Description
JLG 600A 600AJ Service and Maintenance Manual – 3121616 Rev H
This is the complete JLG 600A 600AJ Service and Maintenance Manual, document number 3121616, Revision H, dated June 29, 2018. It applies to machines from serial number 0300177361 to present. Everything a technician needs to inspect, service, repair, and diagnose these JLG boom lifts is in this single PDF: engine service data, chassis and turntable rebuild procedures, hydraulic cylinder repair, boom assembly work, JLG control system analyzer instructions, and full electrical schematics.
File Details
- Manual Type: Service and Maintenance Manual
- Brand: JLG
- Models Covered: 600A, 600AJ
- Document Number: 3121616
- Revision: Rev H
- Date: June 29, 2018
- Serial Number Range: 0300177361 to Present
- Language: English
- File Format: PDF
- Approximate Page Count: 450 pages
Chapters Covered
The JLG 600A 600AJ service manual is organised into the sections below, each following the manufacturer’s original structure:
- Section A – Introduction: Maintenance safety precautions, hydraulic system safety, general maintenance warnings
- Section 1 – General Specifications: Operating specifications, dimensional data, capacities, engine data, tires, torque requirements, hydraulic oil, critical stability weights, operator maintenance and lubrication diagrams
- Section 2 – General Service: Machine preparation, inspection and maintenance schedule, service and guidelines, lubrication, cylinder drift theory and leak testing, pins and composite bearing repair, welding on JLG equipment
- Section 3 – Chassis & Turntable: Tires and wheels, oscillating axle bleeding and lockout test, torque hub disassembly and assembly, free wheeling option, drive motor service, steer adjustments, swing drive, swing hub removal and installation, swing bearing, rotary coupling, generator, engine service (Deutz D2.9 L4 T4F, Deutz D2011 T4i, GM 3.0L, Ford), spark arrester, glow plugs, Deutz EMR 2, bio fuel, GM dual fuel system, counterweight
- Section 4 – Boom & Platform: Platform support, rotator and slave cylinder, main boom powertrack, powertrack maintenance, main boom assembly, upright, tower boom assembly, jib assembly (600AJ), boom cleanliness guidelines, rotary actuator, foot switch adjustment, SkyGuard, bolt-on fall arrest
- Section 5 – Basic Hydraulics Information & Schematics: O-ring lubrication, cylinder theory, cylinder checking procedure, hydraulic cylinders removal and installation, hydraulic cylinder repair (all cylinders), hydraulic pump (gear), variable pump, hydraulic component start-up, main valve block pressure settings, platform valve block pressure settings, hydraulic schematics
- Section 6 – JLG Control System: Analyzer kit instructions, machine personality settings, machine orientation when setting function speeds, CANbus communications, LSS system, resetting the MSSO system, fault code list, control module pin connections
- Section 7 – Basic Electrical Information & Schematics: Multimeter basics, applying silicone dielectric compound, AMP connectors, Deutsch connectors, wiring harness breakdown, electrical schematics
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “JLG 600A 600AJ Service and Maintenance Manual 3121616 Rev H – 2018 PDF” are as follows:
+Section A. Introduction – Maintenance Safety Precautionsp. 3
A Generalp. 3
B Hydraulic System Safetyp. 3
C Maintenancep. 3
+Section 1. Specificationsp. 23
1.1 Operating Specificationsp. 23
1.2 Dimensional Datap. 23
1.3 Capacitiesp. 24
1.4 Engine Datap. 24
1.5 Tiresp. 25
1.6 Torque Requirementsp. 25
1.7 Hydraulic Oilp. 26
1.8 Critical Stability Weightsp. 27
