Oshkosh JLG X17JP Service And Maintenance Manual
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Oshkosh JLG X17JP Service And Maintenance Manual

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Service and Maintenance Manual
Models
X17JP - X500AJ
X20JP - X600AJ
X26JP - X770AJ
3121623
June 29, 2018 - Rev E

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Summary of Contents for Oshkosh JLG X17JP

  • Page 1 Service and Maintenance Manual Models X17JP - X500AJ X20JP - X600AJ X26JP - X770AJ 3121623 June 29, 2018 - Rev E...
  • Page 2 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 3: Introduction - Maintenance Safety Precautions

    INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial plat- form. It is of utmost importance that maintenance person- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SEC- nel pay strict attention to these warnings and precautions TION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR to avoid possible injury to themselves or others, or dam-...
  • Page 4 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISON LOG Original Issue A - October 21, 2013 Revised B - November 3, 2016 Revised C - March 29, 2017 Revised D - March 27, 2018 Revised E - June 29, 2018 - Revised Covers –...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS........A GENERAL.
  • Page 6 TABLE OF CONTENTS Changing Hydraulic Oil ............. . . 2-4 Lubrication Specifications .
  • Page 7 TABLE OF CONTENTS PERKINS ENGINE................3-30 Model: 402D .
  • Page 8 TABLE OF CONTENTS SECTION 5 - HYDRAULICS MAIN COMPONENTS IDENTIFICATION AND LOCATION ........5-1 X17JP-X500AJ and X20JP-X600AJ .
  • Page 9 TABLE OF CONTENTS Automatic Reductions Drive Speed (X17JP-X500AJ and X26JP-X770AJ Only) ..5-43 Control Valve Turntable Functions........... 5-43 5.13 OUTRIGGERS AUTO-RETRACTION .
  • Page 10 TABLE OF CONTENTS SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS GENERAL................. . 7-1 MULTIMETER BASICS .

  • Page 11: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS CAPACITIES Table 1-1. Drive Hub Capacities Machine Type Drive Hub Drive Capacities BONFIGLIOLI AUTO X17JP / X500AJ 0.10 gal (0,4 L) 700C2K I:32 + MAG12 VP 2 SPEED BONFIGLIOLI AUTO X20JP / X600AJ 0,09 gal (0,35 L) 700-2 C2K+ MAG16VP 2 SPEED...

  • Page 12: Track Specifications

    SECTION 1 - SPECIFICATIONS TRACK SPECIFICATIONS Table 1-3. Track Specifications RUBBER BELT TRACK MACHINE PART MODEL TYPE DIMENSIONS DRAWING NUMBER PROFILE 053715L0 BLACK COLOR X17JP X500AJ 180 X 37 X 72 PROFILE 053715LB NON-MARK- PROFILE 257215L0 BLACK COLOR X20JP X600AJ 200 X 48 X 66 PROFILE 257215LB...

  • Page 13: Power Source

    SECTION 1 - SPECIFICATIONS Table 1-4. Ground Bearing Pressure PRESSURES AND REACTIONS TO THE GROUND ON TRACKS ON OUTRIGGER Maximum MODEL *Ground Bearing Pressure Maximum Ground Bearing Pressure [daN/cm²] - [PSI] Ground Bearing Pressure On Each Pad * Average values on hard surface [daN/cm²] - [PSI] [daN] - [lbf] X17JP-X500AJ...

  • Page 14: Honda Engine Igx390 Specifications

    SECTION 1 - SPECIFICATIONS Honda Engine iGX390 Specifications Table 1-6. Specifications Honda Engine iGX390 Model iGX390 Air cooled 4-stroke OHV petrol engine, Engine type 25° inclined cylinder, horizontal shaft, cast iron sleeve Bore x stroke 88 x 64 mm Displacement 389 cm3 Compression ratio 8.2 : 1...

  • Page 15: Hatz Engine 1B40 Specifications

    SECTION 1 - SPECIFICATIONS Specifications Honda Engine iGX440 Table 1-7. Model iGX440U Air cleaner Dual element type Governor STR (Self Tuning Regulator) governor Fuel used Unleaded gasoline with a pump octane rating 86 or higher Hatz Engine 1B40 Specifications Specifications Hatz Engine 1B40 Table 1-8.

  • Page 16: Kubota Engine D902-E3B Specifications

    SECTION 1 - SPECIFICATIONS Kubota Engine D902-E3B Specifications Table 1-10. Specifications Kubota Engine D902-E3B Model D902-E3B Emission Regulation Tier 4 Vertical 4-cycle Liquid Type Cooled Diesel Number of Cylinders Bore mm (in) 72 (2,83) Stroke mm (in) 73,6 (2,9) Displacement L (cu.in) 0,898 (54,80) Compustion System...

  • Page 17: Specifications And Performance Data

    SECTION 1 - SPECIFICATIONS SPECIFICATIONS AND PERFORMANCE DATA Reach Specifications Table 1-11. Machine Reach Specifications X17JP X500AJ X20JP X600AJ X26JP X770AJ ANSI ANSI ANSI 17.06 m 20,15 m 25,70 m Working Height Platform Height 14,96 m 49,08 ft 18,05 m 59,21 ft 23,60 m 77,42 ft...

