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Oshkosh JLG X1000AJ Service And Maintenance Manual

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Service and Maintenance Manual
Models
X33JP - X1000AJ
3121784 Rev A
April 1, 2019

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Summary of Contents for Oshkosh JLG X1000AJ

  • Page 1 Service and Maintenance Manual Models X33JP - X1000AJ 3121784 Rev A April 1, 2019...
  • Page 2 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 3: General

    INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS of the system. NOTICE This machine is powered by an 76VDC (nominal) electrical system. Based on employer, local, and governmental regulations as they pertain to this machine, specific electrical training and certifica- tions may be required before servicing or troubleshooting.
  • Page 4 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS • KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE. • USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS. – JLG Lift – 3121784...
  • Page 5 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISON LOG A - April 1, 2019 Original Issue 3121784 – JLG Lift –...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL................. . 1-A HYDRAULIC SYSTEM SAFETY .
  • Page 7 TABLE OF CONTENTS Hydraulic Oil................2-4 Changing Hydraulic Oil .
  • Page 8 TABLE OF CONTENTS RPM Setting ............... . 3-21 Temperature Ongoings (Heaters And Fans) .
  • Page 9 TABLE OF CONTENTS Main Boom ............... . . 5-13 Telescope .
  • Page 10 TABLE OF CONTENTS ..................6-16 .
  • Page 11 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 12: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS OPERATING SPECIFICATIONS CAPACITIES Model X1000AJ/X33JP Model X1000AJ/X33JP Maximum work load (capacity) 500 lbs (230 kg) Hydraulic Tank 21.1 gal (80 L) Max. Vertical Platform Height 100 ft (30,5 m) Fuel Tank Diesel: 6.6 gal (25 L) Max.

  • Page 13: Lithium Ion Specifications

    SECTION 1 - SPECIFICATIONS LITHIUM ION SPECIFICATIONS MAJOR COMPONENT WEIGHTS Model X1000AJ/X33JP Model X1000AJ/X33JP Battery Pack Engine (Dry Weight) Kubota D902 Diesel: 158 lb. (72 kg) No. of cells in the battery pack: 72 cells Boom Sections Combined 4,916 lb. (2,230 kg) Rated voltage of each cell: 3.2 volt Lift Cylinders...

  • Page 14: 1.10 Functions Speed Range

    SECTION 1 - SPECIFICATIONS 1.10 FUNCTIONS SPEED RANGE MACHINE MODEL X33JP / X1000AJ Test Notes: POWER SYSTEM Engine Lithium 1. Stop watch should be started with the function, FUNCTION TIME Sec not with the controller or switch. TELESCOPE EXTEND 21" - 30" 45'' - 60'' 2.

  • Page 15: 1.12 Component Maintenance Intervals

    SECTION 1 - SPECIFICATIONS 1.12 COMPONENT MAINTENANCE INTERVALS Diesel maintenance intervals ML00540 3121784...

  • Page 16: Lithium Maintenance Intervals

    SECTION 1 - SPECIFICATIONS Lithium maintenance intervals ML00550 3121784...

  • Page 17: 1.13 Lubrication

    SECTION 1 - SPECIFICATIONS 1.13 LUBRICATION Hydraulic Oil HYDRAULIC EP EXTRA ISO 68 V.I.180 HYDRAULIC BIODEGRADABLE / SHELL EP EXTRA Geolube ECO TELLUS S3V ISO 46 V.I.160 Hydraulic 68 V.I.180 / SHELL HYDRAULIC ISO46 -5°C/+50°C TELLUS S3V EP EXTRA 46 V.I.160 (P/N 7527700) ISO 32 V.I.160 HYDRAULIC...

  • Page 18: 1.14 Serial Number Location

    SECTION 1 - SPECIFICATIONS 1.14 SERIAL NUMBER LOCATION A serial number plate is affixed to the right side of the turn table frame. The following illustration showing the posi- tion. ML00530 Figure 1-3. X33JP / X1000AJ Serial Number Plate Location (on side of turn table frame) SL00010 ML00200...

  • Page 19: 1.15 Fastener Torque Charts

    SECTION 1 - SPECIFICATIONS 1.15 FASTENER TORQUE CHARTS Figure 1-5. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) 3121784...
  • Page 20 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) 3121784...
  • Page 21 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) 1-10 3121784...
  • Page 22 SECTION 1 - SPECIFICATIONS Figure 1-8. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 3121784 1-11...
  • Page 23 SECTION 1 - SPECIFICATIONS Figure 1-9. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) 1-12 3121784...
  • Page 24 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 25: General

    SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND this inspection must be increased as environment, severity and frequency of usage requires. MAINTENANCE Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance General Schedule for items requiring inspection during the per- This section provides the necessary information needed...

