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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TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.
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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SECTION NO. TITLE PAGE NO.
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
7.10 H - EMERGENCY DESCEND ELECTRO VALVES - WIDENING CYLINDER SENSOR
OPTIONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
7.11 I - GROUND PART: TRACKS - UNDERCARRIAGE WIDENING - 2° SPEED - PROPORTIONAL
ELECTRO VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11
7.12 J - GROUND PART: OUTRIGGERS - ELECTRIC DIVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
7.13 K - 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
3121448 – JLG Lift – iii
1.1 CAPACITIES
MACHINE TYPE DRIBE HUB DRIVE CAPACITIES
X17JP
X500AJ
X20JP
X600AJ
SECTION 1 - SPECIFICATIONS
SECTION 1. SPECIFICATIONS
Table 1-1. DRIVE HUB CAPACITIES
BONFIGLIOLI
700C2K I:32 + MAG12 VP
BONFIGLIOLI
7C 00/2 2 K A A 36 G016VP30 LA
Table 1-2. HYDRAULIC & FUEL TANK CAPACITIES
AUTO
2 SPEED
2 SPEED 0,32 L (0,08 gal)
0,4 L (0.10 gal)
MACHINE
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)
HYDRAULIC OIL TANK
CAPACITY
GASOLINE DIESEL
FUEL TANK
3121623 – JLG Lift – 1-1
SECTION 1 - SPECIFICATIONS
1.2 TRACKS
Machine
Model
Typ e Part Number
LOW PROFILE BLACK
COLOR
053715L0
Table 1-3. Track Specifications
Rubber Belt Track Undercar-
Dimen-
sions
riage
Drawing
Model
X17JP
X500AJ
X20JP
X600AJ
LOW PROFILE NO
MARKING
LOW PRO-
FILE BLACK
COLOR
053715LB
257215L0
Cm
180X37X
72
Cm
200X48X
66
PT9
PT10
LOW PROFILE NO
MARKING
257215LB
1-2 – JLG Lift – 3121623
MODEL
X17JP-X500AJ
X20JP-X600AJ
1.3 POWER SOURCE
SECTION 1 - SPECIFICATIONS
Table 1-4. Ground bearing pressure
PRESSURES AND REACTIONS TO THE GROUND
ON TRACKS
Maximum ground bearing
pressure
[daN/cm²] - [PSI]
0,67 daN/cm² 9,7 PSI 1731 daN 3892 lbf 2,45 daN/cm² 35.5 PSI
0,64 daN/cm² 9,2 PSI 2150 daN 4833 lbf 3,04 daN/cm² 45 PSI
Maximum ground
bearing pressure
on each pad
[daN] - [lbf]
ON OUTRIGGER
Maximum ground bearing
pressure
[daN/cm²] - [PSI]
Table 1-5. Power configuration
X17JP X20JP
Gasoline Engine Honda iGX440
15 hp (11.1 kW)
Diesel Engine Hatz 1B40
10 hp (7.46 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.
Perkins 402.05
14 hp (10.44 Kw)
3121623 – JLG Lift – 1-3
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
Bore x stroke 88.0 x 72.1 mm (3.46 x 2.84 in)
Maximum horsepower
Recommended maximum operation bhp
Maximum torque
11.2 kW (15.2 HP) / 3,600 min
8.0 kW (10.8 HP) / 3,600 min
29.8 N·m (3.0 kgf·m, 22 lbf·ft)/2,500 min
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
13° B.T.D.C./3,600 min
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
438 cm
3
(26.7cu-in)
-1
-1
-1
(rpm)
-1
(rpm)
(rpm)
(rpm)
-1
(rpm)
1-4 – JLG Lift – 3121623
SECTION 1 - SPECIFICATIONS
HATZ ENGINE 1B40
Table 1-7. SPECIFICATIONS HATZ ENGINE 1B40
Typ e 1B40
Design Air-cooled four-stroke diesel engine
Combustion system Direct injection
Number of cylinders 1
Bore / stroke 88 / 76 mm
Displacement
Lubricating oil capacity without oil sump with oil
sump
Difference between “max” and “min” levels without
oil sump with oil sump
1.5
3.2
0.8
2.2
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
Inlet and exhaust valve
Max. tilt angle in operation, in direction
Weight (incl. fuel tank, air-cleaner, exhaust silencer,
Flywheel 25° down
or automatically
55 kg approx.
recoil starter and electric starter)
Battery capacity max. 12 V / 60 Amp/h
3
462 cm
1)
l, approx.
1)
l, approx.
1)
l, approx.
1)
l, approx.
