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JLG 600A Service Manual

JLG 600A
342 pages
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Service and Maintenance Manual
Models
600A
600AJ
S/N 0300080000
to Present
P/N - 3121201
December 10, 2012

Table of Contents

Other manuals for JLG 600A

Questions and Answers:

JLG 600A Specifications

General IconGeneral
Platform Height60 ft
Horizontal Outreach40 ft
Machine Width8 ft
Power SourceDiesel
Ground Clearance1 ft
Gradeability - 4 Wheel Drive45%
Axle Oscillation8 in
Engine Power74 hp
Platform Capacity - Unrestricted500 lb
Platform Capacity - Restricted1000 lb
Swing360° Continuous

Summary

Introduction and Safety Precautions

Maintenance Safety Precautions

Lists critical safety precautions for maintenance, including using identical replacement parts and observing all warnings.

Section 1: Specifications

Torque Requirements

Specifies torque values for critical fasteners and components, with interval recommendations.

Section 2: General

Machine Preparation, Inspection, and Maintenance

Provides information for operating readiness and safe operating conditions, covering inspections and maintenance programs.

Welding on JLG Equipment

Details instructions for repairs or modifications involving welding on JLG equipment, including what to do and not to do.

Section 3: Chassis & Turntable

Drive Brake - Mico (S/N 56718 TO 81836)

Covers the disassembly, assembly, and integral brake check for Mico drive brakes.

Oscillating Axle Bleeding Procedure and Lockout Test

Details the procedure for bleeding lockout cylinders and performing the oscillating axle lockout test.

Swing Bearing

Covers checks for turntable bearing mounting bolt condition and wear tolerance.

Swing Bearing Replacement

Details the removal and installation procedures for the swing bearing.

Swing Brake - Mico

Covers disassembly, inspection, and assembly procedures for the Mico swing brake.

Rotary Coupling - S/N 81836 TO PRESENT

Provides procedures for installing the seal kit on the rotary coupling.

ECM and Sensors

Describes engine sensors like CKP and CMP, their function, and signal interpretation.

Electronic Governor and Throttle Body

Explains throttle control achieved through an electronic governor managed by the ECM.

Engine Control Module (ECM)

Describes the ECM's responsibility in maintaining spark and fuel injection timing for optimal engine performance.

Ford LPG System

Provides an overview of the LPG system, including components and low temperature limits.

Deutz EMR 2 (S/N 84711 to Present)

Describes the EMR2 system, including sensors, control unit, actuator, and safety features.

GM Engine General Maintenance

Covers general maintenance for the GM engine, including drive belt, electrical system, and oil level checks.

GM Engine Dual Fuel System

Explains how the dual fuel system allows operation on gasoline or LPG, detailing component functions.

Engine Control Module

Describes the ECM's function in controlling engine operation, fuel ratio, and diagnostics.

GM Engine Fuel System Repair

Provides procedures for repairing the GM engine fuel system, including pressure relief and leak tests.

Electronic Throttle Control Replacement

Details the removal and installation procedures for the electronic throttle control device.

Engine Control Module Replacement

Provides procedures for the removal and installation of the engine control module.

Heated Exhaust Gas Oxygen Sensor Replacement

Covers the removal and installation of the heated exhaust gas oxygen sensor.

LP Gas Fitting Inspection

Outlines safety precautions and procedures for inspecting LP gas fittings.

GM Engine LPG Fuel System Diagnosis

Provides diagnostic procedures for the GM engine LPG fuel system.

Symptom Diagnosis

Lists symptoms and guides for diagnosing problems in the LPG fuel system.

Boom Maintenance

Details procedures for boom removal, including disconnects and hardware removal.

Tower Boom

Covers the removal of the tower upright and tower boom assembly.

Articulating Jib Boom

Covers removal, disassembly, inspection, and assembly of the articulating jib boom.

Rotator - Helac (Prior to S/N 0300132474)

Details the disassembly of the Helac rotator.

Rotary Actuator (S/N 0300132474 to Present)

Explains the theory of operation for the rotary actuator.

Testing the Actuator

Details procedures for testing the actuator on a hydraulic test bench for breakaway pressure and leaks.

Troubleshooting

Lists common problems with the rotary actuator, their causes, and solutions.

Lubricating O-Rings in the Hydraulic System

Details methods for lubricating O-rings using cup and brush, dip, or spray methods.

Cylinders - Theory of Operation

Explains the theory of operation for double acting cylinders and systems with holding valves.

Cylinder Checking Procedure

Provides procedures for checking cylinders without counterbalance valves and with single counterbalance valves.

Cylinder Repair

Covers general procedures for cylinder repair, including disassembly and cleaning.

Cylinder Removal and Installation

Details procedures for removing and installing main boom telescope cylinders.

Variable Displacement Pump (M46 Series)

Addresses troubleshooting and gauge installation for the variable displacement pump.

Swashplate Neutral Adjustment

Details the procedure for adjusting the swashplate to achieve neutral position.

EDC Neutral Adjustment

Provides steps for performing neutral adjustment on the Electronic Displacement Control (EDC).

Shaft Seal

Provides instructions for replacing the shaft seal on Series 40 - M46 pumps and motors.

Charge Check and High Pressure Relief Valves

Covers the removal and reinstallation of charge check and high pressure relief valves.

Pressure Setting Procedures

Details pressure setting procedures for main relief, steer, swing, lift, platform level, and jib boom.

Hydraulic Component Start-Up Procedures and Recommendations

Provides guidelines for starting up a new or replaced hydraulic component or system.

Section 6: JLG Control System

Contains information on the JLG control system, including its introduction and configuration.

Adjusting Parameters Using the Hand Held Analyzer

Details how to adjust parameters like drive acceleration using the analyzer.

Analyzer Diagnostics Menu Structure

Provides descriptions of the analyzer's diagnostic menus and personality settings.

Section 7: Basic Electrical Information & Schematics

Contains basic electrical information, multimeter usage, and electrical schematics.

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