JLG 660SJC Manuals

Manuals and User Guides for JLG 660SJC. We have 4 JLG 660SJC manuals available for free PDF download: Service And Maintenance Manual, Operation And Safety Manual, Operator's And Safety Manual

JLG 660SJC Service And Maintenance Manual (216 pages)

Brand: JLG | Category: Lifting Systems | Size: 21.54 MB

A General
3
Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Section 1. Specifications

13
- Capacities
  13
  - Fuel Tank
    13
  - Hydraulic Oil Tank
    13
  - Hydraulic System (Including Tank)
    13
  - Engine Crankcase
    13
- Component Data
  13
  - Engine - Diesel (Liquid-Cooled)
    13
  - Swing System
    13
  - Auxiliary Power Pump
    13
- Performance Data
  14
  - Turning Radius (Outside)
    14
  - Turning Radius (Inside)
    14
  - Boom Elevation
    14
  - Machine Weight Approximately
    14
  - Machine Height (Stowed)
    14
  - Machine Length (Stowed)
    14
  - Machine Width
    14
- Function Speeds
  14
  - Machine Orientation When Doing Speed Tests
    14
  - Test Notes
    15
- Torque Requirements
  15
- Lubrication
  15
  - Deutz F4M1011F Engine
    15
  - Hydraulic Oil
    16
  - Lubrication Specifications
    16
- Pressure Settings
  16
- Cylinder Specifications
  17
- Major Component Weights
  17
- Critical Stability Weights
  17
- Serial Number Locations
  18
- Lubrication Point Location
  20
- Lubrication Chart
  21
Section 2. General

23
- Machine Preparation, Inspection, and Maintenance
  23
- Service and Guidelines
  24
  - General
    24
  - Safety and Workmanship
    24
  - Cleanliness
    24
  - Components Removal and Installation
    24
  - Component Disassembly and Reassembly
    25
  - Pressure-Fit Parts
    25
  - Bearings
    25
  - Gaskets
    25
  - Bolt Usage and Torque Application
    25
  - Hydraulic Lines and Electrical Wiring
    25
  - Hydraulic System
    25
  - Lubrication
    25
  - Battery
    25
  - Lubrication and Servicing
    25
- Lubrication and Information
  26
  - Hydraulic System
    26
  - Hydraulic Oil
    26
  - Changing Hydraulic Oil
    26
  - Lubrication Specifications
    26
- Cylinder Drift Test
  27
  - Platform Drift
    27
  - Cylinder Drift
    27
- Pins and Composite Bearing Repair Guidelines
  27
- Welding on JLG Equipment
  28
  - Do the Following When Welding on JLG Equipment
    28
  - Do NOT Do the Following When Welding on JLG Equipment
    28
- Applying Silicone Dielectric Compound to Electrical Connections
  28
- Inspection and Preventive Maintenance Schedule
  29
Section 3. Turntable

33
- Throttle Checks and Adjustments - Deutz
  33
  - General
    33
  - Procedure
    33
  - Controller Status
    33
  - Failure Modes
    34
- Swing Hub
  35
  - Adjustment Procedures
    35
- Swing Bearing
  35
- Swing Bearing Tolerance Boom Placement
  37
  - Swing Bearing Torque Values
    38
  - Swing Brake - Mico
    39
    
    Disassembly
    39
    
    Inspection
    39
    
    Assembly
    39
- Swing Brake Assembly (Mico)
  40
  - Tilt Alarm Switch
    41
    
    Manual Adjustment
    41
Section 4. Boom & Platform

43
- Platform
  43
  - Platform Sections Replacement
    43
- Boom Rope Torquing Procedures
  43
  - Torque Procedures
    43
- Wear Pads
  44
  - Main Boom
    44
- Wire Rope
  45
  - Inspection
    45
  - Three Month Inspection
    45
  - Year or 7000 Hour Replacement
    45
  - Additional Replacement Criteria
    45
Subject - Section, Paragraph

46
- Boom Maintenance
  46
  - Removal
    46
- Location of Components - Boom Powertrack
  47
- Boom Assembly Cutaway - S Models - Sheet 1 of 3
  48
- Boom Assembly Cutaway - S Models - Sheet 2 of 3
  49
  - Disassembly of Boom Sections
    50
  - Inspection
    51
  - Assembly
    52
- Routing Installation of Retract Wire Ropes
  53
- Boom Powertrack Installation
  55
  - Installation
    56
  - Articulating Jib Boom
    56
    
    Removal
    56
    
    Disassembly
    56
    
    Inspection
    56
    
    Assembly
    57
  - Limit Switch Adjustment
    57
- Limit Switches Adjustments
  58
  - Rotator - Helac
    59
    
