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Oshkosh JLG X1000AJ, Service And Maintenance Manual, Page: 112 / 162

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Oshkosh JLG X1000AJ Service And Maintenance Manual Download Page 112

SECTION 5 - HYDRAULICS

3121784

5-31

5.12 HYDRAULIC PUMP REPAIR

Seal Kit Replacement Instruction

General Suggestions

1.

Check the parts have not been damaged during 
the shipment.

2.

Work in a clean area.

3.

Clean with solvent (except the seals) and air dry 
all components before assembling.

4.

Pay attention not to damage the machined sur-
faces.

5.

The components need to be fitted in place with-
out forcing them. If too much force is required, it 
is due a bad clearances issues.

6.

When hand pressure is not enough, use only 
mallet and never hammer.

7.

Respect the tightening torque for bolts.

External Components Disassembly

CAUTION

USE SOME ALUMINIUM PROTECTION ON THE VICE TO NOT DAMAGE
THE MACHINED SURFACES. PUT THE PUMP IN HORIZONTAL POSITION
AND BLOCK THE COVER IN THE VICE'S JAWS. LOOSEN THE BOLTS. 

First section

Second section

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Summary of Contents for JLG X1000AJ

Page 1: ...Service and Maintenance Manual Models X33JP X1000AJ 3121784 Rev A April 1 2019 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: ...with 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 Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell ...

Page 3: ...rt is provided SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER OPERATOR HYDRAULIC SYSTEM 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 disconnecting or rem...

Page 4: ... PRECAUTIONS b JLG Lift 3121784 KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS 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 5: ...INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS 3121784 JLG Lift c REVISON LOG Original Issue A April 1 2019 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 6: ...als 1 5 1 13 LUBRICATION 1 6 Hydraulic Oil 1 6 1 14 SERIAL NUMBER LOCATION 1 7 1 15 FASTENER TORQUE CHARTS 1 8 SECTION 2 GENERAL 2 1 MACHINE PREPARATION INSPECTION AND MAINTENANCE 2 1 General 2 1 Preparation Inspection and Maintenance 2 1 Pre Start Inspection 2 1 Pre Delivery Inspection and Frequent Inspection 2 1 Annual Machine Inspection 2 1 Preventative Maintenance 2 1 2 2 SERVICE AND GUIDELINE...

Page 7: ...move 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 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 Th...

Page 8: ... Load Cell 4 15 Installing Load Cell 4 15 Removing Footswitch 4 15 Installing Footswitch 4 15 4 8 SKYGUARD INSTALLATION ONE PERSON PLATFORM 4 16 Procedure 4 16 Installation 4 17 Skyguard System 4 20 4 9 SKYGUARD INSTALLATION 2 PERSON PLATFORM 4 22 Procedure 4 22 Installation 4 23 Skyguard System 4 26 SECTION 5 HYDRAULICS 5 1 MAIN HYDRAULIC VALVE BLOCK IDENTIFICATION AND LOCATIONS 5 1 5 2 COMPONENT...

Page 9: ...R 5 31 Seal Kit Replacement Instruction 5 31 External Components Disassembly 5 31 Components disassembly 5 32 Second Section Components Disassembly 5 33 Second Section Seals Disassembly 5 33 Second Section Seals Replacement 5 34 First Section Seals Disassembly 5 34 First Section Seals Disassembly 5 35 First Section Seals Replacement 5 35 Cover Seals Replacement 5 36 Second Section Components Reass...

Page 10: ...SETTING 6 26 New Master Board 6 26 Already Initialized Master Board 6 27 Software Recovery By Modem 6 28 6 6 CODE MENU 6 28 SECTION 7 GENERAL ELECTRICAL INFORMATION SCHEMATICS 7 1 GENERAL 7 1 7 2 MULTIMETER BASICS 7 1 Grounding 7 1 Backprobing 7 1 Min Max 7 2 Polarity 7 2 Scale 7 2 Voltage Measurement 7 2 Resistance Measurement 7 2 Continuity Measurement 7 3 Current Measurement 7 3 Continuity Meas...

Page 11: ...with 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 Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell ...

Page 12: ...1 3km h Maxhydraulicsystempressure 3 046psi 210bar Maximumwindspeed 28mph 12 5m s Maximummanualforce 90lb 400N Electricalsystemvoltage 12V Lithium Ionsystemvoltage 76V Grossmachineweight platformempty Diesel Lithium 16 865lb 7650kg 16 975lb 7700kg Model X1000AJ X33JP HydraulicTank 21 1gal 80L FuelTank Diesel 6 6gal 25L EngineOil Diesel 0 98gal 3 71L PlatformCapacity 2occupants 500lb 230Kg Model D9...

Page 13: ...reephase 2000watt Thechargecycleshavetobeconsideredbasedonthefactthatthereisnotmem oryeffectinthelithiumbatteries i e 2000chargesat100 or4000chargesat 50 etc Model X1000AJ X33JP Engine DryWeight KubotaD902Diesel 158lb 72kg BoomSectionsCombined 4 916lb 2 230kg LiftCylinders LevelCylinder JibCylinder 3rdboomlevelcylinder Liftcylinder Upperliftcylinder SwingActuator Telescopecylinder 16 5lb 7 5kg 26 ...

Page 14: ...Record Time Test Notes 1 Stop watch should be started with the function not with the controller or switch 2 All speed tests are run from ground with remote control connected on the basket 3 Function speeds may vary due to cold thick hydraulic oil Test should be run with the oil tem perature above 100 F 38 C 1 11 HYDRAULIC PRESSURE SETTINGS PSI BAR MACHINE MODEL X33JP X1000AJ POWER SYSTEM Engine Li...

