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JLG X13JP-X370AJ Service And Maintenance Manual Download Page 45

SECTION 3 - CHASSIS & TURNTABLE

3121774

3-15

Twin Power Unities With Diesel Engine Hatz 1B40

Design

4 stroke

Injection

Direct

Number of cylinders

1

Displacement

462 cm³

Bore/Stroke

88/76 mm

Fuel tank capacity

5 l

Cooling system

Air

Lubricating oil pressure (oil temperature 100C)

2,5 bars at 3000 rpm

Lubricating oil capacity (with oil sump)

3,2 l

Max lubricating oil consumption (after running in)

1% of fuel consumption at full load

Direction of rotation, power take-off end

Anti-clockwise

Valve clearance 10-30C

0,10 mm

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

electric starter)

Approx. 55 Kg

Go 

to 

Discount-Equipment.com 

to 

order 

your 

parts

Summary of Contents for X13JP-X370AJ

Page 1: ...Service and Maintenance Manual Models X13JP X370AJ X15JP X430AJ 3121774 June 29 2018 Rev C 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: ...ETY 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 disconnecting...

Page 4: ...ANCE SAFETY PRECAUTIONS b 3121774 REVISION LOG Original Issue Revised A August 4 2017 B March 27 2018 C June 29 2018 Revised Covers Revised 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...

Page 5: ...EPARATION INSPECTION AND MAINTENANCE 2 1 General 2 1 Preparation Inspection and Maintenance 2 1 Pre Start Inspection 2 1 Pre Delivery Inspection and Frequent Inspection 2 1 Annual Machine Inspection 2...

Page 6: ...ation 3 4 3 3 TRACKS EXTENSION REMOVAL 3 5 3 4 TRACK DRIVE 3 6 Product Identification 3 6 3 5 SWING DRIVE IMO 3 7 Technical Data Type Plate 3 7 Structure and Function 3 7 Structure and Function 3 8 Ma...

Page 7: ...es System 5 6 Ground Part Hydraulic System 5 10 Outriggers 5 11 Driver Gear Motors 5 12 Tracks Widening 5 14 Aerial Part Hydraulic System 5 15 5 2 CYLINDER REPAIR 5 19 Specification Cylinders Overview...

Page 8: ...CM1 REPLACEMENT AND SETTING 6 22 New Master Board 6 22 Already Initialized Master Board 6 23 Software Recovery By Modem 6 24 6 6 CODE MENU 6 24 SECTION 7 GENERAL ELECTRICAL INFORMATION SCHEMATICS 7 1...

Page 9: ...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 10: ...X15JP X430AJ 6 34 gal 24 L 1 40 gal 5 3 L 1 3 gal 5 L Table 1 3 Track Specifications MACHINE MODEL RUBBER BELT TRACK TYPE PART NUMBER DIMENSIONS DRAWING X13JP X370AJ X15JP X430AJ LOW PROFILE BLACK COL...

Page 11: ...Engine type Air cooled 4 stroke OHV petrol engine 25 inclined cylinder horizontal shaft cast iron sleeve Bore x stroke 88 x 64 mm Displacement 389 cm3 Compression ratio 8 2 1 Net power 8 6 HP 6 4 kW 3...

Page 12: ...at full load max Lubricating oil pressure oil temperature 100 C 2 5 bars at 3000 r p m approx Direction of rotation power take off end anti clockwise Valve clearance 10 30 C Inlet and exhaust valve 0...

Page 13: ...s 20 36 Table 1 9 Machine Dimensional Data X13JP X370AJ X15JP X430AJ Platform size standard 2 persons 1305 X 690 mm 51 38 X 27 17 in 1335 X 690 mm 52 56 X 27 17 in Stowed width with std 2P platform 39...

Page 14: ...55 JIB UP 7 15 15 25 JIB DOWN 7 15 10 20 BASKET LEVEL UP 33 55 33 55 BASKET LEVEL DOWN 37 50 37 50 MAX DRIVE SPEED with auto two speed 0 87 1 62 mph 1 4 2 6 Km h 0 24 0 50 0 99 mph 0 4 0 8 1 6 Km h Ta...

Page 15: ...other direction Record Time Articulating Jib Platform level and centered with the boom Start with the Jib down Jib Up Record Time Jib Down Record Time Lower Lift Upper Boom horizontal Telescoped In Lo...