  • Page 18: Function Speed Data

    SECTION 1 - SPECIFICATIONS Function Speed Data Table 1-13. Function Speed FUNCTIONS SPEED RANGE MACHINE MODEL X17JP / X500AJ X20JP / X600AJ X26JP / X770AJ POWER SYSTEM Engine Lithium Engine Lithium Engine Lithium FUNCTION TIME Sec TIME Sec TIME Sec TELESCOPE EXTEND 15"...

  • Page 19: Hydraulic Pressure Settings - Psi (Bar)

    SECTION 1 - SPECIFICATIONS HYDRAULIC PRESSURE SETTINGS - PSI (BAR) Table 1-15. Reduction Drive Speed Pressure Settings Table 1-14. Pressure Settings UNDERCARRIAGE AUTOMATIC REDUCTIONS DRIVE SPEED TOWER Left and Right MODEL Control Valve MODEL Control Valve X17JP - X500AJ X17JP - X500AJ 2393 2045 X20JP - X600AJ...

  • Page 20: Lubrication

    SECTION 1 - SPECIFICATIONS LUBRICATION Hydraulic Oil HYDRAULIC EP EXTRA BIODEGRADABLE ISO 68 V.I.180 HYDRAULIC / SHELL EP EXTRA Geolube ECO TELLUS S3V ISO 46 V.I.160 Hydraulic 68 V.I.180 / SHELL HYDRAULIC ISO46 -5°C/+50°C TELLUS S3V EP EXTRA (P/N 7527700) 46 V.I.160 ISO 32 V.I.160 HYDRAULIC...

  • Page 21: Serial Number Location

    SECTION 1 - SPECIFICATIONS SERIAL NUMBER LOCATION A serial number plate is affixed on to the frame a frame. The following illustration showing the position. Figure 1-3. X26JP / X770AJ Serial Number Plate Location (on side of chassis rear compartment cover) Figure 1-2.

  • Page 22: Fastener Torque Charts

    SECTION 1 - SPECIFICATIONS FASTENER TORQUE CHARTS Figure 1-5. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) 1-12 – JLG Lift – 3121623...
  • Page 23 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) 3121623 – JLG Lift – 1-13...
  • Page 24 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) 1-14 – JLG Lift – 3121623...
  • Page 25 SECTION 1 - SPECIFICATIONS Figure 1-8. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 3121623 – JLG Lift – 1-15...
  • Page 26 SECTION 1 - SPECIFICATIONS Figure 1-9. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) 1-16 – JLG Lift – 3121623...
  • Page 27 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 28: General

    SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance MAINTENANCE Schedule for items requiring inspection during the per- formance of these inspections. Reference the appropri- General ate areas of this manual for servicing and maintenance procedures.

  • Page 29: 2.2 Service And Guidelines

    SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance PRIMARY SERVICE TYPE FREQUENCY REFERENCE RESPONSIBILITY QUALIFICATION Pre-Start Prior to use each day; or User or Operator User or Operator Operator and Safety Manual Inspection At each Operator change. Service and Maintenance Man- Pre-Delivery Inspec- Prior to each sale, lease, or Qualified JLG...

  • Page 30: Bearings

    SECTION 2 - GENERAL Bearings Lubrication 1. When a bearing is removed, cover it to keep out Service applicable components with the amount, type, dirt and abrasives. Clean bearings in nonflammable and grade of lubricant recommended in this manual, at cleaning solvent and allow to drip dry.

  • Page 31: Hydraulic Oil

    SECTION 2 - GENERAL Hydraulic Oil 2.4 CYLINDER DRIFT TEST Refer to Section 1 for recommendations for viscosity Maximum acceptable cylinder drift is to be measured ranges. using the following methods. Changing Hydraulic Oil Cylinder Drift 1. Filter elements must be changed after the first 50 hours of operation and every 300 hours (unless Table 2-2.

  • Page 32: Pins And Composite Bearing Repair Guidelines

    SECTION 2 - GENERAL 2.5 PINS AND COMPOSITE BEARING REPAIR 2.6 WELDING ON JLG EQUIPMENT GUIDELINES NOTE: This instruction applies to repairs, or modifications to the machine and to welding performed from the Filament wound bearings. machine on an external structure, or component, 1.
  • Page 33 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 34: Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE RUBBER TRACK MAINTENANCE 4. When correct track tension has been obtained, turn valve (1) in a clockwise direction and tighten it. Clean all traces of grease. Checking Track Tension Stop the machine on firm, level surface.

  • Page 35: Checking The Rubber Tracks

    SECTION 3 - CHASSIS & TURNTABLE Checking The Rubber Tracks PATTERN WORN PARTS Figure 3-4. SPROCKET 3. Separation of the metal cores STEEL WIRE HOLE a. The metal core acts as a type of adhesive of WHEEL SIDE the rubber between the core itself and the METAL CORE steel ropes.

  • Page 36: Replacing The Rubber Tracks

    SECTION 3 - CHASSIS & TURNTABLE e. The damage indicated in paragraphs a, b, 3. To loosen the track, slowly unscrew valve 1 in an and c above, must not be considered fatal anti-clockwise direction for no more than one for the track and, even if in presence of grad- turn.