Page 15: ...SECTION 1 SPECIFICATIONS 1 4 3121784 1 12 COMPONENT MAINTENANCE INTERVALS Diesel maintenance intervals ML00540 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 16: ...SECTION 1 SPECIFICATIONS 3121784 1 5 Lithium maintenance intervals ML00550 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: ... 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 N2300029 FLUID PROPERTIES TYPE CLASSIFICATIONS DESCRIPTION Viscosity at 40 C cst Typical Viscosity Index Mineral Oils Vegetable Oils Synthetic Synthetic Polyol Esters Readily Biodegradable Virtually Non toxi...

Page 18: ...wing illustration showing the posi tion Figure 1 2 Serial Number Plate Figure 1 3 X33JP X1000AJ Serial Number Plate Location on side of turn table frame Figure 1 4 X33JP X1000AJ Serial Number Stamp Location Serial number stamped on chassis SL00010 ML00200 ML00530 ML00530 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 19: ...SECTION 1 SPECIFICATIONS 1 8 3121784 1 15 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 s ...

Page 20: ...SECTION 1 SPECIFICATIONS 3121784 1 9 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 21: ...SECTION 1 SPECIFICATIONS 1 10 3121784 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 22: ...SECTION 1 SPECIFICATIONS 3121784 1 11 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 23: ...SECTION 1 SPECIFICATIONS 1 12 3121784 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 24: ...with 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 Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell ...

Page 25: ...plished 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 increased as environment severity and frequency of usage requires Reference the JLG Pre Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requirin...

Page 26: ...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 becomes less than 90 degrees 3 If a part resists removal check to see whether all nuts bolts cables brackets wiring etc have been removed and that no adjacent parts are interfering Component Disassembly ...

Page 27: ...ts as required to aid assembly Lubrication Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants are not available consult your local supplier for an equivalent that meets or exceeds the specifications listed Battery Clean battery using a non metallic brush and a solution of baking soda and water ...

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 purpose greases usually have the qualities which meet a variety of single purpose grease require ments Should any question arise regarding the use of greases in maintenance stock consult your local sup plie...

Page 29: ...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 and opera tion 2 6 WELDING ON JLG EQUIPMENT NOTE This instruction applies to repairs or modifications to the machine and to welding performed from the machine on an external structure or component Do the Follo...

Page 30: ...SECTION 2 GENERAL 2 6 3121784 NOTES 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 31: ...rease putting the safety of the operator at risk Never loosen greaser 2 When gravel or mud are blocked between the toothed wheel and the track links remove it before loosening 1 Remove the screws and take of adjustment access lid 3 2 To loosen the track slowly unscrew valve 1 in an anti clockwise direction for no more than one turn One turn of valve 1 is sufficient to loosen the track 3 If the gre...

Page 32: ...f adhesive of the rubber between the core itself and the steel ropes Separation may be caused by excessive tension as breakage of the ropes for the following reasons b The metal cores have been wound by the worn toothed wheel as indicated in the fig ure When this wear and abrasion is detected the toothed wheel must be replaced as soon as possible c If it breaks as stated in item 2 Wear and breakag...

Page 33: ...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 safe conditions using the outrig gers Figure 3 6 2 Remove the screws and take of adjustment access lid 3 3 To loosen the track slowly unscrew valve 1 in an anti clockwise direction for no more than one tur...

Page 34: ... stated 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 warning do not start the machine Replacement roller lower wheel and tracks adjuster Figure 3 9 Disassembly 1 Remove the nuts 2 on the lower roller 2 Remove the lower roller 3 3 Remove the front idler 5...

Page 35: ... valve 10 to access all the screws 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 Figure 3 11 Sprocket installation 1 Instal the sprocket 2 Instal the screws 6 1 6 7 11 9 8 12 10 12 11 1 6 7 11 9 8 12 10 12 11 Table 3 1 Final Drive Torque Valves MA...

Page 36: ...rame Figure 3 14 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 15 12 Remove the cylinder NOTE Before to install the undercarriage frame inspect the slide guides 9 a Unscrew the screws 7 b Remove the stop slide guides 8 c Remove the slide guides 9 d Check the thickness of slide guides if less than 3 5 mm damage...

Page 37: ...oduct spare parts assistance etc always give the identi fication data stamped on the ID plate The gearmotor 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 shows how the data is set out MACHINE TYPE SPEED X33JP X1000AJ 701C2K MAG18 AUTOTWOSPEED G o t o D i s...

Page 38: ... 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 struc ture through bolts For this purpose through holes or threads are provided in the inner and outer ring Figure 3 17 Slew drive WD L 1 Connection for options Potentiometer perma nent brake or front ...

Page 39: ... 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 zone is that area of the slew ing ring that is subject to the highest load tak ing all aggressive forces and torques and all occurring load cases into account 2 Arrange the hardness gap of the bearing ring ...

Page 40: ...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 strength Figure 3 21 Tighten crosswise 1 FM for hydraulic bolt tensioning cylinder pretension to 85 of yield strength 1 FM for hydraulic bolt tensioning cylinder pretension to 85 of yield strength Table 3 3...

Page 41: ... 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 Qualifiedperson After Every Additional 500 Operating Hours Or At Least Every 6 Months Check tighten bolts Reduce the inspection interval if there is heavy wear or continuous operation Qualifiedperson Check tilting...

Page 42: ...y 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 bolt quality NOTICE IF A HYDRAULIC CLAMPING FIXTURE WAS USED TO TIGHTEN THE BOLTS THEN A HYDRAULIC CLAMPING FIXTURE MUST ALSO BE USED TO CHECK THE BOLT PRETENSION ALWAYS USE THE SAME TIGHTEN ING PROCEDURE ...