1.9 Operator Maintenancep. 32
+Section 2. Generalp. 43
+2.1 Machine Preparation, Inspection, and Maintenancep. 43
Generalp. 43
Preparation, Inspection, and Maintenancep. 43
Pre-Start Inspectionp. 43
Pre-Delivery Inspection and Frequent Inspectionp. 43
Annual Machine Inspectionp. 43
Preventive Maintenancep. 43
+2.2 Service and Guidelinesp. 44
Generalp. 44
Safety and Workmanshipp. 44
Cleanlinessp. 44
Components Removal and Installationp. 44
Component Disassembly and Reassemblyp. 45
Pressure-Fit Partsp. 45
Bearingsp. 45
Gasketsp. 45
Bolt Usage and Torque Applicationp. 45
Hydraulic Lines and Electrical Wiringp. 45
Hydraulic Systemp. 45
Lubricationp. 45
Batteryp. 45
Lubrication and Servicingp. 45
+2.3 Lubrication and Informationp. 46
Hydraulic Systemp. 46
Hydraulic Oilp. 46
Changing Hydraulic Oilp. 46
Lubrication Specificationsp. 46
+2.4 Cylinder Driftp. 46
Theoryp. 46
Cylinder Leakage Testp. 46
Cylinder Thermal Driftp. 47
2.5 Pins and Composite Bearing Repair Guidelinesp. 47
+2.6 Welding on JLG Equipmentp. 47
Do the Following When Welding on JLG Equipment:p. 47
Do NOT Do the Following When Welding on JLG Equipment:p. 47
+Section 3. Chassis & Turntablep. 55
+3.1 Tires And Wheelsp. 55
Tire Inflationp. 55
Tire Damagep. 55
Tire Replacementp. 55
Wheel Replacementp. 55
Wheel Installationp. 55
+3.2 Oscillating Axle Bleeding Procedure and Lockout Testp. 56
Lockout Cylinder Bleedingp. 56
Oscillating Axle Lockout Testp. 56
+3.3 Torque Hubp. 66
Oil Informationp. 66
Roll and Leak Testingp. 66
Tightening and Torquing Boltsp. 66
Main Disassemblyp. 68
Output Carrier Disassemblyp. 69
Input Carrier Disassemblyp. 69
Hub-Spindle Disassemblyp. 70
Spindle-Brake Disassemblyp. 71
Cover Disassemblyp. 72
Cover Assemblyp. 72
Input Carrier Sub-Assemblyp. 72
Output Planet Gear Sub-Assemblyp. 72
Spindle – Brake Sub-Assemblyp. 73
Hub-Spindle Sub-Assemblyp. 73
Cover Sub-Assemblyp. 74
Main Assemblyp. 74
Integral Brake Checkp. 74
+3.4 Free Wheeling Optionp. 78
Disengage Drive Motors and Brakes for Towing, etc. (Free Wheel)p. 78
Engage Drive Motors and Brakes (Normal Operation)p. 78
+3.5 Drive Motorp. 78
Descriptionp. 78
Shaft Seal Replacementp. 79
Loop Flushing Valvep. 80
Troubleshootingp. 81
Disassemblyp. 82
Inspectionp. 85
Assemblyp. 87
Initial Start-up Proceduresp. 91
3.6 Steer Adjustmentsp. 92
+3.7 Swing Drivep. 93
Roll, Leak And Brake Testingp. 93
Tightening and Torquing Boltsp. 93
Motor Control Valve Disassemblyp. 94
Motor and Brake Disassemblyp. 95
Main Drive Disassemblyp. 96
Hub-Shaft Disassemblyp. 97
Carrier Disassemblyp. 98
Hub-Shaft Assemblyp. 99
Carrier Assemblyp. 99
Main Drive Assemblyp. 100
Motor and Brake Assemblyp. 101
Motor Control Valve Assemblyp. 101
3.8 Swing Hub Removalp. 104
+3.9 Swing Hub Installationp. 104
Procedure For Setting Swing Gear Backlashp. 104
Swing Drive Lubricationp. 105
+3.10 Swing Bearingp. 106
Turntable Bearing Mounting Bolt Condition Checkp. 106
Wear Tolerancep. 106
Swing Bearing Replacementp. 108
Swing Bearing Torque Valuesp. 109
3.11 Rotary Couplingp. 110
+3.12 Generatorp. 114
Every 250 hoursp. 114
Every 500 hoursp. 114
Overload Protectionp. 115
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Ringsp. 115
+3.13 Deutz D2.9 L4 (T4F) Enginep. 117
Check Oil Levelp. 119
Change Engine Oilp. 119
Change Oil Filterp. 120
Change Fuel Filtersp. 120
+3.14 Deutz D2011 (T4i) Enginep. 121
Checking Oil Levelp. 123
Changing Engine Oilp. 123
Changing Oil Filterp. 124
Replace Fuel Filterp. 124
Clean Fuel Strainerp. 124
3.15 Spark Arrester Cleaning Instructionsp. 125
3.16 Glow Plugsp. 125
3.17 Deutz EMR 2p. 126
+3.18 Bio Fuel In Deutz Enginesp. 138
