JLG E600, E600J, E600JP, M600, M600J, M600JP Boom Lift Service Manual
374 pages · Publication 3121711
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What's inside
From the manual's own table of contents: 402 sections, 456 entries. See sample pages (PDF, 582 KB)
General
Hydraulic System Safety
Maintenance10 topics
- Operating Specifications
- Capacities
- Tires
- Function Speed
- Hydraulic Oil
- Torque Requirements
- Major Component Weights
- Serial Number Location
- Operator Maintenance
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative 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 402 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 & Wheels
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation1 topic
- Spindle, 2WD
Setting Wheel Bearing End Play
Specifications
Checking
Greasing Requirements1 topic
- Drive Hub
Roll and Leak Testing
Tightening and Torquing Bolts
Main Disassembly
Output Planet Gear Disassembly
Cover Disassembly
Housing-Spindle Disassembly
Housing-Spindle Subassembly
Output Planet Gear Subassembly
Cover Subassembly
Main Assembly1 topic
- Drive Motor
Removal
Disassembly
Inspection
Assembly
Installation2 topics
- Oscillating Axle Lockout Test (If Equipped)
- Oscillation Cylinder Bleeding
Bleeding Procedure1 topic
- Swing Drive
Roll, Leak and Brake Testing
Motor Control Valve Disassembly
Motor and Brake Disassembly
Hub-shaft Disassembly
Carrier Disassembly
Hub-Shaft Sub-Assembly
Carrier Sub-Assembly
Motor-Brake Subassembly
Motor-Brake Assembly
Motor Control Valve Assembly
Tube Fitting Assembly Procedures
Procedure for Setting Gear Backlash1 topic
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Replacement of Swing Bearing
Swing Bearing Torque Value
Swing Drive Installation1 topic
- Battery Maintenance and Charging
Battery Maintenance, Quarterly
Optional On Board Generator
Battery Charging (On Board Charger)
Removing the Battery Box1 topic
- Battery Charger
Operating Instructions
Maintenance Instructions
Battery Charger Fault Codes
Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell
Checking/Changing the Battery Charger Algorithm1 topic
- Generator
Engine
Alternator
Dynamo and Dynamo Voltage Regulator
Dynamo Output Fuse
Control Fuse
Start Battery
Engine Starter
Start Control Relay
Fuel Control Relay
Glow Plug Control Relay
Glow Plug
Fuel Pump
Fuel Solenoid
Engine Low Oil Pressure Switch
Engine Oil Temperature Sensor
Alternator Output Current Sensor
Engine Speed Sensor
RBS Engine/Generator Controller
Warnings and Safety Precautions
System Controls
System Status and Performance Monitoring
System Settings
RBS Start
RBS shutdown
RBS Alarms and Flash Codes
Resetting the RBS Controller
Maintenance Schedule
Troubleshooting
APU Engine Start Battery Boosting1 topic
- Supplementary Fuse for APU
Tools and Material
Procedure1 topic
- Platform
Platform Valve Removal
Support Removal
Support Installation
Platform Valve Installation2 topics
- Boom Maintenance
- Platform Rotator
Theory of Operation
Tools Required for Assembly/Disassembly
Greasing Thrust Washers1 topic
- Jib Rotator
Operating Principle
Reassembly
Installing Counterbalance Valve
Testing the Actuator
Installation and Bleeding1 topic
- 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
- Hydraulic Cylinders
Axle Lockout Cylinder
Slave Cylinder (E/M600 only)
Slave Cylinder (E/M600J/JP)
Jib Lift Cylinder (E/M600J/JP)
Main Lift Cylinder
Master Cylinder (E/M600)
Master Cylinder (E/M600J/JP)
Steer Cylinder
Telescope Cylinder1 topic
- Cylinder Removal And Installation
Main Boom Telescope Cylinder Removal
Main Boom Telescope Cylinder Installation
Main Boom Lift Cylinder Removal
Main Boom Lift Cylinder Installation
Master Cylinder Removal
Master Cylinder Installation
Slave Cylinder Removal
Slave Cylinder Installation1 topic
- Pressure Setting
Proportional Main Relief
Lift Down
Lift Up
Swing
