JLG X20J Service Manual

Service and Maintenance Manual

Models

X17JP - X500AJ X20JP - X600AJ

P/N - 3121623

October 21, 2013

TABLE OF CONTENTS

SECTION NO.

TITLE

PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

SECTION 1 - SPECIFICATIONS

1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1.2 Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 1.3 Power source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 HONDA ENGINE IGX440 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 HATZ ENGINE 1B40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 PERKINS ENGINE 402D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.4 Specifications and Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 1.5 Function speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1.6 Pressure setting PSI (BAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 1.7 Major components weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9 1.8 Lubrification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 1.9 Serial number location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

SECTION 2 - GENERAL

2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Pre-Delivery Inspection and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3 Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.6 Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Do NOT Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . 2-5

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SECTION 3 - CHASSIS & TURNTABLE

3.1 RUBBER TRACK MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Checking track tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Operations for loosening/tightening the track. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Checking The Rubber Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Replacing The Rubber Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Installing the rubber track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Checking tightness of nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.2 UNDERCARRIGE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8 Replacement roller lower wheel and tracks adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Replacement sprocket and gear motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.3 AXLE EXTENSION REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3.4 TRACK DRIVE - BONFIGLIOLI (2T700C2K032002) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11 3.5 SWING DRIVE (IMO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24 3.6 HONDA ENGINE IGX440 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32 3.7 HATZ ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-69 3.8 PERKINS ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-97 3.9 ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-127 3.11 CHANGING THE ELECTRIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-128

SECTION 4 - BOOM & PLATFORM

4.1 BOOM MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Removal of the Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Disassembly of the Main Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Assembly of the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Installation of the Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.2 BOOM DISASSEMBLY X20JP - X600AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 4.3 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10 Checking wear and deformation of ropes and pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Three month inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.4 ROPES TENSION ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13 4.5 ROTARY ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15 4.6 PLATFORM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23 4.7 LOAD CELL AND FOOTSWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

SECTION 5 - HYDRAULICS

5.1 CYLINDER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 5.2 REPLACEMENT HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 5.3 FUNCTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21 5.4 HYDRAULIC COMPONENT START-UP PROCEDURES AND RECOMMENDATIONS. . . . . . . . . .5-33 5.5 PRESSURE SETTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-35

SECTION 6 - JLG CONTROL SYSTEM

6.1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-1
6.2	PLATFORM/REMOTE CONTROL STATION LCD DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-2
6.3	CANBUS COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-10
	Can-Bus diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-13
	Module flashing code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-18
6.4	CALIBRATION REQUIREMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-22
6.5	PLATFORM REMOTE CONTROL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-23
6.6	MENU INPUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-26
6.7	LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-33
6.8	MENU ERRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-34
6.9	RAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-44

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6.10 CURRENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46 6.11 WORKING HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-49 6.12 MACHINE SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-52 6.13 JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-69 6.14 CALIBRATING JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-70 6.15 LITHIUM SYSTEM FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-71

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.1 DESCRIPTION FOR MODELS X17JP/X500AJ - X600AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 7.2 HOW TO READ THE WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 7.3 A - PHOTOCELLS - SAFETY EXCLUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3 7.4 B - SLEW PROXIMITY - 1° ARM SWITCH - STABILIZERS PRESSURE SENSOR . . . . . . . . . . . . .7-4 7.5 C - OUTRIGGERS SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5 7.6 D - CAN NETWORK - CYLINDERS POSITION SENSORS - MODEM. . . . . . . . . . . . . . . . . . . . . . .7-6 7.7 E - ROPES SWITCH - JIB POSITION SWITCH - PEDAL - LOAD CELL . . . . . . . . . . . . . . . . . . . . .7-7 7.8 F - GROUND POSITION CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8 7.9 G - AERIAL SAFETY LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9

7.10H - EMERGENCY DESCEND ELECTRO VALVES - WIDENING CYLINDER SENSOR

OPTIONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

7.11I - GROUND PART: TRACKS - UNDERCARRIAGE WIDENING - 2° SPEED - PROPORTIONAL

ELECTRO VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 7.12 J - GROUND PART: OUTRIGGERS - ELECTRIC DIVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

7.13K - AERIAL PART: BASKET LEVELLING - BASKET ROTATION - JIB - PROPORTIONAL

ELECTRO VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13 7.14 L - AERIAL PART: 1° CYLINDER - 2° CYLINDER - EXTENSION - ROTATION. . . . . . . . . . . . . . . . .7-14 7.15 M - ENGINE DIESEL VERSIONS: RPM REGULATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .7-15 7.16 N - ENGINE DIESEL PERKINS 2 CYLINDERS: SENSOR AND ELECTRO STOP . . . . . . . . . . . . .7-16 7.17 O - ENGINE DIESEL PERKINS 2 CYLINDERS: START AND SPARKS. . . . . . . . . . . . . . . . . . . . . .7-17 7.18 P - ENGINE DIESEL HATZ 1 CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18 7.19 Q - ENGINE GASOLINE HONDA 1 CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19 7.20 R - 12 VOLT POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20 7.21 S - 120/230 VOLT LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21 7.22 T - COMPONENTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22 7.23 U - COMPONENTS ABBREVIATION MEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23 7.26 V - CONNECTORS LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26 7.35 Y - LITHIUM BATTERY SYSTEM 48 VOLT X17JP - X500AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35 7.45 Z - LITHIUM BATTERY SYSTEM 72 VOLT X20JP - X600AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45

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SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

