Description
JLG 600A 600AJ Service and Maintenance Manual – Complete Boom Lift Repair Reference
This JLG 600A 600AJ Service and Maintenance Manual is the factory-issued repair reference for the JLG 600A and 600AJ self-propelled boom lifts, part number 3121201, dated April 1, 2008, and covering serial numbers 0300080000 to Present. This is the final revision of the document, incorporating updates carried through from the original October 15, 2004 issue.
- Manual Type: Service and Maintenance Manual
- Brand / Model: JLG 600A, JLG 600AJ boom lifts
- Document Number: 3121201
- Publication Date: April 1, 2008 (Revised; Original Issue October 15, 2004)
- Serial Number Range: 0300080000 to Present
- Language: English
- Page Count: 306 pages
- File Format: PDF
Chapters Covered in the JLG 600A 600AJ Service and Maintenance Manual
- Section A – Introduction, Maintenance Safety Precautions
- General, Hydraulic System Safety, Maintenance
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “JLG 600A 600AJ Service and Maintenance Manual – Boom Lift Repair PDF (P/N 3121201, 2008)” are as follows:
+Section A. INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONSp. 3
A Generalp. 3
B Hydraulic System Safetyp. 3
C Maintenancep. 3
+Section 1. Specificationsp. 17
1.1 Operating specificationsp. 17
1.2 Capacitiesp. 17
+1.3 Component Datap. 17
Engine Datap. 17
Tiresp. 19
Drive Systemp. 19
Swing Systemp. 19
Pumpsp. 19
Hydraulic Filtersp. 19
Dimensional Datap. 19
+1.4 Function Speedsp. 20
Machine Orientation When Doing Speed Testsp. 20
Test Notesp. 20
1.5 Torque Requirementsp. 20
+1.6 Lubricationp. 21
1.7 Pressure Settingsp. 21
1.8 Cylinder Specificationsp. 21
1.9 Major Component Weightsp. 22
1.10 Critical Stability Weightsp. 23
1.11 Serial Number Locationsp. 23
+1.12 Lubrication & Maintenancep. 24
Draining Oil Build Up From The Propane Regulatorp. 28
Propane Fuel Filter Replacementp. 29
Propane Fuel System Pressure Reliefp. 30
+Section 2. Generalp. 35
+2.1 Machine Preparation, Inspection, and Maintenancep. 35
Generalp. 35
Preparation, Inspection, and Maintenancep. 35
Pre-Start Inspectionp. 35
Pre-Delivery Inspection and Frequent Inspectionp. 35
Annual Machine Inspectionp. 35
Preventative Maintenancep. 35
+2.2 Service and Guidelinesp. 36
Generalp. 36
Safety and Workmanshipp. 36
Cleanlinessp. 36
Components Removal and Installationp. 36
Component Disassembly and Reassemblyp. 37
Pressure-Fit Partsp. 37
Bearingsp. 37
Gasketsp. 37
Bolt Usage and Torque Applicationp. 37
Hydraulic Lines and Electrical Wiringp. 37
Hydraulic Systemp. 37
Lubricationp. 37
Batteryp. 37
Lubrication and Servicingp. 37
+2.3 Lubrication and Informationp. 37
Hydraulic Systemp. 37
Hydraulic Oilp. 38
Changing Hydraulic Oilp. 38
Lubrication Specificationsp. 38
+2.4 Cylinder Drift Testp. 38
Platform Driftp. 38
Cylinder Driftp. 39
2.5 Pins and Composite Bearing Repair Guidelinesp. 39
+2.6 Welding on JLG Equipmentp. 39
Do the Following When Welding on JLG Equipmentp. 39
Do NOT Do the Following When Welding on JLG Equipmentp. 39
+Section 3. Chassis & Turntablep. 47
+3.1 Tires & Wheelsp. 47
Tire Inflationp. 47
Tire Damagep. 47
Wheel and Tire Replacementp. 47
Wheel Installationp. 47
+3.2 Drive Torque hubp. 48
Roll, Leak and Brake Testingp. 48
Tightening and Torquing Boltsp. 49
Main Disassemblyp. 49
Input Carrier Disassemblyp. 53
Hub-Spindle Disassemblyp. 54
Spindle-Brake Disassemblyp. 55
Cover Disassemblyp. 57
Input Carrier Sub-Assemblyp. 58
