JLG 601S Telescopic Boom Lift Manuals

JLG 601S Telescopic Boom Lift Manuals

Manuals and User Guides for JLG 601S Telescopic Boom Lift. We have 1 JLG 601S Telescopic Boom Lift manual available for free PDF download: Service And Maintenance Manual

JLG 601S Service And Maintenance Manual

JLG 601S Service And Maintenance Manual (244 pages)

Brand: JLG | Category: Lifting Systems | Size: 18 MB

Table of Contents

A General
5
Bhydraulic System Safety
5
Maintenance
5
Table of Contents
7
Section 1. Specifications

17
- Capacities
  17
  - Fuel Tank
    17
  - Hydraulic Oil Tank
    17
  - Hydraulic System (Including Tank)
    17
  - Torque Hub, Drive
    17
  - Engine Crankcase
    17
- Component Data
  17
  - Engine - Diesel (Liquid-Cooled)
    17
  - Drive System
    17
  - Swing System
    18
  - Hydraulic Gear Pump (at 1800 RPM)
    18
  - Auxiliary Power Pump
    18
  - Hydraulic Filter - In-Line
    18
- Performance Data
  18
  - Turning Radius (Outside)
    18
  - Turning Radius (Inside)
    18
  - Boom Elevation
    18
  - Machine Weight Approximately
    18
  - Machine Height (Stowed)
    18
  - Test Notes
    19
- Torque Requirements
  19
- Lubrication
  20
  - Ford LRG425 Engine
    20
  - Deutz F3M1011F Engine
    20
  - Hydraulic Oil
    21
  - Lubrication Specifications
    21
- Pressure Settings
  21
  - Rexroth Valve
    21
- Cylinder Specifications
  22
- Major Component Weights
  22
- Critical Stability Weights
  22
- Serial Number Locations
  23
- Lubrication Diagram
  24
- Lubrication Chart
  25
Section 2 - General

27
- Machine Preparation, Inspection, and Maintenance
  27
- Service and Guidelines
  28
  - General
    28
  - Safety and Workmanship
    28
  - Cleanliness
    28
  - Components Removal and Installation
    28
  - Component Disassembly and Reassembly
    29
  - Pressure-Fit Parts
    29
  - Bearings
    29
  - Gaskets
    29
  - Bolt Usage and Torque Application
    29
  - Hydraulic Lines and Electrical Wiring
    29
  - Hydraulic System
    29
  - Lubrication
    29
  - Battery
    29
  - Lubrication and Servicing
    29
- Lubrication and Information
  30
  - Hydraulic System
    30
  - Hydraulic Oil
    30
  - Changing Hydraulic Oil
    30
  - Lubrication Specifications
    30
- Cylinder Drift Test
  31
  - Platform Drift
    31
  - Cylinder Drift
    31
- Pins and Composite Bearing Repair Guidelines
  31
- Welding on JLG Equipment
  32
  - Do the Following When Welding on JLG Equipment
    32
  - Do NOT Do the Following When Welding on JLG Equipment
    32
- Applying Silicone Dielectric Compound to Electrical Connections
  32
- AMP Connector
  33
  - Applying Silicone Dielectric Compound to AMP Connectors
    33
  - Assembly
    33
  - Connector Assembly Figure 1
    33
  - Connector Assembly Figure 2
    33
  - Connector Assembly Figure 3
    33
  - Connector Assembly Figure 4
    33
  - Disassembly
    35
  - Wedge Lock
    35
  - Service - Voltage Reading
    35
- Connector Installation
  36
- Inspection and Preventive Maintenance Schedule
  37
Section 3. Chassis & Turntable

41
- Torque Hub, Drive
  41
  - Disassembly
    41
  - Cleaning and Inspection
    41
  - Repair
    41
- Torque Hub, Drive (Fairfield)
  41
  - Assembly
    44
  - Torque Hub, Drive (Fairfield)
    49
  - Torque Hub, Drive (Auburn Gear)
    50
    
    Disassembly
    50
    
    Assembly
    50
    
    Torque Hub, Drive (Auburn Gear)
    51
  - Drive Brake - Ausco
    52
    
    Disassembly
    52
    
    Inspection
    52
    
    Assembly
    52
- Drive Brake Assembly (Ausco)
  53
  - Drive Brake - Mico
    54
    