Table 1-1. DRIVE HUB CAPACITIES

	MACHINE	TYPE DRIBE HUB	DRIVE	CAPACITIES
	X17JP	BONFIGLIOLI	AUTO	0,4 L (0.10 gal)
	X500AJ	700C2K I:32 + MAG12 VP	2 SPEED
	X20JP	BONFIGLIOLI	2 SPEED	0,32 L (0,08 gal)
	X600AJ	7C 00/2 2 K A A 36 G016VP30 LA

Table 1-2. HYDRAULIC & FUEL TANK CAPACITIES

MACHINE	HYDRAULIC OIL TANK	FUEL TANK
	CAPACITY
		GASOLINE	DIESEL
X17JP / X500AJ	10,56 gal (40 L)	1.55 gal (5.9 L)	1.3 gal (5 L)
X20JP / X600AJ	10,56 gal (40 L)	1.55 gal (5.9 L)	2.6 gal (10 L)

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SECTION 1 - SPECIFICATIONS

1.2 TRACKS

Table 1-3. Track Specifications

				Rubber Belt Track		Undercar-
	Machine			Dimen-		riage
	Model	Type	Part Number		Drawing
				sions
						Model
		LOW PRO-
		FILE BLACK	053715L0
		COLOR
	X17JP			Cm
				180X37X		PT9
	X500AJ
				72
		LOW PRO-	053715LB
		FILE NO
		MARKING

	LOW PRO-
	FILE BLACK	257215L0
	COLOR
X20JP			Cm	PT10
			200X48X
X600AJ
		66
	LOW PRO-	257215LB
	FILE NO
	MARKING

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Table 1-4. Ground bearing pressure

PRESSURES AND REACTIONS TO THE GROUND

	ON TRACKS				ON OUTRIGGER
MODEL	Maximum ground bearing			Maximum ground		Maximum ground bearing
	pressure			bearing pressure		pressure
	[daN/cm²] - [PSI]			on each pad		[daN/cm²] - [PSI]
				[daN] - [lbf]
X17JP-X500AJ	0,67 daN/cm²		9,7 PSI	1731 daN	3892 lbf	2,45 daN/cm²	35.5 PSI
X20JP-X600AJ	0,64 daN/cm²		9,2 PSI	2150 daN	4833 lbf	3,04 daN/cm²	45 PSI

1.3 POWER SOURCE

Table 1-5. Power configuration

		X17JP		X20JP
	Gasoline Engine		Honda iGX440
			15 hp (11.1 kW)
	Diesel Engine	Hatz 1B40		Perkins 402.05
		10 hp (7.46 kW)		14 hp (10.44 Kw)
	Electric Motor	90Ah 48V Lithium-Ion		90Ah 70V Lithium-Ion
	AC Electric Motor		110V 50 Hz (2,2 KW)
			120V 60 Hz (1.2 kW)
			230V 50 Hz (2.2 kW)
			230V 60 Hz (2.2 kW)
NOTE: RPM Tolerances are ± 50.

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SECTION 1 - SPECIFICATIONS

HONDA ENGINE iGX440

Table 1-6. SPECIFICATIONS HONDA ENGINE iGX440
Model	iGX440U
Description code	GCAWK
Type	4-stroke, overhead camshaft, single cylinder, inclined by 15°
Displacement	438 cm3 (26.7cu-in)
Bore x stroke	88.0 x 72.1 mm (3.46 x 2.84 in)
Maximum horsepower	11.2 kW (15.2 HP) / 3,600 min-1 (rpm)
Recommended maximum operation bhp	8.0 kW (10.8 HP) / 3,600 min-1 (rpm)
Maximum torque	29.8 N·m (3.0 kgf·m, 22 lbf·ft)/2,500 min-1 (rpm)
Compression ratio	8.1 : 1
Minimum fuel consumption	328 g/kW·h (241 g/HP·h, 0.53 lb/HP·h)
Ignition system	CDI
Ignition timing (at no load)	10° B.T.D.C./1,400 min-1 (rpm)
	13° B.T.D.C./3,600 min-1 (rpm)
Spark plug	BKR7E-E (NGK), K22PR-UR (DENSO)
Lubrication system	Forced splash type
Oil capacity	1.10 l (1.16 US qt, 0.97 lmp qt)
Cooling system	Forced air
Starting system	Recoil and starter motor
Stopping system	Ignition primary circuit open
Carburetor	Horizontal type batter fly valve
Air cleaner	Dual element type
Governor	STR (Self Tuning Regulator) governor
Fuel used	Unleaded gasoline with a pump octane rating 86 or higher

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HATZ ENGINE 1B40

	Table 1-7. SPECIFICATIONS HATZ ENGINE 1B40
	Type	1B40
	Design	Air-cooled four-stroke diesel engine
	Combustion system	Direct injection
	Number of cylinders	1
	Bore / stroke	88 / 76 mm
	Displacement	462 cm3
	Lubricating oil capacity without oil sump with oil	1.5 1) l, approx.
	sump	3.2 1) l, approx.
	Difference between “max” and “min” levels without	0.8 1) l, approx.
	oil sump with oil sump	2.2 1) l, approx.
	Lubricating oil consumption (after running in)	1% of fuel consumption at full load max.)
	Lubricating oil pressure (oil temperature 100 °C)	2.5 bars at 3000 r.p.m. (approx.)
	Direction of rotation, power take-off end	anti-clockwise
	Valve clearance 10 - 30 °C	0.10 mm
	Inlet and exhaust valve
		or automatically 2)
	Max. tilt angle in operation, in direction	Flywheel 25° down 3) all other directions 35°3)
	Weight (incl. fuel tank, air-cleaner, exhaust silencer,	55 kg approx.
	recoil starter and electric starter)
	Battery capacity	max. 12 V / 60 Amp/h

