JLG 600S 600SJ 660SJ Service & Maintenance Manual 3121202 – January 2018 PDF
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492-page JLG service and maintenance manual for 600S, 600SJ and 660SJ boom lifts, P/N 3121202, revised January 30, 2018. Covers specifications, inspections, chassis and turntable repairs, boom and platform service, hydraulics, control-system diagnostics, and electrical and hydraulic schematics for the stated serial ranges.
Description
JLG 600S 600SJ 660SJ Service & Maintenance Manual 3121202 – January 2018 PDF
The JLG 600S 600SJ 660SJ Service & Maintenance Manual 3121202 – January 2018 PDF is a detailed technical reference for servicing, inspecting, troubleshooting and repairing the 600S, 600SJ and 660SJ boom lift models. This 492-page manual covers machines within SN 0300087000 through 0300171769 and SN B300000100 through B300000969, with serial-specific procedures identified throughout the document where component designs changed.
The manual goes well beyond routine maintenance. It combines operating and component specifications with chassis repair, wheel-drive and swing-system overhaul, boom and platform procedures, hydraulic cylinder service, pump and valve diagnostics, control-system analyzer information, engine and fuel-system material, electrical testing guidance, and extensive hydraulic and electrical schematics. For technicians working on a JLG 600S, 600SJ or 660SJ, the manual provides one structured reference for both mechanical repairs and system-level diagnosis.
File Details
- Manual type: Service and Maintenance Manual
- Brand: JLG
- Models: 600S, 600SJ, 660SJ
- Serial coverage: SN 0300087000 through 0300171769; SN B300000100 through B300000969
- Part number: 3121202
- Revision date: January 30, 2018
- Language: English
- Pages: 492
- File format: PDF
Specifications, Maintenance and Machine Service Data
The opening sections give the service data needed before major repairs begin. Operating specification tables cover such items as platform capacity, gradeability, turning radius, tire loading, ground bearing pressure, travel speed and approximate machine weights. Separate tables address capacities, dimensional data, torque requirements, tires, hydraulic oils, drive and swing systems, auxiliary power pump data, hydraulic filtration, performance information, cylinder dimensions, major component weights and critical stability weights.
Engine information is provided for configurations referenced in the manual, including Ford LRG – 425 and LRG – 423 applications, Deutz F4M1011F/F4M2011 and D2011L04, Caterpillar 3044C/3.4 and GM 3.0L. The specifications section includes fuel and lubrication capacities, engine speeds and other application-specific service information. Maintenance pages identify lubrication points, service intervals, filter replacement intervals and inspection requirements, supported by a maintenance and lubrication diagram.
Inspection material covers pre-start, pre-delivery, frequent and annual inspection considerations along with preventive maintenance. The general service guidance also deals with cleanliness, component removal and installation, pressure-fit parts, bearings, gaskets, fastener use, hydraulic lines, electrical wiring, lubrication, batteries, hydraulic contamination and cylinder drift testing.
Chapters Covered
- Introduction – Maintenance Safety Precautions
- General maintenance precautions, hydraulic system safety and maintenance requirements
- Section 1 – Specifications
- Operating specifications, capacities and component data
- Engine and dimensional data
- Torque requirements and tire specifications
- Hydraulic oil and lubrication information
- Drive system, swing system, auxiliary power pump and hydraulic filters
- Performance data and cylinder specifications
- Major component and critical stability weights
- Operator maintenance and lubrication intervals
- Propane regulator oil draining, fuel filter replacement and fuel-system pressure relief
- Serial number locations and fastener torque charts
- Section 2 – General
- Machine preparation, inspection and maintenance
- Pre-start, pre-delivery, frequent and annual inspections
- Preventative maintenance and service guidelines
- Component removal, disassembly and reassembly practices
- Bearings, gaskets, bolts, hydraulic lines and electrical wiring
- Hydraulic oil changing and lubrication information
- Cylinder drift theory, leakage testing and thermal drift
- Pins and composite bearing repair guidelines
- Welding precautions for JLG equipment
- Section 3 – Chassis & Turntable
- Tires, wheels and wheel torque procedures
- Oscillating axle bleeding and lockout testing
- Free wheeling and drive-hub engagement
- Wheel drive assembly removal and installation
- Drive hub testing, disassembly and assembly
- 2WD and 4WD drive motor service for applicable serial ranges
- Drive motor inspection, troubleshooting, shaft seal and speed sensor service
- Steering adjustments and swing hub removal and installation
- Swing gear backlash and lubrication
- Swing hub, motor, brake and bearing procedures
- Rotary coupling service for different machine build and serial ranges
- Engine installation and generator maintenance
- Ford EFI and LPG systems
- Deutz EMR 2 diagnostics and bio-fuel information
- GM engine maintenance, dual-fuel system repair and LPG diagnosis
- Section 4 – Boom & Platform
- Platform support removal and installation
- Rotator and slave cylinder service
- Main boom powertrack removal, installation and maintenance
- Main boom removal, disassembly, inspection, assembly and installation
- Articulating jib boom procedures
- Limit switch and cam valve adjustment
- Platform section replacement