Output Planet Gear Sub-Assemblyp. 58
Spindle – Brake Sub-Assemblyp. 58
Hub-Spindle Sub-Assemblyp. 59
Cover Sub-Assemblyp. 60
Main Assemblyp. 60
Integral Brake Checkp. 60
+3.3 Drive Brake – Mico (S/N 56718 to 81836)p. 64
Disassemblyp. 64
Assemblyp. 64
Bleedingp. 66
+3.4 Free Wheeling Optionp. 67
To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.p. 67
To Engage Drive Motors and Brakes (Normal Operation)p. 67
+3.5 Drive Motor – 4WD (Prior to S/N 81836)p. 67
Spare Parts Kitsp. 67
Replacing the Drive Shaft Sealp. 69
Disassembly and Assemblyp. 70
Assembly Notesp. 73
Taper Roller Bearing Initial Tensionp. 75
Testing and Setupp. 75
+3.6 Drive Motor – 2WD (Prior to S/N 81836)p. 76
Shaft Seal Replacementp. 76
+3.7 Drive Motor (S/N 81836 to Present)p. 76
Descriptionp. 76
Shaft Seal Replacementp. 77
Troubleshootingp. 78
Loop Flushing Valvep. 79
Disassemblyp. 80
Inspectionp. 84
Assemblyp. 86
Initial Start-up Proceduresp. 91
+3.8 Oscillating Axle Bleeding Procedure and Lockout Testp. 92
Lockout Cylinder Bleedingp. 92
Oscillating Axle Lockout Testp. 92
+3.9 Swing Hubp. 93
Adjustment Proceduresp. 93
+3.10 Swing Bearingp. 93
Turntable Bearing Mounting Bolt Condition Checkp. 93
Wear Tolerancep. 94
Swing Bearing Replacementp. 96
Swing Bearing Torque Valuesp. 97
+3.11 Swing Brake – Micop. 98
Disassemblyp. 98
Inspectionp. 98
Assemblyp. 98
3.12 Rotary Coupling – s/n 81836 to Presentp. 100
+3.13 Generatorp. 105
Every 250 hoursp. 105
Every 500 hoursp. 105
Overload Protectionp. 105
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Ringsp. 105
3.14 Spark Arrester Cleaning Instructionsp. 107
+3.15 Dual Fuel Systemp. 107
Changing from Gasoline to LP Gasp. 107
Changing from LP Gas to Gasolinep. 107
+3.16 Ford EFI Enginep. 107
Performing Diagnosticsp. 107
ECM AND SENSORSp. 108
Fuel Systemp. 114
+3.17 Ford LPG Systemp. 119
Descriptionp. 119
Regulatorp. 119
Megajectorp. 119
Mixerp. 119
Lockoff Solenoidp. 121
Megajector Diagnostic Code Descriptionsp. 121
3.18 Deutz EMR 2 (S/N 84711 to Present)p. 124
+3.19 GM Engine General Maintenancep. 137
Maintenance of the Drive Beltp. 137
Engine Electrical System Maintenancep. 137
Checking/Filling Engine Oil Levelp. 137
Changing The Engine Oilp. 138
Coolant Fill Procedure – Dual Fuel Enginep. 138
+3.20 GM Engine Dual Fuel Systemp. 139
Fuel Filterp. 140
Electric Lock Offp. 140
EPR Assemblyp. 140
Low Pressure Regulator (LPR)p. 141
Air Fuel Mixerp. 141
Electronic Throttle Control (ETC)p. 142
Engine Control Modulep. 142
Heated Exhaust Gas Oxygen Sensorp. 143
Gasoline Multi Point Fuel Injection System (MPFI)p. 143
Gasoline Fuel Pumpp. 143
Gasoline Pressure And Temperature Sensor Manifoldp. 143
Fuel Filterp. 144
Fuel Injector Railp. 144
Fuel Injectorp. 144
+3.21 GM Engine Fuel System Repairp. 144
Propane Fuel System Pressure Reliefp. 144
Propane Fuel System Leak Testp. 144
Propane Fuel Filter Replacementp. 145
Electronic Pressure Regulator (EPR) Assembly Replacementp. 145
Temperature Manifold Absolute Pressure (TMAP) Sensorp. 147
Electronic Throttle Control Replacementp. 147
Mixer Replacementp. 148
Coolant Hose Replacementp. 149
Vapor Hose Replacementp. 149
Engine Control Module Replacementp. 149
Heated Exhaust Gas Oxygen Sensor Replacementp. 149
3.22 LP Gas Fitting Inspectionp. 150
+3.23 GM Engine LPG Fuel System Diagnosisp. 151
Fuel System Descriptionp. 151
Diagnostic Aidsp. 151
+Section 4. Boom & Platformp. 165
+4.1 Wear Padsp. 165
Tower Boomp. 165
Main Boomp. 165
+4.2 Boom Maintenancep. 167
