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601S Service Manual
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Jlg 601S Service Manual User Manual Page 135
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TROUBLESHOOTING
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SECTION 4 - BOOM & PLATFORM
3120866
– JLG Lift –
4-5
Figure 4-7. Boom Assemb
ly Cutaway - Sheet 2 of 3
1
2
...
130
131
132
133
134
135
136
137
138
139
140
...
239
240
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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