JLG 600A, 600AJ Boom Lift Service Manual
450 pages · Publication 3121616
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What's inside
From the manual's own table of contents: 519 sections, 596 entries. See sample pages (PDF, 593 KB)
General
Hydraulic System Safety
Maintenance10 topics
- Operating Specifications
- Dimensional Data
- Capacities
- Engine Data
- Tires
- Torque Requirements
- Hydraulic Oil
- Critical Stability Weights
- Operator Maintenance
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventive Maintenance1 topic
- Service and Guidelines
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Lubrication and Servicing1 topic
- Lubrication and Information
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift
Show all 519 sections
Theory
Cylinder Leakage Test
Cylinder Thermal Drift2 topics
- Pins and Composite Bearing Repair Guidelines
- Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment1 topic
- Tires And Wheels
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation1 topic
- Oscillating Axle Bleeding Procedure and Lockout Test
Lockout Cylinder Bleeding
Oscillating Axle Lockout Test1 topic
- Torque Hub
Oil Information
Roll and Leak Testing
Tightening and Torquing Bolts
Main Disassembly
Output Carrier Disassembly
Input Carrier Disassembly
Hub-Spindle Disassembly
Spindle-Brake Disassembly
Cover Disassembly
Cover Assembly
Input Carrier Sub-Assembly
Output Planet Gear Sub-Assembly
Spindle - Brake Sub-Assembly
Hub-Spindle Sub-Assembly
Cover Sub-Assembly
Main Assembly
Integral Brake Check1 topic
- Free Wheeling Option
Disengage Drive Motors and Brakes for Towing, etc. (Free Wheel)
Engage Drive Motors and Brakes (Normal Operation)1 topic
- Drive Motor
Description
Shaft Seal Replacement
Loop Flushing Valve
Troubleshooting
Disassembly
Inspection
Assembly
Initial Start-up Procedures2 topics
- Steer Adjustments
- Swing Drive
Roll, Leak And Brake Testing
Motor Control Valve Disassembly
Motor and Brake Disassembly
Main Drive Disassembly
Hub-Shaft Disassembly
Carrier Disassembly
Hub-Shaft Assembly
Carrier Assembly
Main Drive Assembly
Motor and Brake Assembly
Motor Control Valve Assembly2 topics
- Swing Hub Removal
- Swing Hub Installation
Procedure For Setting Swing Gear Backlash
Swing Drive Lubrication1 topic
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Replacement
Swing Bearing Torque Values2 topics
- Rotary Coupling
- Generator
Every 250 hours
Every 500 hours
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings1 topic
- Deutz D2.9 L4 (T4F) Engine
Check Oil Level
Change Engine Oil
Change Oil Filter
Change Fuel Filters1 topic
- Deutz D2011 (T4i) Engine
Checking Oil Level
Changing Engine Oil
Changing Oil Filter
Replace Fuel Filter
Clean Fuel Strainer4 topics
- Spark Arrester Cleaning Instructions
- Glow Plugs
- Deutz EMR 2
- Bio Fuel In Deutz Engines
Bio Fuel
Biological Contamination In Fuels2 topics
- GM Engine
- GM Engine General Maintenance
Drive Belt Maintenance
Engine Electrical System Maintenance
Checking/Filling Engine Oil Level
Coolant Fill Procedure - Dual Fuel Engine1 topic
- GM Engine Dual Fuel System
Fuel Filter
Direct Electronic Pressure Regulator (DEPR)
Air Fuel Mixer
Electronic Throttle Control (ETC)
Electric Lock Off
Engine Control Module (ECM)
Heated Exhaust Gas Oxygen Sensor
Gasoline Multi Point Fuel Injection System (MPFI)
Gasoline Fuel Pump
Gasoline Pressure And Temperature Sensor Manifold
Fuel Injector Rail
Fuel Injector1 topic
- GM Engine Fuel System Repair
Propane Fuel System Pressure Relief
Propane Fuel System Leak Test
Propane Fuel Filter Replacement
Direct Electronic Pressure Regulator (DEPR) Maintenance And Inspection