  • Page 37: Checking Tightness Of Nuts And Bolts

    SECTION 3 - CHASSIS & TURNTABLE UNDERCARRIGE COMPONENTS a. Fully extend the undercarriage. b. Remove the tracks (see sub-section 3.1). c. Remove the key ignition, and a tag with warning do not start the machine. Figure 3-8. Checking tightness of nuts and bolts Figure 3-9.

  • Page 38: Replacement Sprocket And Gear Motor

    SECTION 3 - CHASSIS & TURNTABLE Replacement sprocket and Gear Motor Gear motor installation 1. Fix the screws 11. 2. Instal the valve 10. 3. Connect the Hydraulic hoses 4. Instal the cover 9. Figure 3-11. Sprocket remove 1. Fully extend the undercarriage. Figure 3-12.

  • Page 39: Axle Extension Removal

    SECTION 3 - CHASSIS & TURNTABLE AXLE EXTENSION REMOVAL 8. Using a suitable lifting device (minimum 441 lb. (200kg) capacity) to remove the track frame. Figure 3-16. 9. Remove screw and nut 3 and 6. Figure 3-13. 10. Remove the pin 4. 1.

  • Page 40: Final Drive

    SECTION 3 - CHASSIS & TURNTABLE Information FINAL DRIVE For all enquiries regarding general information on the Table 3-2. Final Drive Models product, spare parts, assistance etc, always give the identi- fication data stamped on the ID plate. MACHINE TYPE SPEED The gearmotor has two ID plates, one gives data on the X17JP - X500AJ...

  • Page 41: Swing Drive (Imo)

    SECTION 3 - CHASSIS & TURNTABLE SWING DRIVE (IMO) Structure and function Brief description Technical Data – Type Plate 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 enclos- ing housing.

  • Page 42: Transporting Unpacked Slew Drives

    SECTION 3 - CHASSIS & TURNTABLE Transporting Unpacked Slew Drives Attachment: 1. Screw the 3 eye bolts into the 3 threads that are distributed uniformly on the circumference of the slew drive. SCREW IN THE EYE BOLTS TO THE FULL THREAD LENGTH! IMPROP- ERLY ATTACHED, UNSUITABLE, OR DAMAGED EYE BOLTS MAY CAUSE THE SLEW DRIVE TO FALL AND CAUSE LIFE-THREATENING INJURIES.

  • Page 43: Bolting The Slew Drive

    SECTION 3 - CHASSIS & TURNTABLE Bolting The Slew Drive Table 3-3. MOUNTING PRETENSION FORCE MOUNTING BOLT DO NOT USE IMPACT SCREWDRIVERS. USING AN IMPACT SCREW- DIMENSIONS DRIVER MAY CAUSE IMPERMISSIBLE DEVIATIONS BETWEEN THE BOLT STRENGTH CLASS 10.9 in TIGHTENING FORCES. FAILURE OF THE BOLTED UNION WITH THE MOUNTING STRUCTURE MAY CAUSE SEVERE PERSONAL INJURY OR MATERIAL DAMAGE.

  • Page 44: Maintenance Schedule

    SECTION 3 - CHASSIS & TURNTABLE Maintenance Schedule If increased wear is detected during regular inspections, then reduce the required maintenance intervals according Maintenance tasks are described in the sections below to the actual indications of wear. that are required for optimal and trouble-free operation. If you have questions concerning maintenance tasks and intervals, please contact our customer service.

  • Page 45: Maintenance Tasks

    SECTION 3 - CHASSIS & TURNTABLE Maintenance Tasks 1. Detached bolt Inspecting The Mounting Bolts NOTICE Execution only by a specialist. TO COMPENSATE FOR SETTLING, THE BOLTS MUST BE RETIGHTENED • Special tools required: WITH THE PRESCRIBED TIGHTENING TORQUE. RETIGHTENING MUST Torque wrench BE EXECUTED WITHOUT EXERTING ADDITIONAL EXTERNAL STRESS ON THE BOLTED UNION.

  • Page 46: Lubricating The Slew Drive

    SECTION 3 - CHASSIS & TURNTABLE Lubricating The Slew Drive NOTICE REGULARLY LUBRICATE THE SLEW DRIVES TO PROLONG THEIR SER- VICE LIFE AND ENSURE SAFE OPERATION. NOTICE ALWAYS USE THE LUBRICANTS SPECIFIED IN THE ORDER DRAWING. IF USING OTHER LUBRICANTS PAY ATTENTION TO THE RELATIVE MIX ABILITY OF THE SUBSTANCES.

  • Page 47: Honda Engine Igx440

    SECTION 3 - CHASSIS & TURNTABLE HONDA ENGINE IGX440 Serial Number Location The engine serial number is stamped on the cylinder NOTE: Refer to the supplier Engine applicable Honda Ser- barrel. Refer to this when ordering parts or making tech- vice Manual.

  • Page 48: Specifications

    SECTION 3 - CHASSIS & TURNTABLE Specifications Dimensions And Weight MODEL iGX440U PTO types 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°...

  • Page 49: Wiring Diagrams

    SECTION 3 - CHASSIS & TURNTABLE Wiring Diagrams With starter motor and charge coil (20A) type 3-16 – JLG Lift – 3121623...

