JLG 600AJ Boom Lift Service Manual
428 pages · Publication 31215031
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- Models
- 600AJ
- Manual type
- Service Manual
- Pages
- 428
- Publication
- 31215031
- Condition
- Brand new
What's inside
From the manual's own table of contents: 478 sections, 569 entries. See sample pages (PDF, 605 KB)
General
Hydraulic System Safety
Maintenance1 topic
- Operating Specifications
Machine Specifications1 topic
- Dimensional Data
Machine Dimensional Data9 topics
- Capacities
- Engine Data
- Tires
- Torque Requirements
- Hydraulic Oil
- Critical Stability Weights
- Operator Maintenance
- Thread Locking Compound
- Torque Charts
SAE Fastener Torque Chart
Metric Fastener Torque Chart1 topic
- 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
Show all 478 sections
Lubrication and Servicing1 topic
- Lubrication and Information
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift
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 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 Procedures9 topics
- Steer Adjustments
- Chassis Tilt Indicator System
- Drive Orientation System
- Transport Position Sensing System
- Beyond Transport - Drive Speed Cutback System
- Drive/Steer – Boom Function Interlock System
- Oscillating Axle System
- Drive System
- 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 Fuels8 topics
- Ford Engine
- Counterweight
- Platform Control Enable System
- Platform Load Control System
- Ground Control Keyswitch System
- Function Speed Control System
- SkyGuard Protection
- 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
- Boom Cleanliness Guidelines
- Rotary Actuator
Theory of Operation
Required Tools
Installing Counterbalance Valve
Testing Actuator
Testing Actuator for Internal Leaks
Installation and Bleeding3 topics
- Foot Switch Adjustment
- Platform Load Sensing System
- Skyguard
Operation
Function Test
Diagnostics & Troubleshooting1 topic
- Bolt-on External Fall Arrest
Inspection Before Use1 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
Upright Level Cylinder
Cleaning and Inspection
Master Cylinder
Main Boom Lift Cylinder
Main Boom Telescope Cylinder
Tower Boom Telescope Cylinder
Platform Level (Slave) Cylinder
Jib Lift Cylinder
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 Notes3 topics
- CANbus Communications
- MSSO (Machine Safety System Override)
- 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 Measurement2 topics
- Applying Silicone Dielectric Compound Electrical Connections
- Dielectric Grease Application
AMP Mate-N-Lok
AMP Faston
AMP Micro-Fit
AMP Mini Fit Jr
Mini Fit Sr
DIN Connectors
Exceptions
Enclosures
Carling Switch Connectors1 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
- Telematics Gateway
Telematics-Ready (TCU) Plug1 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 - Ford MSG 425
Engine and Hydraulic Operating Temperature Specifications - Deutz
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
Output Carrier Disassemb
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
Swing Bearing Removal
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
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
Location of Components Platform Support
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
Bolt-On External Fall Arrest Cable Tension
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
Capscrew Removal
Composite Bearing Installation
Rod Seal Installation
Cylinder Head Seal Installation
Wiper Seal Installation
Installation of Head Seal Kit
Seating the Tapered Bearing
Hydrolock Piston Seal Installation
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
Main Control Valve - 4WS
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 Flow Chart Software Version P6.30 - Sheet 1 of 7
Analyzer Flow Chart Software Version P6.30 - Sheet 2 of 7
Analyzer Flow Chart Software Version P6.30 - Sheet 3 of 7
Analyzer Flow Chart Software Version P6.30 - Sheet 4 of 7
Analyzer Flow Chart Software Version P6.30 - Sheet 5 of 7
Analyzer Flow Chart Software Version P6.30 - Sheet 6 of 7
Analyzer Flow Chart Software Version P6.30 - Sheet 7 of 7
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
Platform Control Module (China Market)
Voltage Measurement (DC)
Current Measurement (DC)
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
Telematics Gateway Harness - Sheet 1 of 3
Telematics Gateway Harness - Sheet 2 of 3
Telematics Gateway Harness - Sheet 3 of 3
Electrical Components 1 of 2
Electrical Components 2 of 2
Platform Console Box SkyGuard - Sheet 1 of 2
Platform Console Box SkyGuard - Sheet 2 of 2
Platform Console Box with SkyGuard
Platform Valve Harness Assembly
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
Main Valve Harness (China Market)
Deutz D2011 (T4i) Engine Harness
Deutz D2011 (T4i) Engine Harness - Sheet 1 of 2 (China Market)
Deutz D2011 (T4i) Engine Harness - Sheet 2 of 2 (China Market)
Deutz TD2.9L4 (T4F) Engine harness
Ford Engine Harness
MSG425 Engines - Sheet 1 of 2
MSG425 Engines - Sheet 2 of 2
Electrical Schematic - Sheet 1 of 18
Electrical Schematic - Sheet 2 of 18
Electrical Schematic - Sheet 3 of 18
Electrical Schematic - Sheet 4 of 18
Electrical Schematic - Sheet 5 of 18
Electrical Schematic - Sheet 6 of 18
Electrical Schematic - Sheet 7 of 18
Electrical Schematic - Sheet 8 of 18
Electrical Schematic - Sheet 9 of 18
Electrical Schematic - Sheet 10 of 18
Electrical Schematic - Sheet 11 of 18
Electrical Schematic - Sheet 12 of 18
Electrical Schematic - Sheet 13 of 18
Electrical Schematic - Sheet 14 of 18
Electrical Schematic - Sheet 15 of 18
Electrical Schematic - Sheet 16 of 18
Electrical Schematic - Sheet 17 of 18
Electrical Schematic - Sheet 18 of 18
Deutz TD 2.9L Specifications
Mobilfluid 424
Mobile DTE 10 Excel 32
Quintolubric 888-46 Specs
Mobil EAL 224H
Mobil EAL H 46 Specs
Mobil EAL 46 Specs
Exxon Univis HVI 26 Specs
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
Drive Mode Speeds
Coupling Port Information Table - 2WS
Coupling Port Information Table - 4WS
Engine Fault Codes (Deutz Engine)
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 (Software Version P6.30)
Machine Configuration Programming Settings (Software Version P6.30)
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 (428 pages). Open the sample pages (PDF, 603 KB)
- Specifications, page 20: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 140: Figure 3-89. EMR2 Fault Codes - Sheet 5 of 5
- Diagram, page 386: SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS
- Color page, page 187: SECTION 4 - BOOM & PLATFORM
- Color page, page 221: SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 600AJ are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 31215031$69.81
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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, 428 pages
Quantity one is the manual described above.
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Ships in 1 business day.
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Other editions and similar models
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