  • Page 26: 2.2 Service And Guidelines

    SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance PRIMARY SERVICE TYPE FREQUENCY REFERENCE RESPONSIBILITY QUALIFICATION Pre-Start Prior to use each day; or User or Operator User or Operator Operation and Safety Manual Inspection At each Operator change. Service and Maintenance Man- Pre-Delivery Inspec- Prior to each sale, lease, or Qualified JLG...

  • 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

    SECTION 2 - GENERAL Hydraulic Oil 2.4 CYLINDER DRIFT TEST Refer to Section 1 for recommendations for viscosity Maximum acceptable cylinder drift is to be measured ranges. using the following methods. Changing Hydraulic Oil Cylinder Drift 1. Filter elements must be changed after the first 50 hours of operation and every 300 hours (unless Table 2-2.

  • Page 29: Pins And Composite Bearing Repair Guidelines

    SECTION 2 - GENERAL 2.5 PINS AND COMPOSITE BEARING REPAIR 2.6 WELDING ON JLG EQUIPMENT GUIDELINES NOTE: This instruction applies to repairs, or modifications to the machine and to welding performed from the Filament wound bearings. machine on an external structure, or component, 1.
  • Page 30 SECTION 2 - GENERAL NOTES: 3121784...

  • Page 31: Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE RUBBER TRACK MAINTENANCE 4. When correct track tension has been obtained, turn valve (1) in a clockwise direction and tighten it. Clean all traces of grease. Checking Track Tension Stop the machine on firm, level surface.

  • Page 32: Checking The Rubber Tracks

    SECTION 3 - CHASSIS & TURNTABLE Checking The Rubber Tracks PATTERN WORN PARTS Figure 3-4. SPROCKET 3. Separation of the metal cores STEEL WIRE HOLE a. The metal core acts as a type of adhesive of WHEEL SIDE METAL CORE the rubber between the core itself and the steel ropes.

  • Page 33: Replacing The Rubber Tracks

    SECTION 3 - CHASSIS & TURNTABLE e. The damage indicated in paragraphs a, b, 3. To loosen the track, slowly unscrew valve 1 in an and c above, must not be considered fatal anti-clockwise direction for no more than one for the track and, even if in presence of grad- turn.

  • Page 34: Checking Tightness Of Nuts And Bolts

    SECTION 3 - CHASSIS & TURNTABLE 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 3-8.

  • Page 35: Replacement Sprocket And Gear Motor

    SECTION 3 - CHASSIS & TURNTABLE Replacement sprocket and Gear Motor Gear motor installation 1. Fix the screws 11. 2. Instal the valve 10. 3. Connect the Hydraulic hoses 4. Instal the cover 9. Figure 3-10. Sprocket remove 1. Fully extend the undercarriage. Figure 3-11.

  • Page 36: Axle Extension Removal

    SECTION 3 - CHASSIS & TURNTABLE AXLE EXTENSION REMOVAL 9. Remove screw and nut 3 and 6. 10. Remove the pin 4. 1. Stabilize the machine on level surface. 11. Disconnect, tag and plug the hydraulic hoses 2. Extend the undercarriage. from the cylinder extension.

  • Page 37: Final Drive

    SECTION 3 - CHASSIS & TURNTABLE Information FINAL DRIVE For all enquiries regarding general information on the Table 3-2. Final Drive Models product, spare parts, assistance etc, always give the identi- fication data stamped on the ID plate. MACHINE TYPE SPEED The gearmotor has two ID plates, one gives data on the X33JP - X1000AJ...

  • Page 38: 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 39: Transporting Unpacked Slew Drives

    SECTION 3 - CHASSIS & TURNTABLE Transporting Unpacked Slew Drives Attachment: 1. Screw the 3 eye bolts into the 3 threads that are distributed uniformly on the circumference of the slew drive. SCREW IN THE EYE BOLTS TO THE FULL THREAD LENGTH! IMPROP- ERLY ATTACHED, UNSUITABLE, OR DAMAGED EYE BOLTS MAY CAUSE THE SLEW DRIVE TO FALL AND CAUSE LIFE-THREATENING INJURIES.

  • Page 40: Bolting The Slew Drive

    SECTION 3 - CHASSIS & TURNTABLE Bolting The Slew Drive Table 3-3. MOUNTING PRETENSION FORCE MOUNTING BOLT DO NOT USE IMPACT SCREWDRIVERS. USING AN IMPACT SCREW- DIMENSIONS DRIVER MAY CAUSE IMPERMISSIBLE DEVIATIONS BETWEEN THE BOLT STRENGTH CLASS 10.9 in TIGHTENING FORCES. FAILURE OF THE BOLTED UNION WITH THE MOUNTING STRUCTURE MAY CAUSE SEVERE PERSONAL INJURY OR MATERIAL DAMAGE.