  • Page 50: Engines & Controls Adjustments And Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Engines & Controls Adjustments And Troubleshooting • LED OFF Battery or key switch malfunction Experience of engine doesn’t start or not run correctly, fol- Fuse 3A or 30A blown lowing this procedure to recognize an engine trouble, or a Wires harness failure machine control system problem.

  • Page 51: Engine Harness By-Pass

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-30. Location of the Engine oil level sensor For additional instruction refer to the Engine Service Man- Figure 3-32. ual for a complete troubleshooting. Disconnect the white plugs of the engine harness from the machine harness.

  • Page 52: Fuel System Check

    SECTION 3 - CHASSIS & TURNTABLE Fuel System Check Follow these Instructions to check the fuel flow into the carburetor float bowl. Figure 3-35. On engines with the key switch, it should be possible to try and start also by the key switch. Figure 3-37.

  • Page 53: Fuel Tank Inspection

    SECTION 3 - CHASSIS & TURNTABLE Fuel Tank Inspection Unscrew the two lock nuts and remove the bottom plate Replace the fuel filter if not dirt free. Figure 3-41. Disconnect the hose Figure 3-39. Unscrew the four bolts and lift the tank Figure 3-42.

  • Page 54: Spark Test

    SECTION 3 - CHASSIS & TURNTABLE Spark Test Use these Instructions to check the condition of the spark plug and if spark occurs. Figure 3-45. Connect the wire plug to the spark plug. Keeping the spark plug against the engine, pull the man- ual rope recoil starter to see if a spark occurs.

  • Page 55: Replacement Of Engine Ecu

    SECTION 3 - CHASSIS & TURNTABLE Replacement Of Engine ECU The engine ECU has specific software for the machine arrangement. Install or replace ECM programmed only, orderable on JLG spare part system, otherwise contact Honda servicers. Figure 3-48. Gently take out the ECM and disconnect the two plugs harness.

  • Page 56: Hatz Engine

    SECTION 3 - CHASSIS & TURNTABLE HATZ ENGINE Model: HATZ 1B40 3121623 – JLG Lift – 3-23...

  • Page 57: Description Of The Engine

    SECTION 3 - CHASSIS & TURNTABLE Description Of The Engine 1. Type plate 12. Engine mountings 2. Cylinder head cover 13. Ignition key 3. Exhaust silencer 14. LED display 4. Exhaust mesh insert 15. Intake opening for cooling and combustion air 5.

  • Page 58: Technical Data

    SECTION 3 - CHASSIS & TURNTABLE Technical data Type 1B40 Design Air-cooled four-stroke diesel engine Combustion system Direct injection Number of cylinders Bore / stroke 88 / 76 Displacement Lubricating oil capacity without oil sump with oil sump l, approx. l, approx.

  • Page 59: Engine Type Plate

    SECTION 3 - CHASSIS & TURNTABLE Engine Type Plate MOTORENFABRIK HATZ GMBH GMBH D-94099 RUHSTORF KENNZ. MOTOR / FABRIK NO. ABE /AUSF. MADE IN GERMANY Engine serial number on crankcase The type plate is placed on the noise insulating hood and includes the following engine information: 1.

  • Page 60: Operation

    SECTION 3 - CHASSIS & TURNTABLE Operation When adding oil or checking the oil level, the engine must be horizontal. 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 –...

  • Page 61: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting These instructions are valid for engines with the key start switch only. Figure 3-53. On engine harness plug connector make a bridge between PIN 1 and PIN 2. Figure 3-51. Identify behind the engine the harness plug that connect- ing the engine and the machine system.
  • Page 62 SECTION 3 - CHASSIS & TURNTABLE Those instructions are valid for engines with no key switch. Figure 3-57. Figure 3-55. LED’s On when Pin 12 feed with 12 Volt. On engine right side access to the harness, and disconnect To turn off the engine remove the supply voltage to Pin the engine harness plug.

  • Page 63: Perkins Engine

    SECTION 3 - CHASSIS & TURNTABLE PERKINS ENGINE Engine Identification Perkins engines are identified by a serial number. This Model: 402D number is shown on a serial number plate that is mounted above the fuel injection pump on the right hand side of the engine block.

  • Page 64: Fuel Filter Base - Remove And Install

    SECTION 3 - CHASSIS & TURNTABLE Fuel Filter Base - Remove and Install 4. Remove bolt (1) and remove fuel filter base (2) from the mounting bracket. Removal Procedure Installation Procedure NOTICE NOTICE DO NOT ALLOW DIRT TO ENTER THE FUEL SYSTEM. THOROUGHLY KEEP ALL PARTS CLEAN FROM CONTAMINANTS.

  • Page 65: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting These Instructions are valid for machines with the engine the key switch. Figure 3-60. On grey connector make a wire to connect the pin 1 to the positive terminal of the battery and another at pin 2 to ground or battery.
  • Page 66 SECTION 3 - CHASSIS & TURNTABLE These Instructions are valid for machines with no engine key switch. Figure 3-65. On Female connector jump the follows wires: • Pin12 (12 Volt supply) battery positive terminal. Figure 3-63. • Pin 7 (Glow plugs) hook up if necessary for few second only.