Generalp. 138
Bio Fuelp. 138
Biological Contamination In Fuelsp. 139
3.19 GM Enginep. 140
+3.20 GM Engine General Maintenancep. 142
Drive Belt Maintenancep. 142
Engine Electrical System Maintenancep. 142
Checking/Filling Engine Oil Levelp. 142
Changing Engine Oilp. 143
Coolant Fill Procedure – Dual Fuel Enginep. 143
+3.21 GM Engine Dual Fuel Systemp. 144
Fuel Filterp. 144
Direct Electronic Pressure Regulator (DEPR)p. 146
Air Fuel Mixerp. 146
Electronic Throttle Control (ETC)p. 147
Electric Lock Offp. 147
Engine Control Module (ECM)p. 147
Heated Exhaust Gas Oxygen Sensorp. 148
Gasoline Multi Point Fuel Injection System (MPFI)p. 148
Gasoline Fuel Pumpp. 148
Gasoline Pressure And Temperature Sensor Manifoldp. 148
Fuel Filterp. 149
Fuel Injector Railp. 149
Fuel Injectorp. 149
+3.22 GM Engine Fuel System Repairp. 149
Propane Fuel System Pressure Reliefp. 149
Propane Fuel System Leak Testp. 149
Propane Fuel Filter Replacementp. 150
Direct Electronic Pressure Regulator (DEPR) Maintenance And Inspectionp. 150
Check/Drain Oil Build-Up In 2-Stage Vaporizerp. 151
Air Fuel Mixer/Throttle Control Device Maintenance And Inspectionp. 151
Exhaust System And Catalytic Converter Inspection And Maintenancep. 152
Temperature Manifold Absolute Pressure (TMAP) Sensorp. 152
Throttle Body (ETC) Replacementp. 152
Mixer Replacementp. 152
Electronic Pressure Regulator (EPR) Replacementp. 153
Regulator Replacementp. 153
Coolant Hose Replacementp. 153
Vapor Hose Replacementp. 153
Engine Control Module Replacementp. 154
Heated Exhaust Gas Oxygen Sensor Replacementp. 154
+3.23 GM Engine LPG Fuel System Diagnosisp. 155
Fuel System Descriptionp. 155
Diagnostic Aidsp. 155
3.24 Ford Enginep. 168
3.25 Counterweightp. 185
+Section 4. Boom & Platformp. 187
+4.1 Platformp. 187
Support Removalp. 187
Support Installationp. 188
+4.2 Rotator and Slave Cylinderp. 190
Removalp. 190
Installationp. 191
+4.3 Main Boom Powertrackp. 192
Removalp. 192
Installationp. 192
+4.4 Powertrack Maintenancep. 193
Remove Linkp. 193
Install New Linkp. 196
Replace Fixed End Bracketsp. 199
Replace Moving End Bracketsp. 200
+4.5 Main Boom Assemblyp. 202
Removalp. 202
Disassemblyp. 203
Inspectionp. 203
Assemblyp. 204
Installationp. 204
+4.6 Uprightp. 205
Removalp. 205
Installationp. 205
+4.7 Tower Boom Assemblyp. 206
Removalp. 206
Disassemblyp. 206
Inspectionp. 207
Assemblyp. 207
Installationp. 208
+4.8 Jib Assembly – 600AJp. 208
Removalp. 208
Disassemblyp. 208
Inspectionp. 209
Installationp. 209
4.9 Boom Cleanliness Guidelinesp. 210
+4.10 Rotary Actuatorp. 211
Theory of Operationp. 211
Required Toolsp. 211
Disassemblyp. 213
Inspectionp. 217
Assemblyp. 218
Installing Counterbalance Valvep. 222
Testing Actuatorp. 223
Testing Actuator for Internal Leaksp. 223
Installation and Bleedingp. 223
Troubleshootingp. 224
4.11 Foot Switch Adjustmentp. 225
+4.12 Skyguardp. 226
Operationp. 226
Functional Testp. 226
Diagnostic & Troubleshootingp. 227
+4.13 Bolt On Fall Arrestp. 228
Inspection Before Usep. 228
Installationp. 228
+Section 5. Basic Hydraulics Information & Schematicsp. 231
+5.1 Lubricating O-rings In The Hydraulic Systemp. 231
Cup and Brushp. 231
Dip Methodp. 232
Spray Methodp. 232
Brush-on Methodp. 232
+5.2 Cylinders – Theory of Operationp. 233
Systems With Double Acting Cylindersp. 233
Systems With Holding Valvesp. 233
+5.3 Cylinder Checking Procedurep. 233
Cylinders Without Counterbalance Valves – Master Cylinder and Steer Cylinderp. 233
Cylinders With Single Counterbalance Valvep. 234
Cylinders With Dual Counterbalance Valvesp. 234
+5.4 Hydraulic Cylindersp. 235
Cylinder Locationsp. 235
Main Boom Telescope Cylinder Removalp. 236