  • Page 41: Maintenance Schedule

    SECTION 3 - CHASSIS & TURNTABLE Maintenance Schedule If increased wear is detected during regular inspections, then reduce the required maintenance intervals according Maintenance tasks are described in the sections below to the actual indications of wear. that are required for optimal and trouble-free operation. If you have questions concerning maintenance tasks and intervals, please contact our customer service.

  • Page 42: Maintenance Tasks

    SECTION 3 - CHASSIS & TURNTABLE Maintenance Tasks 1. Detached bolt Inspecting The Mounting Bolts NOTICE Execution only by a specialist. TO COMPENSATE FOR SETTLING, THE BOLTS MUST BE RETIGHTENED • Special tools required: WITH THE PRESCRIBED TIGHTENING TORQUE. RETIGHTENING MUST Torque wrench BE EXECUTED WITHOUT EXERTING ADDITIONAL EXTERNAL STRESS ON THE BOLTED UNION.

  • Page 43: 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 44: Kubota Diesel Engine Model D902

    SECTION 3 - CHASSIS & TURNTABLE KUBOTA DIESEL ENGINE MODEL D902   Type Vertical 4-Cycle Liquid Cooled Diesel Combustion System Intake System Naturally Aspirated Diesel fuel intake system Electric Pump Number of cylinders Power 16,1 Kw (21,6 Hp) / 3200 rpm Max rpm 3200 rpm Direction of rotation...

  • Page 45: Engine Plate

    SECTION 3 - CHASSIS & TURNTABLE Engine Plate The engine plate with serial number is placed on the engine head close to muffler collector and includes the following engine information: 1. Engine model 2. Engine serial number 3. Engine code No The information shown above is necessary for any engine spare parts or information required.
  • Page 46 SECTION 3 - CHASSIS & TURNTABLE The fuel system of the diesel engine is fed by an electric fuel pump mounted beside the fuel tank as indicated by picture below. 3-16 3121784...

  • Page 47: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting To shutdown the engine disconnect wire of Pin 10. The engine will continue to run for a while until it ends the fuel Those Instructions valid for all machines serial number on the line. On engine left side remove the engine hood and cut the Engine Speed Sensor strap to access to the harness, plug.

  • Page 48: Diesel Engine Rpm Control

    SECTION 3 - CHASSIS & TURNTABLE Diesel Engine RPM control THERMIC ENGINE REPLACEMENT On Diesel powered units a throttle actuator controls the 1. Place and stabilize the machine on a flat and fuel to manage the engine speed based on operating con- level surface.

  • Page 49: Electric Motor Replacement

    SECTION 3 - CHASSIS & TURNTABLE ELECTRIC MOTOR REPLACEMENT 1. Place and stabilize the machine on a flat and level surface, rotate the turret 90° (Figure 3-32.). 2. Turn machine OFF and remove the Key switch, make sure that plug connector is disconnect, and the machine is isolate from any electrical power supply.
  • Page 50 SECTION 3 - CHASSIS & TURNTABLE Figure 3-35. 14. Install cover and test the machine. 3-20 3121784...

  • Page 51: Lithium Machine With 83V Lithium Battery System

    SECTION 3 - CHASSIS & TURNTABLE LITHIUM MACHINE WITH 83V LITHIUM Battery Charger BATTERY SYSTEM The on-board battery charged is activated when its plugged, if present it has to be used the plug fitted on the Charge Information lithium pack, otherwise the one close to the magneto- thermic switch.

  • Page 52: Temperature Ongoings (Heaters And Fans)

    SECTION 3 - CHASSIS & TURNTABLE Here below is listed the rpm setting according to the Temperature Ongoings (Heaters And Fans) movement required and to the speed selected. Lithium battery pack discharge and/or recharge, with pos- itive lithium battery level (SOC>0), is possible over 14°F (- LITHIUM SYSTEM RPM SETTING 10°C).
  • Page 53 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 54: Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM TOWER BOOM MICROSWITCH REPLACEMENT ML00350 6. Pull the bottom of microswith (wire side) to dis- connect it. Right side Left side ML00320 1. Stabilize machine on flat level ground. 2.

