An hour from now you could have the gauge teed in and be setting main relief pressure on your 601S by the factory procedure: the 218-page JLG 601S service manual PDF, OEM No. 3120866, is the complete JLG shop book for this telescopic aerial work platform. Wiring diagrams and hydraulic schematics close out the volume, laid out so you can trace a dead solenoid circuit or run the hydraulic circuit checks port by port. Chassis and turntable work fills roughly a third of the pages, torque hub teardown through swing bearing replacement, and a dedicated section walks you through the ADE control system analyzer, access levels and personality settings included. Spin the return filter off and fit a 10 micron absolute element, then torque wheel lugs to 170 ft. lbs. (231 Nm). Guessed pressure figures put platforms on the ground. This bookmarked, keyword-searchable PDF rides along wherever the lift is parked.
What's Inside This JLG 601S Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction - Maintenance Safety Precautions | 5-14 | Hydraulic System Safety, Maintenance |
| Specifications | 15-24 | Capacities (Fuel Tank, Hydraulic Oil Tank, Hydraulic System, Torque Hub, Drive, Engine Crankcase) |
| General | 25-38 | Machine Preparation, Inspection, And Maintenance, Service and Guidelines, Lubrication and Information |
| Chassis & Turntable | 39-108 | Torque Hub, Drive (Disassembly, Cleaning and Inspection, Repair, Assembly), Drive Brake - Ausco (Disassembly, Inspection |
| Boom & Platform | 109-128 | Boom Maintenance (Removal, Disassembly Boom Sections, Inspection, Assembly, Installation), Boom Rope Torquing Procedures (Torque Procedures), Wear Pads (Main Boom) |
| Hydraulics | 129-154 | Cylinders - Theory of Operation (Systems Incorporating: Double Acting Cylinders, Holding Valves), Valves - Theory of Operation (Solenoid Control Valve - Rexroth, Relief Valves) |
| Jlg Control System (Ade) | 155-196 | Introduction, To Connect the Jlg Control System Analyzer, Using the Analyzer, Changing the Access Level of the Hand Held Analyzer, Parameters Using the Hand Held Analyzer |
| Schematics | 197-218 | Troubleshooting, Hydraulic Circuit Checks |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Wire Rope | 15 FT. LBS (20 Nm) | p. 17 |
| Wheel Lugs | 170 FT. LBS. (231 Nm) | p. 17 |
| Hydraulic Filter - In-line (Return - Bypass Type) | 10 Microns Absolute | p. 16 |
| Hydraulic Filter - In-line (Charge) | 10 Microns Absolute | p. 16 |
| Hydraulic Gear Pump (at 1800 RPM) Displacement | 16 cm[3] (1.02 cu. in.) | p. 16 |
| Auxiliary Power Pump Displacement | 14 cm[3] (.244 cu. in.) | p. 16 |
| Foot switch adjustment travel | 1/4 in. (6.35 mm) | p. 127 |
| Horizontal limit switch activation | 4.5° ± 2.5° | p. 121 |
| Horizontal limit switch reset | 5° ± 2.5° | p. 121 |
| Fuel Tank Capacity | 98.4 Liters | p. 15 |
| Hydraulic Oil Tank Capacity | 121 Liters | p. 15 |
| Ford LRG-425 Engine Oil Capacity | 4.25 Liters | p. 15 |
JLG 601S Common Problems This Manual Covers
JLG 601S boom functions slow and weak under load, hydraulics sluggish after warm-up
Check hydraulic oil level and condition first; the tank holds 121 liters. Test main relief pressure next; it must hold 3000 PSI per the spec on page 19. If pressure sags under load, remove the control inlet screen, clean it, and torque the plug to 20 to 30 in. lbs. (2.2 to 3.4 Nm) per page 147.
Manual Section: Hydraulics p. 129Platform settles overnight at height, lift cylinder drifts down within hours of parking
Check the lift cylinder holding valve before pulling the cylinder; contamination in the cartridge causes most drift complaints. Clean the valve, cycle the boom, and retest. If the platform still settles, reseal the lift cylinder using the procedures in the Hydraulics section starting on page 129, then verify main relief pressure reaches 3000 PSI.
Manual Section: Cylinder Drift TestPlatform swing only works in one direction, all other boom functions respond normally
Test the swing solenoid coil for an open circuit before replacing parts. Connect the JLG analyzer per the control system section starting on page 155 and read stored faults; an open circuit code points to the coil or harness. Trace wiring with the diagram on page 202. If electrical checks pass, verify swing relief pressure at 1700 PSI.
Manual Section: Jlg Control System (Ade) p. 155Machine stuck in creep mode with tilt light on, drive and lift speed limited
Park on level ground and cycle power to clear the fault. Check the chassis tilt sensor with the analyzer; the sensor spec on page 172 lists a 19 degree tilt angle. Inspect the sensor connector for moisture and corrosion, then dry and reseat it. Recalibrate before condemning the sensor; most tilt faults trace to connectors.
Manual Section: ADE Control System Diagnostics p. 172Platform controls cut out intermittently, functions come back after tapping the foot switch
Adjust the foot switch so functions engage within the last 1/4 in. (6.35 mm) of pedal travel, per the spec on page 127. Inspect switch contacts and platform box connectors for corrosion and broken wires. Test harness continuity against the wiring diagram on page 202 before replacing the switch or joystick.
Manual Section: Boom & Platform p. 127Frequently Asked Questions
What are the torque specifications for the JLG 601S wheel lugs?
The wheel lug torque specification for the JLG 601S is 170 ft. lbs. (231 Nm). This maintenance task should be performed at an interval of 150 hours. p. 17
How do I troubleshoot a JLG 601S fault code?
To troubleshoot a fault code, connect the JLG Control System Analyzer to the platform or ground control module. Once connected, select the 'HELP' menu to view active faults, or scroll through the 'DIAGNOSTICS' menu to view logged fault history. Detailed fault code descriptions and removal procedures are provided in Table 6-2 or Table 6-3 depending on your machine's serial number. p. 157
What is the fuel tank capacity for the JLG 601S?
The fuel tank capacity for the JLG 601S is 98.4 liters (26 gallons). p. 15
What is the procedure for changing the hydraulic oil on a JLG 601S?
JLG recommends changing the hydraulic oil annually. When changing the oil, ensure the system is clean, replace the filter element, and use Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152. p. 28
What is the torque specification for the swing bearing bolts on a JLG 601S?
The swing bearing bolts must be torqued to 326 Nm (240 ft. lbs.) with Loctite. This should be checked after the first 50 hours of operation and every 600 hours thereafter. p. 68
How is this JLG 601S Service Manual delivered?
Immediate download of the complete 218-page searchable Service Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Does this JLG 601S manual allow printing?
Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need. Any home or office printer works.
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