Flow Control / Bang Bang Main Relief
Steer
Platform Level Down
Platform Level Up Relief
Jib Relief2 topics
- Introduction
- To Connect the 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 Performing Test
Test Notes
Help Descriptions and Fault Flash Codes
Analyzer Diagnostics Menu Structure
System Self Test5 topics
- Calibrating Steer
- Calibrating Tilt Sensor
- Calibrating Load Sensing
- Calibration of Motor (with New ZAPI Module)
- 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
- Checking Switches
Basic Check
Limit Switches
Automatic Switches
Switch Wiring - Low Side, High Side1 topic
- Applying Silicone Dielectric Compound to Electrical Connections
Installation of Dielectric Grease
Deutsch HD, DT, DTM, DRC Series
AWP Seal
AMP Mate-N-Lok
DIN Connectors
Exclusions1 topic
- AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
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
Connector Labels
Component Labels
Serial Number Location
Operator Maintenance and Lubrication Diagram
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 (METRIC Fasteners - Sheet 4 of 5)
Torque Chart (METRIC Fasteners - Sheet 5 of 5)
Hydraulic Oil Specification
Spindle Assembly
Main Disassembly Drawing 1
Main Disassembly Drawing 2
Housing Spindle Disassembly
Main Assembly Drawing
Hub Assembly - Sheet 1 of 2
Hub Assembly - Sheet 2 of 2
Drive Motor
Drive Components
Oscillating Axle - Sheet 1 of 2
Oscillating Axle - Sheet 2 of 2
Axle Oscillation Lockout Valve - Sheet 1 of 2
Axle Oscillation Lockout Valve - Sheet 2 of 2
Swing Motor Assembly - Sectional View
Swing Motor Assembly - Sheet 1 of 2
Swing Motor Assembly - Sheet 2 of 2
Motor Control Valve
Motor and Brake
Brake
Hub Shaft
Carrier
Setting Gear Backlash
Swing Bearing Feeler Gauge Check
Swing Bearing Tolerance Measuring Point
Swing Drive and Bearing Installation
Swing Bearing Torque Sequence
Battery Cable Routing
Batteries and Battery Charger
Battery Charger
Generator
Counterweight
Location of Components Platform Support
Platform Support Torque Values
Boom Assembly - Sheet 1 of 3
Boom Assembly - Sheet 2 of 3
Boom Assembly - Sheet 3 of 3
Boom Limit Switch Adjustment
Transport Limit Switch (CE Only)
Rotary Actuator (Exploded View)
Rotator- Assembly Drawing
Operating Principle - Jib Rotator
Jib Rotator Assembly
Tool for Removing End Cap
Rotator Counterbalance Valve
Bolt-On External Fall Arrest Cable Tension
Bolt-On External Fall Arrest System
Cylinder Barrel Support
Capscrew Removal
Cylinder Rod Support
Tapered Bushing Removal
Composite Bearing Installation
Rod Seal Installation
Cylinder Head Seal Installation
Wiper Seal Installation
Installation of Head Seal Kit
Piston Seal Kit Installation
Seating the Tapered Bushing
Rod Assembly Installation
Cartridge Valve Installation
Cylinder Head Removal
Jib Lift Cylinder
Main Lift Cylinder (E/M600J/JP)
Master Cylinder (E/M600 only)
Installation of Piston Seal Kit
Valve Removal
Hydraulic Tank and Pump
Hydraulic Cylinder Location
Main Control Valve - Hydraulic
Platform Control valve Assembly
Hydraulic Schematics - Sheet 1 of 2
Hydraulic Schematics - Sheet 2 of 2
Hand Held Analyzer
Analyzer Flow Chart, Version 1.3 - Sheet 1 of 5
Analyzer Flow Chart, Version 1.3 - Sheet 2 of 5
Analyzer Flow Chart, Version 1.3 - Sheet 3 of 5
Analyzer Flow Chart, Version 1.3 - Sheet 4 of 5
Analyzer Flow Chart, Version 1.3 - Sheet 5 of 5
Control Module Location
Analyzer Connecting Points
Platform Control Module - Sheet 1 of 2
Platform Control Module - Sheet 2 of 2
Power Module - LH
Power Module - RH
Ground Control Module - Sheet 1 of 3
Ground Control Module - Sheet 2 of 3
Ground Control Module - Sheet 3 of 3
Voltage Measurement (DC)
Current Measurement (DC)
Application to Female Contacts
Use of Seal Plugs
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
Platform Console Harness - Sheet 1 of 4
Platform Console Harness - Sheet 2 of 4