Page 43: ...l 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 If it is evident that moisture has penetrated into the slew drive or has been absorbed by the grease you must re lubricate more intensively Figure 3 23 Lubricating the slew drive 1 Fresh lubricant 2 Lubri...

Page 44: ...ectricPump 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 Stroke 73 6mm 2 9in Fuel tank capacity 40litres Emission Regulation Tier4F Dry Weight according to Kubota s standards 72Kg 158 8Lbs 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...

Page 45: ...ngine head close to muffler collector and includes the following engine information 1 Engine model 2 Engine serial number 3 Engine code No The information shown above is necessary for any engine spare parts or information required 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 46: ...ABLE 3 16 3121784 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 o r d e r y o u r p a r t s ...

Page 47: ...ry for few second only Pin 5 Starter For a moment utilize hook up this pin for as key starter To shutdown the engine disconnect wire of Pin 10 The engine will continue to run for a while until it ends the fuel on the line Engine Speed Sensor A sensor in the diesel engine detects the engine rpm s and communicates this data to the master controller Figure 3 26 Speed Sensor on Kubota D902 Speed Senso...

Page 48: ...ilize the machine on a flat and level surface 2 Turn machine OFF and remove the key ignition and a tag with warning do not start the machine 3 Remove the cover 1 Figure 3 30 Engine cover 4 Disconnect tag and isolate the wires from the engine 5 Disconnect the oil pipes and cooling lines then drain the 2 circuits Figure 3 31 Image 3 1 Replace the engine and tighten the screws Torque screws to 16 2 f...

Page 49: ...frame 7 Carefully lift remove the electrical motor and separate from the pumps adapter 8 After the electrical motor has been removed loosen the screw 3 and pull off the coupler 4 Figure 3 33 9 For the electrical motor installation follow the procedure in opposite order from step 5 to step 8 10 After mounting the electrical motor tighten four mounts bolts item 2 to 29 5 ft lb 40N m while the bolts ...

Page 50: ...SECTION 3 CHASSIS TURNTABLE 3 20 3121784 Figure 3 35 14 Install cover and test the machine 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 51: ...k at 12 5 Volt so Lithium system includes a DC DC transformer that convert the 76 Volt into 13 5 Volt Machine is equipped with 12 Volt battery necessary to switch ON Lithium system Electric Motor Electric motor is fed through an inverter that convert the lithium pack direct current DC into alternative three phase current RPM Regulation System RPM regulation is carried out by the following compo ne...

Page 52: ...onmental temperature the fans system auto matically cool down the cells they are automatically acti vated by the BMS when cells temperature raises over 98 6 F 37 C they are automatically switched off when cells temperature goes down the 95 F 35 C Diagnostics And Fault Codes The main devices composing the lithium batteries system are able to carry out self diagnosis informing the operator by the re...

Page 53: ...with 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 Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell ...

Page 54: ...rom microswitch 6 Pull the bottom of microswith wire side to dis connect it 7 Push contact in to microswitch and secure by turning screw clockwise 90 8 Place the microswitch on bracket Hand tighten nuts 2 9 Adjust microswitch to the ropes balancer tooth Microswitch must be pressed 10 Tighten nuts 2 11 Place cover on tower boom and secure with screws 1 1 1 Left side Right side ML00320 2 ML00330 ML0...

Page 55: ... Stabilize machine on flat level ground 2 Remove screws from boom cover and remove cover 3 Extend main boom until side window is uncov ered by internal boom section DURING THE MAIN BOOM EXTENSION MACHINE WILL OPEN THE JIB AND TOWER BOOM AUTOMATICALLY ML00370 ML00380 ML00390 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: ...cer 7 Unscrew all three bolts from microswitch cover 8 Remove microswitch cover 9 Unscrew screws and remove microswitch 10 Turn screw counter clockwise to unlock contact from microswitch 6 Pull the bottom of microswith wire side to dis conect it 7 Push contact in to microswitch and secure by turning screw clockwise 90 ML00400 ML00410 ML00420 ML00340 ML00350 ML00360 G o t o D i s c o u n t E q u i ...

Page 57: ...cer screw in hole and secure with n 1 washer Ø16 and M16 tensioner nut 12 Tighten nut to 44 25 in lbs 5 Nm 13 Tighten front side nuts to 44 25 in lbs 5 Nm Keep ropes from rotating using a 14 mm wrench while tightening front side nuts 14 Switch on the machine and retract the main boom until end of stroke is reached ML00420 ML00430 ML00440 ML00450 ML00460 G o t o D i s c o u n t E q u i p m e n t c ...

Page 58: ...rotating using a 14 mm wrench while tightening front side nuts 17 Once tensioner nuts are torqued to 44 25 in lbs 5 Nm torque to 88 5 in lbs 10 Nm 18 Loosen all slide adjusters two to three turns 19 Switch on the machine extend and retract the main boom two to three times Verify correct functionality 20 Tighten slide adjusters 21 Verify proper rope tensioner nut torque value 22 Tighten a second nu...

Page 59: ...croswitch should be just touching rope balancer cam 26 Tighten screws to secure microswitch 27 Install cover and secure with screws Back side microwsitch replacement 1 Unscrew screws and remove microswitch 2 Turn screw counter clockwise to unlock contact from microswitch 6 Pull the bottom of microswith wire side to dis conect it ML00510 ML00380 ML00510 ML00340 ML00350 ML00360 G o t o D i s c o u n...

Page 60: ...h and secure by turning screw clockwise 90 8 Verify microswitch clearance on back side Mis croswitch should be just touching rope balancer cam 9 Tighten screws to secure microswitch ML00510 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 61: ...k 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 fully lift boom assembly clear of turntable and lower to ground or suitable supported work surface Disassembly of the Main Boom 1 Loosen jam nuts on aft end of fly boom wear pad adjustment and loosen adjustments 2 U...