Main Boom Telescope Cylinder Installationp. 236
Main Boom Lift Cylinder Removalp. 237
Main Boom Lift Cylinder Installationp. 237
Upright Level Cylinder Removalp. 238
Upright Level Cylinder Installationp. 238
Tower Boom Lift Cylinder Removalp. 239
Tower Lift Cylinder Installationp. 240
Tower Telescope Cylinder Removalp. 240
Tower Telescope Cylinder Installationp. 240
+5.5 Hydraulic Cylinder repairp. 241
Tower Boom Lift Cylinderp. 241
Cleaning and Inspectionp. 244
Assemblyp. 245
Upright Level Cylinderp. 247
Cleaning and Inspectionp. 250
Assemblyp. 251
Master Cylinderp. 253
Cleaning and Inspectionp. 256
Assemblyp. 257
Main Boom Lift Cylinderp. 259
Cleaning and Inspectionp. 262
Assemblyp. 263
Main Boom Telescope Cylinderp. 265
Cleaning and Inspectionp. 268
Assemblyp. 269
Tower Boom Telescope Cylinderp. 271
Cleaning and Inspectionp. 274
Assemblyp. 275
Platform Level (Slave) Cylinderp. 277
Cleaning and Inspectionp. 280
Assemblyp. 281
Jib Lift Cylinder (600AJ Only)p. 283
Cleaning and Inspectionp. 286
Assemblyp. 287
Steer Cylinderp. 289
Cleaning and Inspectionp. 291
Assemblyp. 292
Axle Lockout Cylinderp. 293
+5.6 Hydraulic Pump (Gear)p. 295
Disassemblyp. 295
Inspect Parts For Wearp. 297
General Informationp. 298
Reverse Shaft Rotation of Pumpp. 298
Assemblyp. 298
Placing Pump Back Into Servicep. 301
+5.7 Variable Pumpp. 301
Ports and Pressure Gaugesp. 301
NFPE Controlp. 301
Remove and Install FNR and NFPE Modulesp. 302
Remove and Install FNR and NFPE Control Orificesp. 302
Charge Relief Valvep. 302
Shaft Seal and Shaft Replacementp. 305
Hydraulic Pump W/Hayes Pump Drive Coupling Lubricationp. 306
Charge Pumpp. 307
5.8 Hydraulic Component Start-Upp. 308
+5.9 Main Valve Block Pressure Settingsp. 309
Main Reliefp. 309
Upper (Main) Lift Downp. 309
Swingp. 309
2-Wheel Steerp. 309
4-Wheel Steerp. 309
+5.10 Platform Valve Block Pressure Settingsp. 309
Platform Level Extendp. 309
Platform Level Retractp. 309
Articulating Jibp. 309
5.11 Hydraulic Schematicsp. 314
+Section 6. JLG Control Systemp. 323
+6.1 JLG Control System Analyzer Kit Instructionsp. 323
Introductionp. 323
Connect JLG Control System Analyzerp. 324
Using the Analyzerp. 324
Changing the Access Level of the Hand Held Analyzerp. 325
Adjusting Parameters Using the Hand Held Analyzerp. 326
Machine Setupp. 327
Level Vehicle Descriptionp. 327
6.2 Machine Personality Settingsp. 337
+6.3 Machine Orientation When Setting Function Speedsp. 360
6.4 CANbus Communicationsp. 361
+6.5 LSS Systemp. 362
Diagnostic Menup. 363
Calibration Procedurep. 364
Testing & Evaluationp. 369
Troubleshootingp. 370
6.6 Resetting The MSSO Systemp. 371
+Section 7. Basic Electrical Information & Electrical Schematicsp. 387
7.1 Generalp. 387
+7.2 Multimeter Basicsp. 387
Groundingp. 387
Backprobingp. 387
Min/Maxp. 387
Polarityp. 387
Scalep. 387
Voltage Measurementp. 387
Resistance Measurementp. 388
Continuity Measurementp. 388
Current Measurementp. 389
+7.3 Applying Silicone Dielectric Compound to Electrical Connectionsp. 389
Installation of Dielectric Greasep. 390
Deutsch HD, DT, DTM, DRC Seriesp. 390
AMP Sealp. 390
AMP Mate-N-Lokp. 391
DIN Connectorsp. 391
Exclusionsp. 391
+7.4 AMP Connectorp. 393
Assemblyp. 393
Disassemblyp. 395
Wedge Lockp. 395
Service – Voltage Readingp. 395
+7.5 Deutsch Connectorsp. 397
DT/DTP Series Assemblyp. 397
DT/DTP Series Disassemblyp. 397
HD30/HDP20 Series Assemblyp. 398
HD30/HDP20 Series Disassemblyp. 398
+7.6 Telematics Gatewayp. 399
Telematics-Ready (TCU) Plugp. 399
+7.7 Wiring Harnessp. 403
Connector Labelsp. 403
Component Labelsp. 403
7.8 Wiring Harness Breakdownp. 405
7.9 Electrical Schematicsp. 430