PERKINS ENGINE 402D

Table 1-8. SPECIFICATIONS PERKINS ENGINE 402D

Type	402D-05 Engine
Maximum Operating Speed (rpm)	3600 rpm
Cylinders and Arrangement	In-Line two cylinder
Bore	67 mm (2.64 inch)
Stroke	72 mm (2.83 inch)
Displacement	0.507 L (30.939 in3)
Aspiration	NA(1)
Compression Ratio	23.5:1
Firing Order	1-2
Rotation that is viewed from the flywheel	Counterclockwise
Valve Lash Setting (Inlet)	0.20 mm (0.008 inch)
Valve Lash Setting (Exhaust)	0.20 mm (0.008 inch)
Injection	Indirect

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SECTION 1 - SPECIFICATIONS

1.4SPECIFICATIONS AND PERFORMANCE DATA

Reach Specifications

Table 1-9. Reach Specifications

	X17JP	X20JP		X500AJ	X600AJ
	CE	CE		ANSI	ANSI
Max working Height	16.96 m	20.05 m		NA	NA
(inclusive operator)
Max Height (basket floor)	14,96 m	18,05 m		49' 06"	59' 19"
Horizontal Outreach	7 m	9.20 m		22' 95"	30' 17"
Up & Over Height	15'	18'.01"		15'	18'.01"
	(7.80 m)	(8.20 m)		(7.80 m)	(8.20 m)
Swing (non continuous)			360°
Jib - overall length	1,68 m	1,68 m		1,68 m	1,68 m
Gradeability			36,4%
Ground slope limit stabilization	12°	15°		12°	15°
Limit Approach / Depart angles		Front 20° /
			Rear 20°

Dimensional Data

Table 1-10. SPECIFICATIONS PERKINS ENGINE 402D

	X17JP/	X20JP/
	X500AJ	X600AJ
Platform size (standard 2 persons)	0.69m x 1.34m
Platform size (narrow one person)	0.62mx0.79m
Stowed width (with std. 2P platform)	1,34 m
Stowed width (without platform)	0.80 m
Stowed height (on tracks)	2 m	1.99 m
Stowed length (on tracks)	4.53 m	5 m
Outrigger footprint	2.89m x 2,88m	2.92m x 2.93m
Gross machine weight:
Gasoline	2230 Kg	2840 Kg
Diesel	2230 Kg	2880 Kg
Lithium battery	2300 Kg	2990 Kg

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1.5 FUNCTION SPEEDS

Table 1-11. Functions speed (in seconds)
FUNCTIONS SPEED RANGE
FUNCTION	TIME Sec	TIME Sec
	X17JP	X20JP
	X500AJ	X600AJ
TELESCOPE EXTEND	15" - 20"	21" - 28"
TELESCOPE RETRACT	16" - 22"	16" - 20"
TOWER BOOM UP	21" - 24"	30" - 35"
TOWER BOOM DOWN	19" - 22"	30" - 35"
UPPER BOOM UP	25" - 29"	35" - 40"
UPPER BOOM DOWN	24" - 30"	35" - 40"
BASKET ROTATE RIGTH	7" - 10"	7" - 10"
BASKET ROTATE LEFT	7" - 10"	7" - 10"
SWING LEFT	40" - 45"	45" - 50"
SWING RIGTH	40" - 45"	45" - 50"
JIB UP	7" - 10"	7" - 10"
JIB DOWN	7" - 10"	7" - 10"
BASKET LEVEL UP	40" - 58"	33" - 55"
BASKET LEVEL DOWN	35" - 52"	37" - 50"
DRIVE SPEED	TO BE	TO BE
	COMPLETED	COMPLETED

Machine Orientation When Doing Speed Tests

Lift: Boom Retracted. Telescope Retracted. Lift Up, Record Time, Lift Down, Record Time.

Swing: Machine stabilized, upper Boom at Full Elevation. Telescope Retracted. Swing the Turntable to the end stop. Swing the Opposite Direction, Record Time.

Telescope: Boom at Full Elevation; Telescope Retracted; Telescope Out, Record Time. Telescope In, Record Time.

Platform Rotate: Platform level and completely rotated one direction. Rotate the opposite direction, Record Time. Rotate the other direction, Record Time.

Articulating Jib: Platform level and centered with the boom. Start with the Jib down. Jib Up, Record Time. Jib Down, Record Time.

Lower Lift: Upper Boom horizontal. Telescoped In. Lower Lift Up, Record Time. Lower Lift Down, Record Time.

TEST NOTES

Drive: Test to be done on a smooth level surface. Drive Select Switch should be set at 2WD High Engine. Start approximately 25 ft. (7.62 m) from starting point so that the unit is at maximum speed when starting the test.

1.Stop watch should be started with the function, not with the controller or switch.

2.All speed tests are run from ground with remote control connected on the basket.

3.Function speeds may vary due to cold, thick hydraulic oil. Test should be run with the oil temperature above 100° F (38° C).

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1.6 PRESSURE SETTINGS - PSI (BAR)

	Table 1-12. Pressure settings
			UNDERCARRIAGE			TOWER
	Model		Left and Right
						Control Valve
			Control Valve
			Bar	PSI		Bar		PSI
	X14JP-X500 AJ		165	2393		185		2045
	X20JP-X600AJ
	Table 1-13. Pressure settings
	Model		Automatic reductions drive speed
			Bar			PSI
	X17JP - X500AJ		26			380
	X20JP - X600AJ		NA			NA

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1.7 MAJOR COMPONENT WEIGHTS

Table 1-14. Weight components

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1.8 LUBRICATION

Figure 1-1.