Page 62: ...th 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 out to gain access to telescope cylinder attach pin hole 7 Measure the distance between the telescope cylinder port block attach point on base boom section and the attach point on fly boom sec tion 8 Co...

Page 63: ...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 into position with a soft headed mallet ensuring that attach holes in pins are aligned with attach holes in boom struc ture Secure with hardware 5 Connect all hosing and wiring 6 Install the platform to th...

Page 64: ...tion on the pulleys 7 Three month inspection 1 Remove all protection sumps from the third arm and the two extensions Use a flashlight torch to visually check the state of the ropes and the extension pulleys 2 Check the correct rope tension trying to bend them manually If they are pulled correctly they should not be able to move more than a few mil limeters 3 Check that in the extension arms exit p...

Page 65: ...or about 30 40cm 3 Tighten the nut for the traction of the fixing rocker arm of the return ropes to a torque of 10Nm Figure 4 7 Return ropes fixing rocker arm 4 Completely extend the extensions and retract them by about 30 40cm 5 Tighten the bolts of the two output cables so that the threaded terminals come out of 65 3 mm from the rocker arm During adjustment keep the ropes blocked to prevent them...

Page 66: ...r 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 installa tion 4 Torque the 1 4 inch bolts 110 to 120 inch pounds 12 4 to 13 5 Nm Do not torque over 125 inch pounds 14 1 Nm Torque the 5 16 inch bolts 140 inch pounds 15 8 Nm Do not torque over 145 inch pounds 1...

Page 67: ...e 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 posts and lower until seated 2 Secure the platform to the jib mounting posts with the aluminum threaded caps Do not over tighten 3 Re install the platform remote control box into the mounting support on th...

Page 68: ... 3 Reinstall the basket See section basket installation Figure 4 12 Removing Footswitch 1 Turn the machine off and unplugged from the power supply 2 Remove the basket of the machine See paragraph basket removal 3 Remove screws 5 securing support footswitch 6 4 Loosen the fixing screw foot 1 5 Remove the footswitch 1 disconnecting the wiring from ECM3 Installing Footswitch 1 Fit and secure with scr...

Page 69: ...Qualified 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 machine to rest position 3 Remove the key and shut the engine OFF 4 Allow the machine and system fluids to cool 5 Disconnect the battery power from the machine Welded Mount ITEM PART NUMBER D...

Page 70: ...gure 4 15 Figure 4 15 2 Align and attach Platform Sensor Mount 12 onto the SkyGuard Switch 11 as shown in Fig ure 4 16 3 Attach Platform Sensor Covers 9 to SkyGuard switch assembly at both ends See Figure 4 16 Figure 4 16 4 Position SkyGuard switch assembly with sensor cover onto the SkyGuard Support Bracket 8 as shown in Figure 4 17 SkyGuard Switch Assembly SkyGuard Bracket 8 7 3 2 12 11 9 G o t ...

Page 71: ...ighten 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 shear block support before installation Figure 4 17 9 Route the SkyGuard switch harness along Sky Guard support bracket right side and under the platform control box Secure the harness using tie straps See...

Page 72: ...ystem 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 button 1 optional Press button 8 next Press button 4 skyguard Press Button 1 ON Figure 4 22 Press button 9 esc Press button 9 esc Press button 9 esc Press button 9 esc Remote control screen should be on mai...

Page 73: ... cutout The table below outlines these functions Main Lift Up Main Lift Dn Main Tele In Main Tele Out Swing Drive Forward Drive Reverse Tower Lift Up Tower Lift Down Platform Level Platform Rotate Jib Lift Go Home All Functions R C C R C C C R C C C C C R IndicatesReversalisActivated C IndicatesCutoutisActivated N AIndicatesthefunctiondoesnotexistforthismodel G o t o D i s c o u n t E q u i p m e ...

Page 74: ...SECTION 4 BOOM PLATFORM 3121784 4 21 Figure 4 24 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 75: ...fied 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 machine to rest position 3 Remove the key and shut the engine OFF 4 Allow the machine and system fluids to cool 5 Disconnect the battery power from the machine ITEM PART NUMBER DESCRIPTION QTY Wel...

Page 76: ...gure 4 27 Figure 4 27 2 Align and attach Platform Sensor Mount 12 onto the SkyGuard Switch 11 as shown in Fig ure 4 28 3 Attach Platform Sensor Covers 9 to SkyGuard switch assembly at both ends See Figure 4 28 Figure 4 28 4 Position SkyGuard switch assembly with sensor cover onto the SkyGuard Support Bracket 8 as shown in Figure 4 27 SkyGuard Switch Assembly SkyGuard Bracket 8 7 3 2 12 11 9 G o t ...

Page 77: ...ighten 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 shear block support before installation Figure 4 29 9 Route the SkyGuard switch harness along Sky Guard support bracket right side and under the platform control box Secure the harness using tie straps See...

Page 78: ...ystem 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 button 1 optional Press button 8 next Press button 4 skyguard Press Button 1 ON Figure 4 34 Press button 9 esc Press button 9 esc Press button 9 esc Press button 9 esc Remote control screen should be on mai...

Page 79: ... cutout The table below outlines these functions Main Lift Up Main Lift Dn Main Tele In Main Tele Out Swing Drive Forward Drive Reverse Tower Lift Up Tower Lift Down Platform Level Platform Rotate Jib Lift Go Home All Functions R C C R C C C R C C C C C R IndicatesReversalisActivated C IndicatesCutoutisActivated N AIndicatesthefunctiondoesnotexistforthismodel G o t o D i s c o u n t E q u i p m e ...

