JLG X13JP-X370AJ Service And Maintenance Manual
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JLG X13JP-X370AJ Service And Maintenance Manual

JLG X13JP-X370AJ Service And Maintenance Manual

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Service and Maintenance Manual
Models
X13JP - X370AJ
X15JP - X430AJ
3121774
June 29, 2018 - Rev C

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Summary of Contents for JLG X13JP-X370AJ

  • Page 1 Service and Maintenance Manual Models X13JP - X370AJ X15JP - X430AJ 3121774 June 29, 2018 - Rev C...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 3: General

    INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial plat- form. It is of utmost importance that maintenance person- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SEC- nel pay strict attention to these warnings and precautions TION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR to avoid possible injury to themselves or others, or dam-...
  • Page 4 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISION LOG A - August 4, 2017 Original Issue B - March 27, 2018 Revised C - June 29, 2018 - Revised Covers Revised 3121774...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL..................A HYDRAULIC SYSTEM SAFETY .
  • Page 6 Do the Following When Welding on JLG Equipment ........2-5 Do NOT Do the Following When Welding on JLG Equipment ......2-5 SECTION 3 - CHASSIS &...
  • Page 7 X13JP-X370AJ ........
  • Page 8 TABLE OF CONTENTS DIAGNOSTIC BY SERVICE MENU ............6-7 Menu Input .
  • Page 9 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 10: Specifications

    Table 1-1. Drive Hub Capacities Machine Type Drive Hub Drive Capacities 700 C1H40 STANDARD SPEED 0.13 gal (0,5 L) X13JP-X370AJ X15JP-X430AJ 700 C2K AUTO 2 SPEED 0.10 gal (0,4 L) Table 1-2. Hydraulic & Fuel Tank Capacities HYDRAULIC OIL TANK MACHINE...

  • Page 11: Power Source

    SECTION 1 - SPECIFICATIONS POWER SOURCE Power Configurations Table 1-5. X13JP-X370AJ X15JP-X430AJ Honda iGX390 Gasoline Engine 11.7 hp (8,7 kW) / 3600 RPM Hatz 1B40 Diesel Engine 10 hp (7,5 kW) Lithium 100Ah 36V 110V 50 Hz (2,2 KW) 120V 60 Hz (1,2 kW)

  • Page 12: Hatz Engine 1B40 Specifications

    SECTION 1 - SPECIFICATIONS Hatz Engine 1B40 Specifications Specifications Hatz Engine 1B40 Table 1-7. Type 1B40 Design Air-cooled four-stroke diesel engine Combustion system Direct injection Number of cylinders Bore / stroke 88 / 76 mm Displacement 462 cm Lubricating oil capacity without oil sump: l, approx.

  • Page 13: Specifications And Performance Data

    SECTION 1 - SPECIFICATIONS SPECIFICATIONS AND PERFORMANCE DATA Reach Specifications Table 1-8. Machine Reach Specifications X13JP CE X370AJ ANSI X15JP CE X430AJ ANSI Max. working Height (inclusive operator) 13,30 m 15,40 m 11,20 m 36,74 ft 13,30 m 59,21 ft Max.

  • Page 14: Function Speed Data

    SECTION 1 - SPECIFICATIONS Function Speed Data Table 1-10. Function Speed FUNCTIONS SPEED RANGE MACHINE MODEL X15JP / X430AJ POWER SYSTEM Engine Lithium FUNCTION TIME Sec TELESCOPE EXTEND 12" - 17" 23'' - 32'' TELESCOPE RETRACT 12" - 17" 23'' - 32'' TOWER BOOM UP 16"...

  • Page 15: Machine Orientation When Performing Speed Tests

    Record Time. Rotate the other direction, Record Time. HYDRAULIC PRESSURE SETTINGS - PSI (BAR) Table 1-12. Pressure Settings UNDERCARRIAGE TOWER Left and Right Control Valve MODEL Control Valve X13JP-X370AJ 2610 2393 X15JP-X430AJ Table 1-13. Reductions Drive Speed Pressure Setting AUTOMATIC REDUCTIONS DRIVE SPEED MODEL X13JP-X370AJ...

  • Page 16: Lubrication

    SECTION 1 - SPECIFICATIONS LUBRICATION Hydraulic Oil Figure 1-1. Hydraulic Oil Temperature Operating Range 3121774...
  • Page 17 SECTION 1 - SPECIFICATIONS FLUID PROPERTIES TYPE CLASSIFICATIONS DESCRIPTION Pakelo Hydraulic EP Extra ISO 68 Pakelo Hydraulic EP Extra ISO 46 47.3 GeolubeECO HydraulicISO 46 (P/N 17527700) Pakelo Hydraulic EP Extra ISO 32 Pakelo Hydraulic EP Extra ISO 22 SHELL TELLUS S3V 68 SHELL TELLUS S3V 46 MobilEAL EnvirosynH46 (P/N2300029) SHELL TELLUS S3V 32...