Page 16: ...SECTION 1 SPECIFICATIONS 3121774 1 7 1 6 LUBRICATION Hydraulic Oil Figure 1 1 Hydraulic Oil Temperature Operating Range 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 17: ...IFICATIONS DESCRIPTION Viscosity at 40 C cst Typical Viscosity Index Mineral Oils Vegetable Oils Synthetic Synthetic Polyol Esters Readily Biodegradable Virtually Non toxic Fire Resistant Pakelo Hydra...

Page 18: ...N The serial number plate is fastening onto the frame on fork lifting pockets on X15JP X430AJ and X13JP X370AJ Figure 1 2 Serial Number Plate Figure 1 3 Serial Number Plate Location G o t o D i s c o...

Page 19: ...SECTION 1 SPECIFICATIONS 1 10 3121774 1 8 FASTENER TORQUE CHARTS Figure 1 4 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 s...

Page 20: ...SECTION 1 SPECIFICATIONS 3121774 1 11 Figure 1 5 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 21: ...SECTION 1 SPECIFICATIONS 1 12 3121774 Figure 1 6 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 22: ...SECTION 1 SPECIFICATIONS 3121774 1 13 Figure 1 7 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 23: ...SECTION 1 SPECIFICATIONS 1 14 3121774 Figure 1 8 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 24: ...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 25: ...shed for each machine in service for 3 months or 150 hours 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 incr...

Page 26: ...ed 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 nent...

Page 27: ...s as required to aid assembly Lubrication Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants ar...

Page 28: ...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 purpos...

Page 29: ...ot 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 and opera...

Page 30: ...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 31: ...follow the procedure illustrated in the following para graph Figure 3 2 Tensioning Check 2 Tensioning Rubber Track DANGER THE GREASE CONTAINED IN THE HYDRAULIC TRACKS IS UNDER PRES SURE IF THE VALVE T...

Page 32: ...ports stable below the undercarriage frame to support the machine DANGER BEFORE INSTALLING THE RUBBER TRACKS MAKE SURE THAT YOU ARE ALWAYS IN SAFE CONDITIONS WITH THE MACHINE SUSPENDED FROM THE GROUN...

Page 33: ...adjuster 4 2 Install the front idler 5 3 Install the lower roller 3 4 Apply loctite 243 and torque the nuts 2 on the lower roller at 125 Nm 92 ft lbs Replacement Sprocket and Gear Motor Figure 3 9 Re...

Page 34: ...allation Sprocket Installation 1 Instal the sprocket 2 Instal the screws 6 Figure 3 11 Sprocket Installation 1 6 7 11 9 8 12 10 12 11 Table 3 1 Final Drive Torque Valves MACHINE MODEL SPROCKET SCREW N...

Page 35: ...ame Figure 3 15 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 16 12 Remove the cylinder NOTE Before to install...

Page 36: ...tes 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 shows how the data is se...

Page 37: ...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 mounting st...

Page 38: ...minimum insertion depth of 1 5 x the bolt diameter must be selected Transport within the company shall only be executed horizontally Figure 3 22 Always Use The Full Length Of The Thread Maintenance Ta...

Page 39: ...hoses are filled with grease at commissioning and that the storage tanks are regularly topped up with grease An automatic re lubricating system significantly facili tates re lubrication for the racewa...

Page 40: ...e functions set with the summing oil flow the sum of the oil flow is feasible while operating the function only and not in combine with other func tions at the same moment For the time of activation o...

Page 41: ...ard Honda Engine or to the piston actuator for the Diesel engines The Engine relays board is the same for gasoline or diesel machines even some relay has different functions The Engine relays board an...

Page 42: ...wer 8 7 kW at 3600 rpm Continuous net power 7 0 kW at 3600 rpm Maximum net torque 26 4 N m at 2500 rpm Fuel consumption at continuous net power 3 5 L h at 3600 rpm Compression ratio 8 2 1 Lubricating...

Page 43: ...gh which are prear ranged preset the rpm s The two contacts in the ECM1 module are the ENGINE SPEED 1 and ENGINE SPEED 2 and the engine rpm s regulate as the following conditions ENGINE SPEED 1 ENGINE...

Page 44: ...Serial Number Location The serial number is stamped on the cylinder block Refer to this when ordering parts or making technical inquiries SERIAL NUMBER LOCATION G o t o D i s c o u n t E q u i p m e n...

Page 45: ...essure oil temperature 100C 2 5 bars at 3000 rpm Lubricating oil capacity with oil sump 3 2 l Max lubricating oil consumption after running in 1 of fuel consumption at full load Direction of rotation...

