Oshkosh JLG X17JP, Service And Maintenance Manual

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...