  • Page 18: Serial Number Location

    SECTION 1 - SPECIFICATIONS SERIAL NUMBER LOCATION The serial number plate is fastening onto the frame on fork lifting pockets on X15JP/X430AJ and X13JP/X370AJ. Figure 1-3. Serial Number Plate Location Figure 1-2. Serial Number Plate 3121774...

  • Page 19: Fastener Torque Charts

    SECTION 1 - SPECIFICATIONS FASTENER TORQUE CHARTS Figure 1-4. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) 1-10 3121774...
  • Page 20 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) 1-11 3121774...
  • Page 21 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) 1-12 3121774...
  • Page 22 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 1-13 3121774...
  • Page 23 SECTION 1 - SPECIFICATIONS Figure 1-8. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) 1-14 3121774...
  • Page 24 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 25: General

    (13) months from and inspections performed per JLG's recommendations the date of the prior Annual Machine Inspection. JLG with any and all discrepancies corrected, this product Industries recommends this task be performed by a Fac- will be fit for continued use.

  • Page 26: 2.2 Service And Guidelines

    Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Inspection and applicable JLG inspection form. In service for 3 months or 150 hours, whichever Frequent Service and Maintenance Manual comes first; or Out of service for a period of more...

  • Page 27: Bearings

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

  • Page 28: Hydraulic Oil

    0.02 0.53 for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils. 0.021 0.54 JLG Industries recommends changing the hydrau- 0.013 0.35 lic oil annually. 0.026 0.68 2. Use every precaution to keep the hydraulic oil 0.013...

  • Page 29: Pins And Composite Bearing Repair Guidelines

    • Ground only to structure being welded. 2. Filament wound bearings should be replaced if any of the following is observed: Do NOT Do the Following When Welding on JLG a. Frayed or separated fibers on the liner surface. Equipment b.
  • Page 30 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 31: Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE RUBBER TRACK MAINTENANCE/REPLACEMENT Tensioning Rubber Track Checking Track Tension DANGER Stop the machine on a flat and solid ground. Raise the THE GREASE CONTAINED IN THE HYDRAULIC TRACKS IS UNDER PRES- machine off the ground safely and, if needed, support it by SURE.

  • Page 32: Installing Rubber Track

    SECTION 3 - CHASSIS & TURNTABLE Installing Rubber Track DANGER 1. Starting with the machine undercarriage raised THE GREASE CONTAINED IN THE HYDRAULIC TRACKS IS UNDER PRES- in conditions of safety provided of suitable sup- SURE. IF THE VALVE TRACK TENSION IS TOO LOOSE, IT COULD BE ports stable below the undercarriage frame to EXPELLED UNDER THE EFFECT OF THE PRESSURE OF GREASE, SERI- support the machine.

  • Page 33: Undercarrige Components

    SECTION 3 - CHASSIS & TURNTABLE UNDERCARRIGE COMPONENTS Replacement Sprocket and Gear Motor Machine Positioning 1. Stabilize the machine on level ground. 2. Fully extend the undercarriage. 3. Remove the tracks (see sub-section 3.1). 4. Remove the key ignition, and a tag with warning do no start the machine.

  • Page 34: Gear Motor Installation

    Figure 3-11. Sprocket Installation Figure 3-10. Gear Motor Installation Table 3-1. Final Drive Torque Valves SPROCKET SCREW N. 6 FINAL DRIVE SCREW N. 11 MACHINE MODEL TORQUE VALUES TORQUE VALUES X13JP-X370AJ M10x18 - Nm 50 M10x25 - Nm 70 X15JP-X430AJ 3121774...

  • Page 35: Tracks Extension Removal

    SECTION 3 - CHASSIS & TURNTABLE 8. Using a suitable lifting device to remove the TRACKS EXTENSION REMOVAL track frame. Figure 3-15. 9. Remove screw and nut 3 and 6. Figure 3-12. Sprocket Installation 10. Remove the pin 4. 1. Stabilize the machine on level surface. 11.

  • Page 36: Track Drive

    ID plate. MACHINE TYPE SPEED The gear motor has two ID plates; one gives data on the X13JP-X370AJ gearbox and the other data on the hydraulic motor. 700C1H40 C/F STANDARD SPEED X15JP-X430AJ The plates must not be removed or damaged during the X13JP-X370AJ life of the product.

  • Page 37: Swing Drive (Imo)

    SECTION 3 - CHASSIS & TURNTABLE SWING DRIVE (IMO) Structure and Function Brief description Technical Data – Type Plate Slew drives are used for concurrent transmission of axial and radial forces, as well as transmission of tilting moments. Slew drives consist of a ball or roller slewing ring, hydraulic or electric drives, and a completely enclos- ing housing.

