Jlg 601S Service Manual manuals

Jlg 601S Service Manual User Manual (240 pages)

Brand: Jlg | Category: Special machinery | Size: 17.97 MB |

English

Table of contents

P/N - 3120866

1

ADE System Identification

3

– JLG Lift –

4

PRECAUTIONS

5

REVISON LOG

6

(Continued)

10

TABLE OF CONTENTS

11

SECTION 1. SPECIFICATIONS

17

1-2 – JLG Lift – 3120866

18

SECTION 1 - SPECIFICATIONS

19

Te st N o tes

19

1.5 TORQUE REQUIREMENTS

19

1.6 LUBRICATION

20

Ford LRG425 Engine

20

Deutz F3M1011F Engine

20

Hydraulic Oil

21

Lubrication Specifications

21

1.7 PRESSURE SETTINGS

21

1.8 CYLINDER SPECIFICATIONS

22

1.9 MAJOR COMPONENT WEIGHTS

22

1.11 SERIAL NUMBER LOCATIONS

23

SECTION 2. GENERAL

27

2-2 – JLG Lift – 3120866

28

3120866 – JLG Lift – 2-3

29

2-4 – JLG Lift – 3120866

30

3120866 – JLG Lift – 2-5

31

2-6 – JLG Lift – 3120866

32

SECTION 2 - GENERAL

33

2.8 AMP CONNECTOR

33

AMP Connectors

33

Wedge Lock

35

Service - Voltage Reading

35

3.1 TORQUE HUB, DRIVE

41

3-2 – JLG Lift – 3120866

42

3120866 – JLG Lift – 3-3

43

3120866 – JLG Lift – 3-5

45

3-6 – JLG Lift – 3120866

46

3120866 – JLG Lift – 3-7

47

3-8 – JLG Lift – 3120866

48

3120866 – JLG Lift – 3-9

49

3120866 – JLG Lift – 3-11

51

3.3 DRIVE BRAKE - AUSCO

52

3120866 – JLG Lift – 3-13

53

3.4 DRIVE BRAKE - MICO

54

3120866 – JLG Lift – 3-15

55

Bleeding

56

Spare Parts Kits

57

3-18 – JLG Lift – 3120866

58

Disassembly and Assembly

59

3-20 – JLG Lift – 3120866

60

3120866 – JLG Lift – 3-21

61

3-22 – JLG Lift – 3120866

62

Assembly Notes

63

3-24 – JLG Lift – 3120866

64

Te st i n g a n d Se t u p

65

3.6 DRIVE MOTOR ADJUSTMENT

66

Description

67

Shaft Seal Replacement

67

Loop Flushing Valve

68

3120866 – JLG Lift – 3-31

71

3-32 – JLG Lift – 3120866

72

3120866 – JLG Lift – 3-33

73

Slipper retainer

75

Ball guide

75

3120866 – JLG Lift – 3-37

77

3-38 – JLG Lift – 3120866

78

3120866 – JLG Lift – 3-39

79

3-40 – JLG Lift – 3120866

80

Initial Start-up Procedures

81

3-42 – JLG Lift – 3120866

82

PROCEDURE AND LOCKOUT TEST

83

Lockout Cylinder Bleeding

83

Oscillating Axle Lockout Test

83

3.10 STEER ADJUSTMENTS

84

3120866 – JLG Lift – 3-45

85

.0015" Feeler Gauge

86

3120866 – JLG Lift – 3-47

87

3-48 – JLG Lift – 3120866

88

Swing Bearing Torque Values

89

3.13 SWING BRAKE - AUSCO

89

3120866 – JLG Lift – 3-51

91

3.14 SWING MOTOR

92

Reassembly

93

Motor Timing

94

3120866 – JLG Lift – 3-55

95

3-56 – JLG Lift – 3120866

96

3120866 – JLG Lift – 3-57

97

3-58 – JLG Lift – 3120866

98

Mounting-Controller

99

3-60 – JLG Lift – 3120866

100

3120866 – JLG Lift – 3-61

101

Troubleshooting

102

3120866 – JLG Lift – 3-63

103

3.19 THROTTLE CHECKS AND

104

ADJUSTMENTS - DEUTZ ENGINE

104

(PRIOR TO S/N 61306)

104

3120866 – JLG Lift – 3-65

105

Failure Modes

106

3120866 – JLG Lift – 3-67

107

Checking the Ignition

108

3.22 CHECKING THE FUEL

109

S/N 58209)