Check/Drain Oil Build-Up In 2-Stage Vaporizer
Air Fuel Mixer/Throttle Control Device Maintenance And Inspection
Exhaust System And Catalytic Converter Inspection And Maintenance
Temperature Manifold Absolute Pressure (TMAP) Sensor
Throttle Body (ETC) Replacement
Mixer Replacement
Electronic Pressure Regulator (EPR) Replacement
Regulator Replacement
Coolant Hose Replacement
Vapor Hose Replacement
Engine Control Module Replacement
Heated Exhaust Gas Oxygen Sensor Replacement1 topic
- GM Engine LPG Fuel System Diagnosis
Fuel System Description
Diagnostic Aids3 topics
- Ford Engine
- Counterweight
- Platform
Support Removal
Support Installation1 topic
- Rotator and Slave Cylinder
Removal
Installation2 topics
- Main Boom Powertrack
- Powertrack Maintenance
Remove Link
Install New Link
Replace Fixed End Brackets
Replace Moving End Brackets6 topics
- Main Boom Assembly
- Upright
- Tower Boom Assembly
- Jib Assembly - 600AJ
- Boom Cleanliness Guidelines
- Rotary Actuator
Theory of Operation
Required Tools
Installing Counterbalance Valve
Testing Actuator
Testing Actuator for Internal Leaks
Installation and Bleeding2 topics
- Foot Switch Adjustment
- Skyguard
Operation
Functional Test
Diagnostic & Troubleshooting1 topic
- Lubricating O-rings In The Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method1 topic
- Cylinders - Theory of Operation
Systems With Double Acting Cylinders
Systems With Holding Valves1 topic
- Cylinder Checking Procedure
Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder
Cylinders With Single Counterbalance Valve
Cylinders With Dual Counterbalance Valves1 topic
- Hydraulic Cylinders
Cylinder Locations
Main Boom Telescope Cylinder Removal
Main Boom Telescope Cylinder Installation
Main Boom Lift Cylinder Removal
Main Boom Lift Cylinder Installation
Upright Level Cylinder Removal
Upright Level Cylinder Installation
Tower Boom Lift Cylinder Removal
Tower Lift Cylinder Installation
Tower Telescope Cylinder Removal
Tower Telescope Cylinder Installation1 topic
- Hydraulic Cylinder repair
Tower Boom Lift Cylinder
Cleaning and Inspection
Upright Level Cylinder
Master Cylinder
Main Boom Lift Cylinder
Main Boom Telescope Cylinder
Tower Boom Telescope Cylinder
Platform Level (Slave) Cylinder
Jib Lift Cylinder (600AJ Only)
Steer Cylinder
Axle Lockout Cylinder1 topic
- Hydraulic Pump (Gear)
Inspect Parts For Wear
General Information
Reverse Shaft Rotation of Pump
Placing Pump Back Into Service1 topic
- Variable Pump
Ports and Pressure Gauges
NFPE Control
Remove and Install FNR and NFPE Modules
Remove and Install FNR and NFPE Control Orifices
Charge Relief Valve
Shaft Seal and Shaft Replacement
Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication
Charge Pump2 topics
- Hydraulic Component Start-Up
- Main Valve Block Pressure Settings
Main Relief
Upper (Main) Lift Down
Swing
2-Wheel Steer
4-Wheel Steer1 topic
- Platform Valve Block Pressure Settings
Platform Level Extend
Platform Level Retract
Articulating Jib2 topics
- Hydraulic Schematics
- JLG Control System Analyzer Kit Instructions
Introduction
Connect JLG Control System Analyzer
Using the Analyzer
Changing the Access Level of the Hand Held Analyzer
Adjusting Parameters Using the Hand Held Analyzer
Machine Setup
Level Vehicle Description2 topics
- Machine Personality Settings
- Machine Orientation When Setting Function Speeds
Test Notes2 topics
- CANbus Communications
- LSS System
Diagnostic Menu
Calibration Procedure
Testing & Evaluation3 topics
- Resetting The MSSO System
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement1 topic