  • Page 38: Maintenance Tasks

    SECTION 3 - CHASSIS & TURNTABLE Structure and Function Maintenance Tasks Inspecting The Mounting Bolts NOTICE TO COMPENSATE FOR SETTLING, THE BOLTS MUST BE RETIGHTENED WITH THE PRESCRIBED TIGHTENING TORQUE. RETIGHTENING MUST BE EXECUTED WITHOUT EXERTING ADDITIONAL EXTERNAL STRESS ON THE BOLTED UNION.

  • Page 39: Lubricating The Slew Drive

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

  • Page 40: Power System X15Jp - X430Aj

    SECTION 3 - CHASSIS & TURNTABLE POWER SYSTEM X15JP - X430AJ NOTE: For the outriggers function, the engine revs will automatically regulate follow the position of the The X15JP - X430AJ can be configured as twin powered, outriggers. With all outriggers lift from the ground, which include an engine Gasoline or Diesel and a fixed the engine run at max rpm, with one or more outrig- speed electric motor single phase, or electrical Lithium...

  • Page 41: Electric Motor Function System

    SECTION 3 - CHASSIS & TURNTABLE Electric Motor Function System Engine RPM Control System Operating with the electric motor, there is unique func- The demand of the appropriate pre set engine rev come tions speed. from the Master board (ECM1) and signal is sent through the Engine relays board, Engine bridge box 1 and 2 to the Summing oil flow - Operating with the electric motor...

  • Page 42: Twin Power Unities With Gasoline Engine Honda Igx390

    SECTION 3 - CHASSIS & TURNTABLE Twin Power Unities With Gasoline Engine Honda IGX390 Design 4 strokes, overhead camshaft Ignition system Ignition timing variable ignition timing Number of cylinders single cylinder inclined by 25° Displacement 389 cm Bore per Stroke 88/64 mm Cooling system forced air...
  • Page 43 SECTION 3 - CHASSIS & TURNTABLE The ECM1 module correspond to the Honda electronic module are the "ENGINE SPEED 1" and "ENGINE SPEED 2", unit control by two contacts through which are prear- and the engine rpm's regulate as the following conditions: ranged preset the rpm's.
  • Page 44 SECTION 3 - CHASSIS & TURNTABLE 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 3-14 3121774...

  • Page 45: Twin Power Unities With Diesel Engine Hatz 1B40

    SECTION 3 - CHASSIS & TURNTABLE Twin Power Unities With Diesel Engine Hatz 1B40 Design 4 stroke Injection Direct Number of cylinders Displacement 462 cm³ Bore/Stroke 88/76 mm Fuel tank capacity Cooling system 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)
  • Page 46 SECTION 3 - CHASSIS & TURNTABLE Type Plate ENGINE SERIAL NUMBER The type plate is placed on the cylinder head insulating hood and includes the following details: 1. Engine type 2. Code (only for special equipment) 3. Engine serial number (stamp on the cylinder block) 4.
  • Page 47 SECTION 3 - CHASSIS & TURNTABLE The ECM1 module commands the Actuator Piston that In case of replacement of the actuator piston require the drives the engine throttle lever to achieve the preset revs. adjustment of the shaft length. The ECM1 module, by the speed sensor placed in front of See the section engines for the complete instructions &...

  • Page 48: Lithium Powered Unities

    SECTION 3 - CHASSIS & TURNTABLE Lithium Powered Unities Lithium Cells 36V Lithium Battery System 24 cells, 12 couples of cells Number of cells in the battery pack connected in series Nominal voltage of each cell 3 Volt Capacity of one cell 50 Amps/h Nominal features of the complete pack 36 Volt -100 Amps/h...
  • Page 49 SECTION 3 - CHASSIS & TURNTABLE Electric Motor Electric Motor Three-Phase Control Speed System ECM1 module communicates the required preset rpm revs to the inverter, then the inverter feed the electric motor Three-phase with the correct frequency in order to achieve the nominal 36 Volt revs selected.
  • Page 50 SECTION 3 - CHASSIS & TURNTABLE Temperature Ongoings (Heaters and Fans) Diagnostics and Fault Codes Lithium battery pack discharge and/or recharge, with The main devices composing the lithium batteries sys- positive lithium battery level (SOC>0), is possible tem are able to carry out self-diagnosis informing the over -10°C.
  • Page 51 SECTION 3 - CHASSIS & TURNTABLE Lithium System Components Location Upper Layer SUPPLEMENTARY DC-DC INSULATOR TRANSFORMER INVERTER FRONTAL FAN BATTERY CHARGER 3-21 3121774...
  • Page 52 SECTION 3 - CHASSIS & TURNTABLE Lower Layer CELLS PACK INTERNAL CONTACTOR MAIN FUSE CELLS PACK WITHOUT COVER 3-22 3121774...
  • Page 53 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 54: Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM f. Remove hardware securing the lower boom BOOM MAINTENANCE pivot pin. Using a suitable brass drift and hammer, remove pin from the turntable. NOTICE g. Using all applicable safety precautions, care- IF PERFORMING MAINTENANCE ON THE BOOM, DO NOT USE A LIFTING fully lift boom assembly clear of turntable DEVICE TO LIFT THE BOOMS UNLESS THE HOLDING VALVES HAVE BEEN...
  • Page 55 SECTION 4 - BOOM & PLATFORM Figure 4-1. Position Pins X13JP-X370AJ Figure 4-2. Position Pins X15JP - X430AJ 3121774...

