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 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.

il ize the machine on level ground.

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

TM

)

Torque

(Lub)

Torque

(Loctite® 262

TM

OR Vibra-

TITE

TM

131)

Torque

(Loctite®

242

TM

or 271

TM

OR Vibra-

TITE

TM

111 or

140)

Clamp

Load

Torque

(Dry or Loctite®

263

TM

)

K = 0.20

Torque

(Lub OR Loctite®

242

TM

or 271

TM

OR

Vibra-TITE

TM

111 or

140)
K= 0.18

Torque

(Loctite® 262

TM

OR

Vibra-TITE

TM

131)

K=0.15

Clamp Load

See Note 4

Torque

(Dry or Loctite®

263

TM

)

K = .17

Torque

(Lub OR Loctite®

242

TM

or 271

TM

OR Vibra-TITE

TM

111 or 140)

K = .16

Torque

(Loctite® 262

TM

OR Vibra-TITE

TM

131)
K = .15

Sq mm KN [N.m] [N.m] [N.m] [N.m] KN [N.m] [N.m] [N.m] kN [N.m] [N.m] [N.m]

3 0,5 5,03 2,19 1,3 1,0 1,2 1,4 3,13

3.5 0,6 6,78 2,95 2,1 1,6 1,9 2,3 4,22

4 0,7 8,78 3,82 3,1 2,3 2,8 3,4 5,47

5 0,8 14,20 6,18 6,2 4,6 5,6 6,8 8,85

6 1 20,10 8,74 11 7,9 9,4 12 12,5 12,5 13 12 11

7 1 28,90 12,6 18 13 16 19 18,0 25 23 19 18,0 21 20 19

8 1,25 36,60 15,9 26 19 23 28 22,8 37 33 27 22,8 31 29 27

10 1,5 58,00 25,2 50 38 45 55 36,1 70 65 55 36,1 61 58 54

12 1,75 84,30 36,7 88 66 79 97 52,5 125 115 95 52,5 105 100 95

14 2 115 50,0 140 105 126 154 71,6 200 180 150 71,6 170 160 150

16 2 157 68,3

219 164 197 241

97,8

315 280 235 97,8 265 250 235

18 2,5 192 83,5 301 226 271 331 119,5 430 385 325 119,5 365 345 325

20 2,5 245 106,5 426 320 383 469 152,5 610 550 460 152,5 520 490 460

22 2,5 303 132,0 581 436 523 639 189,0 830 750 625 189,0 705 665 625

24 3 353 153,5 737 553 663 811 222,0 1065 960 800 220,0 900 845 790

27 3 459 199,5 1080 810 970 1130 286,0 1545 1390 1160 286,0 1315 1235 1160

30 3,5 561 244,0 1460 1100 1320 1530 349,5 2095 1885 1575 349,5 1780 1680 1575

33 3,5 694 302,0 1990 1490 1790 2090 432,5 2855 2570 2140 432,5 2425 2285 2140

36 4 817 355,5 2560 1920 2300 2690 509,0 3665 3300 2750 509,0 3115 2930 2750

42 4,5 1120 487,0 4090 3070 3680 4290 698,0 5865 5275 4395 698,0 4985 4690 4395

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.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

Spec #4150701Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

CLASS 10.9 METRIC (HEX HEAD) BOLTS

CLASS 10 METRIC NUTS

CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

CLASS 8.8 METRIC (HEX HEAD) BOLTS

CLASS 8 METRIC NUTS

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*

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%

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-11.

3121623 – JLG Lift – 3-7

SECTION 3 - CHASSIS & TURNTABLE

1

4

5

3

2

1

6

7

11

9

8

12

10

12

11

3.2 UNDERCARRIGE COMPONENTS

a. Fully extend the undercarriage.

b. Remove the tracks (see paragraph 3.1).

c. Remove the key ignition, and a tag with warning

do not start the machine.

Figure 3-12.

Replacement roller lower wheel and tracks adjuster

4. Apply loctite 243 and torque the nuts 2 on the lower
roller at 125Nm.

Replacement sprocket and Gear Motor

Figure 3-14.

Sprocket remove

1. Fully extend the undercarriage.

2. Remove the tracks (see paragraph 3.1).

3. Remove the key ignition, and a tag with warning do

not start the machine.

4. Remove screws 6.

5. Remove the sprocket 7.

Figure 3-13.

Disassembly

1. Remove the nuts 2 on the lower roller.

2. Remove the lower roller 3.

3. Remove the front idler 5.

4. Remove the tracks adjuster 4.

ASSEMBLY

1. Fit the tracks adjuster 4.

2. Instal the front idler 5.

Gear motor remove

1. Remove cover 9.

2. Disconnect and tag the hydraulic hoses from the

gearmotor.

3. Remove the valve 10 to access all the screws 11 (on
single speed versions only).

4. Remove the screws 11.

5. Remove the gearmotor 12.

3. Instal the lower roller 3.

3-8 – JLG Lift – 3121623

SECTION 3 - CHASSIS & TURNTABLE

1

6

7

11

9

8

12

10

12

11

Gear motor installation

1. Fix the screws 11.

2. Instal the valve 10.

3. Connect the Hydraulic hoses

4. Instal the cover 9.

Sprocket installation

1. Instal the sprocket

2. Instal the screws 6

Table 3-1. Final drive torque valves

Machine model Description Torque valve Loctite type+

X17J P - X500AJ Screw TECEI M 10X25

12,9

X20JP - X600AJ Screw TECEI M 10X25

12,9

84 Nm Loctite 243

84 Nm Loctite 243

3121623 – JLG Lift – 3-9

SECTION 3 - CHASSIS & TURNTABLE

1

2

3

5

6

4

7

8

9

9

3.3 AXLE EXTENSION REMOVAL

Figure 3-15.

1. Stabilize the machine on level surface.

2. Extend the undercarriage.

3. Engine and key off.

4. Remove the key ignition, and a tag with warning do not

start the machine.

5. Open the hydraulic cap, and operate the function
undercarriage extend/retract to discharge any residual
pressure in the system.

8. Using a suitable lifting device (minimum 200kg capac­ity) to remove the track frame.

Figure 3-18.

9. Remove screw and nut 3-6.

10. Remove the pin 4.

11. Disconnect, tag and plug the hydraulic hoses from the

cylinder extension.

12. Remove the cylinder.

Figure 3-16.

6. Remove the cotter pin 1 (figure 3-16)

7. Remove the pin 2.

Figure 3-17.

Figure 3-19.

NOTE: Before to install the undercarriage frame inspect the slide

guides 9.

a. Unscrew the screws 7.

b. Remove the stop slide guides 8.

c. Remove the slide guides 9.

d. Check the thickness of slide guides, if less than

3.5 mm, damage, with deep scratches or with
deformation, replace its. Otherwise clean them
and install by adding Grease GR MU EP1 before
to install the track guides.

e. Use medium strength Loctite (Loctite 243) on

screws 7 and tightening torque of 10 Nm.

3-10 – JLG Lift – 3121623

3.4 TRACK DRIVE - BONFIGLIOLI (2T700C2K032002)

Table 3-2.

MACHINE TYPE SPEED

X17JP - X500AJ

X20JP - X600AJ

700C2K

7002C2K

AUTO TWO

TWO SPEED

SECTION 3 - CHASSIS & TURNTABLE

INFORMATION

FOR ALL ENQUIRIES REGARDING GENERAL INFOR­MATION ON THE PRODUCT, SPARE PARTS, ASSIS­TANCE ETC, ALWAYS GIVE THE IDENTIFICATION
DATA STAMPED ON THE ID PLATE.

SPEED

The gearmotor has two plates, one gives data on the
gearbox and the other data on the hydraulic motor.

Product Identification

The data to identify the product are shown on the identifi­cation plate attached to it.

The plates must not be removed or damaged during the
life of the product. The following illustration shows how
the data is set out.

Figure 3-20.