    Theory of Operation
    59
    
    Required Tools
    59
- Rotator Assembly (Helac)
  60
- Rotary Actuator - Exploded View
  61
- Rotary Actuator - Assembly Drawing
  62
  - Disassembly
    63
  - Inspection
    67
  - Assembly
    67
  - Foot Switch Adjustment
    72
  - SUPERFLEX Controller
    72
    
    System Overview
    72
    
    System Elements
    72
    
    General Description
    73
    
    SUPERFLEX Terminal Identification
    73
    
    SUPERFLEX Terminal Assignments
    73
- Wiring Diagram - Single Coil Uni-Directional Flow Control Valve - 1 Axis
  74
- Digisensor Troubleshooting
  80
- OPTIMIZER Keypad
  82
Section 5. Hydraulics

99
- Cylinders - Theory of Operation
  99
  - Systems Incorporating Double Acting Cylinders
    99
  - Systems Incorporating Holding Valves
    99
- Valves - Theory of Operation
  99
  - Solenoid Control Valve - Rexroth
    99
  - Relief Valves
    99
- Cylinder Checking Procedure
  99
- Cylinder Repair
  101
  - Disassembly
    101
  - Cleaning and Inspection
    102
  - Assembly
    103
- Installation of Head Seal Kit
  104
- Tapered Bushing Installation
  105
- Rod Assembly Installation
  106
  - Cylinder Removal and Installation
    107
    
    Main Boom Telescope Cylinder Removal
    107
    
    Main Boom Telescope Cylinder Installation
    107
    
    Main Boom Lift Cylinder Removal
    108
    
    Main Boom Lift Cylinder Installation
    108
  - Pressure Setting Procedures
    109
    
    Main Relief, Steer, Swing and Lift down
    109
    
    Platform Level
    109
    
    Articulating Jib Boom (if Equipped)
    109
Subject - Section, Paragraph

107
Section 6. Undercarriage Prior to S/N 0300070975

125
- Track Carrier Roller
  125
  - Removal
    125
  - Installation
    126
  - Disassembly
    126
- Track Carrier Roller - Exploded View
  127
  - Track Carrier Roller
    128
  - Assembly
    129
  - Track Roller
    132
    
    Removal
    132
- Track Roller - Exploded View
  133
  - Disassembly
    134
  - Assembly
    135
  - Installation
    138
  - Track
    139
    
    Separate
    139
    
    Connect
    140
  - Front Idler and Recoil Spring
    142
    
    Removal
    142
    
    Installation
    142
    
    Front Idler Disassembly
    143
    
    Front Idler Assembly
    144
    
    Recoil Spring Disassembly
    146
    
    Recoil Spring Assembly
    149
  - Track Adjuster
    151
    
    Removal
    151
    
    Disassembly
    151
    
    Track Adjuster
    152
    
    Assembly
    153
    
    Installation
    154
  - Final Drive Sprocket
    155
    
    Installation
    155
    
    Removal
    156
  - Travel Brake Valve
    156
  - Travel Motor
    156
- Travel Motor
  157
  - Travel Brake Valve
    158
    
    Disassembly
    158
  - Travel Brake Valve
    159
    
    Assembly
    159
    
    Installation Procedure
    160
  - Travel Motor
    161
    
    Disassembly
    161
    
    Assembly
    162
    
    Installation
    164
  - Final Drive
    165
    
    Removal
    165
    
    Disassembly
    166
Subject - Section, Paragraph

158
- Final Drive
  167
  - Assembly
    174
  - Installation
    180
  - Final Drive Oil - Change
    181
  - Final Drive Oil Level Check
    182
  - Swivel
    182
    
    Removal
    182
- Swivel Assembly
  184
  - Disassembly
    185
  - Assembly
    185
  - Installation
    185
  - Towing Information
    186
    
    Towing the Machine
    186
    
    Final Drive Sun Gear Removal
    187
  - Track Adjustment - Adjust
    187
    
    Measuring Track Tension
    188
    
    Tightening the Track
    188
    
    Loosening the Track
    188
    
    Track Adjustment - Inspect
    188
  - Undercarriage- Check
    188
Section 7. Undercarriage S/N 0300070975 to Present

189
- Assembly
  189
- Chassis Service Notes - Sheet 1 of 2
  190
- Chassis Service Notes - Sheet 2 of 2
  191
- Hose Routing - Sheet 1 of 2
  194
- Hose Routing - Sheet 2 of 2
  195
  - Track Tensioning
    198
  - Rubber Track Pad Installation
    199
Section 8. Schematics