  • Page 56: Inspection

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

  • Page 57: Installation Of The Boom Assembly

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

  • Page 58: Proximity Sensor Adjustment

    SECTION 4 - BOOM & PLATFORM PROXIMITY SENSOR ADJUSTMENT PLATFORM REMOVAL/INSTALLATION Adjust the proximity sensor in order to obtain a gap of 2 Removal mm between the sensor and the undercarriage ring plate. NOTE: If the platform is removed only track movement is allowed.

  • Page 59: Skyguard Installation - One Person Platform

    PLATFORM This Kit: The purpose of this instruction is to install a SkyGuard sys- • None tem on JLG Compact Crawler Boom (platform capacity of one person) models listed below and with below pictured Tools & Equipment Required: SkyGuard Bracket.

  • Page 60: For Reference

    SECTION 4 - BOOM & PLATFORM For Reference: Installation: 1. Install the SkyGuard Support Bracket (8) onto the welded mounts on platform rails. Secure the SkyGuard Switch support bracket using four Bolts (2), relevant Assembly Washers (7) and Nuts (3). See Figure 4-11. SkyGuard Bracket Figure 4-10.
  • Page 61 SECTION 4 - BOOM & PLATFORM 9. Route the SkyGuard switch harness along Sky- 4. Position SkyGuard switch assembly with sensor cover onto the SkyGuard Support Bracket (8) as Guard support bracket (right side) and under the shown in Figure 4-13. platform control box.
  • Page 62 12. Check for the proper functioning of SkyGuard system. NOTICE IF PLATFORM REMOVAL WILL BE NECESSARY, SKY GUARD EXTERNAL CONNECTOR HAS TO BE DISCONNECTED. THEN RECONNECTED WHEN THE PLATFORM IS INSTALLED ON THE MACHINE. NOTE: If further information is required, please contact the JLG Service Department. 3121774...

  • Page 63: Skyguard System

    SECTION 4 - BOOM & PLATFORM SkyGuard System When the SkyGuard sensor is activated, functions that were in use at the time of actuation will reverse or cutout. The table below outlines these functions. M ain Lift Main Tele Main Tele Tower Lift Tower Lift Main...

  • Page 64: Skyguard Installation - Two Person Platform

    PLATFORM This Kit: The purpose of this instruction is to install a SkyGuard sys- • None tem on JLG Compact Crawler Boom (platform capacity of one person) models listed below and with below pictured Tools & Equipment Required: SkyGuard Bracket.

  • Page 65: For Reference

    SECTION 4 - BOOM & PLATFORM For Reference: Installation: 1. Install the SkyGuard Support Bracket (8) onto the welded mounts on platform rails. Secure the SkyGuard Switch support bracket using four Bolts (2), relevant Assmbly Washers (7) and Nuts (3). See Figure 4-19. SkyGuard Bracket Figure 4-18.
  • Page 66 SECTION 4 - BOOM & PLATFORM 4. Position SkyGuard switch assembly with sensor 9. Route the SkyGuard switch harness along Sky- cover onto the SkyGuard Support Bracket (8) as Guard support bracket (right side) and under the shown in Figure 4-21. platform control box.
  • Page 67 NOTICE IF PLATFORM REMOVAL WILL BE NECESSARY, SKY GUARD EXTERNAL CONNECTOR HAS TO BE DISCONNECTED. THEN RECONNECTED WHEN THE PLATFORM IS INSTALLED ON THE MACHINE. NOTE: If further information is required, please contact the JLG Service Department. 4-14 3121774...

  • Page 68: Skyguard System

    SECTION 4 - BOOM & PLATFORM SkyGuard System When the SkyGuard sensor is activated, functions that were in use at the time of actuation will reverse or cutout. The table below outlines these functions. M ain Lift Main Tele Main Tele Tower Lift Tower Lift Main...
  • Page 69 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 70: Hydraulics

    SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS The hydraulic components compartment on the right side HYDRAULIC SYSTEM inside the bonnet contains the ground valve blocks, the hydraulic manifold, the deviator valve, the double pump Main Components Identification And Location valve, the blow off manifold, the second speed manifold The ground control box located on the right side of the and the hand pump.
  • Page 71 SECTION 5 - HYDRAULICS Hydraulic manifold aluminium block contains deviator valve, double pump valve and second speed valve. SECOND SPEED DOUBLE PUMP VALVE VALVE DEVIATOR VALVE Figure 5-2. Valve Diagram DEVIATOR VALVE DOUBLE PUMP VALVE SECOND SPEED VALVE Figure 5-3. Valve 3121774...