3121623 – JLG Lift – 3-11

SECTION 3 - CHASSIS & TURNTABLE

Lifting and handling

If the handling occurs when the product is still
packaged, simply follow the instructions given on the
packaging and/or use normal hoisting means.

NOTE: For the weight of the gearmotor refer to Table 1-14

Figure 3-21.

3-12 – JLG Lift – 3121623

SECTION 3 - CHASSIS & TURNTABLE

TECHNICAL INFORMATIONS

PRODUCT DESCRIPTION

The Bonfiglioli Trasmital gearmotors of the series
decribed in this manual are designed and built for
application as track drive for crawled machines
equipped with open or closed loop hydraulic circuit
depending on the application.

The unit includes:

Planetary gearbox

- 2/3 reduction stages planetary gearbox, with
rotating housing

- Connecting flange to the machine frame

- Connecting flange to the sprocket.

Hydraulic motor

Orbit fixed displacement motor including:

- Brake valve, this valve is installed for drive applications
on tracked vehicles such as mini excavators and similar
with open loop circuits; -Internal brake port directly con­trolled by the motor supply ports.

Figure 3-22. Hydraulic scheme X17JP - X500AJ

3121623 – JLG Lift – 3-13

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-23. Hydraulic scheme X20JP - X600AJ

3-14 – JLG Lift – 3121623

The illustrations show the parts and the main functions of
the gearmotor.

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-24.

3121623 – JLG Lift – 3-15

SECTION 3 - CHASSIS & TURNTABLE

Legend:

Figure 3-25.

1 M10x1 Filling and draining oil plug

2 M10x1 Level oil plug

P1 - P2 3/8“ G 19 TPI (depth 14 mm) Motor port

Table 3-3.

3-16 – JLG Lift – 3121623

DIRECTION OF ROTATION

When assembling the track drive on the machine and
connecting the hoses, follow instructions shown in
below sketch for proper direction of rotation.

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-26.

Ta b l e 3 - 4 .

3121623 – JLG Lift – 3-17

SECTION 3 - CHASSIS & TURNTABLE

CONNECTION OF THE HYDRAULIC SYSTEM

1. Clean the surface to be connected on the hydraulic

motor.

2. Connect the hoses to the hydraulic motor ports (for
hoses sizes and dimensions refer to the installation
drawing).

Motor open loop hydraulic circuit

a. Service ports: P1-P2

b. Drain port: T1 or T2

c. 2 speed control port: Ps

3-18 – JLG Lift – 3121623

GEARBOX LUBRICATION

The motor and the gearbox have separate lubrication. The
gearbox is lubricated by oil splashing. The recommended oil
type has to be EP characteristics according to
MIL-L-2105 C & API GL5.
For standard working conditions, the recommended oil is:

For heavy duty working conditions (high loads, high duty
cycles or high ambient temperatures), the recommended oil
is:

SECTION 3 - CHASSIS & TURNTABLE

In the following table the most common brands of lubricant
and the types recommended are shown.

DURING THE OPERATION THE OIL TEMPERATURE MUST NOT
EXCEED 85-90° C INTERMITTENT.

IN CASE OF LUBRICATION WITH SYNTHETIC OILS, IS RECOM­MENDED TO USE ONLY OILS WITH PAO BASE IF NOT OTHER­WISE SPECIFIED WHEN ORDERING. DO NOT MIX TOGETHER
OILS OF DIFFERENT BRANDS OR CHARACTERISTICS. USE OILS
LISTED IN THE TABLE OR SIMILAR PRODUCTS WITH EQUIVA­LENT CHARACTERISTICS IN ORDER TO NOT MODIFY THE BRAKE
PERFORMANCES (IF PRESENT).

For information about characteristics of lubricating oils and
their proper use, please consult the lubricant suppliers
directly.

3121623 – JLG Lift – 3-19

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-27.

3-20 – JLG Lift – 3121623

SECTION 3 - CHASSIS & TURNTABLE

OIL FILLING

THE GEARBOX IS SUPPLIED WITHOUT OIL; ANYWAY IT HAS
FILLING, DRAINING AND OIL LEVEL PLUGS. BEFORE PUTTING
THE GEARBOX INTO OPERATION, IT IS NECESSARY TO FILL IT

WITH OIL.

Proceed according to the following instructions:

1. Check that the gearbox axis is horizontal. Rotate the
gearbox housing until the drain plug (1A) is on the
bottom of the vertical axis of the end cover.

2. Unscrew the fill and level oil plugs (1A-1B).

3. Add the lubricating oil from the hole (1A) with the

features listed in section "Gearbox lubrication" untill
it flows out from the level hole (1B).

4. Screw the filling and level oil plugs (1A-1B)

5. Run the gearmotor, after a few minutes, stop and

check the oil level.

6. If necessary, refill with lubricant oil.

OIL DRAINING AND REPLACEMENT

1. Check that the gearbox axis is horizontal. Rotate the

gearbox housing until the drain plug (1B) is on the
bottom of the vertical axis of the end cover.

REMOVE THE OIL PLUGS WITH EXTREME CAUTION
BECAUSE AN OVERPRESSURE INSIDE THE UNIT
COULD STRONGLY EXPEL THEM.

2. Unscrew the plugs (1A-1B) and let the oil flow in a

large enough container; in order to facilitate the
draining must be oil still warm.

3. Wait a few minutes until all the oil is drained and
then proceed to screw on the plugs (1A-1B).

4. Proceed with the oil fill-up according to the following
procedures listed in Section "Oil filling".

For further information see the installation drawing.
Tighten the plugs by a torque wrench at a torque shown on
the table in the end of this manual.

DO NOT DISPOSE OF THE OIL IN THE NATURAL ENVIRONMENT
BUT BE CAREFUL TO ELIMINATE IT IN COMPLIANCE WITH THE
RELATIVE RULES AND REGULATIONS THAT GOVERN LOCALLY.

CHECK THE CORRECT OIL LEVEL AFTER FILLING THROUGH THE
APPROPRIATE PLUG.

Oil quantity to fill the gearbox is indicated on the following
table or on the product installation drawing (Indicative
values).
Believe are reported the standard gearbox oil filling draining
sketches.

3121623 – JLG Lift – 3-21

SECTION 3 - CHASSIS & TURNTABLE

NOTE: Oil qt. (l ± 10%): 0,3 l

FILL, LEVEL AND DRAIN OIL PLUG DIMENSIONS ARE INDICATED
ON THE PRODUCT INSTALLATION DRAWING.

For gearboxes with filling and draining oil hub side, refer to
the installation drawing.

3-22 – JLG Lift – 3121623

SECTION 3 - CHASSIS & TURNTABLE

TROUBLESHOOTING

The following table is a guideline to identify the troubles in
the track drive.

Ta b l e 3 - 5 .

Anomalies Causes Remedies

External oil leakage:

From the lifetime seal a) Lifetime damaged a) Replace lifetime seal

From the end cover a) O-ring seal damaged a) Replace O-ring seals

From the plugs of the cover a) Plug seal damaged

b) Plugs or screws loose

From hydraulic motor a) O-ring seals damaged

b) Plugs or screws loose

a) Replace plug seal

b) Tighten the plugs/screws

a) Replace O-ring seals

b) Tighten the plugs/screws

c) Internal motor parts damaged

Too much noise:

Inside the hydraulic motor (mechani­cal noise)

Hydraulic noise (during the slowing
down of the motor speed)

Inside the gearmotor (reductions) a) Internal damage a) Check the gearbox

Overheating a) Insufficient oil level

Insufficient power a) Internal motor parts damaged

Insufficient braking torque Parking brake malfunctioning

Sprocket locked a) Hydraulic motor locked

a) Internal motor parts damaged a) Check the hydraulic motor

a) Internal motor parts damaged

b) Hydraulic circuit malfunctioning

Other:

b) Hydraulic oil too warm

c) Brake not fully released

b) Malfunctioning valves

a) Motor feed not correct

b)Low volumetric efficiency

b) Parking brake locked

c) Check the hydraulic motor

a) Check the hydraulic motor

b) Check the pressure to the motor
ports is ≥ 3 bar Verify hydraulic circuit

a) Check the oil level and refill if nec­essary

b) Check the hydraulic circuit

a) Check the hydraulic motor

b) Check valves

a) Check the hydraulic circuit

b) Check the hydraulic motor

a) Check hydraulic motor

b) Check the complete brake release

c) Mechanical components damaged

c) Replace damaged parts

3121623 – JLG Lift – 3-23

SECTION 3 - CHASSIS & TURNTABLE

3.5 SWING DRIVE (IMO)

TECHNICAL DATA – TYPE PLATE

Figure 3-28. Type plate

The type plate is on the housing and contains the follow­ing information:

•Manufacturer

• Drawing no./type

• Identification code consisting of:

• Order number, year of manufacture and consecutive
number

•Module

• Web address

Structure and function

BRIEF DESCRIPTION

Slew drives are used for concurrent transmission of axial
and radial forces, as well as transmission of tilting
moments. Slew drives consist of a ball or roller slewing
ring, hydraulic or electric drives, and a completely enclos­ing housing. Force is transmitted to the mounting struc­ture through bolts. For this purpose through holes or
threads are provided in the inner and outer ring.