Removalp. 167
Disassembly of Boom Sectionsp. 168
Inspectionp. 168
Assemblyp. 169
Installationp. 169
+4.3 Tower Boomp. 170
Removalp. 170
Disassemblyp. 171
Inspectionp. 172
Assemblyp. 172
Installationp. 173
+4.4 Articulating Jib Boomp. 173
Removalp. 173
Disassemblyp. 173
Inspectionp. 174
Assemblyp. 174
4.5 Limit Switches and Cam Valve Adjustmentp. 174
+4.6 Platformp. 177
Platform Sections Replacementp. 177
+4.7 Rotator – Helacp. 177
Disassemblyp. 177
Inspectionp. 179
Assemblyp. 179
4.8 Foot Switch Adjustmentp. 180
4.9 Boom Synchronizing Procedurep. 180
+Section 5. Hydraulicsp. 183
+5.1 Lubricating O-Rings in the Hydraulic Systemp. 183
Cup and Brushp. 183
Dip Methodp. 184
Spray Methodp. 184
Brush-on Methodp. 184
+5.2 Cylinders – Theory of Operationp. 185
Systems Incorporating Double Acting Cylindersp. 185
Systems Incorporating Holding Valvesp. 185
+5.3 Cylinder Checking Procedurep. 185
Cylinders Without Counterbalance Valves – Master Cylinder and Steer Cylinderp. 185
Cylinders With Single Counterbalance Valvep. 185
Cylinders With Dual Counterbalance Valvesp. 186
+5.4 Cylinder Repairp. 186
Disassemblyp. 186
Cleaning and Inspectionp. 188
Assemblyp. 189
+5.5 Cylinder Removal and Installationp. 192
Main Boom Telescope Cylinder Removalp. 192
Main Boom Telescope Cylinder Installationp. 192
Main Boom Lift Cylinder Removalp. 193
Main Boom Lift Cylinder Installationp. 194
Upright Level Cylinder Removalp. 194
Upright Level Cylinder Installationp. 196
Tower Boom Lift Cylinder Removalp. 197
Tower Lift Cylinder Installationp. 198
Tower Telescope Cylinder Removalp. 198
Tower Telescope Cylinder Installationp. 198
+5.6 Variable Displacement pump (M46 series)p. 209
Troubleshootingp. 209
Inspections and Adjustmentsp. 212
Minor Repair and Replacementp. 215
+5.7 Valves – Theory of Operationp. 219
Solenoid Control Valve – Rexrothp. 219
Relief Valvesp. 219
+5.8 Pressure Setting Proceduresp. 220
Main Relief, Steer, Swing and Lift Downp. 220
Platform Levelp. 220
Articulating Jib Boom (If Equipped)p. 220
4 Wheel Steer (If Equipped)p. 224
5.9 Hydraulic Component Start-Up Procedures and Recommendationsp. 224
5.10 Hydraulic Pump W/hayes Pump Drive Coupling Lubricationp. 225
+Section 6. JLG Control Systemp. 227
6.1 Introductionp. 227
6.2 To Connect the JLG Control System Analyzerp. 229
6.3 Using the Analyzerp. 229
6.4 Changing the Access Level of the Hand Held Analyzerp. 231
6.5 Adjusting Parameters Using the Hand Held Analyzerp. 233
6.6 Machine Setupp. 234
6.7 Level Vehicle Descriptionp. 234
6.8 Machine Personality Settingsp. 243
6.9 Analyzer Diagnostics Menu Structurep. 274
+Section 7. Basic Electrical Information & Schematicsp. 279
7.1 Generalp. 279
+7.2 Multimeter Basicsp. 279
Groundingp. 279
Backprobingp. 279
Min/Maxp. 279
Polarityp. 279
Scalep. 279
Voltage Measurementp. 279
Resistance Measurementp. 280
Continuity Measurementp. 280
Current Measurementp. 281
7.3 Applying Silicone Dielectric Compound to Electrical Connectionsp. 281
+7.4 AMP Connectorp. 282
Applying Silicone Dielectric Compound to AMP Connectorsp. 282
Assemblyp. 282
Disassemblyp. 284
Wedge Lockp. 284
Service – Voltage Readingp. 284
+7.5 Deutsch Connectorsp. 286
DT/DTP Series Assemblyp. 286
DT/DTP Series Disassemblyp. 286
HD30/HDP20 Series Assemblyp. 287
HD30/HDP20 Series Disassemblyp. 287
- Section 1 – Specifications
