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– JLG Lift –

3121623

TABLE OF CONTENTS

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

CYLINDER DRIFT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

PINS AND COMPOSITE BEARING REPAIR GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

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

3 - CHASSIS & TURNTABLE

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

UNDERCARRIGE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Replacement roller lower wheel and tracks adjuster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Replacement sprocket and Gear Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Sprocket remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Gear motor remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Gear motor installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Sprocket installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

AXLE EXTENSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

FINAL DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

SWING DRIVE (IMO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Technical Data – Type Plate  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Transporting Unpacked Slew Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Positioning The Swing Drive  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Bolting The Slew Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-10
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-11
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-11
Maintenance Tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-12
Lubricating The Slew Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-13
Inspecting The Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-13

HONDA ENGINE IGX440 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-14
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-15
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-16
Engines & Controls Adjustments And Troubleshooting   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-17
Engine Harness By-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-18
Fuel System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-19
Fuel Tank Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-20
Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-21
Replacement Of Engine ECU  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-22

HATZ ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Model: HATZ 1B40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-23
Description Of The Engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-24
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-25
Engine Type Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-26
Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-27
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-28

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Содержание JLG X17JP

Страница 1: ...Service and Maintenance Manual Models X17JP X500AJ X20JP X600AJ X26JP X770AJ 3121623 June 29 2018 Rev E G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 2: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Страница 3: ...M SAFETY It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pres sures Every effort should be made to relieve any system pressure prior to disconnec...

Страница 4: ...Lift 3121623 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 G o t o D i s c o u n t E q u...

Страница 5: ...IGHTS 1 9 1 7 LUBRICATION 1 10 Hydraulic Oil 1 10 1 8 SERIAL NUMBER LOCATION 1 11 1 9 FASTENER TORQUE CHARTS 1 12 SECTION 2 GENERAL 2 1 MACHINE PREPARATION INSPECTION AND MAINTENANCE 2 1 General 2 1 P...

Страница 6: ...remove 3 5 Gear motor remove 3 5 Gear motor installation 3 5 Sprocket installation 3 5 3 3 AXLE EXTENSION REMOVAL 3 6 3 4 FINAL DRIVE 3 7 Product Identification 3 7 3 5 SWING DRIVE IMO 3 8 Technical D...

Страница 7: ...g Wear And Deformation Of Ropes And Pulleys 4 8 Assembly 4 9 Installation To Machine 4 10 Three month inspection 4 11 4 4 WIRE ROPE TENSION ADJUSTMENT PROCEDURE 4 11 4 5 ROTARY ACTUATOR 4 13 ARP Serie...

Страница 8: ...Assembly 5 24 Cylinder Assembling 5 27 Cylinder Repair Without Sensor 5 27 Piston With Nut Disassembling 5 28 Cylinder Assembly 5 28 Seals Head Replacing 5 29 Cylinder Inspection 5 29 Bushing Replace...

Страница 9: ...X770AJ CAN BUS Device Layout 6 25 Electronic Module LED Flashing Codes 6 28 6 5 SENSORS AND DEVICES NOT COMMUNICATING THROUGH CAN BUS 6 31 Electrical System Sections 6 34 Inclination Sensor System 6 3...

Страница 10: ...oltage Measurement 7 2 Resistance Measurement 7 2 Continuity Measurement 7 3 Current Measurement 7 3 Continuity Measurement Over Long Distances 7 4 Requirements 7 4 Procedure 7 4 7 3 ELECTRICAL SCHEMA...

Страница 11: ...ONFIGLIOLI 701 C2K MAG18VP AUTO 2 SPEED 0 16 gal 0 6 L Table 1 2 Hydraulic Fuel Tank Capacities MACHINE HYDRAULIC OIL TANK CAPACITY FUEL TANK To S N C170000892 FUEL TANK S N C170000893 to Present GASO...

Страница 12: ...X17JP X500AJ LOW PROFILE BLACK COLOR 053715L0 Cm 180 X 37 X 72 LOW PROFILE NON MARK ING 053715LB X20JP X600AJ LOW PROFILE BLACK COLOR 257215L0 Cm 200 X 48 X 66 LOW PROFILE NON MARK ING 257215LB X26JP...

