Jlg 601S Service Manual User Manual Page 19
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- Table of contents
- TROUBLESHOOTING
- BOOKMARKS
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SECTION 1 - SPECIFICATIONS
3120866 – JLG Lift – 1-3
Te st N o tes
1. Stop watch should be started with the function, not
with the controller or switch.
2. All speed tests are run from the platform. These
speeds do not reflect the ground control operation.
3. The platform speed knob control must be at full
speed (turned clockwise completely).
4. Function speeds may vary due to cold, thick hydrau-
lic oil. Test should be run with the oil temperature
above 38° C (100° F).
5. Some flow control functions may not work with the
speed knob clicked into the creep position.
1.5 TORQUE REQUIREMENTS
Table 1-1. Function Speeds (In Seconds)
Function Time
Lift Up 46-60
Lift Down 33-43
Swing Right & Left* 79-101
Telescope Out 50-67
Telescope In 35-40
Platform Rotate Right & Left** 16-25
Drive Forward & Reverse (4WD) 37-45
Drive Above Horizontal - Forward & Reverse (2WD &
4WD)
43-136
*Max 10% Difference Between Left & Right
**Max 15% Difference Between Left & Right
4150130 - E
Table 1-2. Torque Requirements
Description
Tor q u e Va l u e
(Dry)
Interval Hours
Bearing To
Chassis
240 ft. lbs.
(326 Nm)
See Note
50/600*
Bearing To
Turntable
240 ft. lbs.
(326 Nm)
See Note
50/600*
Wire Rope 15 FT. LBS
(20 Nm)
150
Wheel Lugs 170 FT. LBS.
(231 Nm)
150
*Check swing bearing bolts for security after first 50
hours of operation and every 600 hours thereafter.
NOTE: When maintenance becomes necessary or
a fastener has loosened, refer to the
Torque Chart to determine proper torque
value.
- 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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