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Table 1-15.

*Readily biodegradable classification indicates one of the following: CO2 Conversion > 60% per EPA 560/6-82-003 / CO2 Conversion > 80% per CEC-L-33-A-93

**Virtually Non-toxic classification indicates an LC50 > 5000 per OECD 203

***Fire Resistant classification indicates Factory Mutual Research Corp. (FMRC) Approval

Flash point (C.O.C) for 68-46-32-22: 210°C

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1.9 SERIAL NUMBER LOCATION

A serial number plate is affixed on to the frame a frame.

The following illustration showing the position.

Figure 1-2. Plate

SER IAL NUM BER

PLA TE LOCATION

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NOTES:

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SECTION 2 - GENERAL

SECTION 2. GENERAL

2.1MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.

Preparation, Inspection, and Maintenance

It is important to establish and conform to a comprehensive inspection and preventive maintenance program. The following table outlines the periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult your national, regional, or local regulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as environment, severity and frequency of usage requires.

Pre-Start Inspection

It is the User’s or Operator’s primary responsibility to perform a Pre-Start Inspection of the machine prior to use daily or at each change of operator. Reference the Operator’s and Safety Manual for completion procedures for the Pre-Start Inspection. The Operator and Safety Manual must be read in its entirety and understood prior to performing the Pre-Start Inspection.

Pre-Delivery Inspection and Frequent Inspection

The Pre-Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject JLG product model.

The Pre-Delivery Inspection and Frequent Inspection procedures are performed in the same manner, but at different times. The Pre-Delivery Inspection shall be performed prior to each sale, lease, or rental delivery. The Frequent Inspection shall be accomplished for each machine in service for 3 months or 150 hours (whichever comes first); out of service for a period of more than 3 months; or when purchased used. The frequency of this inspection must be increased as environment, severity and frequency of usage requires.

Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the performance of these inspections. Reference the appropriate areas of this manual for servicing and maintenance procedures.

Annual Machine Inspection

The Annual Machine Inspection must be performed by a Factory-Certified Service Technician on an annual basis, no later than thirteen (13) months from the date of the prior Annual Machine Inspection. JLG Industries, Inc. recognizes a Factory-Certified Service Technician as a person who has successfully completed the JLG Service Training School for the subject JLG product model. Reference the machine Service and Maintenance Manual and appropriate JLG inspection form for performance of this inspection.

Reference the JLG Annual Machine Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the performance of this inspection. Reference the appropriate areas of this manual for servicing and maintenance procedures.

For the purpose of receiving safety-related bulletins, it is important that JLG Industries, Inc. has updated ownership information for each machine. When performing each Annual Machine Inspection, notify JLG Industries, Inc. of the current machine ownership.

Preventative Maintenance

In conjunction with the specified inspections, maintenance shall be performed by a qualified JLG equipment mechanic. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject JLG product model.

Reference the Preventative Maintenance Schedule and the appropriate areas of this manual for servicing and maintenance procedures. The frequency of service and maintenance must be increased as environment, severity and frequency of usage requires.

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Table 2-1. Inspection and Maintenance

	Type	Frequency	Primary	Service	Reference
			Responsibility	Qualification
	Pre-Start	Prior to use each day; or	User or Operator	User or Operator	Operator and Safety Man-
	Inspection	At each Operator change.			ual
	Pre-Delivery	Prior to each sale, lease, or	Owner, Dealer, or	Qualified JLG	Service and Maintenance
	Inspection	rental delivery.	User	Mechanic	Manual and applicable JLG
					inspection form.
	Frequent	In service for 3 months or 150 hours,	Owner, Dealer, or	Qualified JLG	Service and Maintenance
	Inspection	whichever comes first; or	User	Mechanic	Manual and applicable JLG
		Out of service for a period of more than			inspection form.
		3 months; or
		Purchased used.
	Annual Machine	Annually, no later than 13 months from	Owner, Dealer, or	Factory-Certified	Service and Maintenance
	Inspection	the date of the prior inspection.	User	Service Techni-	Manual and applicable JLG
				cian	inspection form.
	Preventative	At intervals as specified in the Service	Owner, Dealer, or	Qualified JLG	Service and Maintenance
	Maintenance	and Maintenance Manual.	User	Mechanic	Manual

2.2 SERVICE AND GUIDELINES

General

The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this book.

Safety and Workmanship

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

Cleanliness

1.The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provided to keep air, fuel, and oil supplies clean; however, these items must be maintained on a scheduled basis in order to function properly.

2.At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter.

3.Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their containers until they are ready to be used.

Components Removal and Installation

1.Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be parallel to each other and as near perpendicular as possible to top of part being lifted.

2.Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90 degrees.

3.If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., have been removed and that no adjacent parts are interfering.

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Component Disassembly and Reassembly

When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.

Pressure-Fit Parts

When assembling pressure-fit parts, use an anti-seize or molybdenum disulfide base compound to lubricate the mating surface.

Bearings

1.When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing.

2.Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.

3.If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearings until they are ready to install.

4.Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race.

Gaskets

Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious system damage.

Bolt Usage and Torque Application

1.Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent.

2.Unless specific torque requirements are given within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in accordance with recommended shop practices. (See Torque Chart Section 1.)

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit. This will assure that they are correctly reinstalled.

Hydraulic System

1.Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system.

2.Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate components, as required, to aid assembly.