  • Page 55: Main Boom Microswitch Replacement

    SECTION 4 - BOOM & PLATFORM MAIN BOOM MICROSWITCH REPLACEMENT ML00370 Figure 4-1. Main Boom Microswitch Locations Front side microswitch replacement 1. Stabilize machine on flat level ground. ML00390 Extend main boom until side window is uncov- ered by internal boom section. ML00380 2.
  • Page 56 SECTION 4 - BOOM & PLATFORM ML00420 9. Unscrew screws and remove microswitch. ML00400 4. Unscrew all ropes locknuts. There re two in front side and one in back side. ML00340 10. Turn screw counter-clockwise to unlock contact 5. Loosen both tensioner nuts from front side. Do not remove.
  • Page 57 SECTION 4 - BOOM & PLATFORM ML00420 8. Place microswitch on bracket and secure with screws. ML00450 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. ML00430 9.
  • Page 58 SECTION 4 - BOOM & PLATFORM ML00490 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. 15.

  • Page 59: Back Side Microwsitch Replacement

    SECTION 4 - BOOM & PLATFORM Back side microwsitch replacement ML00510 23. Tighten the adjuster slides. Gap must be no 1. Unscrew screws and remove microswitch. larger than 0.04 in (1 mm) in every boom section. Boom sections must be centered on longitudinal axis.
  • Page 60 SECTION 4 - BOOM & PLATFORM 7. Push contact in to microswitch and secure by turning screw clockwise 90°. ML00510 8. Verify microswitch clearance on back side. Mis- croswitch should be just touching rope balancer cam. 9. Tighten screws to secure microswitch. 3121784...

  • Page 61: Boom Maintenance

    SECTION 4 - BOOM & PLATFORM BOOM MAINTENANCE g. Using all applicable safety precautions, care- fully lift boom assembly clear of turntable and lower to ground or suitable supported NOTICE work surface. IF PERFORMING MAINTENANCE ON THE BOOM, DO NOT USE A LIFTING Disassembly of the Main Boom DEVICE TO LIFT THE BOOMS UNLESS THE HOLDING VALVES HAVE BEEN REMOVED FIRST.

  • Page 62: Inspection

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

  • Page 63: 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 64: Inspection

    SECTION 4 - BOOM & PLATFORM INSPECTION Three month inspection 1. Remove all protection sumps from the third arm Checking Wear And Deformation Of Ropes And and the two extensions. Use a flashlight torch to Pulleys visually check the state of the ropes and the extension pulleys.

  • Page 65: Ropes Tension Adjustment Procedure

    SECTION 4 - BOOM & PLATFORM ROPES TENSION ADJUSTMENT PROCEDURE keep the ropes blocked to prevent them turning with the nuts. Make use of the relevant seat for NOTE: Do not clamp on threads. the wrench on the cable socket. Figure 4-6.

  • Page 66: Counterbalance Valve

    SECTION 4 - BOOM & PLATFORM Counterbalance Valve 3. The bolts that come with the valve are grade 8 bolts. New bolts should be installed with a new Refer to Figure 4-10., Rotator Counterbalance Valve. valve. Loctite #242 should be applied to the shank of the three bolts at the time of installa- 1.

  • Page 67: Platform Removal/Installation

    SECTION 4 - BOOM & PLATFORM PLATFORM REMOVAL/INSTALLATION Platform Installation NOTE: If the platform is removed only track movement is 1. LIft the platform and align the platform mounts allowed. with the jib mounting posts and lower until seated. 1. Remove the platform/remote control box from 2.

  • Page 68: Load Cell And Footswitch Removal/Installation

    SECTION 4 - BOOM & PLATFORM LOAD CELL AND FOOTSWITCH REMOVAL/ Removing Footswitch INSTALLATION 1. Turn the machine off and unplugged from the power supply. Removing Load Cell 2. Remove the basket of the machine. (See paragraph basket removal). 1. Turn the machine off and unplugged from the 3.

  • Page 69: Skyguard Installation - One Person Platform

    SECTION 4 - BOOM & PLATFORM SKYGUARD INSTALLATION - ONE PERSON Parts List: PLATFORM ITEM PART NUMBER DESCRIPTION 0641414 Bolt, 1/4-20 x 1 3/4 LG The purpose of this instruction is to install a SkyGuard sys- tem on JLG Compact Crawler Boom (platform capacity of 0700812 Bolt (Metric), 8 x 25 LG one person) models listed below and with below pictured...

  • Page 70: Installation

    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 4-15. SkyGuard Bracket Figure 4-14.
  • Page 71 SECTION 4 - BOOM & PLATFORM 9. Route the SkyGuard switch harness along Sky- 5. Insert a Shear Block Support (10) through shear block housing on the SkyGuard support bracket Guard support bracket (right side) and under the and into the platform sensor mount. See Figure 4- platform control box.
  • Page 72 SECTION 4 - BOOM & PLATFORM 11. Open load cell board (ECM3) box, locate connec- 15. POWER ON the machine. tors X604 and X603, then disconnect them. See • Press button 6 (service) on the remote control Figure 4-20. • Press button 7 (set up) •...