  • Page 72: Hydraulic Diagram

    SECTION 5 - HYDRAULICS Hydraulic Diagram Table 5-1. Hydraulic Diagram Index POS. DESCRIPTION HAND PUMP ELECTRIC MOTOR GASOLINE/DIESEL ENGINE DOUBLE GEAR PUMP PUMPS SUCTION COLLECTOR HYDRAULIC MANIFOLD WITH INTEGRATED PUMP OUTLET BLOCK HYDRAULIC OIL FILTER BLOWOFF MANIFOLD LEFT SIDE UNDERCARRIAGE VALVE BLOCK (4 ELEMENTS) RIGHT SIDE UNDERCARRIAGE VALVE BLOCK (3 ELEMENTS) OUTRIGGER VALVES BLOCK OUTRIGGER CYLINDER...
  • Page 73 SECTION 5 - HYDRAULICS TO THE AERIAL PART VALVE BLOCK Figure 5-4. Pumps and Undercarriage Part Hydraulic Diagram 3121774...
  • Page 74 SECTION 5 - HYDRAULICS FROM THE DEVIATOR VALVE Figure 5-5. Aerial Part Hydraulic Diagram 3121774...

  • Page 75: Pumps And Hydraulic Lines System

    SECTION 5 - HYDRAULICS Pumps and Hydraulic Lines System NOTE: Lithium machine is equipped with only one double tandem pump unit 3,15 cc/rev each, connected to The machine hydraulic system is powered by n.3 pumps the three-phase electric motor, and the hand pump. units: All of the pumps units outlines are conveyed through the 1.
  • Page 76 SECTION 5 - HYDRAULICS The hydraulic tank is pressurized type. must be pressurized again (with cork screwed) fully extending outriggers and then the booms at turtle mode, Every time that hydraulic oil tank is opened (depressur- to avoid cavitation. ized), such as in case of hydraulic oil filter replacement, it DOUBLE PUMP “B”...
  • Page 77 SECTION 5 - HYDRAULICS Telescope opening and first and second booms lifting are Double pump valve is not fed with contemporaneously speed up by this way both with diesel engine and electric movements and is not fed at minimum speed “TURTLE”. motor.
  • Page 78 SECTION 5 - HYDRAULICS TO THE AERIAL PART TO THE RIGHT TO THE BLOWOFF VALVE BLOCK VALVE BLOCK MANIFOLD LEFT VALVE BLOCK RIGHT VALVE BLOCK PRESSURE GAUGE PRESSURE GAUGE TO THE SECOND TO THE LEFT SPEED ACTIVATION VALVE BLOCK Figure 5-10. Hydraulic System From the three valve blocks (two for ground part and one for aerial part) the outgoing oil is collected by the blowoff manifold to the tank filter.

  • Page 79: Ground Part Hydraulic System

    SECTION 5 - HYDRAULICS maximum pressure valve, one proportional valve and an Ground Part Hydraulic System ON-OFF valve for each ground part movement. The ground part is controlled by two hydraulic valve blocks (right side and left side), both equipped with one LEFT-SIDE RIGHT-SIDE VALVE BLOCK...

  • Page 80: Outriggers

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

  • Page 81: Driver Gear Motors

    SECTION 5 - HYDRAULICS different hydraulic speeds in order to change tracks Driver Gear Motors speeds further that rpm regulation. Each drive gear motors runs forward or backward inde- When that coil is energized oil is sent to both drive gear pendently, it's so possible to turn the machine.
  • Page 82 SECTION 5 - HYDRAULICS This second speed system is also controlled by an brated maximum pressure (30 bar) it will automatically auto2speed valve, in case of a higher torque is required to open the auto2speed valve reducing the gear rate and the the drive gear motors, such as driving uphill, the second tracks speed.

  • Page 83: Tracks Widening

    SECTION 5 - HYDRAULICS SECOND SPEED DRAINAGE LINES SIGNALS (HOSES 3 AND 4) (HOSES 1 AND 2) Figure 5-17. Second Speed Signals And Drainage Track widening system oil is sent to both cylinders Tracks Widening through the track widening manifold that is installed on Tracks widening or narrowing is carried out by two cylin- hydraulic components compartment.