Страница 13: ...33 lbf 3 04 daN cm 45 PSI X26JP X770AJ 0 53 daN cm2 7 6 PSI 3124 daN 7023 lbf 4 42 daN cm2 65 PSI Table 1 5 Power Configurations X17JP X500AJ X20JP X600AJ X26JP X770AJ Gasoline Engine up to C170000892...

Страница 14: ...le 1 7 Specifications Honda Engine iGX440 Model iGX440U Description code GCAWK Type 4 stroke overhead camshaft single cylinder inclined by 15 Displacement 438 cm3 26 7cu in Bore x stroke 88 0 x 72 1 m...

Страница 15: ...ad 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 0 10 mm or a...

Страница 16: ...n 0 898 54 80 Compustion System IDI Intake System Naturally Aspirated Maximum Speed rpm 3200 Output Gross Intermittent KW 16 1 hp 21 6 ps 21 9 Direction of Rotation Counterclockwise viewed on flywheel...

Страница 17: ...AJ X26JP X770AJ Platform size standard 2 persons 27 16 in x 52 56 in 690 mm x 1335 mm Stowed width with std 2P platform 52 56 in 1335 mm Stowed width without platform 30 70 in 780 mm 30 70 in 780 mm 3...

Страница 18: ...un 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 tem perature above 100 F 38 C Table 1 13 Function...

Страница 19: ...inder 8 17 6 8 17 6 8 17 6 Basket Rotator 20 44 17 37 4 17 37 4 Cylinder JIB 12 26 4 12 26 4 12 26 4 Upper JIB Link 10 22 10 22 10 22 Lower JIB Link 15 33 15 33 15 33 Arms JIB 24 52 9 24 52 9 24 52 9...

Страница 20: ...V I 160 SHELL TELLUS S3V 32 V I 160 15 C 30 C HYDRAULIC EP EXTRA ISO 22 V I 180 SHELL TELLUS S3V 22 V I 180 24 C 20 C BIODEGRADABLE Geolube ECO Hydraulic ISO46 P N 7527700 MobilEAL EnvirosynH46 P N23...

Страница 21: ...frame The following illustration showing the position Figure 1 2 Serial Number Plate Figure 1 3 X26JP X770AJ Serial Number Plate Location on side of chassis rear compartment cover Figure 1 4 X17JP X20...

Страница 22: ...CTION 1 SPECIFICATIONS 1 12 JLG Lift 3121623 1 9 FASTENER TORQUE CHARTS Figure 1 5 Torque Chart Sheet 1 of 5 SAE Fasteners G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t...

Страница 23: ...SECTION 1 SPECIFICATIONS 3121623 JLG Lift 1 13 Figure 1 6 Torque Chart Sheet 2 of 5 SAE Fasteners G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 24: ...SECTION 1 SPECIFICATIONS 1 14 JLG Lift 3121623 Figure 1 7 Torque Chart Sheet 3 of 5 SAE Fasteners G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 25: ...SECTION 1 SPECIFICATIONS 3121623 JLG Lift 1 15 Figure 1 8 Torque Chart Sheet 4 of 5 METRIC Fasteners G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 26: ...SECTION 1 SPECIFICATIONS 1 16 JLG Lift 3121623 Figure 1 9 Torque Chart Sheet 5 of 5 METRIC Fasteners G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 27: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Страница 28: ...urs which ever 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 re...

Страница 29: ...lifted 2 Should it be necessary to remove a component on an angle keep in mind that the capacity of an eye bolt or similar bracket lessens as the angle between the supporting structure and the compo...

Страница 30: ...nents 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 lubricant...

Страница 31: ...of each sys tem before placing the machine back in service Lubrication Specifications Specified lubricants as recommended by the compo nent manufacturers are always the best choice how ever multi pur...

Страница 32: ...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 dam age the bearing during installation an...

Страница 33: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Страница 34: ...he 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...

Страница 35: ...e 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 wou...

Страница 36: ...R 2 When gravel or mud are blocked between the toothed wheel and the track links remove it before loosening Removing The Rubber Track 1 Stop the machine on solid level land lift it and support it in s...

Страница 37: ...tated in this manual ilize the machine on level ground 3 2 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 war...

Страница 38: ...s 11 on single speed versions only 4 Remove the screws 11 5 Remove the gearmotor 12 Gear motor installation 1 Fix the screws 11 2 Instal the valve 10 3 Connect the Hydraulic hoses 4 Instal the cover 9...