Page 80: ...SECTION 4 BOOM PLATFORM 3121784 4 27 Figure 4 36 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 81: ...SECTION 4 BOOM PLATFORM 4 28 3121784 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 82: ...ht track c Front left outrigger d Rear left outrigger e Front right outrigger f Rear right outrigger g Widening system 2 Aerial Valve Block a Tower extension b Tower boom c Main extension d Main boom e Turn table rotation ML0040 1 2 3 ML00050 a b c d e f g ML00060 a b c d 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 83: ...ECTION 5 HYDRAULICS 5 2 3121784 3 Platform Valve Block a Jib cylinder b Platform leveling c Platform rotation ML00070 a b 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 84: ...Safety Valve Block Aerial Ground Electric Valve Deviator X153 The aerial ground deviator sends oil to the ground valve block or to the aerial valve block ML00080 ML00090 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 85: ... is set during production auto two speed system Pumps Electric Valve X125 The pumps electric valve sends the second pump s oil to the ground pump valve block or the aerial valve block at the ground to improve the movement speeds NOTE Platform leveling always has priority ML00100 ML00110 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 86: ...gages the little pump used to improve movement speeds if oil pressure exceeds 2175 psi 150 bar Aerial Dump Valve Ground X166 The aerial dump valve is a second safety valve for the aer ial system on the ground ML00120 ML00130 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 87: ...RAULICS 5 6 3121784 Aerial Dump Valve Jib X190 The aerial dump valve is a second safety valve for the aer ial system on the jib ML00140 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 88: ...SECTION 5 HYDRAULICS 3121784 5 7 Ground Valve Block ML00150 ML00160 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 8 3121784 5 3 SCHEMATIC Figure 5 1 Hydraulic Schematic Sheet 1 of 2 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 3121784 5 9 Figure 5 2 Hydraulic Schematic Sheet 2 of 2 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: ...Double pump valve is not fed with contemporaneously movements and is not fed at minimum speed TURTLE 5 5 GROUND COMPONENT HYDRAULIC SYSTEM The ground control manifold valves control outriggers left and right track drive and track widening The ground control valves are controlled by a hydraulic valve block equipped with one maximum pressure valve six proportional valves and an ON OFF valve for grou...

Page 92: ...ed valve reducing the gear rate and the tracks speed Auto2speed allows to manage automatically the available power providing on demand an higher torque with a slower speed or an faster speed with a lower torque Second speed activation oil coming from second speed valve coil is sent to both drive gear motors through the second speed manifold SMALLER CHAMBER FASTER SPEED SMALLER TORQUE BIGGER CHAMBE...

Page 93: ... off manifold 5 9 BOOM COMPONENT HYDRAULIC SYSTEM The boom components controlled by the aerial valve block are tower extension tower boom main extension main boom and turn table rotation The boom components are controlled by an hydraulic manifold valve equipped with proportional valve and an ON OFF valve for each aerial part movement Boom component manifold valves are fed by pressure line A throug...

Page 94: ...pe Telescope system is composed by two parts the tower boom that contains the first telescope and the main boom that contains the second telescope They are all opened or closed together by an unique internal cylinder and a system of ropes and pulleys Microswitches detect the ropes positions within the boom sections Jib Jib is moved by one cylinder while moving jib the platform is kept level thanks...

Page 95: ...SECTION 5 HYDRAULICS 5 14 3121784 5 10 CYLINDER REPAIR Specification Cylinders Overview Figure 5 3 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 96: ...SECTION 5 HYDRAULICS 3121784 5 15 Figure 5 4 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 97: ...SECTION 5 HYDRAULICS 5 16 3121784 Figure 5 5 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 98: ...SECTION 5 HYDRAULICS 3121784 5 17 Figure 5 6 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 99: ...M12x1 5 20 8 M14x1 5 25 10 M16x1 5 30 12 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 50 150 200 55 150 200 60 200 250 65 200 250 70 250 300 75 250 300 80 300 350 90 350 400 100 400 450 110 450 500 120 500 550 130 500 550 140 500 550 150 500 550 160 550 ...

Page 100: ...ible NOTICE AVOID USING EXCESSIVE FORCE WHEN CLAMPING THE CYLINDER IN A VISE APPLY ONLY ENOUGH FORCE TO HOLD THE CYLINDER SECURELY EXCESSIVE FORCE CAN DAMAGE THE CYLINDER TUBE 3 Remove the counterbalance valve from the side of the cylinder barrel NOTICE CYLINDER ARE UNDER PRESSURE NOTICE DO NOT TAMPER WITH OR ATTEMPT TO ADJUST THE COUNTERBAL ANCE VALVE CARTRIDGE IF ADJUSTMENT IS NECESSARY REPLACE ...

Page 101: ...d air with caution on the connec tion in order to push the sensor out of the hos ing NOTICE WHEN SLIDING THE ROD AND PISTON ASSEMBLY OUT OF THE TUBE PREVENT THE THREADED END OF THE TUBE FROM DAMAGING THE PISTON KEEP THE ROD CENTERED WITHIN THE TUBE TO HELP PRE VENT BINDING NOTICE BE CAREFUL IN THIS OPERATION IN ORDER TO AVOID TO BREAK THE WIRE OR DAMAGE THE SENSOR G o t o D i s c o u n t E q u i p...

Page 102: ... trichlorethylene Carefully clean cavities grooves threads etc NOTE If a white powdery residue 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 3 Blow pressurized air on the connection of the manifold for cleaning 4 Verify the integrity of the tube checking that the surface doesn t present...