110

Performing Diagnostics

110

Engine Module and Sensors

111

3-72 – JLG Lift – 3120866

112

3120866 – JLG Lift – 3-73

113

3-74 – JLG Lift – 3120866

114

3120866 – JLG Lift – 3-75

115

3-76 – JLG Lift – 3120866

116

3120866 – JLG Lift – 3-77

117

3-78 – JLG Lift – 3120866

118

3120866 – JLG Lift – 3-79

119

3120866 – JLG Lift – 3-81

121

3120866 – JLG Lift – 3-83

123

ENGINE MODULE INPUTS/OUTPUTS

123

THROTTLE POSITION (TP) SENSOR

123

USE OF CIRCUIT TESTING TOOLS

123

3-84 – JLG Lift – 3120866

124

Fuel System

125

3-86 – JLG Lift – 3120866

126

FUEL METERING SYSTEM PURPOSE

126

3-88 – JLG Lift – 3120866

128

3120866 – JLG Lift – 3-89

129

ELECTRONIC IGNITION

129

IGNITION COIL

129

ENGINE MODULE (ECM OR EPM)

129

3-90 – JLG Lift – 3120866

130

4.1 BOOM MAINTENANCE

131

Disassembly Boom Sections

132

3120866 – JLG Lift – 4-3

133

4-4 – JLG Lift – 3120866

134

3120866 – JLG Lift – 4-5

135

4-6 – JLG Lift – 3120866

136

Inspection

137

Assembly

138

3120866 – JLG Lift – 4-9

139

Installation

140

Torque Procedures

140

4.3 WEAR PADS

141

Main Boom

141

4-12 – JLG Lift – 3120866

142

ADJUSTMENT

143

4.6 ROTATOR - HELAC

144

Disassembly

144

4-16 – JLG Lift – 3120866

146

3120866 – JLG Lift – 4-17

147

Lift, Swing, and Drive Cards

148

Flow Control Card

148

4.8 FOOT SWITCH ADJUSTMENT

149

4-20 – JLG Lift – 3120866

150

SECTION 5. HYDRAULICS

151

SECTION 5 - HYDRAULICS

152

5.4 CYLINDER REPAIR

152

Cleaning and Inspection

154

5.5 CYLINDER REMOVAL AND

158

INSTALLATION

158

Boom Lift Cylinder Removal

159

Inspections and Adjustments

163

Minor Repair and Replacement

166

Platform Level

170

4 Wheel Steer (If Equipped)

170

5-24 – JLG Lift – 3120866

174

6.1 INTRODUCTION

177

6-2 – JLG Lift – 3120866

178

SYSTEM ANALYZER

179

6.3 USING THE ANALYZER

179

6-4 – JLG Lift – 3120866

180

HAND HELD ANALYZER

181

6-6 – JLG Lift – 3120866

182

6.6 MACHINE SETUP

184

6.7 LEVEL VEHICLE DESCRIPTION

184

3120866 – JLG Lift – 6-9

185

6-10 – JLG Lift – 3120866

186

3120866 – JLG Lift – 6-11

187

6-12 – JLG Lift – 3120866

188

4150365 - 3

189

6-14 – JLG Lift – 3120866

190

3120866 – JLG Lift – 6-15

191

6-16 – JLG Lift – 3120866

192

3120866 – JLG Lift – 6-17

193

6-18 – JLG Lift – 3120866

194

3120866 – JLG Lift – 6-19

195

6-20 – JLG Lift – 3120866

196

3120866 – JLG Lift – 6-21

197

6-22 – JLG Lift – 3120866

198

3120866 – JLG Lift – 6-23

199

6-24 – JLG Lift – 3120866

200

3120866 – JLG Lift – 6-25

201

6-26 – JLG Lift – 3120866

202

3120866 – JLG Lift – 6-27

203

6-28 – JLG Lift – 3120866

204

3120866 – JLG Lift – 6-29

205

4150364 - 6

206

3120866 – JLG Lift – 6-31

207

6-32 – JLG Lift – 3120866

208

3120866 – JLG Lift – 6-33

209

6-34 – JLG Lift – 3120866

210

3120866 – JLG Lift – 6-35

211

6-36 – JLG Lift – 3120866

212

STRUCTURE

213

6-38 – JLG Lift – 3120866

214

3120866 – JLG Lift – 6-39

215

6-40 – JLG Lift – 3120866

216

3120866 – JLG Lift – 6-41

217

6-42 – JLG Lift – 3120866

218

SECTION 7. SCHEMATICS

219

SECTION 7 - SCHEMATICS

220

JLG Worldwide Locations

240

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