201

JLG 660SJC Service And Maintenance Manual (238 pages)

Brand: JLG | Category: Boom Lifts | Size: 43.01 MB

General
3
Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Specifications
17
Operating Specifications
17
Dimensional Data
17
Capacities
19
Engine Data
19
Critical Stability Weights
19
Hydraulic Oil
20
Torque Requirements
21
Maintenance and Lubrication
24
General
34
Machine Preparation, Inspection, and Maintenance
34
Preparation, Inspection, and Maintenance
34
Pre-Start Inspection
34
Pre-Delivery Inspection and Frequent Inspection
34
Annual Machine Inspection
34
Preventive Maintenance
34
Service and Guidelines
35
General
35
Safety and Workmanship
35
Cleanliness
35
Components Removal and Installation
35
Component Disassembly and Reassembly
36
Pressure-Fit Parts
36
Bearings
36
Gaskets
36
Bolt Usage and Torque Application
36
Hydraulic Lines and Electrical Wiring
36
Hydraulic System
36
Lubrication
37
Battery
37
Lubrication and Servicing
37
Lubrication and Information
37
Hydraulic System
37
Hydraulic Oil
37
Changing Hydraulic Oil
37
Lubrication Specifications
37
Cylinder Drift
38
Theory
38
Cylinder Leakage Test
38
Cylinder Thermal Drift
38
Pins and Composite Bearing Repair Guidelines
39
Welding on JLG Equipment
39
Do the Following When Welding on JLG Equipment
39
Do NOT Do the Following When Welding on JLG Equipment
39
Chassis & Turntable
47
Chassis Components and Servicing
47
Service Notes
48
Track and Chain
50
Replace Track
51
Track Tensioning
52
Rubber Track Pad Installation
52
Rollers
55
Idler Roller Assembly
58
Swing Drive Hub
59
Removal
59
Assembly/Disassembly
59
Installation
59
Procedure for Setting Swing Gear Backlash
60
Swing Drive Lubrication
60
Swing Bearing
61
Turntable Bearing Mounting Bolt Condition Check
61
Wear Tolerance
61
Swing Bearing Replacement
63
Swing Bearing Torque Values
64
Rotary Coupling
67
Assembly/Disassembly
67
Deutz TD2.9 L4 Engine
70
Check Oil Level
74
Change Engine Oil
74
Change Oil Filter
74
Change Fuel Filters
75
Spark Arrester Cleaning Instructions
75
Glow Plugs
75
Deutz D2011L04 Engine
97
Checking Oil Level
101
Changing Engine Oil
101
Changing Oil Filter
102
Replace Fuel Filter
102
Clean Fuel Strainer
103
Spark Arrester Cleaning Instructions
103
Glow Plugs
103
Deutz TD 2.9 L4 GUO III Engine
108
Counterweight
112
Generator
114
Every 250 Hours
114
Every 500 Hours
114
Overload Protection
114
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
115
Boom & Platform
117
Transport Position Sensing System
117
Beyond Transport - Drive Speed Cutback System
117
Dual Capacity System
117
Platform Load Sensing System
117
Electronic Platform Leveling
117
Fuel Level Cutout System
118
Platform
118
Support Removal
118
Support Installation
119
Rotator and Slave Cylinder
121
Removal
121
Assembly/Disassembly
121
Installation
121
Main Boom Assembly
123
Removal
123
Boom Disassembly
125
Assembly
128
Installation
131
Main Boom Lift Cylinder
132
Removal
132
Installation
132
Main Boom Powertrack
133
Installation
133
Wire Rope
136
Inspection
136
Three Month Inspection
137
Additional Inspection Required if
137
Year or 7000 Hour Replacement
137
Additional Replacement Criteria
137
Wire Rope Tensioning Adjustment
137
Wire Rope Tensioning Procedure
137
Wire Rope Service Indicator
138
Jib (if Equipped)
138
Boom Cleanliness Guidelines
139
Foot Switch Adjustment
140
Platform Control Enable System
140
Powertrack Maintenance
141
Remove Link
141
Install New Link
144
Replace Fixed End Brackets
147
Replace Moving End Brackets
148
Skyguard
150
Operation
150
Function Test
150
Diagnostics & Troubleshooting
151
Basic Hydraulics Information & Schematics
153
Lubricating O-Rings in the Hydraulic System
153
Cup and Brush
153
Dip Method
154
Spray Method
154
Brush-On Method
154
Hydraulic Connection Assembly and Torque Specification
155
Tapered Thread Types
155
Straight Thread Types, Tube and Hose Connections
155
Straight Thread Types, Port Connections
156
Flange Connection Types
156
Tightening Methods
156
Assembly and Torque Specifications
157
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections
158
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections
159
Assembly Instructions for 37° (JIC) Flare Fittings
160
Assembly Instructions for 45° SAE Flare Fittings
163
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
165
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
167
Assembly Instructions for Bulkhead (BH) Fittings
169
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings
179
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends
186
Assembly Instructions for Adjustable Port End (BSPP) Fittings
188
Assembly Instructions for Flange Connections: (FL61 and FL62)
195
Double Wrench Method
198
FFWR and TFFT Methods
199
Adjustable Stud End Assembly
199
O-Ring Installation (Replacement)
200
Cylinder Locations
201
Main Lift Cylinder
202
Telescope Cylinder
207
Platform Level (Slave) Cylinder
213
Jib Lift Cylinder (660SJC Only)
219
Hydraulic Pump (Gear)
224
Removal
224
Assembly/Disassembly
224
Installation
224
Variable Pump
225
Removal
225
Assembly/Disassembly
225
Installation
225
Load Sense Compensator
226
Main Relief Valve
226
Load Sense Relief Valve
226
Turntable Swing Relief Valve
226
Load Sense Compensator
227
Main Relief Valve
227
Load Sense Relief Valve
227
Turntable Swing Relief Valve
227
Main High Pressure Relief Valve
229
Low Pressure Relief Valve
229
Platform Jib down Relief Valve
229
Hydraulic Schematics
235