Page 46: ...the following details 1 Engine type 2 Code only for special equipment 3 Engine serial number stamp on the cylinder block 4 Max Engine speed For spare parts orders it is necessary to mention these data...

Page 47: ...ule by the speed sensor placed in front of the engine flywheel verify that the revs are those expect In case of replacement of the actuator piston require the adjustment of the shaft length See the se...

Page 48: ...nitors cells parameters including their ten sions and their temperatures while in case of failure opens the internal contactor insulating the Lithium pack Battery Charger The on board battery charged...

Page 49: ...un at min revs Operating the counter clocking turn of the tracks the electric motor revs are set at lower speed For the time of activation of multiple areal functions at the same moment with jib baske...

Page 50: ...ctric net work battery charger activated While heaters are working on the display will appear the icon batteries cold and machine could be moved only in lower speed turtle In hot environmental tempera...

Page 51: ...ABLE 3121774 3 21 Lithium System Components Location Upper Layer SUPPLEMENTARY INSULATOR DC DC TRANSFORMER INVERTER FRONTAL FAN BATTERY CHARGER 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...

Page 52: ...ECTION 3 CHASSIS TURNTABLE 3 22 3121774 Lower Layer CELLS PACK INTERNAL CONTACTOR MAIN FUSE BMS CELLS PACK WITHOUT COVER 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 53: ...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 54: ...e 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 full...

Page 55: ...SECTION 4 BOOM PLATFORM 4 2 3121774 Figure 4 1 Position Pins X13JP X370AJ Figure 4 2 Position Pins X15JP X430AJ 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 56: ...5 Attach the powertrack to the aft end of fly boom section Secure powertrack with the attaching hardware 6 Using suitable lifting equipment slide fly boom section out to gain access to telescope cyli...

Page 57: ...nt 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...

Page 58: ...caps that secure the platform to the jib platform mounting posts 3 Lift the platform off the mounting posts in an upward direction Place platform aside for later installation Installation 1 Lift the...

Page 59: ...c Parts List Procedure 1 Park the machine on the firm level surface fully retract lower the boom 2 Extend all the four outriggers set them to the auto levelling mode and set the machine to rest positi...

Page 60: ...7 and Nuts 3 See Figure 4 11 2 Align and attach Platform Sensor Mount 12 onto the SkyGuard Switch 11 as shown in Fig ure 4 12 3 Attach Platform Sensor Covers 9 to SkyGuard switch assembly at both end...

Page 61: ...nd relevant Washer 6 on platform sensor mount See Figure 4 13 NOTE Tighten the Bolt 5 using appropriate allen wrench 8 Repeat Steps 4 through 7 to secure SkyGuard switch assembly on the other side of...

Page 62: ...ton 8 next Press button 4 SkyGuard Press Button 1 ON Figure 4 16 Asterisk must show next to the ON position Press button 9 esc Press button 9 esc Press button 9 esc Press button 9 esc Remote control s...

Page 63: ...low outlines these functions M ain Lift 3 Boom Up Main Tele Extension In Main Tele Extension Out Main Swing Drive Forward Drive Reverse Tower Lift 1 Boom Up Tower Lift 1 Boom Down Basket Level Basket...

Page 64: ...d JLG equipment mechanic Parts List Procedure 1 Park the machine on the firm level surface fully retract lower the boom 2 Extend all the four outriggers set them to the auto levelling mode and set the...

Page 65: ...four Bolts 2 relevant Washers 7 and Nuts 3 See Figure 4 19 Figure 4 19 2 Align and attach Platform Sensor Mount 12 onto the SkyGuard Switch 11 as shown in Fig ure 4 20 3 Attach Platform Sensor Covers...

Page 66: ...and relevant Washer 6 on platform sensor mount See Figure 4 21 NOTE Tighten the Bolt 5 using appropriate allen wrench 8 Repeat Steps 4 through 7 to secure SkyGuard switch assembly on the other side of...

Page 67: ...ton 8 next Press button 4 SkyGuard Press Button 1 ON Figure 4 24 Asterisk must show next to the ON position Press button 9 esc Press button 9 esc Press button 9 esc Press button 9 esc Remote control s...

Page 68: ...low outlines these functions M ain Lift 3 Boom Up Main Tele Extension In Main Tele Extension Out Main Swing Drive Forward Drive Reverse Tower Lift 1 Boom Up Tower Lift 1 Boom Down Basket Level Basket...

