JLG 601S Boom Lift Service Manual
220 pages · Publication 3120866
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- Models
- 601S
- Manual type
- Service Manual
- Pages
- 220
- Publication
- 3120866
- Condition
- Brand new
What's inside
From the manual's own table of contents: 283 sections, 355 entries. See sample pages (PDF, 626 KB)
General
Hydraulic System Safety
Maintenance1 topic
- Capacities
Fuel Tank
Hydraulic Oil Tank
Hydraulic System (Including Tank)
Torque Hub, Drive
Engine Crankcase1 topic
- Component Data
Engine - Diesel (Liquid-Cooled)
Drive System
Steer System
Swing System
Hydraulic Gear Pump (at 1800 RPM)
Auxiliary Power Pump
Hydraulic Filter - In-line1 topic
- Performance Data
Turning Radius (Outside)
Turning Radius (Inside)
Boom Elevation
Machine Weight approximately
Machine Height (Stowed)
Machine Length (Stowed)
Machine Width
Wheel base1 topic
- Function Speeds
Machine Orientation When Doing Speed Tests
Show all 283 sections
Test Notes2 topics
- Torque Requirements
- Lubrication
Ford LRG425 Engine
Deutz F3M1011F Engine
Hydraulic Oil
Lubrication Specifications6 topics
- Pressure Settings
- Cylinder Specifications
- Major Component Weights
- Critical Stability Weights
- Serial Number Locations
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance1 topic
- Service and Guidelines
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Lubrication and Servicing1 topic
- Lubrication and Information
Changing Hydraulic Oil1 topic
- Cylinder Drift Test
Platform Drift
Cylinder Drift2 topics
- Pins and Composite Bearing Repair Guidelines
- Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment2 topics
- Applying Silicone Dielectric Compound to Electrical Connections
- AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
Assembly
Disassembly
Wedge Lock
Service - Voltage Reading1 topic
- Torque Hub, Drive
Cleaning and Inspection
Repair2 topics
- Torque Hub, Drive (Auburn Gear)
- Drive Brake - Ausco
Inspection1 topic
- Drive Brake - Mico
Bleeding1 topic
- Drive Motor (Prior to S/N 85132)
Spare Parts Kits
Replacing the Drive Shaft Seal
Disassembly and Assembly
Assembly Notes
Taper Roller Bearing Initial Tension
Testing and Setup2 topics
- Drive Motor Adjustment Procedure (Prior to S/N 85132)
- Drive Motor (S/N 85132 to Present)
Description
Shaft Seal Replacement
Loop Flushing Valve
Troubleshooting
Initial Start-up Procedures1 topic
- Free Wheeling Option
To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc
To Engage Drive Motors and Brakes (Normal Operation)1 topic
- Oscillating Axle Bleeding Procedure and Lockout Test
Lockout Cylinder Bleeding
Oscillating Axle Lockout Test2 topics
- Steer Adjustments
- Swing Hub
Adjustment Procedures1 topic
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Replacement
Swing Bearing Torque Values2 topics
- Swing Brake - Ausco
- Swing Motor
Reassembly
Motor Timing1 topic
- Tilt Alarm Switch (Machines with External Tilt Sensor)
Manual Adjustment2 topics
- Spark Arrester Cleaning Instructions
- Dual Fuel System
Changing from Gasoline to LP Gas
Changing from LP Gas to Gasoline1 topic
- Electric Governor Installation and Adjustments - Ford Engine
Quick-start Installations
Mounting-Actuator
Linkage
Mounting-Controller
Wiring
Check-Out and Initial Start-Up Procedures
Multi-Turn Adjustment (High Engine, Mid Engine, Overspeed, Starter Lockout)
Single-Turn Adjustment (Gain, Factory Adjust)1 topic
- Throttle Checks and Adjustments - Deutz Engine (Prior to S/N 61306)
Procedure
Controller Status
Failure Modes2 topics
- Automatic Choke Adjustment - Ford Engine
- Cold Weather Starting Difficulty
Checking the Carburetor
Checking the Ignition2 topics
- Checking the Fuel
- Ford EFI Engine (machines after S/N 58209)
Performing Diagnostics
Engine Module and Sensors
Fuel System1 topic