JLG 660SJC Operation And Safety Manual (120 pages)

s/n 74785 to present

Brand: JLG | Category: Lifting Systems | Size: 2.7 MB

Table of Contents
7
Section - Paragraph, Subject Page

10
- Table of Contents
  
  10
Section - Paragraph, Subject Page

11
Section 1. Safety Precautions

11
- General
  11
- Pre-Operation
  11
  - Operator Training and Knowledge
    11
  - Workplace Inspection
    12
  - Machine Inspection
    12
- Operation
  13
  - General
    13
  - Trip and Fall Hazards
    13
  - Electrocution Hazards
    14
- Minimum Approach Distances (M.A.D.)
  15
  - Tipping Hazards
    16
  - Crushing and Collision Hazards
    17
  - Towing, Lifting, and Hauling
    18
  - Additional Hazards / Safety
    19
- Beaufort Scale (for Reference Only)
  20
Section 2 - User Responsibilities, Machine Preparation, and Inspection

21
Section 3 - Machine Controls and Indicators

35
Section 4 - Machine Operation

55
- Description
  55
- Engine Operation
  56
  - Starting Procedure
    56
  - Shutdown Procedure
    57
  - Traveling (Driving)
    57
- Grades and Sideslopes
  58
- Machine Motion Hazard
  59
  - Traveling Forward or Reverse
    60
  - Stability
    62
- Position of Least Backward Stability
  62
- Position of Least Forward Stability
  63
  - Steering
    64
  - Parking and Stowing
    64
  - Platform
    64
    
    Platform Level Adjustment
    64
    
    Platform Rotation
    64
  - Boom
    65
    
    Swinging the Boom
    65
    
    Raising and Lowering the Main Boom
    65
    
    Telescoping the Main Boom
    66
  - Shut down and Park
    66
  - Tie down and Lifting
    66
    
    Tie down
    66
    
    Lifting
    66
  - 4.10 Auxiliary Power
    67
- Machine Tie down
  68
- Lifting Chart
  69
  - Hydraulic Tool Circuit Instructions (Optional)
    70
    
    Tool Circuit
    70
  - 4.12 Placards and Decals
    72
- Decal Installation - Sheet 1 of 10
  73
- Decal Installation - Sheet 2 of 10
  74
- Decal Installation - Sheet 3 of 10
  75
- Decal Installation - Sheet 4 of 10
  76
- Decal Installation - Sheet 5 of 10
  77
- Decal Installation - Sheet 6 of 10
  78
- Decal Installation - Sheet 7 of 10
  79
- Decal Installation - Sheet 8 of 10
  80
- Decal Installation - Sheet 9 of 10
  81
- Decal Installation - Sheet 10 of 10
  82
- SC Decal Legend - Prior to S/N 0300148842
  83
  - Present
    85
  - S/N 0300148842
    89
  - Present
    91
Section 5 - Emergency Procedures

93
- General
  93
- Incident Notification
  93
- Emergency Operation
  94
  - Operator Unable to Control Machine
    94
  - Platform or Boom Caught Overhead
    94
Section 6. General Specifications & Operator Maintenance