Page 103: ...the piston remove any accessible seals NOTE Apply heat to break the bond of the sealant between the piston and the rod before the piston can be removed CAUTION WARM THE SURFACE INDICATED MAX 300 C Avoid overheating or the parts may become distorted or damaged Apply sufficient torque for removal while the parts are still hot The sealant often leaves a white powdery residue on threads and other part...

Page 104: ...rings Install new seals back up rings and o rings on the piston and the head using the proper tool Cylinder Mounting Cylinder Inspection 5 Inspect internal surfaces and all parts for wear damage etc If the inner surface of the tube does not display a smooth finish or is scored or dam aged in any way replace the tube 6 Remove light scratches on the piston rod or inner surface of the tube with a 400...

Page 105: ...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 Specifications for tightening guidelines for the piston Sensor Assembling Spacer has chamfer 12 Mount spacer with chamfer face outside 13 Lubricate the o ring 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 ...

Page 106: ...c tool to insert the sensor 17 Push the tool carefully 18 Remove the set screw insert the pin and than fix the set screw Pay attention do not overtighten the set screw because the sensor could be damaged Tightening torque 5 Nm seal with AREXON 35A77 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: ...cylinder 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 possible NOTICE AVOID USING EXCESSIVE FORCE WHEN CLAMPING THE CYLINDER IN A VISE APPLY ONLY ENOUGH FORCE TO HOLD THE CYLINDER SECURELY EXCESSIVE FORCE CAN DAMAGE THE CYLINDER TUBE 3 Remove the c...

Page 108: ...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 the proper tools for specific installation tasks Clean tools are required for assembly 2 Install new seals back up rings and o rings on the piston and the head 3 Fasten the rod eye in a soft jawed vi...

Page 109: ... 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 replaced Replace the seals on the piston DO NOT attempt to sal vage cylinder seals sealing rings or o rings ALWAYS use a new complete seal kit when rebuilding hydraulic compo nents Consult the parts manual ...

Page 110: ...sidue 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 Specifications for tightening guidelines for the piston Bushing Replacement 1 Carefully grind the bush with a milling cutter for plastic 2 After that the bushing has been removed inspect the internal ...

Page 111: ... TO LET AIR ESCAPE RE TIGHTENING TORQUE 6 FT LB 8 Nm 5 11 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 screws 16 4 Remove from the pump 15 from the adapter 12 5 Loosen nut 10 and remove the coupling 11 and plate 14 from the pump shaft 15 6 Move the new pump the particular 14 Pump installation 1 Install the ...

Page 112: ...need to be fitted in place with out forcing them If too much force is required it is due a bad clearances issues 6 When hand pressure is not enough use only mallet and never hammer 7 Respect the tightening torque for bolts External Components Disassembly CAUTION USE SOME ALUMINIUM PROTECTION ON THE VICE TO NOT DAMAGE THE MACHINED SURFACES PUT THE PUMP IN HORIZONTAL POSITION AND BLOCK THE COVER IN ...

Page 113: ... key 2 3 Put the pump on the work bench and remove the bolts and the washers Components disassembly 1 Remove the first section from the second sec tion 2 Remove the connecting hub and the dowel pins 3 Remove the rear cover 1 2 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 114: ...on the plate and the body It will be used later during reassembly 2 Remove the gears and the pressure plates Second Section Seals Disassembly 1 Remove the seals from the body 2 Remove from the plate the back up ring 1 and the seal 2 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 115: ...e 2 Fit the new seal 1 and back up ring 2 on the plate First Section Seals Disassembly 1 Remove the front cover 2 Using a marker draw a reference mark on the plate and the body It will be used later during reassembly 3 Remove the gears and the pressure plates 1 2 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 116: ... the plate the back up ring 1 and the seal 2 First Section Seals Replacement 1 Use clean grease on the pressure plate to help the seals stay in place before fitting them 2 Fit the new seal 1 and back up ring 2 on the plate 3 Fit the new seal 1 and back up ring 2 on the plate 1 2 2 1 1 2 2 1 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 117: ...the seat seal 5 Insert the shaft seal Pay attention to the assem bling direction of the shaft seal see section Using a mallet push all the way down the CASAPPA tool pn 06100091 6 Insert the second shaft seal Pay attention to the assembling direction of the shaft seal see sec tion Using a mallet push all the way down the CASAPPA tool pn 06100091 7 Insert the back up ring 8 Using a mallet push all t...

Page 118: ...previously 2 Reassemble the rear cover First Section Components Reassembly Reassemble the gears and the plates Use as reference the mark made previously Components Reassembly 1 Put back the flange and the pins Put the con necting hub into the second section shaft 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 119: ...wel pins 4 Put the appropriate CASAPPA tool pn 06100090 on the drive shaft or protect with adhesive tape to avoid damaging the shaft seal 5 Use grease on the CASAPPA tool Assemble the cover on the pump 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 120: ...P CAN ROTATE AFTER THE OPERATION IN BOTH DIRECTIONS THE SHAFT MUST EAS ILY ROTATE IF THE SHAFT IS LOCKED THIS MEANS THAT SOME OF THE SEALS HAVE COME OUT OF THEIR SEATS DURING ASSEMBLY IF THIS HAPPENS THE WHOLE OPERATION MUST BE DONE AGAIN AND THE DAMAGED SEALS REPLACED 2 Put back the shaft key 2 Insert the washer and tighten the nut 1 Tightening torque 10 Nm 1 2 G o t o D i s c o u n t E q u i p m...

Page 121: ...to its specified torque If the tank needs to be pressurized in order to start the flow of oil a vacuum reading should be taken at the inlet of the pump during operation in order to verify that the pump is not being asked to draw an inlet vacuum higher than it is capable of 3 Be certain to fill the pump and or motor housing with clean hydraulic fluid prior to start up Fill the housing by pouring fi...