  • Page 73: Skyguard System

    SECTION 4 - BOOM & PLATFORM NOTE: If further information is required, please contact the JLG Service Department. 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.
  • Page 74 SECTION 4 - BOOM & PLATFORM 3121784 4-21...

  • Page 75: Skyguard Installation - 2 Person Platform

    SECTION 4 - BOOM & PLATFORM SKYGUARD INSTALLATION - 2 PERSON 0641414 Bolt, 1/4-20 x 1 3/4 LG PLATFORM 0700812 Bolt (Metric), 8 x 25 LG 3290801 Nut, M8 x 1.25 The purpose of this instruction is to install a SkyGuard sys- 3300430 Nut, Acorn 1/4- 20 tem on JLG Compact Crawler Boom (capacity of two per-...

  • Page 76: Installation

    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 4-27. SkyGuard Bracket Figure 4-26.
  • Page 77 SECTION 4 - BOOM & PLATFORM 9. Route the SkyGuard switch harness along Sky- 5. Insert a Shear Block Support (10) through shear block housing on the SkyGuard support bracket Guard support bracket (right side) and under the and into the platform sensor mount. See Figure 4- platform control box.
  • Page 78 SECTION 4 - BOOM & PLATFORM 11. Open load cell board (ECM3) box, locate connec- 15. POWER ON the machine. tors X604 and X603, then disconnect them. See • Press button 6 (service) on the remote control Figure 4-32. • Press button 7 (set up) •...

  • Page 79: Skyguard System

    SECTION 4 - BOOM & PLATFORM NOTE: If further information is required, please contact the JLG Service Department. 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.
  • Page 80 SECTION 4 - BOOM & PLATFORM 3121784 4-27...
  • Page 81 SECTION 4 - BOOM & PLATFORM 4-28 3121784...

  • Page 82: Hydraulics

    SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS MAIN HYDRAULIC VALVE BLOCK IDENTIFICATION AND LOCATIONS ML0040 1. Ground Valve Block 2. Aerial Valve Block ML00060 ML00050 a. Tower extension a. Left track b. Tower boom b. Right track c. Main extension c.
  • Page 83 SECTION 5 - HYDRAULICS 3. Platform Valve Block ML00070 a. Jib cylinder b. Platform leveling c. Platform rotation 3121784...

  • Page 84: Components

    SECTION 5 - HYDRAULICS COMPONENTS Safety Valve Block ML00080 Aerial/Ground Electric Valve Deviator (X153) ML00090 The aerial/ground deviator sends oil to the ground valve block or to the aerial valve block. 3121784...

  • Page 85: Second Speed Electric Valve (X150)

    SECTION 5 - HYDRAULICS Second Speed Electric Valve (X150) ML00100 The second speed electric valve engages the second chamber on the motor gear. Maximum pressure valve is set during production (auto-two speed system). Pumps Electric Valve (X125) ML00110 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.

  • Page 86: Second Pump Pressure Sensor (X141)

    SECTION 5 - HYDRAULICS Second Pump Pressure Sensor (X141) ML00120 The second pump pressure sensor disengages the little pump (used to improve movement speeds) if oil pressure exceeds 2175 psi (150 bar). Aerial Dump Valve-Ground (X166) ML00130 The aerial dump valve is a second safety valve for the aer- ial system (on the ground).

  • Page 87: Aerial Dump Valve-Jib (X190)

    SECTION 5 - HYDRAULICS Aerial Dump Valve-Jib (X190) ML00140 The aerial dump valve is a second safety valve for the aer- ial system (on the jib). 3121784...

  • Page 88: Ground Valve Block

    SECTION 5 - HYDRAULICS Ground Valve Block ML00150 ML00160 3121784...

  • Page 89: Schematic

    SECTION 5 - HYDRAULICS SCHEMATIC Figure 5-1. Hydraulic Schematic-Sheet 1 of 2 3121784...
  • Page 90 SECTION 5 - HYDRAULICS Figure 5-2. Hydraulic Schematic-Sheet 2 of 2 3121784...

  • Page 91: Hydraulic System Pump And Pressure Lines

    SECTION 5 - HYDRAULICS HYDRAULIC SYSTEM PUMP AND PRESSURE GROUND COMPONENT HYDRAULIC SYSTEM LINES The ground control manifold valves control, outriggers, The machine hydraulic system is powered by two pump left and right track drive, and track widening. units: The ground control valves are controlled by a hydraulic •...
  • Page 92 SECTION 5 - HYDRAULICS This second speed system is also controlled by an auto2speed valve, in case of an higher torque is required to the drive gear motors, such as driving uphill, the second speed line pressure will raise and if it overcomes the calibrated maximum pressure (26 bar) it will automatically open the auto2speed valve reducing the gear rate and the tracks speed.