Lubrication

Service applicable components with the amount, type, and grade of lubricant recommended in this manual, at the specified intervals. When recommended lubricants are not available, consult your local supplier for an equivalent that meets or exceeds the specifications listed.

Battery

Clean battery, using a non-metallic brush and a solution of baking soda and water. Rinse with clean water. After cleaning, thoroughly dry battery and coat terminals with an anti corrosion compound.

Lubrication and Servicing

Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart in Section 1.

2.3 LUBRICATION AND INFORMATION

Hydraulic System

1.The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenance, or by permitting the pump to cavitate due to insufficient system warm-up or leaks in the pump supply (suction) lines.

2.The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage. Hydraulic system filters should be checked, cleaned, and/or replaced as necessary, at the speci-

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SECTION 2 - GENERAL

fied intervals required in the Lubrication Chart in Section 1. Always examine filters for evidence of metal particles.

3.Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil.

4.It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is operating, are recommended for use.

NOTE: Metal particles may appear in the oil or filters of new machines due to the wear-in of meshing components.

Hydraulic Oil

Refer to Section 1 for recommendations for viscosity ranges.

Changing Hydraulic Oil

1.Filter elements must be changed after the first 50 hours of operation and every 300 hours (unless specified otherwise) thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils. JLG Industries recommends changing the hydraulic oil annually.

2.Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to clean all possible contaminants from the service container. Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed.

3.While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service.

Lubrication Specifications

Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose grease requirements. Should any question arise, regarding the use of greases in maintenance stock, consult your local supplier for evaluation. Refer to Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Chart.

2.4 CYLINDER DRIFT TEST

Maximum acceptable cylinder drift is to be measured using the following methods.

Cylinder Drift

Table 2-2. Cylinder Drift

CYLINDER BORE		MAX ACCEPTABLE DRIF
DIAMETER		IN 1 MINUTES
inches	mm	inches	mm
2,17	55	0.020	0.53
2.36	60	0.021	0.54
2,56	65	0.029	0.74
2,95	75	0.013	0.35
3,15	80	0.011	0.29
3,94	100	0.007	0.20
4.52	115	0.005	0.15

Drift is to be measured at the cylinder rod with a calibrated dial indicator. The cylinder oil must be at ambient temperature and temperature stabilized.

The cylinder must have the normal load, which is the normal platform load applied.

If the cylinder passes this test, it is acceptable.

2-4

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SECTION 2 - GENERAL

2.5PINS AND COMPOSITE BEARING REPAIR GUIDELINES

Filament wound bearings.

1.Pinned joints should be disassembled and inspected if the following occurs:

a.Excessive sloppiness in joints.

b.Noise originating from the joint during operation.

2.Filament wound bearings should be replaced if any of the following is observed:

a.Frayed or separated fibers on the liner surface.

b.Cracked or damaged liner backing.

c.Bearings that have moved or spun in their housing.

d.Debris embedded in liner surface.

3.Pins should be replaced if any of the following is observed (pin should be properly cleaned prior to inspection):

a.Detectable wear in the bearing area.

b.Flaking, pealing, scoring, or scratches on the pin surface.

c.Rusting of the pin in the bearing area.

4.Re-assembly of pinned joints using filament wound bearings.

a.Housing should be blown out to remove all dirt and debris...bearings and bearing housings must be free of all contamination.

b.Bearing / pins should be cleaned with a solvent to remove all grease and oil...filament wound bearing are a dry joint and should not be lubricated unless otherwise instructed (i.e. sheave pins).

c.Pins should be inspected to ensure it is free of burrs, nicks, and scratches which would damage the bearing during installation and operation.

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.)

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2-5

SECTION 2 - GENERAL

NOTES:

2-6

– JLG Lift –

3121623

SECTION 3 - CHASSIS & TURNTABLE

SECTION 3. CHASSIS & TURNTABLE

3.1 RUBBER TRACK MAINTENANCE

Checking track tension

Stop the machine on firm, level surface. Lift the machine into safe conditions and place stable supports under the undercarriage frame for total support. Parallel with the central roller of the under-carriage, measure distance (A) from the bottom of the roller to the rigid inside of the rubber belt. Track tension is normal if measurement (A) is between 10 and 15 mm.

If track tension is not within the measurements specified above, loose or too taught, follow the procedures illustrated in the paragraph below.

A

Figure 3-1.

Operations for loosening/tightening the track

The grease contained in the hydraulic track is pressurised. For this reason, do not loosen the greasing valve (1) by more than 1 turn; if the valve is loosened too much, it risks being expelled under the effect of the pressure of the grease, putting the safety of the operator at risk. Never loosen greaser (2).

When gravel or mud are blocked between the toothed wheel and the track links, remove it before loosening.

1.Remove the screws and take of adjustment access lid 3.

2.To loosen the track, slowly unscrew valve 1 in an anti-clockwise direction for no more than one turn. One turn of valve 1 is sufficient to loosen the track.

3.If the grease does not start to drain, turn the track slowly.

4.When correct track tension has been obtained, turn valve (1) in a clockwise direction and tighten it. Clean all traces of grease.

Figure 3-2.

5.To tighten the track, connect a grease gun to greaser (2) and add grease until belt tension is within the specified values.

IT IS NOT NORMAL IF THE TRACK REMAINS TAUGHT AFTER HAVING TURNED VALVE (1) IN AN ANTI-CLOCKWISE DIRECTION OR IF THE TRACK IS STILL LOOSE AFTER HAVING PUT GREASE INTO GREASER (2). NEVER TRY TO REMOVE THE TRACKS OR DISASSEMBLE THE TRACK-TENSIONED CYLINDER BECAUSE THE GREASE PRESSURE INSIDE THE TRACK IS VERY DANGEROUS.