Across these sections, this JLG 600A 600AJ repair manual gives a technician the full service picture — not just a single system. It opens with capacity and stability data, walks through scheduled maintenance and lubrication intervals, then moves into component-level rebuild procedures for the chassis, drivetrain, boom, and platform. Hydraulic coverage includes every cylinder on the machine, the gear pump, the variable pump, and pressure settings for the main and platform valve blocks. Electrical coverage runs from basic multimeter technique and connector assembly up to full wiring schematics for the platform and ground controls, engine harnesses, and the telematics gateway. The JLG control system section covers the hand-held analyzer, personality ranges and defaults, machine configuration programming, LSS calibration and testing, and a full fault code list. The manual closes with complete hydraulic and electrical schematics.
Engines Covered
- Deutz D2.9 L4 (T4F) – oil level check, engine oil and filter change, fuel filter replacement
- Deutz D2011 (T4i) – oil level check, engine oil and filter change, fuel filter replacement, fuel strainer cleaning
- Deutz EMR 2 – engine-side equipment, troubleshooting flow chart, connection diagrams, pin identification, fault codes
- GM 3.0L – drive belt maintenance, engine electrical system, oil level check and fill, oil change, coolant fill procedure for dual fuel engine, dual fuel system components, DEPR, air fuel mixer, ETC, lock off, ECM, HEGO sensor, MPFI, fuel pump, pressure and temperature sensor manifold, fuel filter, injector rail, injector, LPG fuel system diagnosis
- Ford MSG 425 – engine installation, fault code cross reference list, CAN to DTC cross reference
Who This Manual Is For
This JLG 600A 600AJ service manual is written for the qualified JLG equipment mechanic performing pre-delivery inspections, frequent inspections, annual machine inspections, and preventive maintenance. It is equally useful for a shop rebuilding a swing drive, a technician replacing a hydraulic cylinder, an electrician tracing a fault through the CANbus or the platform control box, or a fleet owner who wants the correct torque values, pressure settings, and cylinder drift limits on hand before a repair begins. The safety precautions in Section A and the maintenance schedule in Section 2 give the framework for keeping the machine in safe operating condition, while the component-level procedures in the later sections support the actual repair work.
Why This Manual Matters
Boom lift service is not guesswork. Cylinder drift limits, torque specs, valve block pressures, gear backlash values, and pin and composite bearing tolerances all come with defined figures in this manual. Guessing at a swing gear backlash or a relief valve setting risks damage to the machine and creates a safety hazard for the operator. Having the exact procedure and the exact number in front of you on the shop floor means the repair is done to spec the first time, and the annual machine inspection or function test can be signed off with confidence.
Instant PDF Delivery
The JLG 600A 600AJ Service and Maintenance Manual is delivered as an instant PDF download after purchase. There is no shipping, no waiting for a printed book, and no restriction on which device you use. Open it on a laptop in the shop, a tablet on the machine, or print the pages you need for the job and keep the rest clean. The file stays on your device for as long as you need it, so the next service on the 600A or 600AJ is already covered.
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