Jlg 601S Service Manual User Manual Page 32
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- Table of contents
- TROUBLESHOOTING
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SECTION 2 - GENERAL
2-6 – JLG Lift – 3120866
2.6 WELDING ON JLG EQUIPMENT
NOTE: This instruction applies to repairs, or modifications to
the machine and to welding performed from the
machine on an external structure, or component,
Do the Following When Welding on JLG
Equipment
• Disconnect the battery.
• Disconnect the moment pin connection (where fitted)
• Ground only to structure being welded.
Do NOT Do the Following When Welding on
JLG Equipment
• Ground on frame and weld on any other area than the
chassis.
• Ground on turntable and weld on any other area than
the turntable.
• Ground on the platform/support and weld on any other
area than the platform/support.
• Ground on a specific boom section and weld on any
other area than that specific boom section.
• Allow pins, wear pads, wire ropes, bearings, gearing,
seals, valves, electrical wiring, or hoses to be between
the grounding position and the welded area.
FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY
RESULT IN COMPONENT DAMAGE (I.E. ELECTRONIC MODULES,
SWING BEARING, COLLECTOR RING, BOOM WIRE ROPES ETC.)
2.7 APPLYING SILICONE DIELECTRIC
COMPOUND TO ELECTRICAL
CONNECTIONS
Silicone Dielectric Compound must be used on all electri-
cal connections for the following reasons:
• To prevent oxidation at the mechanical joint between
male and female pins.
• To prevent electrical malfunction caused by low level
conductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric
Compound to the electrical connectors. This procedure
applies to all plug connections not enclosed in a box. Sili
-
cone grease should not be applied to connectors with
external seals.
1. To prevent oxidation, silicone grease must be
packed completely around male and female pins on
the inside of the connector prior to assembly. This is
most easily achieved by using a syringe.
NOTE: Over a period of time, oxidation increases electrical
resistance at the connection, eventually causing cir-
cuit failure.
2. To prevent shorting, silicone grease must be packed
around each wire where they enter the outside of the
connector housing. Also, silicone grease must be
applied at the joint where the male and female con
-
nectors come together. Any other joints (around
strain reliefs, etc.) where water could enter the con-
nector should also be sealed.
NOTE: This condition is especially common when machines
are pressure washed since the washing solution is
much more conductive than water.
3. Anderson connectors for the battery boxes and bat-
tery chargers should have silicone grease applied to
the contacts only.
NOTE: Curing-type sealants might also be used to prevent
shorting and would be less messy, but would make
future pin removal more difficult.
- 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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