  • Page 84: Aerial Part Hydraulic System

    SECTION 5 - HYDRAULICS The aerial part is controlled by an hydraulic valve blocks Aerial Part Hydraulic System equipped with one maximum pressure valve, one propor- The conditions while aerial part could be moved is tional valve and an ON-OFF valve for each aerial part detailed on chapter 5.
  • Page 85 SECTION 5 - HYDRAULICS Aerial part valve block is fed by line “A” through deviator Through aerial part valve block are fed the turret rotation valve and oil rate is controlled through the proportional motor, the cylinder for moving 1 and 2 booms, the cyl- valve managed by the control module.
  • Page 86 SECTION 5 - HYDRAULICS Third Boom Basket Levelling Third boom is moved by one cylinder, this cylinder is Basket levelling close circuit is composed by two cylinders, equipped with an internal sensor that measures its open- one on the basket and one on the third boom connection ing position.
  • Page 87 SECTION 5 - HYDRAULICS Turret could be rotated 180° each side till a mechanical Turret Rotation block, achieving a total rotation. Turret rotation is carried out by a rotation hydraulic motor moved by a worm screw on a bearing ring. MECHANICAL BLOCK Figure 5-24.

  • Page 88: Cylinder Repair

    SECTION 5 - HYDRAULICS CYLINDER REPAIR Specification - Cylinders Overview Figure 5-26. Piston Thread 5-19 3121774...
  • Page 89 SECTION 5 - HYDRAULICS Figure 5-27. Piston With Nut Thread 5-20 3121774...
  • Page 90 SECTION 5 - HYDRAULICS Figure 5-28. Telescope Cylinder 5-21 3121774...
  • Page 91 SECTION 5 - HYDRAULICS Figure 5-29. Cylinder With Sensor 5-22 3121774...

  • Page 92: Hydraulic Cylinders Torque Specifications

    SECTION 5 - HYDRAULICS Hydraulic Cylinders Torque Specifications Screws Torque Specifications TIGHTENING TORQUE HEAD TORQUE [Nm] HEAD DIAMETER CYLINDER SCREWS TORQUE VALUE (mm) DRILLED SCREW 3/8" 70N/m SCREW M8 25N/m SCREW M6 11N/m SCREW M4 3N/m CAP 1/4" 30N/m PURGE SCREW 8N/m GREASE NIPPLE 2N/m...

  • Page 93: Cylinder Assembling

    SECTION 5 - HYDRAULICS Cylinder Assembling Cylinder Repair Without Sensor Pay attention to not damage the sensor Rod Removal General Cylinder Disassembly 1. Clean the cylinder with a suitable cleaner before disassembly. Remove all dirt, debris and grease from the cylinder. 2.

  • Page 94: Piston With Nut Disassembling

    SECTION 5 - HYDRAULICS 3. Remove the piston head from the rod and care- Piston With Nut Disassembling fully slide the head gland off the end of the rod. NOTICE PROTECT THE FINISH ON THE ROD AT ALL TIMES. DAMAGE TO THE SURFACE OF THE ROD CAN CAUSE SEAL FAILURE.

  • Page 95: Seals Head Replacing

    SECTION 5 - HYDRAULICS Seals Head Replacing Cylinder Inspection 1. Remove all seals, backup rings and o-rings from 1. Inspect internal surfaces and all parts for wear, the piston head and all seals, backup rings and damage, etc. If the inner surface of the tube does o-rings.

  • Page 96: Bushes Replacement

    SECTION 5 - HYDRAULICS Replace the seals on the piston. DO NOT Bushes Replacement attempt to salvage cylinder seals, sealing rings 1. Carefully grind the bush with a milling cutter for or o-rings. ALWAYS use a new, complete seal kit plastic.

  • Page 97: Emptying Of The Cylinder

    SECTION 5 - HYDRAULICS Emptying Of The Cylinder REPLACEMENT HYDRAULIC PUMP Vent Valve Pump Removal Air inside the circuit has to be removed in order to avoid 1. Open the top cap of the hydraulic oil tank. vibration and irregular motion of the cylinder, vent valves 2.

  • Page 98: Hydraulic Schematics

    SECTION 5 - HYDRAULICS HYDRAULIC SCHEMATICS X13JP-X370AJ Figure 5-30. X13JP-X370AJ - Hydraulic Schematic - Fixed Undercarriage 5-29 3121774...
  • Page 99 SECTION 5 - HYDRAULICS Figure 5-31. X13JP-X370AJ - Hydraulic Schematic - Extendable Undercarriage 5-30 3121774...

  • Page 100: X15Jp-X430Aj

    SECTION 5 - HYDRAULICS X15JP-X430AJ TO THE BOOM COMPONENT VALVE BLOCK Figure 5-32. X15JP/X430AJ - Hydraulic Schematic - 1 of 2 5-31 3121774...
  • Page 101 SECTION 5 - HYDRAULICS FROM THE DEVIATOR VALVE Figure 5-33. X15JP/X430AJ - Hydraulic Schematic - 2 of 2 5-32 3121774...
  • Page 102 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 103: Jlg Control System

    PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 mum cycle time. INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/ The JLG Remote Control has a built in Display and by a ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE push buttons, could show any present faults.