Figure 3-29. Slew drive WD-L

1. Connection for options: Potentiometer, permanent

brake or front-end brake

2. Worm shaft

3. Lubricating nipple

4. Ball slewing ring

5. Option: Drive motor

6. Bolted unions for the mounting structure

7. Housing

8. Lubricating nipple

3-24 – JLG Lift – 3121623

TRANSPORTING UNPACKED SLEW DRIVES

SECTION 3 - CHASSIS & TURNTABLE

Attachment:

1. Screw the 3 eye bolts into the 3 threads that are dis-

tributed uniformly on the circumference of the slew
drive.

SCREW IN THE EYE BOLTS TO THE FULL THREAD LENGTH!
IMPROPERLY ATTACHED, UNSUITABLE, OR DAMAGED EYE
BOLTS MAY CAUSE THE SLEW DRIVE TO FALL AND CAUSE LIFE­THREATENING INJURIES.

2. Attach lifting gear to the eye bolts.

3. Start the transport.

Figure 3-30. Use suitable lifting gear/never transport

product vertically

Unpacked slew drives can be transported with lifting gear
when using eye bolts under the following conditions

• The lifting gear must be configured appropriately for
the weight of the transport units.

• The ring bolts must be configured appropriately for the
weight of the transport unit.

• The slew drive shall only be transported by itself, with­out attached parts.

• Maintain the insertion depth prescribed by the manu­facturer.

• If insertion depth is not prescribed, then a minimum
insertion depth of 1.5 x the bolt diameter must be
selected.

• Transport within the company shall only be executed
horizontally.

POSITIONING THE SWING DRIVE

4. Determine the main load-carrying zone. The main

load-carrying zone is that area of the slewing ring
that is subject to the highest load, taking all aggres­sive forces and torques, and all occurring load
cases into account.

5. Arrange the hardness gap of the bearing ring
charged with point load so that it is offset by 90° rel­ative to the main load-carrying zone. The main load­carrying zone is in the main slewing range.

THE HARDNESS GAP OR THE FILLING PLUG IN A SLEWING RING
CONSTITUTE A ZONE OF DECREASED LOAD-CARRYING CAPAC­ITY. THE SERVICE-LIFE OF THE SLEW DRIVE WILL BE REDUCED
SIGNIFICANTLY, IF THE HARDNESS GAP IS IN THE MAIN SLEW­ING RANGE. FRACTURE OF BEARING RING FOR EXAMPLE MAY
CAUSE SLEW DRIVE FAILURE. CONSEQUENTLY PLACE THIS
MARKED POINT IN A REDUCED LOAD ZONE IF POSSIBLE.

6. Use a feeler gauge to check whether the support
surface of the slew drive is completely supported by
the mounting structure. If this is not the case, the
support surface of the mounting structure must be
reworked.

Figure 3-31. Always use the full length of the thread

3121623 – JLG Lift – 3-25

SECTION 3 - CHASSIS & TURNTABLE

7.

Figure 3-32. Check the support surface

BOLTING THE SLEW DRIVE

DO NOT USE IMPACT SCREWDRIVERS. USING AN IMPACT
SCREWDRIVER MAY CAUSE IMPERMISSIBLE DEVIATIONS
BETWEEN THE BOLT TIGHTENING FORCES. FAILURE OF THE
BOLTED UNION WITH THE MOUNTING STRUCTURE MAY CAUSE
SEVERE PERSONAL INJURY OR MATERIAL DAMAGE.

MOUNT THE SLEW DRIVE IN UNSTRESSED STATE.

Strictly comply with the procedure specified below to
avoid impermissible deviations between the bolt tighten­ing forces:

FIRST FASTEN THE HOUSING, THEN FASTEN THE
TOOTHED BEARING RING!

8. Use medium strength Loctite (Loctite 243) on
screws.

9. Pretension the bolts, with washers if required, cross­wise in 3 steps, 30%, 80%, and 100% of the tighten­ing torque, or the hydraulically applied pretension
force.

10. In this process turn the unscrewed ring several
times. Repeat the procedure for the bearing ring that
has not yet been bolted.

Figure 3-33. Tighten crosswise

Ta b l e 3 - 6 .

Mounting

bolt dimen-

sions

Mounting pretension force

1)

F

M

Strength class 10.9 in

kN lbs

M24 282 63396

M27 367 82505

M30 448 100714

M33 554 124544

M36 653 146800

M42 896 201429

M45 1043 234476

M48 1177 264600

M52 1405 315857

M56 1622 364640

M60 1887 424215

M64 2138 480642

M68 2441 548759

If using a hydraulic bolt-tensioning cylinder the tensioning
forces for the bolt pretension should not exceed 90% of
yield strength.

3-26 – JLG Lift – 3121623

SECTION 3 - CHASSIS & TURNTABLE

1)

FM for hydraulic bolt-tensioning cylinder pretension ed

to 85% of yield strength.

Table 3-7.

Mounting

bolt dimen-

sions

Mounting pretension force

1)

F

M

Strength class 10.9 in

kN lbs

1 – 8 UNC 301 67668

1 1/8 – 7 UNC 379 85203

1 1/4 – 7 UNC 481 108133

1 3/8 – 6 UNC 573 128816

1 1/2 – 6 UNC 697 156692

1 5/8 – 6 UNC 832 187041

1 3/4 – 5 UNC 942 211770

1)

FM for hydraulic bolt-tensioning cylinder pretensioned

to 85% of yield strength.

3. Main load-carrying zone

4. Lower mounting structure

Figure 3-35. Measurement setup

5. Dial gauge

6. Upper mounting structure

7. Slew Drive

8. Lower mounting structure

DETERMINING THE TILTING CLEARANCE

Tilting clearance increases as raceway system wear
increases. To determine the increase in tilting clearance a
basic measurement must be executed in installed status
and prior to first-time operation. This is the only way to
determine changes.

Figure 3-34. Determine tilting clearance

1. Upper mounting structure

2. Tilting direction

Procedure:

Tilting clearance measurement

9. Switch off the system and safeguard it from being
turned on again.

10. Permanently mark the measuring point in the main
load direction on the housing and on the bearing
ring.

11. Attach the dial gauge as shown in Fig. 24.

12. Apply defined tilt torque, at least 50% of max. oper-

ating load, in direction "A".

13. Set dial gauge to zero.

14. Apply defined tilt torque, at least 50% of max. oper-

ating load, in direction "B". The displayed measured
value m1 corresponds to the existing tilting clear­ance and serves as the base value that will be used
for comparison in later inspections.

15. Log and document all measured values.

• All inspections at a later point in time must be executed
on the same measuring point, with the same loads, at
the same relative position of the bearing rings, and in
the same sequence.

• At pure axial or radial load check the tilting clearance
by applying an additional tilting load.