Platform Console Harness - Sheet 3 of 4
Platform Console Harness - Sheet 4 of 4
Platform Beacon Harness
Upper Valve Harness - Sheet 1 of 2
Upper Valve Harness - Sheet 2 of 2
Boom Limit Switch Harness
Transport Limit Switch Harness
Transport Boom Harness
Load Sensing System Harness (LSS) - Sheet 1 of 2
Load Sensing System Harness (LSS) - Sheet 2 of 2
Lower Valve Harness - Sheet 1 of 3
Lower Valve Harness - Sheet 2 of 3
Lower Valve Harness - Sheet 3 of 3
Turntable Harness - Sheet 1 of 3
Turntable Harness - Sheet 2 of 3
Turntable Harness - Sheet 3 of 3
Amber Beacon Harness
Ground Panel Harness - Sheet 1 of 3
Ground Panel Harness - Sheet 2 of 3
Ground Panel Harness - Sheet 3 of 3
Traction Harness - Sheet 1 of 4
Traction Harness - Sheet 2 of 4
Traction Harness - Sheet 3 of 4
Traction Harness - Sheet 4 of 4
Steering SNSR Harness
Traction to Turntable Harness
Chassis Head/Tail Light Harness - Sheet 1 of 2
Chassis Head/Tail Light Harness - Sheet 2 of 2
Inverter Ign Harness
Platform Work Light Harness
Generator Ign Harness - Sheet 1 of 2
Generator Ign Harness - Sheet 2 of 2
SkyGuard Harness - Sheet 1 of 2
SkyGuard Harness - Sheet 2 of 2
Gen to Plate Interface Harness
Soft Touch Harness - Sheet 1 of 2
Soft Touch Harness - Sheet 2 of 2
Console Harness with SkyGuard and 1 CELL LSS - Sheet 1 of 4
Console Harness with SkyGuard and 1 CELL LSS - Sheet 2 of 4
Console Harness with SkyGuard and 1 CELL LSS - Sheet 3 of 4
Console Harness with SkyGuard and 1 CELL LSS - Sheet 4 of 4
Gen 2 Plate Interface Harness
Electrical Schematic - Sheet 1 of 16
Electrical Schematic - Sheet 2 of 16
Electrical Schematic - Sheet 3 of 16
Electrical Schematic - Sheet 4 of 16
Electrical Schematic - Sheet 5 of 16
Electrical Schematic - Sheet 6 of 16
Electrical Schematic - Sheet 7 of 16
Electrical Schematic - Sheet 8 of 16
Electrical Schematic - Sheet 9 of 16
Electrical Schematic - Sheet 10 of 16
Electrical Schematic - Sheet 11 of 16
Electrical Schematic - Sheet 12 of 16
Electrical Schematic - Sheet 13 of 16
Electrical Schematic - Sheet 14 of 16
Electrical Schematic - Sheet 15 of 16
Electrical Schematic - Sheet 16 of 16
Operating Specifications
Capacities
Tire Specifications
Function Speeds
DTE 10 Excel 15 Specs
Mobil EAL Envirosyn H 32 Specs
Mobil EAL Envirosyn SHC 32 Specs
DTE 10 Excel 32 Specs
Torque Requirements
Component Weights
Inspection and Maintenance
Cylinder Drift
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Battery Charger Fault Codes (Delta-Q)
Battery Algorithms
Controller Interface Pin Assignments
SkyGuard Function Table
Analyzer Abbreviations
Machine Configuration Programming Information
Machine Configuration Programming Settings
Personality Ranges/Defaults
Machine Setup Descriptions
JLG Control System Flash Codes
DIAGNOSTICS - Menu Descriptions
System Test Descriptions
System Test Messages
Diagnostic Menu Descriptions
Accessory Weights
SkyGlazier Capacity Reductions
Pipe Rack Capacity Reductions
LSS Troubleshooting Chart
Diagnostic Trouble Codes
Wiring Harness Connector Labels
Inside this manual
Real pages from this service manual (374 pages). Open the sample pages (PDF, 580 KB)
- Specifications, page 17: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 142: SECTION 4 - BOOM & PLATFORM
- Diagram, page 362: SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
- Color page, page 301: SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
- Color page, page 147: SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the E600, E600J, E600JP, M600, M600J, M600JP 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 3121711$69.89
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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, 374 pages
Quantity one is the manual described above.
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Other editions and similar models
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