  • Page 104: Platform - Remote Control Station

    SECTION 6 - JLG CONTROL SYSTEM PLATFORM - REMOTE CONTROL STATION Figure 6-1. Remote Control Turning on the machine and within the operation, the main LCD display screen (Figure 6.1) is activated. There are eight (8) display positions which indicate machine status during various stages of operation.

  • Page 105: Lcd Display Screen

    SECTION 6 - JLG CONTROL SYSTEM This operation has a variable duration. Normally a few sec- POSITION 1: onds are sufficient, however the following screen may Reduced operating area if all outriggers are not fully appear on the display: deployed.
  • Page 106 SECTION 6 - JLG CONTROL SYSTEM POSITION 3: POSITION 5: Displays if selected engine (diesel or electric) is on or off. Displays outriggers are properly set and boom functions The X on the icon indicates the engine is off. are allowed. No display indicates outriggers are not prop- erly set and boom functions are not allowed.
  • Page 107 SECTION 6 - JLG CONTROL SYSTEM POSITION 7: POSITION 8: Can indicate any of the following situations: Indicates emergency lowering has been selected. • An emergency stop is pushed in (off ). Lithium ION - Battery Charge Status and Battery Charger Plugged In.

  • Page 108: Lcd Display Icon Description

    SECTION 6 - JLG CONTROL SYSTEM LCD Display Icon Description The display indicates machine conditions and eventual errors occurred in order to help operator and to have a quick diagnose, here follows icons meanings: Close and Safety state, press Both motors...

  • Page 109: Only Lithium Icons

    SECTION 6 - JLG CONTROL SYSTEM Only Lithium Icons Extra low Error warning, Lithium Machine in speed, check lithium battery level charge because of error list low battery Low voltage Cold weather Connect to the detected on functions electric network...

  • Page 110: Menu Input

    SECTION 6 - JLG CONTROL SYSTEM Menu Input This menu visualizes the current status of all the devices giving an input signal to the ECM1, it's so possible to check eventual changes of status. The device status visualized depends on the signal received by the ECM1 so that it depends on the device itself but also on the connections.
  • Page 111 SECTION 6 - JLG CONTROL SYSTEM Stop button on the remote control ground connected on the ground is pressed - lines A and B of the stop button are open EMRC GND AB Stop button on the remote control ground connected on the ground is released - lines A and B of the stop but-...
  • Page 112 SECTION 6 - JLG CONTROL SYSTEM DOWN The JIB is closed - the control switch is released, line A is open and line B is closed DOWN MICROJIB AB The JIB is open - the control switch is pressed, line A is closed and line B is open...

  • Page 113: Only Lithium Input

    SECTION 6 - JLG CONTROL SYSTEM Only Lithium Input Indicates the charge level of the battery pack, 100% is the maximum, 0% is the minimum Indicates the total voltage of the lithium pack. When the cells are not under charge or under discharge, it tends V LITHIUM to the nominal value that is around 40 Volt, it doesn't matter their charge status.

  • Page 114: Language Menu

    SECTION 6 - JLG CONTROL SYSTEM ERROR menu is composed by the following 5 different Language Menu pages selectable by buttons n.1 and n.2, it's always possi- Through this page it is possible to select the visualization ble to come back to the SERVICE menu main display press- language among ITALIAN, GERMAN, ENGLISH, FRENCH ing button n.9.
  • Page 115 SECTION 6 - JLG CONTROL SYSTEM PAGE 2 PAGE 4 The fourth and fifth pages inform about an eventual error on CAN BUS system indicating the component involved. ERRORS All of the components should be marked with an “OK”, in BYPASA case of a “NO”...

  • Page 116: Working Hours Menu

    SECTION 6 - JLG CONTROL SYSTEM On Lithium models the Engine working HOURS will stay Working Hours Menu always 0. This page indicates the machine working hours displaying The procedure to view or change the working Hours of the engine working hours and electric motor working hours.

  • Page 117: Machine Setup Menu

    SECTION 6 - JLG CONTROL SYSTEM MACHINE SETUP MENU From the SERVICE menu, pressing button 7 “SETUP” accesses the menu SETUP to adjust the parameter settings in order to achieved proper machine performance. When selection the machine model to match the size of...

  • Page 118: Setup - Version

    SECTION 6 - JLG CONTROL SYSTEM Setup - Version Setup - Password By this page is visualized the currently installed machine Some setting requires a password, some passwords are model and power supply version. relevant to more than one setting, some other passwords are dedicated to only one setting.