  • Page 93: Tracks Widening

    SECTION 5 - HYDRAULICS TRACKS WIDENING Tracks widening or narrowing is carried out by two cylinders controlled together in parallel by the same valve-block ele- ment on the left side valve-block. ML00170 Track widening system oil is sent to both cylinders through the track widening manifold that is installed on hydraulic com- ponents compartment just below the hydraulic manifold close to blow-off manifold.

  • Page 94: Tower Boom

    SECTION 5 - HYDRAULICS Depending on the movement required, proportional valve will open accordingly regulating the proper oil rate, than the relevant ON-OFF valves (one each movement) will open addressing the oil to the relevant cylinder or actuator. When the proportional valve coil is not fed, oil is sent to the drainage and then to the tank. The maximum pressure valve has to be calibrated as indicated on use and maintenance manual at 200 bar with Diesel engine or 180 bar with electric motor (185 bar for lithium machine).

  • Page 95: 5.10 Cylinder Repair

    SECTION 5 - HYDRAULICS 5.10 CYLINDER REPAIR Specification - Cylinders Overview Figure 5-3. Piston Thread 5-14 3121784...
  • Page 96 SECTION 5 - HYDRAULICS Figure 5-4. Piston With Nut Thread 3121784 5-15...
  • Page 97 SECTION 5 - HYDRAULICS Figure 5-5. Telescope Cylinder 5-16 3121784...
  • Page 98 SECTION 5 - HYDRAULICS Figure 5-6. Cylinder With Sensor 3121784 5-17...

  • Page 99: Hydraulic Cylinders Torque Specifications

    SECTION 5 - HYDRAULICS Hose Connections Torque Specifications Hydraulic Cylinders Torque Specifications Screws Torque Specifications JUNCTION Ø HOSE METRIC THREAD TORQUE VALUE (N/m) CYLINDER SCREWS TORQUE VALUE M12x1.5 DRILLED SCREW 3/8" 70N/m M14x1.5 SCREW M8 25N/m M16x1.5 SCREW M6 11N/m M18x1.5 SCREW M4 3N/m...

  • Page 100: Equipment And Product List

    SECTION 5 - HYDRAULICS Equipment And Product List 4. Partially extend the rod ~ 15mm and unscrew the head about ~ 15mm. • Spanner Wrench NOTE: The following are general procedures that apply to all of the cylinders with sensor. Procedures that apply to a specific cylinder will be so noted.
  • Page 101 SECTION 5 - HYDRAULICS 7. Push the connector inside the hole and fix the NOTICE plate again. 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.

  • Page 102: Cleanness And Inspection

    SECTION 5 - HYDRAULICS Cleanness And Inspection 3. Blow pressurized air on the connection of the manifold for cleaning. Cylinder Cleaning Instructions 1. Discard all seals, back-up rings and o-rings. Replace with new items from complete seal kits to help ensure proper cylinder function. 2.

  • Page 103: Magnetic Sensor Removal

    SECTION 5 - HYDRAULICS Magnetic Sensor Removal Threaded Piston Disassembly 1. Pull out retain clip with pliers. NOTICE PROTECT THE FINISH ON THE ROD AT ALL TIMES. DAMAGE TO THE SURFACE OF THE ROD CAN CAUSE SEAL FAILURE. Fix the rod into the vice. NOTE: Before attempting to disassemble the piston remove any accessible seals.

  • Page 104: General Cylinder Assembly

    SECTION 5 - HYDRAULICS General Cylinder Assembly Install new seals, back-up rings and o-rings on the piston and the head using the proper tool. 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.
  • Page 105 SECTION 5 - HYDRAULICS Mount the seals in the following order: Refer to “Hydraulic Cylinder Torque Specifications, ” for tightening guidelines for the piston. 9. Seal 10. Support bearing 11. Bearing Sensor Assembling Spacer has chamfer. Install the piston on to the end of the cylinder rod. Loctite® 270TM NOTE: If a white powdery residue is present on threads and parts, it can be removed.
  • Page 106 SECTION 5 - HYDRAULICS 14. Joint the sensor pin with a guidance cable. 18. Remove the set screw, insert the pin and than fix 15. Insert sensor with a cable pass the set screw. Pay attention do not overtighten the set screw because the sensor could be damaged.

  • Page 107: 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 108: Piston With Nut Disassembling

    SECTION 5 - HYDRAULICS Piston With Nut Disassembling 3. Remove the piston head from the rod and care- 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 109: Seals Head Replacing

    SECTION 5 - HYDRAULICS Seals Head Replacing Cylinder Inspection 1. Remove all seals, back-up rings and o-rings from 1. Inspect internal surfaces and all parts for wear, the piston head and all seals, back-up rings and damage, etc. If the inner surface of the tube does orings not display a smooth finish, or is scored or dam- aged in any way, replace the tube.