3121623 – JLG Lift – 3-27

SECTION 3 - CHASSIS & TURNTABLE

MAINTENANCE SCHEDULE

Maintenance tasks are described in the sections below
that are required for optimal and trouble-free operation.

If increased wear is detected during regular inspections,
then reduce the required maintenance intervals according
to the actual indications of wear.

If you have questions concerning maintenance tasks and
intervals, please contact our customer service.

Interval Maintenance task To be executed by

weekly Check seal Qualified person

after 250 operating hours Check tighten bolts Qualified person

Check tilting clearance Qualified person

after every additional
500 operating hours or at
least every 6 months

Check tighten bolts

• Reduce the inspection interval if there is heavy wear or
continuous operation.

Check tilting clearance

• Reduce the inspection interval to 200 operating hours if
the detected increase in tilting clearance is approxi­mately 75% of the permissible tilting clearance increase.

• After further increase reduce the interval between inspec­tions to 50 - 100 hours.

Check circumferential backlash

• Reduce the inspection interval to 200 operating hours if
the detected increase in circumferential backlash is
approximately 75% of the permissible circumferential
backlash increase.

• After further increase reduce the interval between inspec­tions to 50 - 100 hours.

Qualified person

Qualified person

Qualified person

Lubrication

General re-lubrication of slew drives:

• After each cleaning

• Before and after longer periods of standstill, e.g. for
cranes and construction machines during the winter
months.

IMPORTANT

THE MAIN CAUSE FOR SLEWING RING FAILURE IS
INADEQUATE LUBRICATION. THE LUBRICATION
INTERVALS ESSENTIALLY DEPEND ON EXISTING
WORKING AND ENVIRONMENTAL CONDITIONS, AS
WELL AS THE VERSION OF THE SLEW DRIVE. PRE­CISE LUBRICATION INTERVALS CAN ONLY BE
DETERMINED BY TESTS UNDER NORMAL OPERAT­ING CONDITIONS.

3-28 – JLG Lift – 3121623

If comparable results are not available, the following table
can be used as a guide value:

Work conditions Lubricating interval To be executed by

Dry and clean workshop hall (rotary
tables, robots, etc.)

Severe conditions on open terrain
(cranes, excavators, etc.)

Aggressive climatic conditions,
(ocean, desert, arctic climate,

extremely polluted environment,
operating hours per week

Extreme conditions (tunnel boring
machines, steel works, wind turbines)

The specified values are valid for the following conditions:

• Operating temperature on the slew drive < 70° C (158°
F).

• Circumferential speed < 0.5 m/s (1.64 ft/sec) for SP
slew drives.

• Output speed < 5 rpm for WD slew drives.

• Low to moderate load.

Approx. every 300 operating hours, at

Approx. every 100 to 200 operating

hours, at least every 4 months

Every 50 operating hours, at least

≥70

Continuous lubrication (through cen-

tral lubrication or grease cups)

SECTION 3 - CHASSIS & TURNTABLE

Specialist

least every 6 months

Specialist

Specialist

every

2 months

Specialist

COMPLY WITH THE INSTRUCTIONS IN THE OPER­ATING MANUAL PROVIDED BY THE MANUFAC­TURER, FOR LUBRICATION OF OPTIONAL
INTERMEDIATE GEAR UNITS, BRAKES, AND
MOTORS.

IF NECESSARY RE-LUBRICATE PERMANENT
BRAKES. FOR THIS ONLY USE THE SPECIAL GREASE
SHELL RETINAX HDX2.

3121623 – JLG Lift – 3-29

SECTION 3 - CHASSIS & TURNTABLE

MAINTENANCE TASKS

INSPECTING THE MOUNTING BOLTS

IMPORTANT

TO COMPENSATE FOR SETTLING, THE BOLTS MUST
BE RETIGHTENED WITH THE PRESCRIBED TIGHT­ENING TORQUE. RETIGHTENING MUST BE EXE­CUTED WITHOUT EXERTING ADDITIONAL
EXTERNAL STRESS ON THE BOLTED UNION.

Figure 3-36. Inspecting the mounting bolts

1. Detached bolt

CHECKING THE TILTING CLEARANCE

Wear in the raceway system results in an increase in tilting
clearance. Consequently it is necessary to check the tilt­ing clearance in accordance with the maintenance inter­vals.

IF THE MAXIMUM PERMISSIBLE TILTING CLEARANCE INCREASE
IS REACHED, THEN THE SYSTEM MUST BE BROUGHT TO A
STANDSTILL AND THE SLEW DRIVE MUST BE REPLACED IMME­DIATELY, AS SAFE OPERATION CAN NO LONGER BE ENSURED.

Checking the tilting clearance increase dk directly on
the slew drive

The measured value m1 determined at installation serves
as the base value ("Determination of tilting clearance").

• Determine the value mx as described in the "Determin­ing the tilting clearance".

• Subtract the base value m1 from the value mx deter­mined in the inspection measurement:

= mx – m1 ≤ dkperm

d

k

d

perm = 0.45 mm

k

d

perm = 0.0177 in

k

Execution only by a specialist.

• Special tools required:

Torque wrench

Hydraulic clamping fixture

• Replace loose and detached bolts or nuts and washers
with new bolts, nuts and washers.

• Use the same bolt size and bolt quality.

IF A HYDRAULIC CLAMPING FIXTURE WAS USED TO
TIGHTEN THE BOLTS, THEN A HYDRAULIC CLAMP­ING FIXTURE MUST ALSO BE USED TO CHECK THE
BOLT PRETENSION. ALWAYS USE THE SAME TIGHT­ENING PROCEDURE AS SPECIFIED FOR INSTALLA­TION OF THE SLEW DRIVE WHEN CHECKING THE
BOLTED UNION.

Checking the tilting clearance increase dk but not
directly on the slew drive

Proportionally convert the tilting clearance increase each
time a measurement is taken (after the installation mea­surement) and compare with d

perm.

k

3-30 – JLG Lift – 3121623

LUBRICATING THE SLEW DRIVE

IMPORTANT

REGULARLY LUBRICATE THE SLEW DRIVES TO
PROLONG THEIR SERVICE LIFE AND ENSURE SAFE
OPERATION.

IMPORTANT

ALWAYS USE THE LUBRICANTS SPECIFIED IN THE
ORDER DRAWING. IF USING OTHER LUBRICANTS
PAY ATTENTION TO THE RELATIVE MIX ABILITY
OF THE SUBSTANCES. THE STANDARD LUBRICANTS
USED ARE "R.TECC NORPLEX LKP2" FROM RHENUS,
OR THE GREASE "OPTIMOL LONGTIME PD0" FROM
CASTROL. IF IN DOUBT, OR IF THERE IS NO SPECIFI­CATION ON THE DRAWING, CONSULT WITH OUR
CUSTOMER SERVICE. USING THE WRONG LUBRI­CANT MAY CAUSE DAMAGE TO THE SLEW DRIVES
AND REDUCE THE SERVICE LIFE. IN THIS CASE, ANY
WARRANTY SHALL BE EXCLUDED. COMPLY WITH
THE INSTRUCTIONS PROVIDED BY THE LUBRICANT
MANUFACTURER!

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-37. Lubricating the slew drive

1. Fresh lubricant

2. Lubricating nipple, bearing ring

3. Lubricating ring housing

If possible use a central lubrication system to lubricate the
raceway system. In this regard ensure that the hoses are
filled with grease at commissioning and that the storage
tanks are regularly topped up with grease.

An automatic re-lubricating system significantly facil­itates re- lubrication for the raceway system and the
toothing. Functional safety as well as wear behavior
are improved.

Comply with the instructions in the operating manual
provided by the respective manufacturer for lubrica­tion of optional intermediate gear units, brakes, and
motors.

If it is evident that moisture has penetrated into the
slew drive, or has been absorbed by the grease, you
must re-lubricate more intensively.

4. In succession, press grease into all lubricating nip­ples while simultaneously turning the slew drive all
the way through, until a continuous collar of grease
forms under at least one seal.