Страница 39: ...e track frame Figure 3 16 9 Remove screw and nut 3 and 6 10 Remove the pin 4 11 Disconnect tag and plug the hydraulic hoses from the cylinder extension Figure 3 17 12 Remove the cylinder NOTE Before t...

Страница 40: ...armotor has two ID plates one gives data on the gearbox and the other data on the hydraulic motor The plates must not be removed or damaged during the life of the product The following illustration sh...

Страница 41: ...ces 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 Force is transmitted to the mountin...

Страница 42: ...TO FALL AND CAUSE LIFE THREATENING INJURIES 2 Attach lifting gear to the eye bolts 3 Start the transport Positioning The Swing Drive 1 Determine the main load carrying zone The main load carrying zon...

Страница 43: ...es Repeat the procedure for the bearing ring that has not yet been bolted If using a hydraulic bolt tensioning cylinder the tension ing forces for the bolt pretension should not exceed 90 of yield str...

Страница 44: ...be used as a guide value INTERVAL MAINTENANCE TASK TO BE EXECUTED BY Weekly Check seal Qualifiedperson After 250 Operating Hours Check tighten bolts Qualifiedperson Check tilting clearance Qualifiedp...

Страница 45: ...only by a specialist Special tools required Torque wrench Hydraulic clamping fixture Replace loose and detached bolts or nuts and wash ers with new bolts nuts and washers Use the same bolt size and bo...

Страница 46: ...well as wear behavior are improved Comply with the instructions in the operating manual provided by the respective manufacturer for lubrica tion of optional intermediate gear units brakes and motors...

Страница 47: ...pplier Engine applicable Honda Ser vice Manual Serial Number Location The engine serial number is stamped on the cylinder barrel Refer to this when ordering parts or making tech nical inquiries ENGINE...

Страница 48: ...0 8PS 3 600min 1 rpm Maximum torque 29 8N m 3 0kgf m 22lbf ft 2 500min 1 rpm Compression ratio 8 1 1 Minimum fuel consumption 328g kW h 241g PS h 0 53lb PS h Ignition system CDI Ignition timing at no...

Страница 49: ...SECTION 3 CHASSIS TURNTABLE 3 16 JLG Lift 3121623 Wiring Diagrams With starter motor and charge coil 20A type G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 50: ...are valid for engines with and with no key start switch If the engine is not cranking go to the instructions Engine Harness By Pass Figure 3 26 Check the status of the LED on the carburetor control un...

Страница 51: ...ted from the machine harness Figure 3 31 On engine left side removes the two bolts and the gray plate to access to the harness and recognize the wires with white plug connectors Figure 3 32 Disconnect...

Страница 52: ...or float bowl Figure 3 37 a Place a container below the carburetor b Unscrew the drain tap and check if gasoline flows out In the event that gasoline does not flow out proceed with the test below Figu...

Страница 53: ...irt free Figure 3 39 Unscrew the four bolts and lift the tank Figure 3 40 Unscrew the two lock nuts and remove the bottom plate Figure 3 41 Disconnect the hose Figure 3 42 Unscrew and remove and clean...

Страница 54: ...re 3 44 Gently and carefully remove the spark plug 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...

Страница 55: ...ervicers Figure 3 46 Unscrew and remove the air filter support Figure 3 47 Unscrew the three screws on top of the ECM Figure 3 48 Gently take out the ECM and disconnect the two plugs harness Figure 3...

Страница 56: ...SECTION 3 CHASSIS TURNTABLE 3121623 JLG Lift 3 23 3 7 HATZ ENGINE Model HATZ 1B40 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 57: ...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...

Страница 58: ...51 3 21 Difference between max and min levels without oil sump with oil sump l approx l approx 0 81 2 21 Lubricating oil consumption after running in max 1 offuelconsumptionatfull load Lubricating oi...

Страница 59: ...ment 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 cr...

Страница 60: ...g to the ambient tem perature for cold starts 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 Te...

Страница 61: ...Identify behind the engine the harness plug that connect ing the engine and the machine system Figure 3 52 Disconnect the plug X51 Figure 3 53 On engine harness plug connector make a bridge between P...