  • Page 110: Bushing Replacement

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

  • Page 111: Cylinders Bleeding

    SECTION 5 - HYDRAULICS Cylinders Bleeding 5.11 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 are apply to make this kind of operation.

  • Page 112: 5.12 Hydraulic Pump Repair

    SECTION 5 - HYDRAULICS 5.12 HYDRAULIC PUMP REPAIR External Components Disassembly Seal Kit Replacement Instruction Second section First section CAUTION USE SOME ALUMINIUM PROTECTION ON THE VICE TO NOT DAMAGE THE MACHINED SURFACES. PUT THE PUMP IN HORIZONTAL POSITION General Suggestions AND BLOCK THE COVER IN THE VICE'S JAWS.

  • Page 113: Components Disassembly

    SECTION 5 - HYDRAULICS 1. Unscrew the nut and remove the nut and washer (1). 2. Take out the shaft key (2). 3. Remove the rear cover. 3. Put the pump on the work bench and remove the bolts and the washers. Components disassembly 1.

  • Page 114: Second Section Components Disassembly

    SECTION 5 - HYDRAULICS Second Section Components Disassembly Second Section Seals Disassembly 1. Using a marker draw a reference mark on the 1. Remove the seals from the body. plate and the body. It will be used later during reassembly. 2.

  • Page 115: Second Section Seals Replacement

    SECTION 5 - HYDRAULICS Second Section Seals Replacement First Section Seals Disassembly 1. Place on the body the new seals. Use clean 1. Remove the front cover. grease to keep the seal in place. 2. Using a marker draw a reference mark on the plate and the body.

  • Page 116: First Section Seals Replacement

    SECTION 5 - HYDRAULICS First Section Seals Disassembly First Section Seals Replacement 1. Remove the seals from the body. 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.

  • Page 117: Cover Seals Replacement

    SECTION 5 - HYDRAULICS 4. Place on the body the new seals. Use clean 5. Insert the shaft seal. Pay attention to the assem- grease to keep the seal in place. bling direction of the shaft seal (see section). Using a mallet push all the way down the CASAPPA tool pn.

  • Page 118: Second Section Components Reassembly

    SECTION 5 - HYDRAULICS Second Section Components Reassembly First Section Components Reassembly 1. Reassemble the gears and the plates. Use as ref- Use as reference Reassemble the gears and the plates. erence the mark made previously. the mark made previously. 2.
  • Page 119 SECTION 5 - HYDRAULICS 2. Put back the first section. 4. Put the appropriate CASAPPA tool pn 06100090 on the drive shaft or protect with adhesive tape to avoid damaging the shaft seal. 3. Put back the dowel pins. 5. Use grease on the CASAPPA tool. Assemble the cover on the pump.

  • Page 120: Final Assembly And Check

    SECTION 5 - HYDRAULICS 6. Remove the CASAPPA tool pn 06100090. Final Assembly And Check 1. Put the pump in the vice and tighten the bolts with a torque wrench. Tightening torque 30 Nm. NOTICE WITH A CLAMP VERIFY THAT THE SHAFT OF THE PUMP CAN ROTATE AFTER THE OPERATION IN BOTH DIRECTIONS.

  • Page 121: Hydraulic Component Start-Up Procedures And Recommendations

    SECTION 5 - HYDRAULICS that the pump is not being asked to draw an inlet 5.13 HYDRAULIC COMPONENT START-UP vacuum higher than it is capable of. PROCEDURES AND RECOMMENDATIONS 3. Be certain to fill the pump and/or motor housing From a hydrostatic component standpoint, the goal at sys- with clean hydraulic fluid prior to start up.

  • Page 122: 5.14 Outriggers Auto-Retraction

    SECTION 5 - HYDRAULICS It's possible to keep automatic outriggers retraction run- ning till outriggers are completely lifted up. INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERATOR'S ABIL- To achieve the stowed condition outriggers must be com- ITY TO CONTROL THE MACHINE. pletely lifted up till the end of their stroke and have to be manually rotated while unlocked with their pivot.
  • Page 123 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 124: Jlg Control System

    SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM INTRODUCTION 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 NOTICE Settings for smooth control of: acceleration, deceleration, THIS MACHINE IS POWERED BY AN 76VDC (NOMINAL) ELECTRICAL creep, min speed, and max.