- Applying Silicone Dielectric Compound to Electrical Connections
Installation of Dielectric Grease
Deutsch HD, DT, DTM, DRC Series
AMP Seal
AMP Mate-N-Lok
DIN Connectors
Exclusions1 topic
- AMP Connector
Wedge Lock
Service - Voltage Reading1 topic
- Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly1 topic
- Wiring Harness
Connector Labels
Component Labels2 topics
- Wiring Harness Breakdown
- Electrical Schematics
Operator Maintenance and Lubrication Diagram - Deutz D2011
Operator Maintenance and Lubrication Diagram - Deutz TD2.9
Operator Maintenance and Lubrication Diagram - GM 3.0L
Operator Maintenance and Lubrication Diagram - Ford MSG 425
Torque Chart (SAE Fasteners - Sheet 1 of 5)
Torque Chart (SAE Fasteners - Sheet 2 of 5)
Torque Chart (SAE Fasteners - Sheet 3 of 5)
Torque Chart (SAE Fasteners - Sheet 4 of 5)
Torque Chart (METRIC Fasteners - Sheet 5 of 5)
Engine and Hydraulic Operating Temperature Specifications - Deutz
Engine and Hydraulic Operating Temperature Specifications - GM 3.0L
Engine and Hydraulic Operating Temperature Specifications - Ford MSG 425
Wheel Lug Nut Tightening Sequence
Axle Installation - Sheet 1 of 2
Axle Installation - Sheet 2 of 2
Steering Installation (8ft/2.4m Wide Machines Without Tow Package) - Sheet 1 of 2
Steering Installation (8ft/2.4m Wide Machines Without Tow Package) - Sheet 2 of 2
Steering Installation (8ft/2.4m Wide Machines With Tow Package) - Sheet 1 of 2
Steering Installation (8ft/2.4m Wide Machines With Tow Package) - Sheet 2 of 2
Steering Installation (7ft/2.1m Wide Machines) - Sheet 1 of 3
Steering Installation (7ft/2.1m Wide Machines) - Sheet 2 of 3
Steering Installation (7ft/2.1m Wide Machines) - Sheet 3 of 3
Bolt Tightening Sequence
Torque Hub
Torque Hub Main Disassembly
Hub Spindle Disassembly
Spindle Brake Disassembly
Torque Hub Cover
Hub Assembly
Bearing Cup Pressing Tool
Seal Pressing Tool
Drift Pin for Lining Up Thrust Washers with Output Planet Gear
Disconnecting Drive Hubs
Drive Motor Cross Section
Removing Shaft Seal
Loop Flushing Spool
Plugs, Fittings, and Speed Sensor
End Cap
Valve Plate & Rear Shaft Bearing
Cylinder Kit
Shaft Seal
Shaft & Front Bearing
Swash Plate & Servo Piston
Cylinder Kit Disassembly
Servo Piston
Cylinder Kit Assembly
Swash Plate and Journal Bearing
Shaft and Front Bearing
Cylinder Kit Installation
Servo Spring and Minimum Angle Stop
Valve Plate and Rear Bearing
Plugs and Fittings Installation
Steer Adjustments
Motor Control Valve
Motor and Brake
Hub Shaft
Carrier
Swing Drive Assembly
Swing Motor and Brake Assembly
Swing Bearing Bolt Feeler Gauge Check
Swing Bearing Tolerance Measuring Point
Swing Bearing Tolerance Measurement Location & Boom Placement
Swing Bearing Torque Sequence
Rotary Coupling - Sheet 1 of 2
Rotary Coupling - Sheet 2 of 2
Rotary Coupling Port Location - 2WS
Rotary Coupling Port Location - 4WS
Generator Belt Tension
Generator Brushes and Slip Rings
Blow Out Generator
Generator Circuit Breaker Location
Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
Deutz D2.9 L4 (T4F) Engine Installation - Sheet 1 of 2
Deutz D2.9 L4 (T4F) Engine Installation - Sheet 2 of 2
Deutz 2.9 T4F Dipstick Markings
Engine Oil Viscosity
Deutz D2011 (T4i) Engine Installation - Sheet 1 of 2
Deutz D2011 (T4i) Engine Installation - Sheet 2 of 2
Deutz Dipstick Markings
EMR 2 Engine Side Equipment
Deutz EMR 2 Troubleshooting Flow Chart
Deutz EMR 2 Vehicle Side Connection Diagram
Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
EMR 2 Engine Plug Pin Identification
EMR 2 Vehicle Plug Pin Identification
EMR2 Fault Codes - Sheet 1 of 5
EMR2 Fault Codes - Sheet 2 of 5