5. Ensure that old lubricant can escape without
obstruction.

Inspecting the seals

IMPORTANT

DAMAGED SEALS MUST BE REPLACED IMMEDI­ATELY. IF THERE IS CORROSION DAMAGE OR FUNC­TIONAL IMPAIRMENT A CONSEQUENCE OF
DAMAGED SEALS NOT BEING REPLACED AT THE
PROPER TIME, ANY WARRANTY SHALL BE
EXCLUDED. PENETRATING MOISTURE MAY
QUICKLY CAUSE CORROSION IN THE BEARING
RING AND IMPAIRS SAFE OPERATION. NOTE THAT
THE FACTORY-INSTALLED SEAL ONLY OFFERS
PROTECTION AGAINST DUST AND SPLASHING
WATER.

If damage is detected on a seal, contact the customer ser­vice organization without delay.

3121623 – JLG Lift – 3-31

SECTION 3 - CHASSIS & TURNTABLE

ENGINE SERIEL NUMBER

3.6 HONDA ENGINE IGX440

SERIAL NUMBER LOCATION

The engine serial number is stamped on the cylinder bar­rel. Refer to this when ordering parts or making technical
inquiries.

3-32 – JLG Lift – 3121623

SECTION 3 - CHASSIS & TURNTABLE

SPECIFICATIONS

DIMENSIONS AND WEIGHT

Model iGX440U

PTO types S Q V

Overall length 407 mm (16.0 in) 433 mm (17.0 in) 450 mm (17.7 in)

Overall width 505 mm (19.9 in)

Overall height 454 mm (17.9 in)

Maximum angle of inclination 20°

Dry weight 39 kg (86 lbs)

Operating weight 45 kg (99 lbs)

ENGINE

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

Recommended maximum operation bhp

Maximum torque

11.2 kW (15.2 PS) / 3,600 min

8.0 kW (10.8 PS) / 3,600 min

29.8 N·m (3.0 kgf·m, 22 lbf·ft)/2,500 min

-1

-1

(rpm)

(rpm)

-1

(rpm)

Compression ratio 8.1 : 1

Minimum fuel consumption 328 g/kW·h (241 g/PS·h, 0.53 lb/PS·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

-1

-1

(rpm)
(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

Fuel tank capacity 6.5 l (1.72 US gal, 1.43 lmp gal)

3121623 – JLG Lift – 3-33

SECTION 3 - CHASSIS & TURNTABLE

WIRING DIAGRAMS

With starter motor and charge coil (20A) type

3-34 – JLG Lift – 3121623

TROUBLESHOOTING

SELF-DIAGNOSIS AS INDICATED BY THE LED

When the battery is disconnected, self-diagnosis with the
LED is not possible.

The LED for a failure flashes periodically, as shown in the
following figure.

Example: in the case of "2 flashes” the sequence of 0.3
sec. on > 0.3 sec. off > 0.3 sec. on > 1.5 sec. off is
repeated as a cycle.

SECTION 3 - CHASSIS & TURNTABLE

3121623 – JLG Lift – 3-35

SECTION 3 - CHASSIS & TURNTABLE

*1: The engine may or may not stop, depending on the
program in the EDCM.

*2: Rewriting of the program is needed. Contact your
Honda engine distributor.

*3: If the faulty engine temperature sensor is detected
while engine is running, the engine does not stop and the
LED does not flash.

After the engine is stopped, the engine does not start until
the faulty engine temperature sensor is solved.

3-36 – JLG Lift – 3121623

a. Engine does not start (starter motor equipped type).

SECTION 3 - CHASSIS & TURNTABLE

3121623 – JLG Lift – 3-37

SECTION 3 - CHASSIS & TURNTABLE

b. Engine does not start with LED flashing

3-38 – JLG Lift – 3121623

SECTION 3 - CHASSIS & TURNTABLE

3121623 – JLG Lift – 3-39

SECTION 3 - CHASSIS & TURNTABLE

c. LED is lit but engine does not start (starter motor
equipped type) / engine does not start (starter motor
equipped type)

3-40 – JLG Lift – 3121623

SECTION 3 - CHASSIS & TURNTABLE

3121623 – JLG Lift – 3-41

SECTION 3 - CHASSIS & TURNTABLE

d. Engine speed does not increase or engine lacks
power

3-42 – JLG Lift – 3121623

SECTION 3 - CHASSIS & TURNTABLE

3121623 – JLG Lift – 3-43

SECTION 3 - CHASSIS & TURNTABLE

e. Fuel system

3-44 – JLG Lift – 3121623

SECTION 3 - CHASSIS & TURNTABLE

3121623 – JLG Lift – 3-45

SECTION 3 - CHASSIS & TURNTABLE

f. Ignition system

3-46 – JLG Lift – 3121623

COILS AND IGNITION SWITCHES CHECK

P. 2 -1 9

SECTION 3 - CHASSIS & TURNTABLE

3121623 – JLG Lift – 3-47

SECTION 3 - CHASSIS & TURNTABLE

3-48 – JLG Lift – 3121623

SPARK TEST

GASOLINE IS HIGHLY FLAMMABLE AND EXPLOSIVE. YOU CAN
BE BURNED OR SERIOUSLY INJURED WHEN HANDLING FUEL.
KEEP HEAT, SPARKS AND FLAME AWAY. HANDLE FUEL ONLY
OUTDOORS. WIPE UP SPILLS IMMEDIATELY.

DO NOT OPERATE THE STARTER MOTOR FOR MORE THAN 5
SECONDS AT ONE TRY. IF STABLE COMPRESSION IS NOT
OBTAINED WITHIN 5 SECONDS, STOP THE STARTER MOTOR AND
WAIT 10-20 SECONDS TO ALLOW THE STARTER MOTOR TO
COOL, AND REPEAT THE OPERATION AGAIN.

1. Loosen the carburetor drain screw to drain the car­buretor througly.

2. Remove the spark plug cap from the spark plug.

3. Remove the spark plug from the cylinder.

4. Crank the engine several times to expel unburnt

gas.

5. Attach the spark plug cap to the spark plug.

6. Ground negative (-) electrode (i. e. threaded part) of

the spark plug against the cylinder side head cover
bolt.

SECTION 3 - CHASSIS & TURNTABLE

With recoil starter type:

Pull the recoil starter to check whether sparks jump
across the electrodes.

With starter motor type:

Turn the combination switch to the "START" position
to check whether sparks jump across the elec­trodes.

3121623 – JLG Lift – 3-49

SECTION 3 - CHASSIS & TURNTABLE

HARNESS ROUTING

3-50 – JLG Lift – 3121623

SECTION 3 - CHASSIS & TURNTABLE

3121623 – JLG Lift – 3-51

SECTION 3 - CHASSIS & TURNTABLE

ENGINE OIL

Oil level check:

1. Place the engine on a level surface.

2. Turn the oil filler cap counterclockwise 90 degrees to

unlock the cap and remove the oil level gauge from
the oil filler neck. Wipe the oil level gauge clean.

3. Insert the oil level gauge without screwing it into the
oil filler neck. Remove the oil filler cap and check the
oil level shown on the oil level gauge.

4. If the oil level is near or below the lower level mark
on the oil level gauge, fill with the recommended oil
to the upper level mark.

Oil is a major factor affecting performance and service life.
Use 4-stroke automotive detergent oil.

SAE 10W-30 is recommended for general use. Other vis­cosities shown in the chart may be used when the aver­age temperature in your area is within the recommended
range.

Insert the oil level gauge into the oil filler neck and turn the
oil filler cap clockwise 90 degrees to lock the cap.

Recommended oil

SAE 10W-30

API Service classification

SE, SF or SG

3-52 – JLG Lift – 3121623

SECTION 3 - CHASSIS & TURNTABLE

Oil change:

5. Check the engine on a level surface and remove the

oil filler cap.

6. Remove the oil drain bolt and sealing washer. and
drain the oil into a suitable container.

Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you
take use oil In a sealed container to your local recy­cling center or service station for reclamation. Do
not throw it in the trash. pour it into the ground, or
down a drain.