  • Page 67: Kubota Diesel Engine Model D902

    SECTION 3 - CHASSIS & TURNTABLE KUBOTA DIESEL ENGINE MODEL D902 Type Vertical 4-Cycle Liquid Cooled Diesel Combustion System Intake System Naturally Aspirated Diesel fuel intake system Electric Pump Number of cylinders Power 16,1 Kw (21,6 Hp) / 3200 rpm Max rpm 3200 rpm Direction of rotation...

  • Page 68: Engine Plate

    SECTION 3 - CHASSIS & TURNTABLE Engine Plate The engine plate with serial number is placed on the engine head close to muffler collector and includes the following engine information: 1. Engine model 2. Engine serial number 3. Engine code No The information shown above is necessary for any engine spare parts or information required.
  • Page 69 SECTION 3 - CHASSIS & TURNTABLE The fuel system of the diesel engine is fed by an electric fuel pump mounted beside the fuel tank as indicated by picture below. 3-36 – JLG Lift – 3121623...

  • Page 70: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Those Instructions valid for all machines serial number Figure 3-68. Female Connector On Female connector jump the follows wires: • Pin 16 (Ground) to battery negative terminal. Figure 3-66. • Pin 10 (fuel pump) to battery positive terminal. On engine left side remove the engine hood and cut the strap to access to the harness, plug.

  • Page 71: Engine Speed Sensor

    SECTION 3 - CHASSIS & TURNTABLE Engine Speed Sensor A sensor in the diesel engine detects the engine rpm’s and communicates this data to the master controller. Figure 3-71. Speed Sensor on Kubota D902 Figure 3-69. Speed Sensor Installation and Adjustment Speed Sensor Hatz 1B40 Figure 3-72.

  • Page 72: Diesel Engine Rpm Control

    SECTION 3 - CHASSIS & TURNTABLE Diesel Engine RPM control On Diesel powered units a throttle actuator controls the fuel to manage the engine speed based on operating con- ditions. Figure 3-75. Speed Sensor Hatz 1B40 All Diesel Actuator Rod Travel Adjustment Figure 3-73.

  • Page 73: 3.10 Thermic Engine Replacement

    SECTION 3 - CHASSIS & TURNTABLE 3.10 THERMIC ENGINE REPLACEMENT 1. Place and stabilize the machine on a flat and level surface. 2. Turn machine OFF and remove the key ignition, and a tag with warning do not start the machine. 3.

  • Page 74: 3.11 Electric Motor Replacement

    SECTION 3 - CHASSIS & TURNTABLE 3.11 ELECTRIC MOTOR REPLACEMENT 4. Open the cover of the electrical box (7), label and disconnect the wires attached to the electrical 1. Place and stabilize the machine on a flat and motor and isolate the wires end level surface;...
  • Page 75 SECTION 3 - CHASSIS & TURNTABLE Figure 3-83. 12. Energize the system and start the electrical motor 13. Check from the fan side, if the electrical motor run in correct CW direction, otherwise swap the wires connected as shown on (Figure 3-84.). Figure 3-84.
  • Page 76 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 77: Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM BOOM MAINTENANCE f. Remove hardware securing the lower boom pivot pin. Using a suitable brass drift and hammer, remove pin from the turntable. NOTICE g. Using all applicable safety precautions, care- IF PERFORMING MAINTENANCE ON THE BOOM, DO NOT USE A LIFTING fully lift boom assembly clear of turntable DEVICE TO LIFT THE BOOMS UNLESS THE HOLDING VALVES HAVE BEEN...
  • Page 78 SECTION 4 - BOOM & PLATFORM Figure 4-1. Position pins X17JP - X500AJ Figure 4-2. Position pins X20JP - X600AJ – JLG Lift – 3121623...

  • Page 79: Inspection

    SECTION 4 - BOOM & PLATFORM Inspection NOTICE WHEN INSERTING THE TELESCOPE CYLINDER INTO THE BOOM, CARE 1. Inspect all boom pivot pins for wear, scoring or other damage, and for tapering or ovality. MUST BE TAKEN NOT TO DAMAGE THE POWER TRACK ASSEMBLY. Replace pins as necessary.

  • Page 80: Installation Of The Boom Assembly

    SECTION 4 - BOOM & PLATFORM 15. Turn the wear pad to expose the groove on the 2. Install boom pivot pin, ensuring that location of head to insert the cotter. the hole in pivot pin aligns with attach point on upright.

  • Page 81: Boom Disassembly X20Jp - X600Aj

    SECTION 4 - BOOM & PLATFORM BOOM DISASSEMBLY X20JP - X600AJ NOTE: The following procedure assumes the boom is removed from the machine. 1. Extend the boom approximately 2 feet (0.6 m). This will enable access to the bolts that secure the cable mount block to the boom fly section.
  • Page 82 SECTION 4 - BOOM & PLATFORM 1. Using overhead cranes or other suitable lifting/ porting devices will have to be repositioned to supporting devices, carefully pull the telescope support the weight of the cylinder as it is drawn cylinder out from the back of the boom. At the out of the boom.
  • Page 83 SECTION 4 - BOOM & PLATFORM Figure 4-9. 1. Base Boom 8. ExTend Cable 2. Mid Boom 9. Retract Cable 3. Fly Boom 10. Extend Cable Adjustment 4. Telescope Cylinder 11. Retract Cable Adjustment 5. Extend Sheave 12. Proximity Switch 6.