Page 122: ...Retraction In Progress It s possible to keep automatic outriggers retraction run ning till outriggers are completely lifted up To achieve the stowed condition outriggers must be com pletely lifted up till the end of their stroke and have to be manually rotated while unlocked with their pivot The machine is equipped with two pressure switches on the hydraulic manifold one for the right side and one...

Page 123: ...with 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 Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell ...

Page 124: ... SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURA TION The JLG Control System is a 12 volt based control 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 various personality Settings for smooth control of acceleration dece...

Page 125: ...ere are eight 8 display positions which indicate machine status during various stages of operation The remote control is made up of buttons joysticks a key selector switch and a display When the machine s main control board is powered via the engine key the information to be shown on the dis play is sent to the remote control 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 126: ...ring this period NOTE The numbers shown above DOWNLOAD are the data transferred The Download will be completed when about more than 29000 steps are transferred LCD Display Screen At machine start up and during machine operation the main LCD display screen is activated There are eight 8 display positions which indicate machine status during various stages of operation Figure 6 3 POSITION 1 Reduced ...

Page 127: ...isplay 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 and outrigger functions are operational if this symbol below is present No symbol indicates these functions are not operational Drive and steer are operational if all 4 outriggers are not contacting the groun...

Page 128: ...ns are cut out Swing sensor is faulty CANBUS communication is faulty Electronic fault Lithium ION Signals an error in the BMS Battery Management System Skyguard System Enabled Battery cold heater activated system is enabled Safety by pass activated Service Interval Figure 6 10 POSITION 8 Indicates emergency lowering has been selected Lithium ION Battery Charge Status and Battery Char ger Plugged I...

Page 129: ...nload 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 Press pedal Double line sensor error check error menu Error on board input or output check CODE menu Software updating in progress CAN BUS error check CAN TIME CUT menu 12V battery down or 3rd boom ...

Page 130: ...it s possible to identify the installed software version and the machine model settled 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 9 ESC brings back to the main display From SERVICE menu it s possible to enter into other menu and under menus NOTE...

Page 131: ... ON Outrigger n 1 fully open position the switch is pressed and line A is open and line B is closed OFF OFF Outrigger n 1 in transport position the switch is released and lines A and B are open ST2GND AB DOWN DOWN Outrigger n 2 on the ground the switch is released line A is open and line B is closed UP UP Outrigger n 2 lifted the switch is pressed line A is closed and line B is open ST2 OPEN AB ON...

Page 132: ...s released and lines A and B are open BYPASAE AB OFF OFF Aerial ground switch in normal working condition line A is open and line B is closed ON ON The aerial ground switch is activated emergency condition line A is closed and line B is open BYPASTR AB OFF OFF Drive ground switch in normal working condition line A is open and line B is closed ON ON Drive ground switch is activated emergency condit...

Page 133: ...pes OK OFF Left telescope ropes prox switch 4 section ropes not well tensioned or broken PROX FUNI B ON Right telescope ropes prox switch 4 section ropes OK OFF Right telescope ropes prox switch 4 section ropes not well tensioned or broken FUNI MAIN ON ON Telescope extension ropes prox switch main boom ropes not well tensioned or broken OFF OFF Telescope extension ropes prox switch main boom ropes...

Page 134: ...ine closed and aligned ROT BAS AB 24 3755 Left end of stroke 679 2920 SKYGUARD ON Indicates that SkyGuard bar has been pressed OFF Indicates that SkyGuard bar has not been pressed TEMPERAT 37 62 Indicates the temperature of ECM1 in Celsius degrees SUPPLY V 12 15 Indicates the battery voltage or the output voltage from the battery charger V HIGH CELL 3317 Indicates the voltageof the highestcell Whe...

Page 135: ...s 1 Indicates the number of the cell with the highest resistance R AVG CELL 1 Indicates the average resistance mOhm of cells R LOW CELL 0 Indicates the highest resistance mOhm of cells 0 Indicates the number of the cell with the lowest resistance HOURS INV 27 It counts the working hours of electric motor running RPM INV 0 Indicates the electrical motor rpm read by the speed sensor At a certain rpm...

Page 136: ...in within the charge or out within machine operation discharge of battery pack BMS STATUS 1 Indicates the BMS status or fault code if present PIN 101 3 73 PIN 102 0 32 PIN 238 94 99 PIN 241 95 32 PIN 126 0 PIN 125 0 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 137: ...s are both opened or 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 OK ERROR menu is composed by the following 5 different pages selectable by buttons n 1 and n 2 it s always possi ble to come back to the SERVICE menu main display press ing butto...

Page 138: ...Supple ment Manual BYPAS AE Aerial part safeties by pass switch BYPAS TR Ground part safeties by pass switch STOP GRN Stop button on the ground STOP RC UP Remote control stop button on the platform PEDAL Pedal SKYGUARD SkyGuard system ST1 POMS Outrigger n 1 position ST2 POMS Outrigger n 2 position ST3 POMS Outrigger n 3 position ST4 POMS Outrigger n 4 position INCL G Frame tilt sensor ROTATION Tur...

Page 139: ...6 W HOURS KEEPING PRESSED the button 6 use the button1 T to increase and button 2 T to decrease 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 then button 3 to set zero the working hours of Engine and Motor 5 Press button 9 ESC 3 times to escape INC BAS P...

Page 140: ...the proper functioning of the joysticks once selected one joystick by buttons n 1 and n 2 joystick enumeration is indicated here below the display will show its position expressed in step from 0 rest position to 127 joystick fully pressed up or down Moving the selected joystick it s so possible to check its proportionality and its end of the stroke about 127 steps both forward and backward G o t o...