USED ENGINE OIL CONTAINS SUBSTANCES THAT HAVE BEEN
IDENTIFIED AS CARCINOGENIC. IF REPEATEDLY LEFT IN CON­TACT WITH THE SKIN FOR PROLONGED PERIODS, IT MAY CAUSE
SKIN CANCER. WASH YOUR HANDS THOROUGHLY WITH SOAP
AND WATER AS SOON AS POSSIBLE AFTER CONTACT WITH
USED ENGINE OIL.

AIR CLEANER

Cleaning:

A dirty air cleaner will restrict air flow to the carburetor,
reducing engine performance. If the engine is operated in
dusty areas, clean the air cleaner more often than speci­fied In the MAINTENANCE SCHEDULE.

1. Remove the air cleaner cover nut and air cleaner
cover.

2. Remove the wing nut, air cleaner elements (paper
element and foam element) and air cleaner elbow
packing, and separate them. Carefully check both
elements for hole, or tear: and replace if damaged.
Check the air cleaner claw packing for deterioration
or damage.

7. Tighten the oil drain bolt and a new sealing washer
to the specified torque.

TORQUE: 45 N·m (4.5 kgf·m, 33 lbf·ft)

8. Refill with the commended oil.

Engine oil capacity 1.10 l (1.16 US qt, 0.97 lmp qt)

9. Check the oil level and, if the oil level is near or
below the lower limit mark on the oil level gauge, fill
with the recommended oil to the upper level mark.

10. Install the oil filler cap.

3. Foam element: Clean the element in warm soapy

water, rinse and allow to dry thoroughly, or clean
with a Nigh flash point solvent and allow to dry thor­oughly. Dip the element in clear engine oil and
squeeze out all the excess oil. Excess oil will restrict

3121623 – JLG Lift – 3-53

SECTION 3 - CHASSIS & TURNTABLE

air flow through the form element and may cause
the engine to smoke at startup.

4. Paper element: Tap the element lightly several times
on a hard surface to remove excess dirt or blow
compressed air lightly 207 kPa (2.1 kgf/cm2, 30 psi)
or less) through the falter from the inside out. Never
try to brush the dirt off; brushing will force dirt into
the fibers.

SPARK PLUG

Inspection/cleaning:

If the engine has been running, the engine will be very hot
Allow it to coo! before proceeding.

1. Remove the spark plug cap and remove the spark
plug using spark plug wrench.

2. Visually inspect the spark plug. Discard the plug if
the insulator is cracked of chipped.

5. Wipe dirt from the inside of the air cleaner elbow and
all cleaner cover, using a rag. Be careful to prevent
dirt frond entering the air duct that leads to the car­buretor.

6. Install the foam element to the paper element. Install
the air cleaner elbow packing and air cleaner ale'
mints, and tighten the wing nut securely.

Install the air cleaned cover and tighten the air
cleaned cover nut securely.

OPERATING THE ENGINE WITHOUT THE AIR CLEANER ELEMENT
OR WILT THE ELEMENT INSTALLED LOOSELY WITH ALLOW DIRT
TO ENTER THE ENGINE, CAUSING RAPID ENGINE WEAR. INSTALL
THE AIR CLEANER ELEMENT SECURELY.

3. Remove carbon and other deposits with a plus
cleaner or stiff wire brush. Check the sealing washer

for damage.

Spark plug BKR7E-E (NGK) K22PR-UR

(DENSO)

4. Measure the plug gag with a wire-type feeler gauge.
If the measurement is outside the specification,

adjust by bending the side electrode.

3-54 – JLG Lift – 3121623

SECTION 3 - CHASSIS & TURNTABLE

Plug gap 0.7 - 0.8 mm (0.028-0.031 in)

5. Install the spark plug fingerings to beat the washer,
and then tighten with a plug wrench. If reinstalling
the used spark plug, tighten 1/8-1/4 turf after the
spark plug seats. If installing a new spark plug,
tighten 1/2 turn after the spark plug seats.

TORQUE: 18 N·m (1.8 Kgf·m, 13 lfb·ft)

SPARK ARRESTER

Cleaning:

THE ENGINE AND MUFFLER BECOME VERY HOT DURING OPERA­TION AND THEY REMAIN HOT FOR A WHILE AFTER OPERATION.
BE SURE THAT THE ENGINE IA COOL BEFORE MUFFLER
REMOVAL/INSTALLATION.

A LOOSE SPARK PLUG OWN INCOME VET HOT AND CAN DALES,
THE ENGINE. OVERTIGHTENING CAN DAMAGE THE THREADS IN
THE CYLINDER BLOCK.

6. Install the spark plug cap securely.

1. Remove the spark arrester from the muffler.

2. Clean the carbon deposits. from the spark arrester

screed with a brush.

3. Check the spark arrester screen for damage. If the
gnarl arrester is damaged, replace it.

4. Rainfall the spark arrester to the muffler.

3121623 – JLG Lift – 3-55

SECTION 3 - CHASSIS & TURNTABLE

VALVE CLEARANCE

Inspection/adjustment:

Valve clearance inspection and adjustment must be per
formed with the engine cold.

1. Remove the cylinder head cover.

2. With recoil starter type:

Set the piston at top dead center of the compression
stroke (both' valves fully closed) by pulling the recti

starter slowly. The ''∆'' mark on the starter pulley wit
align with the projection on the fan cover when the

pastor is at top dead center of the compression
stroke.

Without retool starter type:

sit the piston at top dead center of the compression
stroke (both valves fully closed) by turning the cool­ing fan setting plate. The projection of the cooling
fan will align with the projection on the fan cover
when the piston is at top dead center of the com­pression stroke.

3. Insert a feeler gauge between the rocker arm and
valve to measure valve clearance.

Valve clearance IN 0.12 ±0.02 mm

EX 0.15 ±0.02 mm

3-56 – JLG Lift – 3121623

SECTION 3 - CHASSIS & TURNTABLE

4. If adjustment is necessary proceed is follows:

a. Hold the tappet adjusting screw using the spe-

cial too and loosen the tappet adjusted screw
lock nut.

b. Turn the tappet adjusting screw to obtain the

specifier clearance.

c. Heighten the tappet adjusting screw lock nut

while holding the rocker arm pivot.

TORQUE: 7.5 N·m (0.75 kgf·m, 5.5 lbf·ft)

Recheck valve clearance after tightening the tappet
adjusting screw lock nut.

5. Install the cylinder head cover.

FUEL TANK

Cleaning:

GASOLINE IS HIGHLY FLAMMABLE END EXPLOSIVE. YOU CAN
RETURNED OR SERIOUSLY INJURED WHEN HANDLING FUEL.
KEEP HEAT, SPARKS AND FLORAL AWAY. HANDLE FUEL ONLY
OUTDOORS. WIPE UP SPILLS IMMEDIATELY.

• After connecting the fuel tube. Check for any sign of
fuel leakage.

1. Drain the fuel from the fuel tank into a suitable con­tainer.

Manual fuel vales type:

Drain tie fuel from the carburetor before removing
the fuel tank, proceed as follows:

a. Turn the fuel valve lever to the OFF position.

b. Loosen the drain screw of the carburetor end

drain tie fuel trio a suitable container.

2. Remove the fuel tank, tank stay and auto fuel valve
and disconnect the fuel tube from the auto feel
valve.

3. Disconnect the fuel lube end remove the fuel filter
and oaring from the fuel lank. Wash the fuel filter in
nonflammable or high flash point solvent. Inspect
the fuel filter screen to be sure it is undamaged.

4. Clean the fuel lank with nonflammable or high flash
point solvent and allow to dry thoroughly.

5. Install the fuel filter, O-ring, fuel valve, fuel tube and
fuel tank cap. Connect the fuel tube to the fuel valve
and install the fuel tank.