0.10 mm
2)
3)
all other directions 35°
3)
PERKINS ENGINE 402D
Table 1-8. SPECIFICATIONS PERKINS ENGINE 402D
Ty pe
Maximum Operating Speed (rpm)
Cylinders and Arrangement
Bore 67 mm (2.64 inch)
Stroke 72 mm (2.83 inch)
Displacement 0.507 L (30.939 in3)
Aspiration
Compression Ratio 23.5:1
Firing Order 1-2
Rotation that is viewed from the flywheel
Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)
Valve Lash Setting (Exhaust)
Injection Indirect
402D-05 Engine
3600 rpm
In-Line two cylinder
(1)
NA
Counterclockwise
0.20 mm (0.008 inch)
3121623 – JLG Lift – 1-5
SECTION 1 - SPECIFICATIONS
1.4 SPECIFICATIONS AND PERFORMANCE DATA
Reach Specifications
Table 1-9. Reach Specifications
Max working Height
(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'
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
Dimensional Data
X17JP
CE
16.96 m 20.05 m NA NA
(7.80 m)
Table 1-10. SPECIFICATIONS PERKINS ENGINE 402D
X20JP
CE
18'.01"
(8.20 m)
X500AJ
ANSI
(7.80 m)
Front 20° /
Rear 20°
15'
X600AJ
ANSI
18'.01"
(8.20 m)
X17JP/
X500AJ
P la tf or m siz e (s ta nd ar d 2 p er so ns ) 0.69 m x 1.34 m
Pla t fo r m siz e (n a r ro w o ne p e rso n ) 0.62 m x 0.79 m
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
O ut ri gg er f oo tp rin t 2.89 m x 2,88 m 2.92 m x 2.93 m
Gross machine weight:
Gasoline
Diesel
Lithium battery
1-6 – JLG Lift – 3121623
2230 Kg
2230 Kg
2300 Kg
X20JP/
X600AJ
2840 Kg
2880 Kg
2990 Kg
1.5 FUNCTION SPEEDS
SECTION 1 - SPECIFICATIONS
Table 1-11. Functions speed (in seconds)
FUNCTIONS SPEED RANGE
FUN CT IO N TIM E S ec
X 17 JP
X500AJ
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
COMPLETED
TIM E S ec
X20JP
X600AJ
TO BE
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.
Te l es c o pe : Boom at Full Elevation; Telescope Retracted;
Telescope Out, Record Time. Telescope In, Record Time.
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.
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.
TE S T N OT E S
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).
3121623 – JLG Lift – 1-7
SECTION 1 - SPECIFICATIONS
1.6 PRESSURE SETTINGS - PSI (BAR)
Table 1-12. Pressure settings
UNDERCARRIAGE
Model
X14JP-X500 AJ
X20JP-X600AJ
Table 1-13. Pressure settings
Model Automatic reductions drive speed
X17JP - X500AJ
X20JP - X600AJ
Left and Right
Control Valve
Bar PSI Bar PSI
165 2393 185 2045
Bar PSI
26 380
NA NA
TOWER
Control Valve
1-8 – JLG Lift – 3121623
1.7 MAJOR COMPONENT WEIGHTS
SECTION 1 - SPECIFICATIONS
Table 1-14. Weight components
3121623 – JLG Lift – 1-9
SECTION 1 - SPECIFICATIONS
1.8 LUBRICATION
Figure 1-1.
1-10 – JLG Lift – 3121623
Table 1-15.
SECTION 1 - SPECIFICATIONS
* 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
3121623 – JLG Lift – 1-11
SECTION 1 - SPECIFICATIONS
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 NU M BER
PLA T E L OC AT I ON
1-12 – JLG Lift – 3121623
NOTES:
SECTION 1 - SPECIFICATIONS
3121623 – JLG Lift – 1-13
SECTION 2. GENERAL
SECTION 2 - GENERAL
2.1 MACHINE 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.
3121623 – JLG Lift – 2-1
SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance
Type Frequency
Pre-Start
Inspection
Pre-Delivery
Inspection
Frequent
Inspection
Annual Machine
Inspection
Preventative
Maintenance
Prior to use each day; or
At each Operator change.
Prior to each sale, lease, or
rental delivery.
In service for 3 months or 150 hours,
whichever comes first; or
Out of service for a period of more than
3 months; or
Purchased used.
Annually, no later than 13 months from
the date of the prior inspection.
At intervals as specified in the Service
and Maintenance 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.
Primary
Responsibility
User or Operator User or Operator Operator and Safety Man-
Owner, Dealer, or
User
Owner, Dealer, or
User
Owner, Dealer, or
User
Owner, Dealer, or
User
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.
Service
Qualification
Qualified JLG
Mechanic
Qualified JLG
Mechanic
Factory-Certified
Service Techni-
cian
Qualified JLG
Mechanic
Reference
ual
Service and Maintenance
Manual and applicable JLG
inspection form.