EMR2 Fault Codes - Sheet 3 of 5
EMR2 Fault Codes - Sheet 4 of 5
EMR2 Fault Codes - Sheet 5 of 5
GM Engine Installation Sheet 1 of 2
GM Engine Installation Sheet 2 of 2
GM Engine Oil Dip Stick
GM 3.0 Duel Fuel System Components
Direct Electronic Pressure Regulator
ELectronic Throttle Control Device
Electric Lock Off Assembly
ECM Assembly
ECM Input-Output Diagram
Heated Exhaust Gas Oxygen Sensor (HEGO)
Gasoline Fuel Pressure and Temperature Manifold Assembly
Filter Lock Assembly
DEPR
Ford Engine Installation Sheet 1 of 4
Ford Engine Installation Sheet 2 of 4
Ford Engine Installation Sheet 3 of 4
Ford Engine Installation Sheet 4 of 4
Counterweight Bolt Torque
Platform Support Torque Values
Rotator and Leveling Cylinder Components
Main Boom Powertrack Components
Main Boom Assembly Components
Tower Upright Components
Tower Boom Components
Tower Boom Powertrack Components
Jib Assembly
Rotary Actuator - Exploded View
Rotator Counterbalance Valve
Actuator Bleed Ports
Foot Switch Adjustment
Skyguard
Boom Positioning and Support, Cylinder Repair
Hydraulic Cylinder Locations
Telescope and Lift Cylinder Installation
Leveling Cylinder Removal
Plunger Valve Override
Cylinder Barrel Support
Marking Cylinder for Alignment
Cylinder Rod Support
Tapered Bushing Removal
Piston Disassembly
Cylinder Head Disassembly
Composite Bushing Installation
Head Seal Kit Installation
Cylinder Head Seals
Piston Seal Kit Installation
Piston Seals
Tapered Bushing Installation
Seating Tapered Bushing
Rod Assembly Installation
Master Cylinder Assembly
Main Boom Lift Cylinder Assembly
Main Boom Telescope Cylinder Assembly
Wear Pad Assembly
Tower Boom Telescope Cylinder Assembly
Platform Level (Slave) Cylinder Assembly
Jib Lift Cylinder Assembly (600AJ)
Piston And Spacer Disassembly
Removing Spanner Nut
Steer Cylinder Assembly
Piston Seal and Wear Ring
Cylinder Head Assembly
Piston Seal and Wear Ring Assembly
Shim Adjustable Charge Relief Valve Components
Gauge Port Locations
Plugs/Fittings Size & Torque
Screw Adjustable Charge Relief Valve Components
Shaft Seal Components
Shaft Seal Installation
Shaft Components
Charge Pump Components
Main Control Valve - 2WS (SN 0300181175 to Present)
Main Control Valve - 4WS (SN 0300181175 to Present)
Location of Components - Platform Control Valve Block
2-Wheel Steer (2WS) Hydraulic Schematic 1 of 2
2-Wheel Steer (2WS) Hydraulic Schematic 2 of 2
4-Wheel Steer (4WS) Hydraulic Schematic 1 of 2
4-Wheel Steer (4WS) Hydraulic Schematic 2 of 2
2-Wheel Drive (2WD) Hydraulic Schematic 1 of 2
2-Wheel Drive (2WD) Hydraulic Schematic 2 of 2
4-Wheel Drive (4WD) Hydraulic Schematic 1 of 2
4-Wheel Drive (4WD) Hydraulic Schematic 2 of 2
Hand Held Analyzer
ADE Block Diagram
Analyzer Software Version 6.8 - Sheet 1 of 6
Analyzer Software Version 6.8 - Sheet 2 of 6
Analyzer Software Version 6.8 - Sheet 3 of 6
Analyzer Software Version 6.8 - Sheet 4 of 6
Analyzer Software Version 6.8 - Sheet 5 of 6
Analyzer Software Version 6.8 - Sheet 6 of 6
Control Module Locations
Analyzer Connecting Points
Ground Control Module Pin Connections 1 of 2
Ground Control Module Pin Connections 2 of 2
Platform Control Module Pin Connections 1 of 2
Platform Control Module Pin Connections 2 of 2
Voltage Measurement (DC)
Current Measurement (DC)
Applying Dielectric Grease
Deutsch Connector
Application to plug/male connector housing
Use of Seal Plugs
AMP Mate-N-Lok Connector
DIN Connector
Connector Assembly Figure 1
AMP Connector
Connector Assembly Figure 2
Connector Assembly Figure 3
Connector Assembly Figure 4
Connector Disassembly
Connector Installation
DT/DTP Contact Installation
DT/DTP Contact Removal