Страница 62: ...e engine harness plug Figure 3 56 On female connector jump the following wires Pin12 12 Volt supply battery positive terminal Pin 5 Starter for a moment utilize hook up this pin as key starter Figure...

Страница 63: ...______________________ Year of Manufacture Perkins dealers or Perkins distributors need all of these numbers in order to determine the components that were included with the engine This permits accura...

Страница 64: ...contaminants from entering the sys tem 1 Turn the fuel supply to the OFF position 2 Loosen hose clamps 3 and disconnect hoses 4 3 If necessary remove fuel filter element 5 Refer to Operations and Mai...

Страница 65: ...utoff to the machine system Figure 3 59 Disconnect the plug X 51 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 o...

Страница 66: ...side to identify the wires with plug connectors Figure 3 64 Disconnect the plug circled Figure 3 65 On Female connector jump the follows wires Pin12 12 Volt supply battery positive terminal Pin 7 Glow...

Страница 67: ...m ElectricPump Number of cylinders 3 Power 16 1Kw 21 6Hp 3200rpm Max rpm 3200rpm Direction of rotation CounterclockwiseViewedonFlywheel Max torque 56Nm 2400rpm Displacement 898 cm Bore 72mm 2 83in Str...

Страница 68: ...e 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 sp...

Страница 69: ...36 JLG Lift 3121623 The fuel system of the diesel engine is fed by an electric fuel pump mounted beside the fuel tank as indicated by picture below G o t o D i s c o u n t E q u i p m e n t c o m t o...

Страница 70: ...e Connector On Female connector jump the follows wires Pin 16 Ground to battery negative terminal Pin 10 fuel pump to battery positive terminal Pin 6 Glow plugs hook up if necessary for few second onl...

Страница 71: ...er Figure 3 69 Speed Sensor Hatz 1B40 Figure 3 70 Speed Sensor on Perkins 402 05 Figure 3 71 Speed Sensor on Kubota D902 Speed Sensor Installation and Adjustment Figure 3 72 1 Install the speed sensor...

Страница 72: ...ased on operating con ditions Figure 3 73 Throttle actuator on Perkins 402 05 Figure 3 74 Throttle actuator on Kubota D902 Figure 3 75 Speed Sensor Hatz 1B40 All Diesel Actuator Rod Travel Adjustment...

Страница 73: ...6JP X770AJ diesel disconnect the oil pipes and cooling lines then drain the 2 cir cuities Figure 3 78 Image 2 Figure 3 79 Image 3 1 Remove the screws items 13 and 5 image 2 2 Remove the engine remove...

Страница 74: ...e electrical motor and isolate the wires end 5 Remove the four bolts that attach the pumps adapter to the electrical motor 6 Remove the four mounts bolts 2 that attach the electrical motor to the fram...

Страница 75: ...rt 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 14 Install cover and test...

Страница 76: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Страница 77: ...om the level link and turntable f Remove hardware securing the lower boom pivot pin Using a suitable brass drift and hammer remove pin from the turntable g Using all applicable safety precautions care...

Страница 78: ...SECTION 4 BOOM PLATFORM 4 2 JLG Lift 3121623 Figure 4 1 Position pins X17JP X500AJ Figure 4 2 Position pins X20JP X600AJ G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 79: ...with holes in side of base section 5 Attach the power track to the aft end of fly boom section Secure power track with the attaching hardware 6 Using suitable lifting equipment slide fly boom section...

Страница 80: ...in order to position boom lift cylinder and level link so that holes in cylinder rod end and level link are aligned with the one in the turntable Insert cylinder pins 4 If necessary gently tap pins in...

Страница 81: ...tension approximately 4 feet 1 2 m long remove the bolts and washers securing the cable mount block to the boom fly section Figure 4 5 5 Remove the four bolts shims and attachment blocks that secure t...

Страница 82: ...the boom At the same time also pull the cable mount block out so the extension cables come out with the tele scope cylinder and do not bind The lifting sup porting devices will have to be repositioned...

Страница 83: ...re from the sheave pin remove pin and sheave from cylinder Figure 4 10 9 Remove hardware which secures the wear pads to the front of base boom section remove wear Figure 4 9 1 Base Boom 2 Mid Boom 3 F...

Страница 84: ...secures the wear pads to the rear end of fly boom section remove wear pads from the top sides and bottom of the fly boom section 16 When removing wire rope from fly boom sec tion push the cable into f...