- Boom Maintenance
Removal
Disassembly Boom Sections
Installation1 topic
- Boom Rope Torquing Procedures
Torque Procedures1 topic
- Wear Pads
Main Boom1 topic
- Wire Rope
Three Month Inspection
Year or 7000 Hour Replacement
Additional Replacement Criteria3 topics
- Limit Switches and Cam Valve Adjustment
- Rotator - Helac
- Drive Card Setup Procedures
Lift, Swing, and Drive Cards
Flow Control Card2 topics
- Foot Switch Adjustment
- Cylinders - Theory of Operation
Systems Incorporating Double Acting Cylinders
Systems Incorporating Holding Valves1 topic
- Valves - Theory of Operation
Solenoid Control Valve - Rexroth
Relief Valves1 topic
- Cylinder Checking Procedure
Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder
Cylinders With Dual Counterbalance Valves2 topics
- Cylinder Repair
- Cylinder Removal and Installation
Main Boom Telescope Cylinder Removal
Main Boom Telescope Cylinder Installation
Boom Lift Cylinder Removal
Boom Lift Cylinder Installation1 topic
- Variable Displacement pump (M46 series)
Inspections and Adjustments
Minor Repair and Replacement1 topic
- Pressure Setting Procedures
Main Relief, Steer, Swing and Lift Down
Platform Level
Wheel Steer (If Equipped)15 topics
- Directional Control Valve
- Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication
- Hydraulic Component Start-Up Procedures and Recommendations
- Introduction
- To Connect the JLG Control System Analyzer
- Using the Analyzer
- Changing the Access Level of the Hand Held Analyzer
- Adjusting Parameters Using the Hand Held Analyzer
- Machine Setup
- Level Vehicle Description
- Machine Personality Settings
- Analyzer Diagnostics Menu Structure
- General
- Troubleshooting
- Hydraulic Circuit Checks
Serial Number Locations
Lubrication Diagram
Torque Chart
Connector Assembly Figure 1
AMP Connector
Connector Assembly Figure 2
Connector Assembly Figure 3
Connector Assembly Figure 4
Connector Disassembly
Connector Installation
Torque Hub, Drive (Fairfield)
Torque Hub, Drive (Auburn Gear)
Drive Brake Assembly (Ausco)
Drive Brake - Mico
Flow Control Pilot Valves
Drive Motor Adjustment
Drive Motor Cross Section
Removing the Shaft Seal
Loop Flushing Spool
Plugs, Fittings, and Speed Sensor
End Cap
Valve Plate & Rear Shaft Bearing
Cylinder Kit
Shaft Seal
Shaft & Front Bearing
Swash Plate & Servo Piston
Cylinder Kit Disassembly
Servo Piston
Cylinder Kit Assembly
Swash Plate and Journal Bearing
Shaft and Front Bearing
Cylinder Kit Installation
Servo Spring and Minimum Angle Stop
Valve Plate and Rear Bearing
Plugs and Fittings Installation
Disconnecting the Drive Hubs
Oscillating Valve Adjustment
Brake Valve Wiring Connection
Drive Manual Control Valve
Steer Adjustments
Swing Torque Hub Adjustment
Swing Bearing Bolt Feeler Gauge Check
Swing Bearing Tolerance Measuring Point
Swing Bearing Tolerance Boom Placement
Swing Bearing Torque Sequence
Swing Brake Assembly (Ausco)
End Cap Removal
Swing Motor
Tilt Switch Adjustment
Addco Adjustments - Deutz
Malfunction Indicator Light and Test Button
EFI Component Location
ECM/EPM Identification
Typical Fuel System
Location of Components - Platform Support
Location of Components - Rotator and Leveling Cylinder
Location of Components - Boom Powertrack
Disassembly of Proximity Switch Assembly
Disassembly of Sheave Assembly
Boom Assembly Cutaway - Sheet 1 of 3
Boom Assembly Cutaway - Sheet 2 of 3
Boom Assembly Cutaway - Sheet 3 of 3
Disassembly Wire Rope Routing Procedure
Dimension of Sheaves When New
Routing Installation of Retract Wire Ropes
Installing the Proximity Switch
Reassembly of Components - Boom Powertrack Assembly
Dimensions of Boom Sections
Clamping Wire Ropes
Location and Thickness of Wear Pads
Limit Switches Adjustments
Removing Portion of End Cap
Heating Setscrew
Removing Setscrew
Removing End Cap