Page 69: ...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 70: ...nt on the right side inside the bonnet contains the ground valve blocks the hydraulic manifold the deviator valve the double pump valve the blow off manifold the second speed manifold and the hand pum...

Page 71: ...viator valve double pump valve and second speed valve DOUBLE PUMP VALVE SECOND SPEED VALVE DEVIATOR VALVE Figure 5 2 Valve Diagram DEVIATOR VALVE SECOND SPEED VALVE DOUBLE PUMP VALVE Figure 5 3 Valve...

Page 72: ...ALVESBLOCK 12 OUTRIGGERCYLINDER 13 DRIVEGEARMOTOR 14 TRACKSWIDENINGCYLINDER 15 MANIFOLD 16 AERIALPARTVALVEBLOCK 7ELEMENTS 17 TURRETROTATIONHYDRAULICMOTOR 18 DOUBLEBALANCINGVALVEFORBASKETLEVELLING 19 B...

Page 73: ...ECTION 5 HYDRAULICS 5 4 3121774 TO THE AERIAL PART VALVE BLOCK Figure 5 4 Pumps and Undercarriage Part Hydraulic Diagram 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 74: ...SECTION 5 HYDRAULICS 3121774 5 5 FROM THE DEVIATOR VALVE Figure 5 5 Aerial Part Hydraulic Diagram 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 75: ...ines should be fed NOTE Lithium machine is equipped with only one double tandem pump unit 3 15 cc rev each connected to the three phase electric motor and the hand pump All of the pumps units outlines...

Page 76: ...coil is energized when with engine or electric motor running all outriggers are touching the ground but remote control is not placed on its support NOTE On lithium machine deviator coil is always ene...

Page 77: ...Double pump valve is not fed with contemporaneously movements and is not fed at minimum speed TURTLE TO THE LEFT VALVE BLOCK TO THE RIGHT VALVE BLOCK TO THE AERIAL PART VALVE BLOCK TO THE SECOND SPEE...

Page 78: ...lowoff manifold to the tank filter TO THE LEFT VALVE BLOCK TO THE RIGHT VALVE BLOCK TO THE BLOWOFF MANIFOLD TO THE AERIAL PART VALVE BLOCK TO THE SECOND SPEED ACTIVATION LEFT VALVE BLOCK PRESSURE GAUG...

Page 79: ...lve one proportional valve and an ON OFF valve for each ground part movement LEFT SIDE VALVE BLOCK RIGHT SIDE VALVE BLOCK ON OFF VALVES PROPORTIONAL VALVE MAX PRESSURE VALVE Figure 5 11 Ground Part Hy...

Page 80: ...eft track drive gear motor and the tracks widening cylinders Right side ground valve block controls the two right side outriggers n 3 and n 4 and the right track drive gear motor Outriggers Outrigger...

Page 81: ...second speed system indeed they are variable capacity so that they can perform two different hydraulic speeds in order to change tracks speeds further that rpm regulation When that coil is energized o...

Page 82: ...acks speed Auto2speed allows to manage automatically the available power providing on demand a higher torque with a slower speed or faster speed with a lower torque Second speed activation oil coming...

Page 83: ...t side valve block Track widening system oil is sent to both cylinders through the track widening manifold that is installed on hydraulic components compartment SECOND SPEED SIGNALS HOSES 3 AND 4 DRAI...

Page 84: ...with one maximum pressure valve one propor tional valve and an ON OFF valve for each aerial part movement PROPORTIONAL VALVE MAXPRESSURE VALVE ON OFF VALVES AERIAL PART VALVE BLOCK Figure 5 19 Aerial...

Page 85: ...and 2nd booms the cyl inder for moving the 3rd boom the telescope cylinder the jib cylinder the basket rotation actuator and the basket levelling circuit On each cylinder and actuator is installed a...

Page 86: ...third boom connection rod basket is automatically kept leveled while third boom is moving because of the basket cylinder is moved by con nection rod cylinder In particular while third boom is opening...

Page 87: ...y 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 we...

Page 88: ...SECTION 5 HYDRAULICS 3121774 5 19 5 2 CYLINDER REPAIR Specification Cylinders Overview Figure 5 26 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...

Page 89: ...SECTION 5 HYDRAULICS 5 20 3121774 Figure 5 27 Piston With Nut 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...