6. After reassembly check for fuel leaks.

3121623 – JLG Lift – 3-57

SECTION 3 - CHASSIS & TURNTABLE

FUEL TUBE

Inspection:

GASOLINE IS HIGHLY FLAMMABLE AND EXPLOSIVE. YOU CAN
BE BURNED OR SERIOUSLY INJURED WHEN HANDLING FUEL.
KEEP HEATH QUIRK: AND FLAME AWAY. HANDLE FULL ONLY
OUTDOORS. WIPE UP SPILLS IMMEDIATELY.

FUEL STRAINER CUP

Cleaning:

GASOLINE IS HIGHLY FLAMMABLE AND EXPLOSIVE. YOU CAN
BE BURNED OR SERIOUSLY INJURED WHEN HANDLING FUEL.
KEEP HEAT, SPARK AND FLAME AWAY. HANDLE FUEL ONLY
OUTDOORS. WIPE UP SPILLS IMMEDIATELY.

• After installing the fuel strainer cup, check for any sign
of fuel leakage.

• After connecting the fuel tube, check for any sign of
fuel leakage.

Check the fuel line for deterioration, damage or leakage.
Replace the fuel line if necessary.

1. Remove the fuel strainer

2. Remove the fuel cup filter and clean it.

3. Install the fuel cup filter and tighten the fuel strainer

cup to the specified torque.

TORQUE: 3.9 N·m (0.4 kgf·m, 2.9 lbf·ft)

3-58 – JLG Lift – 3121623

AIR CLEANER

REMOVAL/INSTALLATION

MUFFLER

REMOVAL/INSTALLATION

THE ENGINE AND MUFFLER BECOME VERY HOT DURING OPERA­TION AND THEY REMAIN HOT FOR A WHILE AFTER OPERATION.
BE SURE THE ENGINE IS COOL BEFORE MUFFLER REMOVAL/
INSTALLATION.

Remove the air cleaner.

SECTION 3 - CHASSIS & TURNTABLE

3121623 – JLG Lift – 3-59

SECTION 3 - CHASSIS & TURNTABLE

EXHAUST PIPE/MUFFLER PROTECTOR

INSTALLATION:

1. Attach a new muffler basket and exhaust pipe to the

cylinder head.

2. Move the exhaust pipe all the way to the fuel tank
side and tighten the 8 mm flange nuts.

3. Attach a new muffler gasket B and muffler to the
exhaust pipe. Tighten the I x 14 mm CT bolt on the
muller stay.

7. Keep some clearance between the exhaust slot and
the spark arrester, and tighten the other three bolts
securely.

FUEL CUT SOLENOID

Measure the resistance between the terminals.

Specified resistance

3.8 - 5.8 Ω

4. Tighten the 8 mm flange nuts to install the muffler on

the exhaust pipe.

After tightening the flange nuts. be sure the muffler
gasket and exhaust pipe are closely attached
together.

5. Put the muffler protector on the muffler and then
loosely tighten the bolts in the numbered sequence
as shown.

6. Align the center of the muffler' protector exhaust slot
wit) the reenter of. the spark arrester, and tighten the
6 x 14 mm CT bolt under the echoed! slot securely.

When 12V battery voltage is applied, check that the fuel
cut solenoid operates normally.

Check the extended length of the needle at ON (battery
connected) position and OFF (battery removed) position.

3-60 – JLG Lift – 3121623

ECOIL STARTER

THE RETURN SPRING MAY BE EJECTED FROM THE HOLDER
WITH ENOUGH FORCE TO INJURE YOU. BE SURE TO RELEASE
THE TENSION ON THE RETURN SPRING BEFORE DISASSEMBLY.

REMOVAL/INSTALLATION

SECTION 3 - CHASSIS & TURNTABLE

REASSEMBLY

8. Insert the starter rope end into the. starter reel and

tie the rope as shown.

3121623 – JLG Lift – 3-61

SECTION 3 - CHASSIS & TURNTABLE

9. Wind the rope onto the reel counterclockwise and
hook the starter rope into the cutout of the starter
reel.

10. Wind the starter spring and install it to the starter reel
by aligning the outer hook to the groove of the reel.

12. Install the ratchet spring and ratchet as shown.

Apply grease to the friction spring and inside of the
ratchet guide. Install the spring end f friction plate,
and then install the ratchet guide by aligning the "
marks of the ratchet guide with the ratchets. Tighten
the setting screw securely.

13. Turn the reel three full turns counterclockwise to pre­soak the starter spring.

∆"

11. Apply grease to the spring hook and boss of the
starter case. Align the spring inner hook to the case
claw on the case by turning the reel counterclock­wise.

3-62 – JLG Lift – 3121623

SECTION 3 - CHASSIS & TURNTABLE

14. Pass the rope through the starter case hole and
started grip and knot the end of the rope as shown.

15. Check the operation of tile ratchet by pulling the
started rope out several times.

RECTIFIER/REGULATOR RECTIFIER

Measure the resistance between the terminals.

• Use a tester that is equivalent to or higher than the per­formance specified:

Internal resistance: 20 Ω/VDC, 9 Ω/VAC

• Be careful not to touch the metallic part of the tester
probe with your fingers, otherwise correct resistance
value cannot be obtained.

• Read the tester manufacturer's operation instructions
carefully before operating the tester. Follow the instruc­tions of the Service manual. Be sure the tester's battery
is fully charged and check the meter before using the
tester.

• Use the R x 1 scale of a commercially available millime­ter that meter shows current flow from negative (-) to
positive (+). If the meter shows current flow in one
direction but not the other, the diode is goad.

3121623 – JLG Lift – 3-63

SECTION 3 - CHASSIS & TURNTABLE

FUSE

1. Check for. a blown fuse; replace if necessary.

2. If the replaced fuse blows out, check the following.

30A FUSE:

a. Check the combination switch.

b. Check the wire harness connecting the combi-

nation switch and ECM (Bl/Y) for open or short
circuit.

c. Check the rectifier or regulator rectifier.

3A FUSE:

d. Check the combination switch.

e. Check the wire harness connecting the combi-

nation swatch and ECM (BI/Y) for open or short
circuit.

3-64 – JLG Lift – 3121623

QUICK TROUBLESHOOTING

1 2

3

5

4

6

6

ON = OK

FLASH = ERROR

HONDA IGX440

SECTION 3 - CHASSIS & TURNTABLE

3121623 – JLG Lift – 3-65

SECTION 3 - CHASSIS & TURNTABLE

FIRST OPERATION

GASOLINE IS HIGHLY FLAMMABLE AND EXPLOSIVE. YOU CANBE
BURNED OR SERIOUSLY INJURED WHEN HANDLING FUEL. KEEP
HEAT, SPARK AND FLAME AWAY. HANDLE FUEL ONLY OUT­DOORS. WIPE UP SPILLS IMMEDIATELY

Check fueling from fuel tank to carburetor.

Fuel filter replacement

Lose drain screw.

Let fuel drain.

Pull recoil 3 or 4 times.

Check fuel coming from fuel tank.

If fuel is not coming from fuel tank proceed to replace fuel
filter in fuel tank.

3-66 – JLG Lift – 3121623

SECOND OPERATION IF PROBLEM IS ON
ENGINE

Spark checking

SECTION 3 - CHASSIS & TURNTABLE

3121623 – JLG Lift – 3-67

SECTION 3 - CHASSIS & TURNTABLE

Changing the ECU.

3-68 – JLG Lift – 3121623

3.7 HATZ ENGINE

TYPE: HATZ 1B40

SECTION 3 - CHASSIS & TURNTABLE

3121623 – JLG Lift – 3-69

SECTION 3 - CHASSIS & TURNTABLE

2

8910

9

11

12

13

14

15

16

17

18

19

20

21

3

4

6

5

7

1 22

DESCRIPTION OF THE ENGINE

1. Type plate

2. Cylinder head cover

3. Exhaust silencer

4. Exhaust mesh insert

5. Oil pressure switch

6. Starter motor

7. Voltage regulator

8. Crankshaft - power take-off

9. Oil drain plug

10. Speed adjustment lever

11. Oil filter

12. Engine mountings

13. Ignition key

14. LED display

15. Intake opening for cooling and combustion air

16. Oil filler pipe and dipstick

17. Recoil starter

18. Engine shutdown pin

19. Dry-type air cleaner

20. Lifting lug

21. Fuel tank cap

22. Noise insulating hood

3-70 – JLG Lift – 3121623

GENERAL NOTES

Te c h n i c a l d a t a

Typ e 1B40

Design Air-cooled four-stroke diesel engine

Combustion system Direct injection

Number of cylinders 1

Bore / stroke mm 88 / 76

Displacement cm3 462

Lubricating oil capacity without oil sump with oil
sump

Difference between “max” and “min” levels without
oil sump with oil sump

Lubricating oil consumption (after running in) max. 1% of fuel consumption

Lubricating oil pressure (oil temperature 100 °C) approx. 2.5 bars at 3000 r.p.m.