Page 141: ...e 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 for the recommended factory settings NOTE Passwords will give you access to level which will permit you to change all machine settings 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...

Page 142: ...ne setting By PASSWORD page it s possible to insert the password required pressing the keyboard buttons password are composed by 4 numbers if password is accepted display will visualize an OK Setup Date By this page is visualized the settled time after having inserted the relevant password 1468 it s possible to adjust it pressing buttons n 1 to modify the day buttons n 2 to modify the month and n ...

Page 143: ...he relevant input menu voice 10 Line A must be set at 360 line B must be set at 0 NOTE Turn table can be set from transport position if the alignment is already perfect Setup Platform Rotation Sensor 1 Turn ON the main key and stabilize the machine 2 Align platform with boom 3 Press button n 6 SERVICE and then press but ton n 7 SETUP 4 Press button n 5 PASSWORD The display will ask for the passwor...

Page 144: ...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 variation at several basket load ing condition the difference between LOAD A and LOAD B values should be less than a certain value Setup ACCELER Calibrating Tilt Sensor This menu allows the calibration of the tilt sensor After replaced t...

Page 145: ...ngs 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 shows RAHM references the position availabil ity latitude and longitude date and hours references INCLINATION SENS CA LIBRATION MACCHINA NOT READY 3 CALIB 9 ESC EXTRA 1 OPTIONAL 2 FIRMWARE 3 CARDS 4...

Page 146: ...erted 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 and ground part If it s selected FALL the warning buzzer is activated at the aerial part lowering moment and telescope retraction If it s selected WARN the warning buzzer is activated in the same condi...

Page 147: ...fter having inserted the relevant password 6661 pressing button n 1 ON outriggers lights will be steady on while they are touching the ground pressing button n 2 FLASH outriggers lights will be flashing while they are touching the ground Optional Page 2 The here aside picture shows the OPTIONAL menu second page display Pressing button n 7 it s possible to come back to the first page of settings Pr...

Page 148: ... restarting by the main key it will be deactivated REBOOT indication means that the machine has to be restarted by the main key to activate the function Optional Page 3 The here aside picture shows the OPTIONAL menu third page display Pressing button n 7 it s possible to come back to the sec ond page of settings Pressing button n 9 ESC brings back to the EXTRA menu SKYGUARD 1 ON 2 OFF REBOOT 9 ESC...

Page 149: ...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 control position selector switch Then turning on the main key it will require the setting of the machine model and version as indicated by the here below procedure To set the master board machine must be ...

Page 150: ...ifferent 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 on the machine model As soon as another master board already initialized on another machine is connected to its connectors as well as when the contacts on the load cell board ECM3 have been changed ...

Page 151: ...al part valve coils which include the gravity emergency descent valves the sum ming 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 one For some faulty affecting on ground part valve coils which include outrigger movements track widening the func t...

Page 152: ...t 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 backward valve coil 28 Outrigger n 1 lowering valve coil 29 Outrigger n 2 lowering valve coil 30 Outrigger n 3 lowering valve coil 31 Outrigger n 4 lowering valve coil 32 Outrigger n 1 lifting valve...

Page 153: ...ed valve coil 53 Tracks widening valve coil 54 Tracks closing valve coil 55 1 2 booms gravity descent valve coil 56 3 boom gravity descent valve coil 57 Deviator aerial part ground part valve coil Table 6 1 DEVICES DEVICE CODE DEVICE DESCRIPTION Table 6 2 ERRORS ERROR CODE ERROR DESCRIPTION 0 No error 1 Initialization error 2 Open load error charge disconnected 3 Open load error short circuit 4 Sh...

Page 154: ...VICE 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 89 12 YES 133 1 YES 145 2 YES 154 8 NO 155 8 NO 166 9 YES COIL CONNECTION ERROR EXAMPLE DEVICE CODE ERROR CODE ACTIVE 12 9 YES 36 7 YES 1 2 booms lifting valve coil 37 5 YES 3 boom lifting valve coil...

Page 155: ...e 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 AFTER KEY RESET EXAMPLE DEVICE CODE ERROR CODE ACTIVE 12 9 YES 37 2 YES 3 boom lifting valve coil 64 2 YES 65 9 NO 66 9 NO 67 4 YES 73 2 NO 89 12 YES 133 1 YES 145 2 YES 154 8 NO 155 8 NO G o t o D ...

Page 156: ...with 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 Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell ...

Page 157: ... troubleshooting your equip ment A digital meter with reasonable accuracy within 7 is recommended for the measurements in these procedures This section shows diagrams of a common digital VOM configured for several different circuit mea surements Instructions for your VOM may vary Please consult the meter operator s manual for more informa tion Grounding Grounding the meter means to take the black ...

Page 158: ...ead on the other port goes to the positive side of the signal Scale M Mega 1 000 000 Displayed Number k kilo 1 000 Displayed Number m milli Displayed Number 1 000 μ micro Displayed Number 1 000 000 Example 1 2 k 1200 Example 50 mA 0 05 A Voltage Measurement Resistance Measurement Figure 7 1 Voltage Measurement DC Figure 7 2 Resistance Measurement If meter is not auto ranging set it to the correct ...

Page 159: ...ponent 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 for the expected current range Be sure to connect the meter leads to the correct jacks for the current range you have selected If meter is not auto ranging set it to the correct range See multi meter ...

Page 160: ...ess is not completely isolated disconnect battery 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 one side jumper from contact of wire 1 and wire 2 4 Measure continuity between wire 1 and wire 2 If there is continuity both wires are good and can be used...

Page 161: ...with 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 Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell ...

Page 162: ...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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