, covering machines from serial number 0300080000 to present. Originally issued October 15, 2004 and revised through March 12, 2008, this manual gives technicians the full factory-level detail needed to service, troubleshoot, and repair these telescopic boom lifts.

File Details

• Manual Type: Service and Maintenance Manual
• Brand/Models: JLG 600S, 600SJ, 660SJ
• Language: English
• Page Count: 304 pages
• File Format: PDF
• Document Number: 3121202
• Revision Date: March 12, 2008
• Serial Number Range: 0300080000 to Present

Chapters Covered

• Introduction – Maintenance Safety Precautions
• Section 1 – Specifications
  • Capacities, Component Data, Engine Data (Ford LRG-425, Deutz F4M1011F/F4M2011, Deutz D2011L04, Caterpillar 3044C, GM 3.0L)
  • Performance Data, Machine Weight, Dimensional Data
  • Function Speeds, Torque Requirements, Lubrication
  • Pressure Settings, Cylinder Specifications
  • Major Component Weights, Critical Stability Weights
  • Lubrication and Operator Maintenance, Serial Number Locations
• Section 2 – General
  • Machine Preparation, Inspection, and Maintenance
  • Service and Guidelines, Lubrication and Information
  • Cylinder Drift Test, Pins and Composite Bearing Repair Guidelines
  • Welding on JLG Equipment
• Section 3 – Chassis & Turntable
  • Drive Torque Hub Disassembly, Assembly and Testing
  • Free Wheeling Option, Drive Motor Service and Troubleshooting
  • Oscillating Axle Bleeding Procedure, Steer Adjustments
  • Swing Hub, Swing Bearing, Swing Brake – Mico
  • Tires & Wheels, Rotary Coupling, Generator
  • Ford EFI Engine Diagnostics, ECM/EPM and Sensors, Fuel System
  • Ford LPG System
• Section 4 – Boom & Platform
  • Boom Rope Torquing Procedures, Wear Pads, Wire Rope Inspection
  • Boom Maintenance – Removal, Disassembly, Assembly, Installation
  • Articulating Jib Boom, Limit Switches and Cam Valve Adjustment
  • Platform Sections Replacement, Rotator – Helac, Foot Switch Adjustment
• Section 5 – Hydraulics
  • Cylinders – Theory of Operation, Cylinder Checking Procedure
  • Cylinder Removal, Installation and Repair
  • Variable Displacement Pump (M46 Series) Troubleshooting
  • Valves – Theory of Operation, Pressure Setting Procedures
• Section 6 – JLG Control System
  • Connecting and Using the JLG Control System Analyzer
  • Machine Setup, Level Vehicle Description
  • Machine Personality Settings, Diagnostics Menu Structure
• Section 7 – Basic Electrical Information & Schematics
  • Multimeter Basics, AMP and Deutsch Connectors
  • Electrical and Hydraulic Schematics

Together these sections give a technician everything needed to move from routine inspection through full component teardown and rebuild, with the specification tables and schematics needed to work to factory tolerances rather than guesswork.

What This JLG 600S 600SJ 660SJ Service Manual Covers

With this JLG 600S 600SJ 660SJ Boom Lift Service and Maintenance Manual you can diagnose drive hub and swing bearing wear, rebuild drive motors and hydraulic cylinders, set relief and pressure valve settings to factory specification, service the Ford, Deutz, Caterpillar and GM engine options fitted to these boom lifts, and work through the JLG Control System Analyzer for fault codes and machine personality settings. Having the correct torque values, cylinder bore and stroke dimensions, and pressure settings on hand means repairs are done to the same standard JLG technicians use, reducing comebacks and premature part failure. This JLG 600S 600SJ 660SJ manual downloads instantly as a PDF after purchase – no shipping wait, no physical book to store. Read it on a laptop, tablet, or phone in the shop, or print out the pages you need for a specific 600S, 600SJ, or 660SJ repair job.