  • Page 84: Inspection

    SECTION 4 - BOOM & PLATFORM pads from the top, sides and bottom of the base INSPECTION boom section. 10. Using an overhead crane or suitable lifting Checking Wear And Deformation Of Ropes And device, remove mid and fly boom sections from Pulleys base section.

  • Page 85: Assembly

    SECTION 4 - BOOM & PLATFORM Assembly pins and secure them with mounting hardware. Position retract wire ropes onto the sheaves. NOTE: When installing fly section wear pads, install same 9. Install sheave guards to rear end of mid boom number and thickness of shims as were removed section and secure with mounting hardware.

  • Page 86: Installation To Machine

    SECTION 4 - BOOM & PLATFORM 19. Apply Loctite #242 to the bolts and fasten the telescope cylinder rod to the boom base section with the bolts, shims, mounting blocks. Figure 4-18. 22. Connect all the hydraulic lines to the cylinder as tagged during the removal procedure.

  • Page 87: Three Month Inspection

    SECTION 4 - BOOM & PLATFORM Three month inspection WIRE ROPE TENSION ADJUSTMENT PROCEDURE 1. Remove all protection sumps from the third arm NOTE: Do not clamp on threads. and the two extensions. Use a flashlight torch to visually check the state of the ropes and the extension pulleys.
  • Page 88 SECTION 4 - BOOM & PLATFORM keep the ropes blocked to prevent them turning with the nuts. Make use of the relevant seat for the wrench on the cable socket. Figure 4-23. 6. Activate the movement of the extendible arms several times and check that the residual loads on the ropes are 10Nm.

  • Page 89: Rotary Actuator

    SECTION 4 - BOOM & PLATFORM ROTARY ACTUATOR Technical Data ARP Series a. Rotary actuator model. b. Construction year. c. Serial number. Please refer to this number in order to obtain every further details from our technical department. d. Max working pressure. Actuator Model Technical Data RP.17/L25H1D2VPH...
  • Page 90 SECTION 4 - BOOM & PLATFORM Figure 4-24. 4-14 – JLG Lift – 3121623...
  • Page 91 SECTION 4 - BOOM & PLATFORM H.987/124DC01/C – H.987/124DC07/C POS. DEFINITION SPECIAL INTERNAL PRODUCTION MOVECO TOOTHED SHAFT D85/D40X187,5 THROUGH HOLE WELDED BODY CYLINDER ASSEMBLY X ...DC01/C WELDED BODY CYLINDER ASSEMBLY X ...DC07/C BUSHING D28XD20X40 X H.987/124DC01/C BOX SUPPORT HEX.HEAD SCREW M6X20 FLAT WASHER D6XD18X2 SELF LOCKING NUT M6 REAR FLANGE D84,4X35,5-124°...

  • Page 92: Disassembly

    SECTION 4 - BOOM & PLATFORM Disassembly CAUTION THE SEALS MUST BE REMOVED USING APPOSITE TOOLS, SEALING SUR- FACES MUST NOT BE DAMAGED. 1. After disassembly all parts must be cleaned and degreased. 2. Clean all parts with compressed air. 3.
  • Page 93 SECTION 4 - BOOM & PLATFORM 13. Now carefully remove shaft A,bearing 5 and thrust ring 4. 14. Make a reference between actuator body C and gear ring G (on side A), so as to reposition it properly during assembly. 16.

  • Page 94: Assembly

    SECTION 4 - BOOM & PLATFORM NOTE: During this operation pay attention to the sealing Assembly elements between the shaft A and piston P. 1. Fix the actuator in a proper way to the bench 8. Place bearing 5 and thrust ring 4 (4+5+4) on side 2.

  • Page 95: Installing Counterbalance Valve

    SECTION 4 - BOOM & PLATFORM Installing Counterbalance Valve 3. The bolts that come with the valve are grade 8 bolts. New bolts should be installed with a new Refer to Figure 4-25., Rotator Counterbalance Valve. valve. Loctite #242 should be applied to the shank of the three bolts at the time of installa- 1.

  • Page 96: Boom Rotation Sensor Assembly - X23Jp - X700Aj

    SECTION 4 - BOOM & PLATFORM BOOM ROTATION SENSOR ASSEMBLY - X23JP - X700AJ 1. Assemble the end couplings (p/n-26741500) using the hex galvanized screws (p/n-BV013000) to the extension pipe (p/n-06745900). Figure 4-28. 4. Route the rotation sensor electrical cable inside the frame as shown below.
  • Page 97 SECTION 4 - BOOM & PLATFORM 9. Make the difference between this distance and the rotation marker size (15mm), then add at least 0.02 in. (0,5mm) to have an interference fit (but not more than 0.06 in. (1,5mm). Adjust to the right measure shifting the two couplings on the pipe to achieve 0.63 in.

  • Page 98: Proximity Sensor Adjustment (X17Jp-X500Aj - X20Jp-X600Aj)

    SECTION 4 - BOOM & PLATFORM PROXIMITY SENSOR ADJUSTMENT (X17JP- X500AJ – X20JP-X600AJ) in order to obtain a gap of 2 Adjust the proximity sensor mm between the sensor and the undercarriage ring plate. Figure 4-36. 4-22 – JLG Lift – 3121623...