Страница 85: ...trail between the bottom surfaces of boom sections Adjust boom if necessary for a total of 1 16 inch 0 062 clearance 11 Install wear pads into the forward position of the base boom section Adjust boo...

Страница 86: ...ned 2 Install boom pivot pin ensuring that location of hole in pin is aligned with attach point on upright 3 If necessary gently tap pin into position with soft headed mallet Secure pin mounting hard...

Страница 87: ...If the tension of the ropes should not be adequate the conditions for use must be restored by scrupulously fol lowing the Ropes Tension Adjustment procedure reported following 4 4 WIRE ROPE TENSION A...

Страница 88: ...nt of the extendible arms several times and check that the residual loads on the ropes are 10Nm 7 This procedure could require several attempts before it is completed correctly 8 The adjustment is cor...

Страница 89: ...Max working pressure For more information and other details see technical drawing Technical Data Actuator Model RP 17 L25H1D2VPH RotationAngle 124 Displacement cm3 81 Weight kg 16 Ports G Workingtempe...

Страница 90: ...SECTION 4 BOOM PLATFORM 4 14 JLG Lift 3121623 Figure 4 24 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 91: ...F 1 REARFLANGED84 4X35 5 124 G 1 TOOTHEDGEARRING M 2 WIPERRINGD101XD81X7 5 P 1 TOOTHPISTOND75XD40X86 S 3 PIND6X12 V 1 DOUBLEOVERCENTERVALVE SEALSKIT includestheparticularsmarkedby NOTE Units A C F P a...

Страница 92: ...M 8 Remove the locking pins S 9 Loosen flange F from shaft A using hole 6 and using an appropriate wrench We recommend make equipment to facilitate the operation NOTE Before unscrewing make a referen...

Страница 93: ...e pins NOTE On gear teeth of piston and gear ring before disen gaging the same make a reference marking a tooth for every detail on which engages with recip rocal 16 Remove all elements sealing by the...

Страница 94: ...engage it with piston P by referring to previously marked tooth NOTE During this operation pay attention to the sealing elements between the shaft A and piston P 8 Place bearing 5 and thrust ring 4 4...

Страница 95: ...actua tor housing 3 The bolts that come with the valve are grade 8 bolts New bolts should be installed with a new valve Loctite 242 should be applied to the shank of the three bolts at the time of in...

Страница 96: ...6 x 12M screws with threadlocker Connect the rotation sensor electrical connector to the connector coming from the electrical box See Figure 4 28 Figure 4 28 4 Route the rotation sensor electrical ca...

Страница 97: ...op and the surface of the first boom support where the rotation marker will be mounted See Figure 4 33 Figure 4 33 9 Make the difference between this distance and the rotation marker size 15mm then ad...

Страница 98: ...IMITY SENSOR ADJUSTMENT X17JP X500AJ X20JP X600AJ Adjust the proximity sensor in order to obtain a gap of 2 mm between the sensor and the undercarriage ring plate Figure 4 36 G o t o D i s c o u n t E...

Страница 99: ...t the platform off the mounting posts in an upward direction Place platform aside for later installation Platform Installation 1 LIft the platform and align the platform mounts with the jib mounting p...

Страница 100: ...CM3 3 Reinstall the basket See section basket installation Figure 4 38 Removing Footswitch 1 Turn the machine off and unplugged from the power supply 2 Remove the basket of the machine See paragraph b...

Страница 101: ...ard mechanic tools including 5 16 7 32 Allen Wrenches Tie Straps Personnel Required Qualified JLG equipment mechanic Parts List Procedure 1 Park the machine on the firm level surface fully retract low...

Страница 102: ...Figure 4 41 Figure 4 41 2 Align and attach Platform Sensor Mount 12 onto the SkyGuard Switch 11 as shown in Fig ure 4 42 3 Attach Platform Sensor Covers 9 to SkyGuard switch assembly at both ends See...

Страница 103: ...E Tighten the Bolt 5 using appropriate allen wrench 8 Repeat Steps 4 through 7 to secure SkyGuard switch assembly on the other side of the Sky Guard support bracket ensuring correct position of the sh...