- Operating Specifications, Capacities, Component Data (Ford LRG-425, Deutz F4M2011, Deutz D2011L04, Caterpillar 3044C, GM 3.0L engine data), Tires, Drive System, Swing System, Pumps, Function Speeds, Torque Requirements, Lubrication, Pressure Settings, Cylinder Specifications, Major Component Weights, Critical Stability Weights, Serial Number Locations, Lubrication & Maintenance
- Section 2 – General
- Machine Preparation, Inspection, and Maintenance; Service and Guidelines; Lubrication and Information; Cylinder Drift Test; Pins and Composite Bearing Repair Guidelines; Welding on JLG Equipment
- Section 3 – Chassis & Turntable
- Tires & Wheels, Drive Torque Hub, Drive Brake – Mico, Free Wheeling Option, Drive Motor (4WD/2WD variants), Oscillating Axle Bleeding, Swing Hub, Swing Bearing, Swing Brake, Rotary Coupling, Generator, Spark Arrester, Dual Fuel System, Ford EFI Engine, Ford LPG System, Deutz EMR 2, GM Engine Maintenance and Fuel System Repair, LP Gas Fitting Inspection, GM LPG Fuel System Diagnosis
- Section 4 – Boom & Platform
- Wear Pads, Boom Maintenance, Tower Boom, Articulating Jib Boom, Limit Switches and Cam Valve Adjustment, Platform, Rotator – Helac, Foot Switch Adjustment, Boom Synchronizing Procedure
- Section 5 – Hydraulics
- Lubricating O-Rings, Cylinders – Theory of Operation, Cylinder Checking Procedure, Cylinder Repair, Cylinder Removal and Installation, Variable Displacement Pump (M46 Series), Valves – Theory of Operation, Pressure Setting Procedures, Hydraulic Component Start-Up Procedures, Hydraulic Pump Lubrication
- Section 6 – JLG Control System
- Introduction, Connecting the JLG Control System Analyzer, Using the Analyzer, Access Levels, Adjusting Parameters, Machine Setup, Level Vehicle Description, Machine Personality Settings, Analyzer Diagnostics Menu Structure
- Section 7 – Basic Electrical Information & Schematics
- Multimeter Basics, Applying Silicone Dielectric Compound, AMP Connectors, Wiring Diagrams (including the Deutz EMR 2 Vehicle Side Connection Diagram)
Taken together, this JLG 600A 600AJ Service and Maintenance Manual gives a technician everything needed to diagnose, service, and rebuild these boom lifts from the ground up – from chassis-level drive hub and brake overhauls to full hydraulic cylinder rebuilds, boom section disassembly, and JLG Control System Analyzer diagnostics across five different engine options (Ford LRG-425 gas, Deutz F4M2011 and D2011L04 diesel, Caterpillar 3044C diesel, and GM 3.0L gas/LPG).
What This JLG 600A 600AJ Manual Helps You Do
With this JLG 600A 600AJ Service and Maintenance Manual, you can carry out drive torque hub disassembly and rebuild, Mico drive brake service, swing bearing torque checks and replacement, boom telescope and lift cylinder removal/installation, variable displacement pump troubleshooting, and JLG Control System Analyzer-based machine setup and diagnostics – all against the factory torque values, pressure settings, and cylinder specifications printed in Section 1. Having the correct procedures and specs in hand means fewer comebacks, safer repairs on a machine that operates at boom elevations over 60 feet, and confidence that hydraulic pressures, torque hub ratios, and cylinder tolerances are set exactly as JLG designed them. The JLG 600A 600AJ Service and Maintenance Manual downloads instantly as a PDF after purchase – no shipping wait, no physical copy to lose track of. Open it on a laptop, tablet, or phone in the shop, or print the pages you need at the bench.
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