  • Page 99: Platform Removal/Installation

    SECTION 4 - BOOM & PLATFORM PLATFORM REMOVAL/INSTALLATION Platform Installation NOTE: If the platform is removed only track movement is 1. LIft the platform and align the platform mounts allowed. with the jib mounting posts and lower until seated. 1. Remove the platform/remote control box from 2.

  • Page 100: Load Cell And Footswitch Removal/Installation

    SECTION 4 - BOOM & PLATFORM LOAD CELL AND FOOTSWITCH REMOVAL/ Removing Footswitch INSTALLATION 1. Turn the machine off and unplugged from the power supply. Removing Load Cell 2. Remove the basket of the machine. (See paragraph basket removal). 1. Turn the machine off and unplugged from the 3.

  • Page 101: Procedure

    SECTION 4 - BOOM & PLATFORM 4.10 SKYGUARD INSTALLATION - ONE PERSON Options/Accessories Prohibited When Installing This Kit: PLATFORM • None The purpose of this instruction is to install a SkyGuard sys- Tools & Equipment Required: tem on JLG Compact Crawler Boom (platform capacity of •...

  • Page 102: Installation

    SECTION 4 - BOOM & PLATFORM For Reference: Installation: 1. Install the SkyGuard Support Bracket (8) onto the welded mounts on platform rails. Secure the SkyGuard Switch support bracket using four Bolts (2), relevant Assembly Washers (7) and Nuts (3). See Figure 4-41. SkyGuard Bracket Figure 4-40.
  • Page 103 SECTION 4 - BOOM & PLATFORM 9. Route the SkyGuard switch harness along Sky- 5. Insert a Shear Block Support (10) through shear block housing on the SkyGuard support bracket Guard support bracket (right side) and under the and into the platform sensor mount. See Figure 4- platform control box.
  • Page 104 SECTION 4 - BOOM & PLATFORM 11. Open load cell board (ECM3) box, locate connec- 15. POWER ON the machine. tors X604 and X603, then disconnect them. See • Press button 6 (service) on the remote control Figure 4-46. • Press button 7 (set up) •...

  • Page 105: Skyguard Anti-Trapping System

    SECTION 4 - BOOM & PLATFORM NOTE: If further information is required, please contact the JLG Service Department. Skyguard Anti-Trapping System When the SkyGuard sensor is activated, functions that were in use at the time of actuation will reverse or cutout. The table below outlines these functions.
  • Page 106 SECTION 4 - BOOM & PLATFORM 4-30 – JLG Lift – 3121623...

  • Page 107: Skyguard Installation - 2 Person Platform

    SECTION 4 - BOOM & PLATFORM 4.11 SKYGUARD INSTALLATION - 2 PERSON Options/Accessories Prohibited When Installing This Kit: PLATFORM • None The purpose of this instruction is to install a SkyGuard sys- Tools & Equipment Required: tem on JLG Compact Crawler Boom (capacity of two per- •...

  • Page 108: Installation

    SECTION 4 - BOOM & PLATFORM For Reference: Installation: 1. Install the SkyGuard Support Bracket (8) onto the welded mounts on platform rails, secure the SkyGuard Switch support bracket using four Bolts (2), relevant Assembly Washers (7) and Nuts (3). See Figure 4-54. SkyGuard Bracket Figure 4-53.
  • Page 109 SECTION 4 - BOOM & PLATFORM 9. Route the SkyGuard switch harness along Sky- 5. Insert a Shear Block Support (10) through shear block housing on the SkyGuard support bracket Guard support bracket (right side) and under the and into the platform sensor mount. See Figure 4- platform control box.
  • Page 110 SECTION 4 - BOOM & PLATFORM 11. Open load cell board (ECM3) box, locate connec- 15. POWER ON the machine. tors X604 and X603, then disconnect them. See • Press button 6 (service) on the remote control Figure 4-59. • Press button 7 (set up) •...

  • Page 111: Skyguard Anti-Trapping System

    SECTION 4 - BOOM & PLATFORM NOTE: If further information is required, please contact the JLG Service Department. Skyguard Anti-Trapping System When the SkyGuard sensor is activated, functions that were in use at the time of actuation will reverse or cutout. The table below outlines these functions.
  • Page 112 SECTION 4 - BOOM & PLATFORM 4-36 – JLG Lift – 3121623...
  • Page 113 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 114: Hydraulics

    SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS MAIN COMPONENTS IDENTIFICATION AND LOCATION X17JP-X500AJ and X20JP-X600AJ 3121623 – JLG Lift –...

  • Page 115: X26Jp-X770Aj

    SECTION 5 - HYDRAULICS X26JP-X770AJ The ground control box located on the right side of the machine contains the aerial part valveblock. The hydraulic components compartment on the right side inside the bonnet contains the ground valveblocks, the hydrau- lic manifold, the deviator valve, the double pump valve and the hand pump. Together with hydraulic components is indicated in brackets the relevant number on hydraulic diagram.
  • Page 116 SECTION 5 - HYDRAULICS HYDRAULIC MANIFOLD AND DOUBLE PUMP VALVE (7) SECOND SPEED BLOCK (6) LEFT SIDE GROUND RIGHT SIDE GROUND DEVIATOR VALVEBLOCK (9) VALVEBLOCK (10) VALVE (8) 3121623 – JLG Lift –...