HD/HDP Contact Installation
HD/HDP Locking Contacts Into Position
HD/HDP Contact Removal
HD/HDP Unlocking Contacts
Electrical Components 1 of 2 (SN 0300181175 to Present)
Electrical Components 2 of 2 (SN 0300181175 to Present)
Platform Console Box without SkyGuard - Sheet 1 of 2
Platform Console Box without SkyGuard - Sheet 2 of 2
Platform Console Box with SkyGuard (SN 0300181175 to Present)
Platform Valve Harness Assembly (SN 0300181175 to Present)
Main Boom Harness without Arctic Package
Main Boom Harness with Arctic Package
Tower Boom Cable Harness without Arctic Package
Tower Boom Cable Harness with Arctic Package
Main Valve Harness - Sheet 1 of 2
Main Valve Harness - Sheet 2 of 2
Deutz D2011 (T4i) Engine Harness
Deutz TD2.9L4 (T4F) Engine harness (SN 0300181175 to Present)
GM Engine Harness
Ford Engine Harness (SN 0300181175 to Present)
Ground Control Box Harness Deutz D2011 (T4i) Engine (SN 0300200809 to Present) - Sheet 1 of 2
Ground Control Box Harness Deutz D2011 Engine (T4i) (SN 0300200809 to Present) - Sheet 2 of 2
Ground Control Box Harness Deutz TD2.9L4 (T4F) Engine (SN 0300177361 to Present)- Sheet 1 of 2
Platform and Ground Control Electrical Schematic - 1 of 2
Platform and Ground Control Electrical Schematic - 2 of 2
Generator Wiring Schematic 1 of 2
Generator Wiring Schematic 2 of 2
Deutz T4i Engine Harness Electrical Schematic
GM/PSI Engine Harness Electrical Schematic
Deutz T4F Engine Harness Electrical Schematic 1 of 2
Deutz T4F Engine Harness Electrical Schematic 2 of 2
Platform Sensor Electrical Schematic 1 of 2
Platform Sensor Electrical Schematic 2 of 2
Ford Engine Electrical Schematic
Ford Engine Harness Electrical Schematic 1 of 2
Ford Engine Harness Electrical Schematic 2 of 2
Generator 2 Platform Harness Electrical Schematic
Operating Specifications
Dimensional Data
Capacities
Deutz TD 2.9 Specifications
Tire Specifications
Torque Requirements
Mobilfluid 424
Mobile DTE 10 Excel 32
Quintolubric 888-46 Specs
Mobil EAL 224
Mobil EAL Envirosyn H 46 Specs
Mobil SHC EAL H 46 Specs
Exxon Univis HVI 26 (Arctic)
Critical Stability Weights
Inspection and Maintenance
Cylinder Drift
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Excessive Noise and/or Vibration
System Operating Hot
No Shift or Slow to Start
Displacement Identifiers
Slipper Foot Thickness & End Play
Cylinder Block Measurements
Coupling Port Information Table - 2WS
Coupling Port Information Table - 4WS
LP Fuel System Diagnosis
Symptom Diagnosis
DTC to SPN/FMI Cross Reference Chart
Fault Code Cross Reference List (Ford Engine)
CAN to DTC Cross Reference (Ford Engine)
SkyGuard Function Table
Hydraulic Pump Bolt Torque Chart
Recommended Gauge Size
Analyzer Abbreviations
Personality Ranges/Defaults
Help Fault Codes, Displayed Faults, and Descriptions
Machine Configuration Programming Information
Machine Configuration Programming Settings
Function Speeds (In Seconds)
Diagnostic Menu Descriptions
Accessory Weights
SkyGlazier Capacity Reductions
Pipe Rack Capacity Reductions
LSS Troubleshooting Chart
Fault Code List
Wiring Harness Connector Labels
Inside this manual
Real pages from this service manual (450 pages). Open the sample pages (PDF, 590 KB)
- Specifications, page 27: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 165: Fuel System Checks
- Diagram, page 405: SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS
- Color page, page 197: SECTION 4 - BOOM & PLATFORM
- Color page, page 392: SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 450 pages
Quantity one is the manual described above.
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