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3-1

SECTION 3 - CHASSIS & TURNTABLE

Checking The Rubber Tracks

PATTERN

STEEL WIRE	SPROCKET
	HOLE

WHEEL SIDE

METAL CORE

Figure 3-3. Rubber Track Structure

The structure of the rubber track is illustrated in Figure 3-3. The steel ropes and the metal core are imbedded into the rubber. The carved profiles are used to give traction when moving over loose land. They are situated in the lower part resting on the ground, while the wheel guides situated inside the track, prevent the track from escaping from the guide rollers.

CAUSES OF DAMAGE

1.Breakage of the steel ropes

Excessive tension causes the steel ropes to break in the following conditions:

a.when stones or foreign bodies accumulate between the track and the under-carriage frame;

b.when the track escapes from its guide;

c.in the case of strong friction such as rapid direction changes.

2.Wear and breakage of the metal cores

As for breakage of the steel ropes, stated above, excessive tension may cause the metal cores to bend or break, as may the following causes:

a.incorrect contact between toothed wheel and track;

b.breakage of internal rollers;

c.functioning on sandy land.

3. Separation of the metal cores

WORN PARTS

Figure 3-4.

a.The metal core acts as a type of adhesive of the rubber between the core itself and the steel ropes. Separation may be caused by excessive tension as breakage of the ropes for the following reasons:

b.The metal cores have been wound by the worn toothed wheel as indicated in the figure. When this wear and abrasion is detected, the toothed wheel must be replaced as soon as possible.

c.If it breaks, as stated in item 2, "Wear and breakage of the metal cores", the track must be replaced because this damage leads to a complete loss of functions.

4.Abrasion and fatigue cracks

a.The cracks at the base of the carved profile occur due to bending fatigue of the rubber caused by the toothed wheel and the tracktensioning wheel.

b.The cracks and bends on the edge of the rubber are due to manoeuvres with the track in presence of cement kerbs and edges.

CRACK

Figure 3-5.

c.The cracks and abrasions in the rubber on the tracks of the roller guide originate from fatigue from the compression of the rubber by the weight of the wheel, together with functioning on sandy land, or repeated and abrupt changes of direction.

d.Abrasion of the carved profiles may occur especially if slewing on concrete surfaces or on gravel or hard surfaces are carried out.

e.The damage indicated in paragraphs a, b, and c above, must not be considered fatal for the track and, even if in presence of gradual

3-2

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SECTION 3 - CHASSIS & TURNTABLE

and progressive damage, they allow the track to continue working. The development of the damage indicated in point 3 leads to the exposure of the metal cores and if they are exposed for more than half of the track circumference, it means that it is time to replace them. It can however still be used.

5.Cracks due to external factors

Cracks on external track surfaces (those in contact with the ground) are often due to contact with gravel, sharp stones, sharp materials, nails, glass, which cause cuts. From the rubber properties point of view, this is inevitable although it does depend on service conditions. Cracks on the internal surface of the circumference and on the edge of the rubber originate from contact of the belt with the structure of the undercarriage or with sharp concrete edges. The increase in cracks is relatively small. Even if it does not appear to be in good condition the track can be used in heavy duty conditions.

Replacing The Rubber Tracks

THE GREASE CONTAINED IN THE HYDRAULIC TRACK IS PRESSURISED. FOR THIS REASON, DO NOT LOOSEN THE GREASING VALVE (1) BY MORE THAN 1 TURN; IF THE VALVE IS LOOSENED TOO MUCH, IT RISKS BEING EXPELLED UNDER THE EFFECT OF THE PRESSURE OF THE GREASE, PUTTING THE SAFETY OF THE OPERATOR AT RISK. NEVER LOOSEN GREASER (2).

When gravel or mud are blocked between the toothed wheel and the track links, remove it before loosening.

Removing The Rubber Track

1.Stop the machine on solid, level land, lift it and support it in safe conditions, using the outriggers.

Figure 3-6.

2.Remove the screws and take of adjustment access lid 3.

3.To loosen the track, slowly unscrew valve 1 in an anti-clockwise direction for no more than one turn. One turn of valve 1 is sufficient to loosen the track.

4.If the grease does not start to drain, turn the track slowly.

5.Insert three steel pipes (4) inside the track in the space between the rollers. Turn the driving wheel backwards (5) in a way that the steel pipes proceed with the track and engage on the track-tensioning wheel. Apply force (6) laterally to allow the track to run and lift it from the track-tensioning wheel.

5

5 20202BH19

4

6

Figure 3-7.

Installing The Rubber Track

ENSURE SAFE CONDITIONS WITH THE MACHINE LIFTED TO PROCEED WITH MOUNTING THE TRACKS.

1.Check that the grease contained in the hydraulic cylinder has been removed.

2.Engage the track links with the toothed wheel and position the other end of the track on the track-ten- sioning wheel.

3.Turn the driving wheel in reverse (7) pushing the track plate inside the frame (8).

4.Position the track using a steel pipe and turn the driving wheel again.

5.Ensure that the track links are correctly engaged in the toothed wheel and in the track-tensioning wheel.

6.Adjust track tension (see paragraph -Operations for loosening/tightening the track).

7.Rest the tracked under-carriage on the ground.

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3-3

SECTION 3 - CHASSIS & TURNTABLE

7

520202BH19

8

Figure 3-8.