Страница 104: ...d system 15 POWER ON the machine Press button 6 service on the remote control Press button 7 set up Press button 5 password Enter password 4 7 7 1 then press button 9 OK Press button 3 extra Press but...

Страница 105: ...l reverse or cutout The table below outlines these functions Main Lift 3 Boom Up Main Tele Extension In Main Tele Extension Out Main Swing Drive Forward Drive Reverse Tower Lift 1 Boom Up R Indicates...

Страница 106: ...SECTION 4 BOOM PLATFORM 4 30 JLG Lift 3121623 Figure 4 51 Pedal Sky Guard System Schematic G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 107: ...chanic tools including 5 16 7 32 Allen wrenches Tie Straps Personnel Required Qualified JLG equipment mechanic Parts List Procedure 1 Park the machine on the firm level surface fully retract lower the...

Страница 108: ...Figure 4 54 Figure 4 54 2 Align and attach Platform Sensor Mount 12 onto the SkyGuard Switch 11 as shown in Fig ure 4 55 3 Attach Platform Sensor Covers 9 to SkyGuard switch assembly at both ends See...

Страница 109: ...TE Tighten the Bolt 5 using appropriate allen wrench 8 Repeat Steps 4 through 7 to secure SkyGuard switch assembly on the other side of the Sky Guard support bracket ensuring correct position of the s...

Страница 110: ...d system 15 POWER ON the machine Press button 6 service on the remote control Press button 7 set up Press button 5 password Enter password 4 7 7 1 then press button 9 OK Press button 3 extra Press but...

Страница 111: ...l reverse or cutout The table below outlines these functions Main Lift 3 Boom Up Main Tele Extension In Main Tele Extension Out Main Swing Drive Forward Drive Reverse Tower Lift 1 Boom Up R Indicates...

Страница 112: ...SECTION 4 BOOM PLATFORM 4 36 JLG Lift 3121623 Figure 4 64 Pedal Sky Guard System Schematic G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 113: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Страница 114: ...HYDRAULICS 3121623 JLG Lift 5 1 SECTION 5 HYDRAULICS 5 1 MAIN COMPONENTS IDENTIFICATION AND LOCATION X17JP X500AJ and X20JP X600AJ G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r...

Страница 115: ...raulic 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 hydra...

Страница 116: ...Lift 5 3 DOUBLE PUMP VALVE 7 DEVIATOR VALVE 8 HYDRAULIC MANIFOLD AND SECOND SPEED BLOCK 6 LEFT SIDE GROUND VALVEBLOCK 9 RIGHT SIDE GROUND VALVEBLOCK 10 G o t o D i s c o u n t E q u i p m e n t c o m...

Страница 117: ...ne of the two lines should be fed NOTE Lithium machine are equipped only with n 2 pumps unit one connected to the electric motor with n 2 pumps 3 15 cc rev each and the hand pump All of the pump unit...

Страница 118: ...il is energized While N or RABBIT speed are selected when some boom manifold movement is in progress double pump valve is fed by the control module in order to feed also with the second pump the boom...

Страница 119: ...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 ON OFF VALVE...

Страница 120: ...block controls the two left side out riggers n 1 and n 2 the left track drive gear motor and the tracks widening cylinders Right side ground valve block controls the two right side outriggers n 3 and...

Страница 121: ...T from remote con trol button the control module will energize that coil When that coil is energized oil is sent to both drive gear motors to move their plate so that their chamber capacity will be re...

Страница 122: ...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 SMALLER CHAMBER FASTER SPEED...

Страница 123: ...llel 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 co...

Страница 124: ...m 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...

Страница 125: ...he turret rotation motor the cylinder for moving 1st and 2nd booms the cylinder for moving the 3rd boom the telescope cylinder the jib cylinder the basket rotation actuator and the basket lev elling c...

Страница 126: ...l thanks to the parallelogram system Basket Leveling Basket levelling close circuit is composed by two cylinders one on the basket and one on the third boom connection rod basket is automatically kept...

Страница 127: ...he cylinder flowing back to the tank through the ON OFF valves so that booms will slow down The coil valve for gravity emergency descent has a blue cap Hydraulic System Sections The hoses that start f...

Страница 128: ...SECTION 5 HYDRAULICS 3121623 JLG Lift 5 15 5 8 CYLINDER REPAIR Specification Cylinders Overview Figure 5 1 Piston Thread G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

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