  • Page 119: Setup - Load Cell Board (Ecm3) Calibration

    SECTION 6 - JLG CONTROL SYSTEM Setup - Load Cell Board (ECM3) Calibration Setup - Acceler (Calibrating Tilt Sensor) After having replaced the master board (ECM1) or the load This menu allows the calibration of the tilt sensor. cell board (ECM3) or having replaced the load cell sensor After replaced the master board (ECM1) or the tilt sensor it's necessary to calibrate the “0”...

  • Page 120: Setup - Extra

    SECTION 6 - JLG CONTROL SYSTEM Setup - Extra - Modem INCLINATION This page could be used in case of RAHM difficult connec- SENS. CA tion; the meanings of the parameters shown by this page are the followings. LIBRATION MACCHINA: NOT STATUS: INIT.
  • Page 121 SECTION 6 - JLG CONTROL SYSTEM Optional (Page1) Beeper By this page, if is installed the optional warning buzzer, it's OPTIONAL menu gives the access to other settings. possible to set the motion alarm, after having inserted the The here aside picture shows the OPTIONAL menu first relevant password "8365".
  • Page 122 SECTION 6 - JLG CONTROL SYSTEM Electric Motor Optional (Page 2) By this page it's possible to set the electric motor power The here aside picture shows the OPTIONAL menu second setting, after having inserted the relevant password page display.
  • Page 123 SECTION 6 - JLG CONTROL SYSTEM RC Speed Skyguard By this page it's possible to set the RC SPEED function, By this page it's possible to set the Skyguard function, when it is activated it avoids to operate tracks maximum when it is activated, by pressing on Skyguard bar it stops speed when operator is not into the basket.

  • Page 124: Master Board (Ecm1) Replacement And Setting

    “1138”, pressing button n.1 it will be settled Machine software contains the software for all the TTC JLG 25 Amp, pressing button n.2 it will be settled 18 Amp. machine models produced till that moment, so that when...

  • Page 125: Already Initialized Master Board

    SECTION 6 - JLG CONTROL SYSTEM Here below the example shows on the image A 3. In case of the engine model selected is not cor- the case of machine model selected is wrong, rect with button n.7 (MOTOR) select the correct and on image B the case of machine model one (for instance “D.RPM”...

  • Page 126: Software Recovery By Modem

    SECTION 6 - JLG CONTROL SYSTEM Software Recovery By Modem CODE MENU In case of main machine software in the master board soft- The machine diagnostic system identify faulty as short cir- ware is corrupted or missing, if the modem contains the...
  • Page 127 SECTION 6 - JLG CONTROL SYSTEM FOR DEVICE INDICATION CHECK TABLE N.1 DEVICE ERROR VALUE FOR ERROR INDICATION CHECK 0x100 TABLE N.2 COUNT ACTIVE 1. PREC 2. NEXT 3. ESC EXAMPLE OF CODE MENU Here follows the list of the main DEVICEs that could...
  • Page 128 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. DEVICES DEVICE CODE DEVICE DESCRIPTION Jib opening valve coil Jib closing valve coil Basket levelling up valve coil Basket levelling down valve coil Turntable right rotation valve coil Turntable left rotation valve coil...
  • Page 129 SECTION 6 - JLG CONTROL SYSTEM EXAMPLES Here follow some examples of what could be displayed on EXAMPLE OF A CODE MENU INDICATION WITH NO ERROR CODE menu. IN PROGRESS STOWED MACHINE WITH NO ERROR DEVICE CODE ERROR CODE ACTIVE...
  • Page 130 SECTION 6 - JLG CONTROL SYSTEM COIL CONNECTION ERROR EXAMPLE DEVICE CODE ERROR CODE ACTIVE vated, except for the third boom lowering that will be re- EXAMPLE OF MACHINE WITH A COIL CONNECTION activated only after its coil anomaly is restored.
  • Page 131 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 132: General Electrical Information & Schematics

    TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH closed connector by backprobing both sides of a con- AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUS- nector terminal and measuring resistance. Do this after TRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A giving each wire a gentle pull to ensure the wires are MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPO-...

  • Page 133: Voltage Measurement

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 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 range • First test meter and leads by touching leads together. (See multimeter’s operation manual).

  • Page 134: Continuity Measurement

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Current Measurement Figure 7-3. Continuity Measurement Figure 7-4. Current Measurement (DC) • Some meters require a separate button press to • Set up the meter for the expected current range. enable audible continuity testing.

  • Page 135: Continuity Measurement Over Long Distances

    The electrical schematics manuals are separate from this accurate measurement. manual. They are available online (Online Express or www.jlg.com - Manuals) in the same folder where this Service Manual was found. Consult the circuit schematic to determine which wires to use in addition to wire under test, here called wire #1 Here is a listing of the schematic manuals available: and wire #2, and how to isolate these wires.
  • Page 136 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...
  • Page 137 3121774...

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