Checking tightness of nuts and bolts

Depending on the use of the platform, it is indispensable to check the parts and the nuts and bolts in general, which are subject to loosening.

Pay particular attention to the frame components, such as track-tensioning wheels, traversing geared motors, driving wheels and guide rollers. Check that they are tightened sufficiently as indicated in the following table.

The values indicated are to be applied unless otherwise stated in this manual.

3-4

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											SOCKET HEAD CAP SCREWS
							Magni Coating (Ref 4150701)*								Zinc Yellow Chromate Fasteners (Ref 4150707)*
									Torque			Torque							Torque			Torque
					Tensile	Clamp Load	Torque		(Loctite® 242TM or 271TM						Clamp Load	Torque			(Loctite® 242TM or 271TM
		Size	TPI	Bolt Dia					OR Vibra-TITETM 111 or			(Loctite® 262TM or Vibra-				(Dry)			OR Vibra-TITETM 111 or			(Loctite® 262TM or Vibra-
					Stress Area	See Note 4	(Dry)	K = .17	140 OR Precoat 85®			TITETM 131)		K=0.15	See Note 4	K = .20			140 OR Precoat 85®			TITETM 131)		K=0.15
									K=0.16										K=0.18
				In	Sq In	LB	IN-LB	[N.m]	IN-LB		[N.m]	IN-LB		[N.m]	LB	IN-LB		[N.m]	IN-LB		[N.m]	IN-LB		[N.m]
		4	40	0,1120	0,00604
			48	0,1120	0,00661
		6	32	0,1380	0,00909
			40	0,1380	0,01015
		8	32	0,1640	0,01400
			36	0,1640	0,01474
		10	24	0,1900	0,01750
			32	0,1900	0,02000
		1/4	20	0,2500	0,0318	2860	122	14	114		13				2860	143		16	129		15
			28	0,2500	0,0364	3280	139	16	131		15				3280	164		19	148		17
				In	Sq In	LB	FT-LB	[N.m]	FT-LB		[N.m]	FT-LB		[N.m]	LB	FT-LB		[N.m]	FT-LB		[N.m]	FT-LB		[N.m]
–LiftJLG –	.9-3Figure	5/16	18	0,3125	0,0524	4720	20	25	20		25	20		25	4720	25		35	20		25	20		25
		1/2	13	0,5000	0,1419	12750	90	120	85		115	80		110	12750	105		145	95		130	80		110
			24	0,3125	0,0580	5220	25	35	20		25	20		25	5220	25		35	25		35	20		25
		3/8	16	0,3750	0,0775	7000	35	50	35		50	35		50	7000	45		60	40		55	35		50
			24	0,3750	0,0878	7900	40	55	40		55	35		50	7900	50		70	45		60	35		50
		7/16	14	0,4375	0,1063	9550	60	80	55		75	50		70	9550	70		95	65		90	50		70
			20	0,4375	0,1187	10700	65	90	60		80	60		80	10700	80		110	70		95	60		80
			20	0,5000	0,1599	14400	100	135	95		130	90		120	14400	120		165	110		150	90		120
		9/16	12	0,5625	0,1820	16400	130	175	125		170	115		155	16400	155		210	140		190	115		155
			18	0,5625	0,2030	18250	145	195	135		185	130		175	18250	170		230	155		210	130		175
		5/8	11	0,6250	0,2260	20350	180	245	170		230	160		220	20350	210		285	190		260	160		220
			18	0,6250	0,2560	23000	205	280	190		260	180		245	23000	240		325	215		290	180		245
		3/4	10	0,7500	0,3340	30100	320	435	300			280		380	30100	375		510	340		460	280		380
			16	0,7500	0,3730	33600	355	485	335		455	315		430	33600	420		570	380		515	315		430
		7/8	9	0,8750	0,4620	41600	515	700	485		660	455		620	41600	605		825	545		740	455		620
			14	0,8750	0,5090	45800	570	775	535		730	500		680	45800	670		910	600		815	500		680
		1	8	1,0000	0,6060	51500	730	995	685		930	645		875	51500	860		1170	775		1055	645		875
			12	1,0000	0,6630	59700	845	1150	795		1080	745		1015	59700	995		1355	895		1215	745		1015
		1 1/8	7	1,1250	0,7630	68700	1095	1490	1030		1400	965		1310	68700	1290		1755	1160		1580	965		1310
			12	1,1250	0,8560	77000	1225	1665	1155		1570	1085		1475	77000	1445		1965	1300		1770	1085		1475
		1 1/4	7	1,2500	0,9690	87200	1545	2100	1455		1980	1365		1855	87200	1815		2470	1635		2225	1365		1855
			12	1,2500	1,0730	96600	1710	2325	1610		2190	1510		2055	96600	2015		2740	1810		2460	1510		2055
		1 3/8	6	1,3750	1,1550	104000	2025	2755	1905		2590	1785		2430	104000	2385		3245	2145		2915	1785		2430
			12	1,3750	1,3150	118100	2300	3130	2165		2945	2030		2760	118100	2705		3680	2435		3310	2030		2760
		1 1/2	6	1,5000	1,4050	126500	2690	3660	2530		3440	2370		3225	126500	3165		4305	2845		3870	2370		3225
			12	1,5000	1,5800	142200	3020	4105	2845		3870	2665		3625	142200	3555		4835	3200		4350	2665		3625