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 Flywheel 25° down 3) all other directions

Weight (incl. fuel tank, air-cleaner, exhaust
silencer, recoil starter and electric starter)

Battery capacity Amp/h max. 12 V / 60 Amp/h

SECTION 3 - CHASSIS & TURNTABLE

l, approx.
l, approx.

l, approx.
l, approx.

mm 0.10

or automatically 2)

35°3)

kg,

approx.

1.5 1)

3.2 1)

0.8 1)

2.2 1)

at full load

55

1)

These values are intended as an approximate guide.

Themax.marking on the dipstick is the deter-mining factor.

2)

Depending on model (see maintenance charts).

3)

Exceeding these limits causes engine breakdown.

Tightening torques

Item Nm

Oil drain plug 50

3121623 – JLG Lift – 3-71

SECTION 3 - CHASSIS & TURNTABLE

MOTORENFABRIK HAT Z KG

D-94099 RUHSTORF

GMBH

CO

+

GMBH

CO

+

TYP

KENNZ.

MOTOR / FABRIK NO.

ABE / AUSF.

MIN NH PVCM

MADE IN GERMANY

-1

3

GMBH

CO

+

TYPE PLATE

The type plate is placed on the noise insulating hood and
includes the following engine information:

1. engine type

2. code (only for special equipment)

3. engine number (also stamped on crankcase)

4. max. engine speed

For any offer as well as spare parts orders it is necessary
to mention these data (also see spare parts list).

Engine serial number on crankcase

3-72 – JLG Lift – 3121623

SECTION 3 - CHASSIS & TURNTABLE

y

-40

-30

-20

-10

0

10

20

30

40

50

10 4

86

68

50

32

14

-4

-22

-40

OIL: SAE...

°C°F

5W/30

5W/40

10W/40

10W/30

15W/40

30

40

122

10 W

max.

OPERATION

ENGINE OIL

Oil quality

Qualified are all trademark oils which fulfil at least one of
the following specifications:

ACEA – B2 / E2 or more significant

API – CD / CE / CF / CF-4 / CG-4or more significant.

If engine oil of a poorer quality is used, reduce oil change
intervals to 150 hours of operation.

Oil viscosity

When adding oil or checking the oil level, the engine must
be horizontal.

Remove oil filler screw and add engine oil.

Lubricating oil capacity: see Chapter Technical data.

Select the viscosity class according to the ambient tem­perature for cold starts.

3121623 – JLG Lift – 3-73

To check the oil level, remove the dipstick, clean it - then
screw it back in and finally remove it again.

Check the oil level on the dipstick and, if necessary, top
up to the max.level.

SECTION 3 - CHASSIS & TURNTABLE

gp

Set speed adjustment lever „1“either to 1/2START or max.
START position, as desired or necessary.

Starting at a lower speed will help to prevent exhaust
smoke.

– Grip the handle with both hands.

Recoil starter (down to –6 °C)

For starting preparations.

Starting procedure

– Pull the starting cable out by the handle until you feel a
slight resistance.

– Let the cable run back; in this way the entire length of
the starting cable can be used to start the engine.

– Devices which are not securely fastened should be
restrained with the foot.

Commence pulling the starting cable vigorously and at an
increasing speed (do not jerk it violently) until the engine
starts.

NOTE: If after several attempts of starting the exhaust begins to

emit white smoke, move the speed adjustment lever to the
STOP position and pull the starting cable out slowly 5
times. Repeat the starting procedure.

Electric starter

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SECTION 3 - CHASSIS & TURNTABLE

– For starting preparations.

– Insert the key to its stop and turn it to position I.

Depending upon the model, the battery charge telltale „2“
and the oil pressure warning light „3“will come on.

The engine temperature display „4“(additionalequipment)
lights up if the temperature at the cylinder head becomes
too high.

Switch off the engine and trace and eliminate the
cause of the problem.

– Turn the key to position II.

– Release the key as soon as the engine runs. The starting
key must spring back to position I and remain there dur-
ing engine operation.

– The battery charge and oil pressure lights should extin­guish directly after the engine starts. The display lamp „1“
lights up to show that the engine is running.

– Prior to starting up again, the key has to be returned to
position 0. When the engine is running the starter repeat
lock in the ignition switch will prevent the starter from
engaging and suffering damage.

(additional equipment)

As soon as the starting key is at Position I, fuel shut-off
valve „1“is electrically released.

The fuel feed to the injection pump is then open and the
engine is ready to start.

When the engine is running, turning the starting key to
position 0 closes the cut-off valve and interrupts the fuel
supply to the injection pump, so that the engine stops.

This shut-off valve is also used for the automatic electrical
shutdown system.

Emergency start

If the shut-off valve is blocking the fuel supply as a result
of an electrical fault and the engine therefore cannot be
started, an emergency start can be attempted.

Proceed as follows for this:

Preheat er system (optional extra)

When starting a cold engine, the preheat indica-tor „5“will
light.

– Start the engine immediately after the light goes out.

Fuel shut-off valve, stop solenoid

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SECTION 3 - CHASSIS & TURNTABLE

– For emergency starting, turn the lever at fuel shut-off
solenoid „1“anti-clockwise by at least 90° using suitable
pliers. The lead seal wire will break off.

– As soon as the emergency start lever is in the starting
position, the electric starter or recoil starter can be used.
The oil level must always be checked before an emer­gency start, as insufficient oil pressure can lead to com­plete damage of the engine within a very short time.

AFTER THIS, THE ENGINE CAN ONLY BE STOPPED WITH THE
STARTING KEY IN THE EMERGENCY OPERATING MODE IF THE
EMERGENCY STARTING LEVER IS FIRST TURNED BACK CLOCK­WISE TO THE STOP POSITION.

Immediately after a period of emergency running, ascer­tain the cause of the fault and have it rectified. Have the
emergency-starting lever sealed once again by a HATZ

service point.

When the automatic electrical shutdown system is used,
the emergency start described above means that liability
for risks must be accepted by the operator (Motorenfab-

rik HATZ assumes no liability).

In case of difficulty contact the nearest HATZ service
point.

Stopping the engine

Speed adjuster, standard version

– Move the speed adjustment lever „1“back to the STOP
position. The engine cuts out.

NOTE: Engines with a fixed lower idling speed cannot be

switched off using the speed adjustment lever. See the
paragraph entitled „Other ways of switching off the
engine“.

Automatic electrical shutdown system

Model with error memory

This is characterized by a brief flashing of all pilot lamps
once the starter key has been turned to position I.

Important!

If the engine cuts out immediately after starting or
switches off by itself during operation, a monitoring ele­ment in the automatic shutdown system has tripped. The
corresponding indicator light will come on. After the
engine has stopped, the display continues to glow for
about 12 seconds. The electrical device then switches
itself off automatically. The display lights up again after the
start key has been turned back to position 0 and then to

position I again.

Trace and eliminate the cause of the operating fault
before trying to restart the engine.

The display light goes out when the engine is next started.

On new or reconditioned engines, after the first 25
operating hours, always:

– Change engine oil.

– Check valve clearances and adjust if necessary.

– Examine screw connections. Do not tighten the cylin-

der head fastening.

If the engine is not used frequently, change the engine

oil after 12 months at the latest, regard-less of the actual
number of hours it has been inn operation.

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