  • Page 117: Hydraulic System Pump And Pressure Lines

    SECTION 5 - HYDRAULICS HYDRAULIC SYSTEM PUMP AND PRESSURE NOTE: Lithium machine are equipped only with n.2 pumps unit, one connected to the electric motor with n.2 LINES pumps 3,15 cc/rev each and the hand pump. The machine hydraulic system is powered by n.3 pumps All of the pump unit pressure lines are conveyed through units: the hydraulic manifold into two pressure lines A and B.
  • Page 118 SECTION 5 - HYDRAULICS "A" pressure line sends oil under pressure to the deviator While "N" or "RABBIT" speed are selected, when some valve, this valve is commanded directly by the control boom manifold movement is in progress, double pump module to feed right side ground valve-block or to aerial valve is fed by the control module in order to feed also part valve-block.

  • Page 119: Ground Component Hydraulic System

    SECTION 5 - HYDRAULICS GROUND COMPONENT HYDRAULIC SYSTEM The ground control manifold valves control, outriggers, left and right track drive, and track widening. The ground control valves are controlled by two hydraulic valve-blocks (right side and left side), both equipped with one maximum pressure valve, one proportional valve and an ON-OFF valve for each ground control movement.

  • Page 120: Outriggers

    SECTION 5 - HYDRAULICS On each ground manifold oil rate is controlled through the OUTRIGGERS proportional valve managed by the control module. Outrigger cylinders are controlled by the cylinder valves Depending on the movement required, proportional valve block that is screwed on the cylinder. When machine is will open accordingly regulating the oil rate, at the same setup on outriggers, oil is kept under pressure on the cyl- time the relevant ON-OFF valves (one each movement)

  • Page 121: Drive Gear Motors

    SECTION 5 - HYDRAULICS DRIVE GEAR MOTORS The second speed block contains the coil in charge to acti- vate the second speed, selecting RABBIT from remote con- Each drive gear motors runs forward or backward inde- trol button the control module will energize that coil. pendently, it's so possible to turn the machine.
  • Page 122 SECTION 5 - HYDRAULICS SMALLER CHAMBER: BIGGER CHAMBER: FASTER SPEED • • SLOWER SPEED SMALLER TORQUE • • HIGHER TORQUE Auto2speed allows to manage automatically the available power, providing on demand an higher torque (with a slower speed) or an faster speed (with a lower torque). Second speed activation oil, coming from second speed valve coil, is sent to both drive gear motors through the second speed manifold.

  • Page 123: Tracks Widening

    SECTION 5 - HYDRAULICS TRACKS WIDENING Tracks widening or narrowing is carried out by two cylinders controlled together in parallel by the same valve-block ele- ment on the left side valve-block. Track widening system oil is sent to both cylinders through the track widening manifold that is installed on hydraulic com- ponents compartment just below the hydraulic manifold close to blow-off manifold.

  • Page 124: Boom Component Hydraulic System

    SECTION 5 - HYDRAULICS BOOM COMPONENT HYDRAULIC SYSTEM The boom components controlled by the boom control manifold valve are, 1st/2nd boom cylinder, 3rd boom cylinder, telescope cylinder, jib cylinder, platform rotator, and platform leveling cylinders. The boom components are controlled by an hydraulic manifold valve equipped with one maximum pressure valve, one proportional valve and an ON-OFF valve for each aerial part movement.

  • Page 125: First And Second Booms

    SECTION 5 - HYDRAULICS Boom component manifold valves are fed by pressure line "A" through deviator valve and oil rate is controlled through the proportional valve managed by the control module. Depending on the movement required, proportional valve will open accordingly regulating the proper oil rate, than the relevant ON-OFF valves (one each movement) will open addressing the oil to the relevant cylinder or actuator.

  • Page 126: Third Boom

    SECTION 5 - HYDRAULICS Third Boom Third boom is moved by one cylinder, this cylinder is equipped with an internal sensor that measures its opening position. While lifting third boom, when it's going to reach its end of the stroke, in order to achieve a smoother machine handling, movement is automatically hydraulically decelerate by reducing the opening of proportional valve.

  • Page 127: Emergency Gravity Descent System

    SECTION 5 - HYDRAULICS Emergency Gravity Descent System Cylinders for 1st and 2nd booms, 3rd boom and jib are equipped with a coil valve for gravity emergency descent, they are controlled by the control module when the remote control button "gravity emergency descent" is pressed. When they are fed they open a calibrated passage and under the gravity effect (weight) they will allow oil to get out from the bottom of the cylinder flowing back to the tank (through the ON-OFF valves), so that booms will slow down.

  • Page 128: Cylinder Repair

    SECTION 5 - HYDRAULICS CYLINDER REPAIR Specification - Cylinders Overview Figure 5-1. Piston Thread 3121623 – JLG Lift – 5-15...

This manual is also suitable for:

Jlg x500ajJlg x20jpJlg x600ajJlg x26jpJlg x770aj

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