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

5-3

TURNTABLE & CHASSIS - 3 SECTION

6-3																																3 SECTION
										Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
																																-
													OR Vibra-TITE			111 or	TITETM		131)			K= 0.20			OR Vibra-TITE			111 or	TITE		131)	CHASSIS
								SAE GRADE 5 BOLTS & GRADE 2 NUTS													SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
													Torque				Torque					Torque			Torque				Torque
					Tensile		Torque			Torque			(Loctite® 242TM or 271TM												(Loctite® 242TM or 271TM				(Loctite® 262TM or Vibra-
																			TM
		Size	TPI	Bolt Dia	Stress Area	Clamp Load		(Dry)		Lubricated					TM		(Loctite® 262			or Vibra-	Clamp Load	(Dry or Loctite® 263)					TM			TM
													140)												140)			K=.18	K=0.15			&
				In	Sq In	LB	IN-LB		[N.m]	IN-LB		[N.m]	IN-LB		[N.m]		IN-LB			[N.m]	LB	IN-LB		[N.m]	IN-LB		[N.m]		IN-LB		[N.m]	TURNTABLE
		4	40	0,1120	0,00604	380	8		0,9	6		0,7
			48	0,1120	0,00661	420	9		1,0	7		0,8
		6	32	0,1380	0,00909	580	16		1,8	12		1,4
			40	0,1380	0,01015	610	18		2,0	13		1,5
		8	32	0,1640	0,01400	900	30		3,4	22		2,5
			36	0,1640	0,01474	940	31		3,5	23		2,6									1320	43		5
		10	24	0,1900	0,01750	1120	43		4,8	32		3,5									1580	60		7
			32	0,1900	0,02000	1285	49		5,5	36		4									1800	68		8
		1/4	20	0,2500	0,0318	2020	96		10,8	75		9	105		12						2860	143		16	129			15
			28	0,2500	0,0364	2320	120		13,5	86		10	135		15						3280	164		19	148			17
JLG–	Figure			In	Sq In	LB	FT-LB		[N.m]	FT-LB		[N.m]	FT-LB		[N.m]		FT-LB			[N.m]	LB	FT-LB		[N.m]	FT-LB		[N.m]		FT-LB		[N.m]
		5/16	18	0,3125	0,0524	3340	17		23	13		18	19		26		16			22	4720	25		35	20			25	20		25
			24	0,3125	0,0580	3700	19		26	14		19	21		29		17			23	5220	25		35	25			35	20		25
		3/8	16	0,3750	0,0775	4940	30		41	23		31	35		48		28			38	7000	45		60	40			55	35		50
–Lift	.10-3		24	0,3750	0,0878	5600	35		47	25		34	40		54		32			43	7900	50		70	45			60	35		50
		7/16	14	0,4375	0,1063	6800	50		68	35		47	55		75		45			61	9550	70		95	65			90	50		70
			20	0,4375	0,1187	7550	55		75	40		54	60		82		50			68	10700	80		110	70			95	60		80
		1/2	13	0,5000	0,1419	9050	75		102	55		75	85		116		68			92	12750	105		145	95		130		80		110
			20	0,5000	0,1599	10700	90		122	65		88	100		136		80			108	14400	120		165	110		150		90		120
		9/16	12	0,5625	0,1820	11600	110		149	80		108	120		163		98			133	16400	155		210	140		190		115		155
			18	0,5625	0,2030	12950	120		163	90		122	135		184		109			148	18250	170		230	155		210		130		175
		5/8	11	0,6250	0,2260	14400	150		203	110		149	165		224		135			183	20350	210		285	190		260		160		220
			18	0,6250	0,2560	16300	170		230	130		176	190		258		153			207	23000	240		325	215		290		180		245
		3/4	10	0,7500	0,3340	21300	260		353	200			285		388		240			325	30100	375		510	340		460		280		380
			16	0,7500	0,3730	23800	300		407	220		298	330		449		268			363	33600	420		570	380		515		315		430
		7/8	9	0,8750	0,4620	29400	430		583	320		434	475		646		386			523	41600	605		825	545		740		455		620
			14	0,8750	0,5090	32400	470		637	350		475	520		707		425			576	45800	670		910	600		815		500		680
		1	8	1,0000	0,6060	38600	640		868	480		651	675		918		579			785	51500	860		1170	770		1045		645		875
			12	1,0000	0,6630	42200	700		949	530		719	735		1000		633			858	59700	995		1355	895		1215		745		1015
		1 1/8	7	1,1250	0,7630	42300	800		1085	600		813	840		1142		714			968	68700	1290		1755	1160		1580		965		1310
			12	1,1250	0,8560	47500	880		1193	660		895	925		1258		802			1087	77000	1445		1965	1300		1770		1085		1475
		1 1/4	7	1,2500	0,9690	53800	1120		1518	840		1139	1175		1598		1009			1368	87200	1815		2470	1635		2225		1365		1855
			12	1,2500	1,0730	59600	1240		1681	920		1247	1300		1768		1118			1516	96600	2015		2740	1810		2460		1510		2055
		1 3/8	6	1,3750	1,1550	64100	1460		1979	1100		1491	1525		2074		1322			1792	104000	2385		3245	2145		2915		1785		2430
			12	1,3750	1,3150	73000	1680		2278	1260		1708	1750		2380		1506			2042	118100	2705		3680	2435		3310		2030		2760
		1 1/2	6	1,5000	1,4050	78000	1940		2630	1460		1979	2025		2754		1755			2379	126500	3165		4305	2845		3870		2370		3225
			12	1,5000	1,5800	87700	2200		2983	1640		2224	2300		3128		1974			2676	142200	3555		4835	3200		4350		2665		3625

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2.ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3.* ASSEMBLY USES HARDENED WASHER

3121623