Service and Maintenance
Manual and applicable JLG
inspection form.
Service and Maintenance
Manual and applicable JLG
inspection form.
Service and Maintenance
Manual
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.
2-2 – JLG Lift – 3121623
SECTION 2 - GENERAL
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.
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.
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.)
3121623 – JLG Lift – 2-3
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-
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.
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
DIAMETER
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.
MAX ACCEPTABLE DRIF
IN 1 MINUTES
3. While the unit is shut down, a good preventive main-
tenance 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.
2-4 – JLG Lift – 3121623
SECTION 2 - GENERAL
2.5 PINS 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 hous-
ing.
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.
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.
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.
FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY
RESULT IN COMPONENT DAMAGE (I.E. ELECTRONIC MODULES,
SWING BEARING, COLLECTOR RING, BOOM WIRE ROPES ETC.)
3121623 – JLG Lift – 2-5
SECTION 2 - GENERAL
NOTES:
2-6 – JLG Lift – 3121623
SECTION 3 - CHASSIS & TURNTABLE
A
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.
Figure 3-1.
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.
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.
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.
3121623 – JLG Lift – 3-1
SECTION 3 - CHASSIS & TURNTABLE
PATTERN
WHEEL SIDE
SPROCKET
HOLE
METAL CORE
STEEL WIRE
g
WORN PARTS
CRACK
Checking The Rubber Tracks
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
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 rub-
ber are due to manoeuvres with the track in
presence of cement kerbs and edges.
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 – JLG Lift – 3121623
SECTION 3 - CHASSIS & TURNTABLE
4
5
6
5
20
2
0
2
B
H
1
9
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).
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.
Figure 3-7.
Installing The Rubber Track
ENSURE SAFE CONDITIONS WITH THE MACHINE
LIFTED TO PROCEED WITH MOUNTING THE
TRACKS.
When gravel or mud are blocked between the toothed wheel
and the track links, remove it before loosening.
Removing The Rubber Track
1. Check that the grease contained in the hydraulic cyl-
inder has been removed.
2. Engage the track links with the toothed wheel and
1. Stop the machine on solid, level land, lift it and sup-
port it in safe conditions, using the outriggers.
position the other end of the track on the track-tensioning 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.
Figure 3-6.
2. Remove the screws and take of adjustment access
6. Adjust track tension (see paragraph -Operations for
loosening/tightening the track).
7. Rest the tracked under-carriage on the ground.
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.
3121623 – JLG Lift – 3-3
SECTION 3 - CHASSIS & TURNTABLE
8
7
52
0
20
2
B
H1
9
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 – JLG Lift – 3121623
Size TPI Bolt Dia
Tensile
Stress Area
Clamp Load
See Note 4
Clamp Load
See Note 4
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]
5/16 18 0,3125 0,0524 4720 20 25 20 25 20 25 4720 25 35 20 25 20 25
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
1/2 13 0,5000 0,1419 12750 90 120 85 115 80 110 12750 105 145 95 130 80 110
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
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.
SOCKET HEAD CAP SCREWS
Torque
(Dry)
K = .20
Torque
(Loctite® 242
TM
or 271
TM
OR Vibra-TITE
TM
111 or
140 OR Precoat 85®
K=0.18
Torque
(Loctite® 262
TM
or Vibra-
TITE
TM
131) K=0.15
Zinc Yellow Chromate Fasteners (Ref 4150707)*Magni Coating (Ref 4150701)*
Torque
(Dry) K = .17
Torque
(Loctite® 242
TM
or 271
TM
OR Vibra-TITE
TM
111 or
140 OR Precoat 85®
K=0.16
Torque
(Loctite® 262
TM
or Vibra-
TITE
TM
131) K=0.15
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
SECTION 3 - CHASSIS & TURNTABLE
Figure 3-9.
3121623 – JLG Lift – 3-5
SECTION 3 - CHASSIS & TURNTABLE
Size TPI Bolt Dia
Tensile
Stress Area
Clamp Load Clamp Load
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]
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
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
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
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
Torque
(Loctite® 242
TM
or 271
TM
OR Vibra-TITE
TM
111 or
140) K=.18
Torque
(Loctite® 262
TM
or Vibra-
TITE
TM
131)
K=0.15
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
(Dry)
Torque
(Loctite® 262
TM
or Vibra-
TITE
TM
131)
Torque
Lubricated
Torque
(Loctite® 242
TM
or 271
TM
OR Vibra-TITE
TM
111 or
140)
SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
3. * ASSEMBLY USES HARDENED WASHER
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
Torque
(Dry or Loctite® 263)
K= 0.20
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3-6 – JLG Lift – 3121623
Figure 3-10.
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