    Disassembly
    54
    
    Assembly
    54
    
    Drive Brake - Mico
    55
    
    Bleeding
    56
  - Drive Motor (Prior to S/N 85132)
    57
    
    Spare Parts Kits
    57
    
    Replacing the Drive Shaft Seal
    58
  - Disassembly and Assembly
    59
  - Assembly Notes
    63
  - Taper Roller Bearing Initial Tension
    63
- Flow Control Pilot Valves
  64
  - Testing and Setup
    65
- Drive Motor Adjustment Procedure (Prior to S/N 85132)
  66
- Drive Motor Adjustment
  66
- Drive Motor (S/N 85132 to Present)
  67
  - Description
    67
  - Shaft Seal Replacement
    67
- Endcap
  67
  - Loop Flushing Valve
    68
  - Troubleshooting
    69
  - Disassembly
    70
- Valve Plate & Rear Shaft Bearing
  71
- Shaft Seal
  72
- Shaft & Front Bearing
  72
- Cylinder Kit Assembly
  72
  - Swash Plate & Servo Piston
    73
  - Inspection
    74
  - Assembly
    76
- Swash Plate and Journal Bearing
  77
- Shaft and Front Bearing
  78
- Cylinder Kit Installation
  78
- Servo Spring and Minimum Angle Stop
  78
- Valve Plate and Rear Bearing
  79
- End Cap
  79
- Shaft Seal
  80
  - Initial Start-Up Procedures
    81
- Free Wheeling Option
  81
  - To Disengage Drive Motors and Brakes (Free Wheel) for Towing, Etc
    81
  - To Engage Drive Motors and Brakes (Normal Operation)
    82
- Oscillating Axle Bleeding Procedure and Lockout Test
  83
  - Lockout Cylinder Bleeding
    83
  - Oscillating Axle Lockout Test
    83
- Oscillating Valve Adjustment
  83
- Drive Manual Control Valve
  83
- Steer Adjustments
  84
- Swing Hub
  85
  - Adjustment Procedures
    85
- Swing Bearing
  85
- Swing Bearing Tolerance Measuring Point
  86
  - Swing Bearing Torque Value
    89
- Swing Brake - Ausco
  89
  - Disassembly
    89
  - Inspection
    90
  - Assembly
    90
- Swing Brake Assembly (Ausco)
  91
- Swing Motor
  92
  - Disassembly
    92
- End Cap Removal
  92
  - Reassembly
    93
  - Motor Timing
    94
  - Swing Motor
    95
- Tilt Alarm Switch (Machines with External Tilt Sensor)
  96
  - Manual Adjustment
    96
- Spark Arrester Cleaning Instructions
  96
- Dual Fuel System
  96
  - Changing from Gasoline to LP Gas
    96
  - Changing from LP Gas to Gasoline
    97
- Electric Governor Installation and Adjustments - Ford Engine
  97
  - General
    97
  - Quick-Start Installations
    97
  - Mounting-Actuator
    97
  - Linkage
    97
  - Mounting-Controller
    98
  - Wiring
    98
  - Check-Out and Initial Start-Up Procedures
    100
  - Multi-Turn Adjustment (High Engine, MID Engine, Overspeed, Starter Lockout)
    100
  - Single-Turn Adjustment (Gain, Factory Adjust)
    100
  - Troubleshooting
    101
- Throttle Checks and Adjustments - Deutz Engine (Prior to S/N 61306)
  103
  - General
    103
  - Procedure
    104
  - Controller Status
    104
  - Failure Modes
    104
  - Automatic Choke Adjustment - Ford Engine
    105
  - Cold Weather Starting Difficulty
    106
    
    Checking the Carburetor
    106
    
    Checking the Ignition
    107
  - Checking the Fuel
    107
  - Ford EFI Engine (Machines after S/N 58209)
    108
    
    Performing Diagnostics
    108
    
    EFI Diagnostics (S/N 58209 to S/N 60188)
    108
    
    Engine Module and Sensors
    109
- ECM Diagnostic Trouble Codes
  110
- EPM Diagnostic Trouble Codes
  111
- ECM/EPM Identification
  122
  - Fuel System
    123
- Typical Fuel System
  124
Section 4. Boom & Platform

129
- Boom Maintenance
  129
  - Removal
    129
  - Disassembly Boom Sections
    130
- Disassembly of Sheave Assembly
  131
- Boom Assembly Cutaway - Sheet 1 of 2
  132
- Boom Assembly Cutaway - Sheet 2 of 2
  133
  - Inspection
    134
  - Assembly
    135
  - Installation
    137
  - Boom Rope Torquing Procedures
    137
    
    Torque Procedures
    137
  - Wear Pads
    138
    
    Main Boom
    138
  - Wire Rope
    139
    
    Inspection
    139
    
    Three Month Inspection
    139
    
    Year or 7000 Hour Replacement
    139
    
    Additional Replacement Criteria
    139
  - Limit Switches and Cam Valve Adjustment
    140
    
    Limit Switch Functional Check
    141
  - Rotator - Helac
    142
    
    Disassembly
    142
    
    Inspection
    143
    
    Assembly
    144
- Rotator Assembly (Helac)
  145
  - Drive Card Setup Procedures
    146
    
    Lift, Swing, and Drive Cards
    146
    
    Flow Control Card
    146
  - Foot Switch Adjustment
    147
Section 5. Hydraulics

149
- Cylinders - Theory of Operation
  149
  - Systems Incorporating Double Acting Cylinders
    149
  - Systems Incorporating Holding Valves
    149
- Valves - Theory of Operation
  149
  - Solenoid Control Valve - Rexroth
    149
  - Relief Valves
    149
- Cylinder Checking Procedure
  149
  - Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder
    149
  - Cylinders with Dual Counterbalance Valves
    150
- Cylinder Repair
  150
  - Disassembly
    150
- Cap Screw Removal
  151
  - Cleaning and Inspection
    152
  - Assembly
    153
- Piston Seal Kit Installation
  154
- Rod Assembly Installation
  155
  - Cylinder Removal and Installation
    156
    
    Main Boom Telescope Cylinder Removal
    156
    
    Main Boom Telescope Cylinder Installation
    156
    
    Boom Lift Cylinder Removal
    157
    
    Boom Lift Cylinder Installation
    157
  - Variable Displacement Pump (M46 Series)
    158
    
    Troubleshooting
    158
Subject - Section, Paragraph

156
Section 6. Jlg Control System (Ade)

175
Section 7 - Schematics

223

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