Jlg 601S Service Manual User Manual Page 17
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- Table of contents
- TROUBLESHOOTING
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SECTION 1 - SPECIFICATIONS
3120866 – JLG Lift – 1-1
SECTION 1. SPECIFICATIONS
1.1 CAPACITIES
Fuel Tank
98.4 Liters (26 gal.)
Hydraulic Oil Tank
Approx. 121 liters (32 U.S. Gallons), 98.4 L (26 gal.) to the
full mark on sight gauge.
Hydraulic System (Including Tank)
Gasoline/Diesel Power - 140.8 liters (37.2 gal.)
Torque Hub, Drive
0.50 liters (17 ounces).
NOTE: Torque hubs should be one half full of lubricant.
Engine Crankcase
Ford LRG-425 Gas w/Filter - 4.25 liters (4.5 quarts).
Deutz F3M1011F Diesel w/Filter - 6 liters (6.3 quarts).
1.2 COMPONENT DATA
Engine - Gas. (Water-Cooled)
Manufacturer/Model - Ford LRG-425.
Oil Capacity.
4.25 liters (4.5 Quarts) w/Filter.
Idle RPM - 1000.
Low RPM - 1800.
High RPM - 2800.
Alternator - 40 Amp, Belt Drive.
Battery - 85 Amphour, 550 Cold Cranking Amps, 12 VDC.
Fuel Consumption.
Low RPM - 13.06 lph (3.45 GPH).
High RPM - 17.41 lph (4.60 GPH).
Horsepower - 54 @ 2400 RPM, full load.
Cooling System - 15 liters (16 Quarts).
Engine - Diesel (Liquid-Cooled)
Manufacturer/Model- Deutz F3M1011F.
Oil Capacity.
4.5 liters (5 Quarts) Cooling System.
6 liters (6.3 Quarts) w/Filter.
10.7 liters (11.3 Quarts) Total Capacity.
Low RPM - 1800.
High RPM - 2800.
Alternator - 60 Amp, belt drive.
Battery - 1000 Cold Cranking Amps, 210 Minutes
Reserve Capacity, 12 VDC.
Horsepower - 48 @ 3000 RPM, full load.
Drive System
Tires - 14 x 17.5, G 14 ply rating, directional tread, pneu-
matic, tire pressure - 6 Bar (90 PSI).
Drive Motor Displacement.
Standard - 46 cm[3] max. 18 cm[3] min.
(2.8 cu. in. max. 1.1 cu. in. min.)
Drive Hub Ratio.
Standard - 43:1 (4WD).
Drive Brake - Automatic spring applied, hydraulically
released disc brakes.
Steer System
Tires - 14 x 17.5, G 14 ply rating, directional tread, pneu-
matic, tire pressure - 6 Bar (90 PSI)
Tires - 14 x 17.5, G 14 ply rating, directional tread, foam
filled.
Toe-in, adjust for 6.35 mm overall.
- 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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