Removing Shaft from Housing
Removing Sleeve from Housing
Actuator Timing
Rotator Assembly (Helac)
Control Card
Cylinder Barrel Support
Cap Screw Removal
Cylinder Rod Support
Tapered Bushing Removal
Gar-Max Bearing Installation
Rod Seal Installation
Poly-Pak Piston Seal Installation
Wiper Seal Installation
Installation of Head Seal Kit
Piston Seal Kit Installation
Tapered Bushing Installation
Seating the Tapered Bearing
Rod Assembly Installation
Troubleshooting - Neutral Difficult or Impossible to Find
Troubleshooting - System Operating Hot
Troubleshooting - Transmission Operates in One Direction Only
Troubleshooting - System Response is Sluggish
Troubleshooting - System Will Not Operate in Either Direction
Variable Displacement Pump
Main Control Valve - Sheet 1 of 2
Main Control Valve - Sheet 2 of 2
Main Control Valve Torque Values
EPBCS Block Diagram
Analyzer Connecting Points
Control Module and Fault Code Indicator Location
Analyzer Flow Chart - Sheet 1 of 3
Analyzer Flow Chart - Sheet 2 of 3
Analyzer Flow Chart - Sheet 3 of 3
Electrical Components Installation (Prior to S/N 62137) - Sheet 1 of 2
Electrical Components Installation (Prior to S/N 62137)- Sheet 2 of 2
Electrical Components Installation (S/N 62137 to Present)-Sheet 1 of 2
Electrical Components Installation (S/N 62137 to Present)-Sheet 2 of 2
Electrical Schematic - Deutz Engine - Sheet 1 of 2
Electrical Schematic - Deutz Engine - Sheet 2 of 2
Electrical Schematic - Ford Dual Fuel Engine - Sheet 1 of 2
Electrical Schematic - Ford Dual Fuel Engine - Sheet 2 of 2
Electrical Schematic - Ford EFI Engine - Sheet 1 of 2
Electrical Schematic - Ford EFI Engine - Sheet 2 of 2
Electrical Schematic - ADE Machines - Sheet 1 of 4
Electrical Schematic - ADE Machines - Sheet 2 of 4
Electrical Schematic - ADE Machines - Sheet 3 of 4
Electrical Schematic - ADE Machines - Sheet 4 of 4
Hydraulic Schematic - Sheet 1 of 4
Hydraulic Schematic - Sheet 2 of 4
Hydraulic Schematic - Sheet 3 of 4
Hydraulic Schematic - Sheet 4 of 4
Function Speeds (In Seconds)
Torque Requirements
Mobil DTE 13M Specs
Cylinder Specifications
Major Component Weights
Critical Stability Weights
Lubrication Chart
Inspection and Maintenance
Inspection and Preventive Maintenance Schedule
Excessive Noise and/or Vibration
System Operating Hot
Won’t Shift or Slow to Start
Displacement Identifiers
Slipper Foot Thickness & End Play
Cylinder Block Measurements
Position Controller Truth Table
ECM Diagnostic Trouble Codes
EPM Diagnostic Trouble Codes
Flow Control Card Settings
Flow Control Card Ramp Time
Function Speeds
Cylinder Head and Tapered Bushing Torque Specifications
Holding Valve Torque Specifications
Personality Ranges/Defaults
Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66939
Help Fault Codes, Displayed Faults, and Descriptions - S/N 66939 to Present
Machine Configuration Programming Information
Fault Code Listing
ADJUSTMENTS - Personality Descriptions
Diagnostic Menu Descriptions
Inside this manual
Real pages from this service manual (220 pages). Open the sample pages (PDF, 624 KB)
- Specifications, page 17: SECTION 1 - SPECIFICATIONS
- Diagram, page 200: SECTION 6 - JLG CONTROL SYSTEM (ADE)
- Troubleshooting, page 209: SECTION 6 - JLG CONTROL SYSTEM (ADE)
- Color page, page 180: SECTION 6 - JLG CONTROL SYSTEM (ADE)
- Color page, page 108: SECTION 3 - CHASSIS & TURNTABLE
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 601S are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 3120866$69.61
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 220 pages
Quantity one is the manual described above.
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Ships in 1 business day.
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Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).