Page 90: ...SECTION 5 HYDRAULICS 3121774 5 21 Figure 5 28 Telescope Cylinder 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: ...SECTION 5 HYDRAULICS 5 22 3121774 Figure 5 29 Cylinder With Sensor 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 92: ...2 M18x1 5 40 15 M22x1 5 60 18 M26x1 5 90 22 M30x2 170 28 M36x2 210 35 M45x2 360 42 M52x2 490 TIGHTENING TORQUE HEAD HEAD DIAMETER mm TORQUE Nm MIN MAX 30 50 100 35 50 100 40 100 150 45 100 150 50 150...

Page 93: ...r with a suitable cleaner before disassembly Remove all dirt debris and grease from the cylinder 2 Clamp the barrel end of the cylinder in a soft jawed vise or other acceptable holding equip ment if p...

Page 94: ...hing with a soft brass wire brush prior to reassembly 3 Remove the piston head from the rod and care fully slide the head gland off the end of the rod Cylinder Assembly General Cylinder Assembly 1 Use...

Page 95: ...emery cloth Use the emery cloth in a rotary motion to polish out and blend the scratch es into the surrounding surface 3 Check the piston rod assembly for run out If the rod is bent it must be replace...

Page 96: ...due is present on threads and parts it can be removed Clean the residue away with a soft brass wire brush prior to reassembly and wipe clean before reinstallation Refer to Hydraulic Cylinder Torque Sp...

Page 97: ...CREW TO LET AIR ESCAPE RE TIGHTENING TORQUE 6 ft lbs 8 Nm 5 3 REPLACEMENT HYDRAULIC PUMP Pump Removal 1 Open the top cap of the hydraulic oil tank 2 Tag disconnect the hoses from the pump 15 3 Loose s...

Page 98: ...YDRAULICS 3121774 5 29 5 4 HYDRAULIC SCHEMATICS X13JP X370AJ G 3 8 Figure 5 30 X13JP X370AJ Hydraulic Schematic Fixed Undercarriage 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...

Page 99: ...SECTION 5 HYDRAULICS 5 30 3121774 2 Figure 5 31 X13JP X370AJ Hydraulic Schematic Extendable Undercarriage 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 100: ...5 HYDRAULICS 3121774 5 31 X15JP X430AJ 2 Figure 5 32 X15JP X430AJ Hydraulic Schematic 1 of 2 TO THE BOOM COMPONENT VALVE BLOCK 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...

Page 101: ...SECTION 5 HYDRAULICS 5 32 3121774 G 3 8 Figure 5 33 X15JP X430AJ Hydraulic Schematic 2 of 2 FROM THE DEVIATOR VALVE 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 102: ...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 103: ...unit installed on the compact crawlers boom lift The JLG Control System has reduced the need for exposed terminal strips diodes and trim pots and provides simplic ity in viewing and adjusting the var...

Page 104: ...splay is used to view the status of the machine and the operating information necessary or useful for the operator When the machine s main control board is powered the data are continually sharing bet...

Page 105: ...the data transferred The Download will be completed when about more than 20000 steps are transferred LCD Display Screen At machine start up and during machine operation the main LCD display screen is...

Page 106: ...d No display indicates outriggers are not prop erly set and boom functions are not allowed Figure 6 8 POSITION 6 Indicates boom jib turntable and base are aligned Drive steer track width adjustment an...

Page 107: ...y Main boom sensor is faulty Boom functions are cut out Swing sensor is faulty CANBUS communication is faulty Electronic fault Lithium ION Signals an error in the BMS Battery Management System Skyguar...

Page 108: ...load the basket from its support Only jib movement allowed Engine preheating active Basket underload Gravity emergency descent Movement not allowed by gravity emergency descent 12V battery voltage low...

Page 109: ...e Diesel or Lithium From SERVICE menu pressing button from n 1 to n 8 it s possible to enter into several menus as for instance press ing button n 1 display will show the INPUT menu Pressing button n...

Page 110: ...ssed line A is closed and line B is open ST3GND AB DOWN DOWN Outrigger n 3 on the ground the switch is released line A is open and line B is closed UP UP Outrigger n 3 lifted the switch is pressed lin...

Page 111: ...e switch contact of outriggers n 3 and n 4is opened the outriggers are open partially open or already closed TEMP ALRMA Optional ON Temperature external probe reached the maximum value the temperature...

Page 112: ...tion of the machine on the X axis in degrees INCLIN Y 0 3 Indicates the inclination of the machine on the Y axis of degrees LOAD AB 134 133 Indicates the weight of the basket about 50 Kg plus the weig...