- Boom rope torquing, wear pads and wire-rope inspections
- Rotator assembly disassembly, inspection, assembly and testing
- Foot switch adjustment
- Section 5 – Basic Hydraulics Information & Schematics
- Hydraulic O-ring lubrication and cylinder theory
- Cylinder checking procedures
- Axle lockout, platform level, jib lift, main boom lift, master, steer and telescope cylinders
- Cylinder removal and installation
- M46 Series variable displacement pump troubleshooting and repair
- Valve theory and relief valves
- Main relief, steer, swing, lift-down and platform-level pressure setting procedures
- Hydraulic component start-up recommendations
- Hydraulic pump drive coupling lubrication
- Six-sheet hydraulic schematic section
- Section 6 – JLG Control System
- JLG Control System Analyzer kit connection and operation
- Analyzer access levels and parameter adjustment
- Machine setup and configuration programming
- 600S, 600SJ and 660SJ machine configuration settings
- Machine personality settings and function speeds
- Analyzer flow charts, diagnostic menus and fault-code information
- Section 7 – Basic Electrical Information & Schematics
- Multimeter use, voltage, resistance, continuity and current measurement
- Electrical grounding and backprobing
- Silicone dielectric compound application
- AMP and DEUTSCH connector assembly and disassembly
- Electrical component installation diagrams
- Ten-sheet electrical schematic set plus GM electrical schematics
Together, these sections make the JLG 600S 600SJ 660SJ service manual useful for work ranging from scheduled inspections and lubrication through complete component removal, disassembly, measurement, reassembly and functional testing. Serial-specific subsections help distinguish different drive motors, swing hubs, rotary couplings, steering cylinders and other components fitted during the production ranges covered by the manual.
Mechanical Repair and Component Overhaul
A large portion of the manual is devoted to repair procedures rather than simple reference data. The chassis and turntable section includes detailed wheel-drive, planetary hub, drive motor, swing hub, swing motor, swing brake, bearing and rotary coupling work. Exploded illustrations and assembly drawings accompany many of these procedures, helping identify the relationship between gears, shafts, bearings, seals, hubs, brakes and hydraulic components during teardown and reassembly.
The boom and platform section provides similarly detailed coverage of the structural and motion components above the turntable. It addresses the main boom, articulating jib on applicable models, powertrack, platform support, rotator, leveling components, wear pads, wire ropes, limit switches and associated adjustments. Inspection and replacement criteria are included where the manual specifies them, including wire-rope inspection intervals and boom-related adjustment procedures.
Hydraulic Testing, Cylinders and Schematics
Hydraulic service receives extensive coverage in the JLG 600S 600SJ 660SJ Service & Maintenance Manual 3121202 – January 2018 PDF. Cylinder theory and checking procedures lead into illustrated repair sections for multiple cylinders used on the machines. The manual includes procedures for cylinder removal and installation as well as internal service illustrations for seals, bushings and related components.
IMAGES PREVIEW
The M46 Series variable displacement pump section includes troubleshooting, inspections, adjustments and repair information. Pressure-setting procedures address main relief, steering, swing, lift-down, platform level and applicable jib or four-wheel-steer circuits. A six-sheet hydraulic schematic set provides circuit-level reference for tracing machine functions and diagnosing hydraulic problems.
Control-System, Engine and Electrical Diagnosis
The JLG control-system section explains use of the hand-held analyzer, including connection, access levels, parameter changes, machine setup, configuration programming, personality settings and diagnostic menus. The manual contains model-specific configuration information for the 600S, 600SJ and 660SJ along with flow charts and fault-code references. This makes the manual relevant not only for mechanical repair but also for diagnosing machine-control problems and checking setup values after service.
Engine-related chapters address several power options used within the covered machines. The material includes engine installation, generator service, Ford EFI diagnostics, Ford LPG components, Deutz EMR 2 troubleshooting and connection information, and GM dual-fuel maintenance and fuel-system diagnosis. Electrical chapters then provide basic test methods, connector servicing and complete schematic coverage for tracing circuits through the machine.
Service the JLG 600S, 600SJ and 660SJ with the Correct Procedures
This manual supports routine maintenance, inspections, component replacement, hydraulic testing, chassis and boom repairs, engine and fuel-system troubleshooting, control-system diagnosis and electrical fault tracing on the covered JLG 600S, 600SJ and 660SJ machines. Having the correct procedures, serial-specific information, adjustment data, torque references and schematics available during a repair helps technicians work from documented specifications instead of relying on guesswork.
Purchase the JLG 600S 600SJ 660SJ Service & Maintenance Manual 3121202 – January 2018 PDF for instant PDF delivery after payment. There is no physical shipping to wait for: the manual can be opened on a computer, tablet or phone and printed when a paper reference is useful in the workshop.
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