95
- Introduction
  95
- Operating Specifications
  95
  - Capacities
    97
  - Engine Data
    97
  - JLG Lift
    97
- Hydraulic Oil
  98
- Mobilfluid 424 Specs
  99
- Exxon Univis HVI 26 Specs
  100
  - Major Component Weights
    101
  - Serial Number Locations
    102
- Engine Operating Temperature Specifications
  103
  - Deutz - Sheet 1 of
    103
- Engine Operating Temperature Specifications
  104
  - Deutz - Sheet 2 of
    104
- Engine Operating Temperature Specifications
  105
  - Caterpillar - Sheet 1 of 2
    105
- Engine Operating Temperature Specifications
  106
  - Caterpillar - Sheet 2 of 2
    106
- Operator Maintenance and Lubrication Diagram
  107
- Operator Maintenance
  108
- Supplemental Information
  113
- 3121156 - JLG Lift
  115

JLG 660SJC Operator's And Safety Manual (74 pages)

Telescopic Crawler Boom Lift

Brand: JLG | Category: Lifting Systems | Size: 3.74 MB

Table of Contents
7
Section - Foreword

9
Subject - Section, Paragraph

9
Section 1 - Safety Precautions

9
- General
  9
- Pre-Operation
  9
- Operation
  10
- Towing, Lifting, and Hauling
  13
- Maintenance
  14
Section 2. Preparation and Inspection

15
- General
  15
- Preparation for Use
  15
- Delivery and Frequent Inspection
  15
- Machine Nomenclature - 660SJC
  18
- Daily Walk-Around Inspection
  19
- Daily Walk-Around Inspection Diagram
  20
- Daily Functional Check
  23
- Drive Function Operating Range Diagrams
  25
- Lubrication Point Location
  26
- Battery Maintenance
  28
- Track Adjustment - Adjust
  28
- Battery Jump Start Post
  28
- Track Orientation
  28
- Final Drive Oil Level Check
  30
Section 3. User Responsibilities and Machine Control

33
Section 4. Machine Operation

55
- Description
  55
- General
  55
- Engine Operation
  56
- Traveling (Driving)
  56
- Machine Motion Hazard
  57
- Steering
  58
- Parking and Stowing
  58
- Platform
  58
- Boom
  59
- Shut down and Park
  59
- Tie down and Lifting
  60
- Towing Information
  60
- Lifting Chart
  60
- Machine Tie down
  62
Section 5. Optional Equipment

65
- Cold Start Kit (Diesel Engine)
  65
- Travel Alarm
  65
- Electric Generator
  65
- Rotating Beacon
  65
- Cylinder Bellows
  65
- Boom Wipers
  65
- Hostile Environment Package
  65
- Motion Alarm
  65
Subject - Section, Paragraph

67
Section 6. Emergency Procedures

67
- General
  67
- Emergency Towing Procedures
  67
- Emergency Controls and Their Locations
  67
- Ground Control Station
  67
- Emergency Operation
  68
- Incident Notification
  68
Section 7. Inspection and Repair Log

69
- Inspection and Repair Log
  69

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JLG 660SJC Manuals

JLG 660SJC Service And Maintenance Manual (216 pages)

Table of Contents

Section 1. Specifications

Section 2. General

Section 3. Turntable

Section 4. Boom & Platform

Subject - Section, Paragraph

Section 5. Hydraulics

Subject - Section, Paragraph

Section 6. Undercarriage Prior to S/N 0300070975

Subject - Section, Paragraph

Section 7. Undercarriage S/N 0300070975 to Present

Section 8. Schematics

JLG 660SJC Service And Maintenance Manual (238 pages)

Table of Contents

JLG 660SJC Operation And Safety Manual (120 pages)

Table of Contents

Section - Paragraph, Subject Page

Table of Contents

Section - Paragraph, Subject Page

Section 1. Safety Precautions

Section 2 - User Responsibilities, Machine Preparation, and Inspection

Section 3 - Machine Controls and Indicators

Section 4 - Machine Operation

Section 5 - Emergency Procedures

Section 6. General Specifications & Operator Maintenance

JLG 660SJC Operator's And Safety Manual (74 pages)

Table of Contents

Section - Foreword

Subject - Section, Paragraph

Section 1 - Safety Precautions

Section 2. Preparation and Inspection

Section 3. User Responsibilities and Machine Control

Section 4. Machine Operation

Section 5. Optional Equipment

Subject - Section, Paragraph

Section 6. Emergency Procedures

Section 7. Inspection and Repair Log

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