Page 113: ...owest cell BMS A CHG 25 Indicates the maximum current Amp that BMS requires to the battery charger with lithium pack not fully charge T MAX CELL 23 Indicates the highest temperature C detected among t...

Page 114: ...both closed there s an error in progress and the icon HELP ERROR will appear on the display In that case into the ERROR menu the involved device ref erence will be marked aside with a NO instead of an...

Page 115: ...EM GRN Stop button on the ground EM RC B Remote control stop button on the basket EM RC G Remote control stop button on the ground FOTO Photocells PEDAL Pedal SKYGUARD SkyGuard system MICRJIB Jib open...

Page 116: ...ecrease the working hours of the ENGINE KEEPING PRESSED the button 6 use the button 7 E to increase and button 8 E to decrease the working hours of the Electric Motor KEEPING PRESSED the button 6 and...

Page 117: ...When selection the machine model to match the size of the machine the personality settings will all default to the factory recommended setting NOTE Refer to the following steps in this Service Manual...

Page 118: ...ssword Some setting requires a password some passwords are relevant to more than one setting some other passwords are dedicated to only one setting By PASSWORD page it s possible to insert the passwor...

Page 119: ...eset will not be possi ble 7 Press button n 9 ESC and then turn OFF the main key 8 Turn ON again the main key and verify by INPUT LOAD A and LOAD B that calibration is correct by checking the variatio...

Page 120: ...gs back to the SETUP menu Setup Extra Modem This page could be used in case of RAHM difficult connec tion the meanings of the parameters shown by this page are the followings Setup Extra GPS This page...

Page 121: ...rted the relevant password 8365 The motion alarm is activated depending on the BEEPER menu setting If it s selected ALL the warning buzzer is activated at all the machine movements both aerial part an...

Page 122: ...ws the OPTIONAL menu second page display Pressing button n 7 it s possible to come back to the first page of settings Pressing button n 9 ESC brings back to the EXTRA menu Service By this page it s po...

Page 123: ...AS Test Not consider Skyguard By this page it s possible to set the Skyguard function when it is activated by pressing on Skyguard bar it stops certain movements After having inserted the relevant pas...

Page 124: ...cted New Master Board When a new master board never used is fitted on the machine the remote control need to be connected to its ground cable and the control position selected accord ingly by the cont...

Page 125: ...fferent on a safety point of view is able to recognize if the machine model selected is not correct This verification is possible because on the load cell board ECM3 a series of contacts input depends...

Page 126: ...oil pump valve the functions could be prevented To restart the functions have to turn OFF ground key OFF and then ON the machine as a result all the function are then active with exception the faulty...

Page 127: ...right side proportional valve coil 23 Ground part left side proportional valve coil 24 Right track forward valve coil 25 Left track forward valve coil 26 Right track backward valve coil 27 Left track...

Page 128: ...ion valve coil 49 Basket left rotation valve coil 50 Aerial part proportional valve coil 51 Pumps sum valve coil 52 Tracks second speed valve coil 53 Tracks widening valve coil 54 Tracks closing valve...

Page 129: ...ICE between the 36 and the 56 will be displayed with ERROR 7 Safety deactivation STOWED MACHINE WITH NO ERROR DEVICE CODE ERROR CODE ACTIVE 11 12 NO 12 9 YES 64 2 YES 65 9 NO 66 9 NO 67 4 YES 73 2 NO...

Page 130: ...re activated only after its coil anomaly is restored 67 4 YES 73 2 NO 89 12 YES 133 1 YES 145 2 YES 154 8 NO 155 8 NO COIL CONNECTION ERROR EXAMPLE DEVICE CODE ERROR CODE ACTIVE COIL CONNECTION ERROR...

Page 131: ...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 132: ...to take the measurement by accessing a connector s contact on the same side as the wires the back of the connector Readings can be done while maintaining circuit continuity this way If the con nector...

Page 133: ...l Use firm contact with meter leads First test meter and leads by touching leads together Resistance should read a short circuit very low resis tance Circuit power must be turned OFF before testing re...

Page 134: ...onent from circuit before testing Use firm contact with meter leads First test meter and leads by touching leads together Meter should produce an audible alarm indicating continuity Set up the meter f...

Page 135: ...ttery terminals also as a precaution 2 Measure continuity between all three wires the wire under test wire 1 and wire 2 These should be open If not repair the shorted wires or replace the harness 3 On...

Page 136: ...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 137: ...3121774 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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