  • Page 125: Platform - Remote Control Station

    SECTION 6 - JLG CONTROL SYSTEM PLATFORM - REMOTE CONTROL STATION Figure 6-1. Remote Control At machine start-up and during machine 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 126: 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. Figure 6-4.
  • Page 127 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 128 SECTION 6 - JLG CONTROL SYSTEM POSITION 7: POSITION 8: Can indicate any of the following situations: • Indicates emergency lowering has been selected. • Lithium ION - Battery Charge Status and Battery Char- • An emergency stop is pushed in (off ). ger Plugged In.

  • Page 129: 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 Machine closed align the and release the...

  • Page 130: 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 lithium cell active DIAGNOSTIC BY SERVICE MENU...

  • Page 131: 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 132 SECTION 6 - JLG CONTROL SYSTEM Outrigger n.3 fully open position - the switch is pressed and line A is open and line B is closed ST3 POS Outrigger n.3 in transport position - the switch is released and lines A and B are open DOWN Outrigger n.4 on the ground - the switch is released, line A is open and line B is closed DOWN...
  • Page 133 SECTION 6 - JLG CONTROL SYSTEM IGNORE GND CTROL IGNORE Engine is running ENGINE ON Engine is not running The ground button for electric motor start is pressed ELE MOT ON The ground button for electric motor start is released Remote control level basket switch RC UP CTRL Ground control level basket switch...

  • Page 134: Only Lithium Input

    SECTION 6 - JLG CONTROL SYSTEM 0.09 INCL X-Y Machine tilt values - X and Y axis in degrees 0.08 0.63 INCL B X-Y Platform tilt values - Y axis in degrees 0.02 Indicates the weight of the platform (about 110 lbs (50 kg) plus the weight in the platform measured in kg by LOAD AB line A and line B.
  • Page 135 SECTION 6 - JLG CONTROL SYSTEM T AVG CELL Indicates the average temperature (Celsius degrees) detected among the cells Indicates the lowest temperature (Celsius degrees) detected among the cells LOW T CELL Indicates the number of the temperature sensor with the lowest temperature detected T BMS Indicates the temperature (Celsius degrees) detected in the BMS REM CAP AH...
  • Page 136 SECTION 6 - JLG CONTROL SYSTEM Output Indicates the amount of current in (within the charge) or out within machine operation (discharge) of battery CURRENT A pack BMS STATUS Indicates the BMS status or fault code if present PIN 101 -3, 73 PIN 102 -0, 32...

  • Page 137: Language Menu

    SECTION 6 - JLG CONTROL SYSTEM Language Menu ERROR menu is composed by the following 5 different 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 138 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. All of the components should be marked with an “OK”, in case of a “NO” it means that component it’s not properly communicating through CAN BUS.

  • Page 139: Working Hours Menu

    SECTION 6 - JLG CONTROL SYSTEM Working Hours Menu This page indicates the machine working hours displaying engine working hours and electric motor working hours. On Lithium machines have to be considered only the elec- tric motor hours. For both models “KEY” indicates the hours with main key switched ON.

  • Page 140: Joystick Menu

    SECTION 6 - JLG CONTROL SYSTEM On Lithium models the Engine working HOURS will stay always 0. The procedure to view or change the working Hours of the electrical motor are the same as per double powered models. Joystick Menu By this page it's possible to verify the proper functioning of the joysticks, once selected one joystick by buttons n.1 and n.2, joystick enumeration is indicated here below, the...

  • Page 141: 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 NOTE: Passwords will give you access to level, which will the machine, the personality settings will all default to the permit you to change all machine settings.

  • Page 142: Setup - Time

    SECTION 6 - JLG CONTROL SYSTEM Setup - Time Setup - Date By this page is visualized the settled time, after having By this page is visualized the settled time, after having inserted the relevant password “8262” it's possible to inserted the relevant password “1468”...

  • Page 143: Setup - Turn Table Sensor

    SECTION 6 - JLG CONTROL SYSTEM Setup - Turn Table Sensor Setup - Platform Rotation Sensor 1. Turn ON the main key and stabilize the machine. 1. Turn ON the main key and stabilize the machine. 2. Rotate the turntable until boom is aligned. 2.

  • Page 144: 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 145: 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 LIBRATION  are the followings. MACCHINA:  NOT  STATUS: INIT.
  • Page 146 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 147 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. “3522”, pressing button n.1 “2.2 KW”...
  • Page 148 SECTION 6 - JLG CONTROL SYSTEM Skyguard By this page it's possible to set the Skyguard function, when it is activated, by pressing on Skyguard bar it stops certain movements. After having inserted the relevant password “4771”, press- ing button n.1 “ON” and restarting by the main key it will be activated, pressing button n.2 “OFF”...

  • Page 149: Master Board (Ecm1) Replacement And Setting

    SECTION 6 - JLG CONTROL SYSTEM CHG Set MASTER BOARD (ECM1) REPLACEMENT AND For a lithium machine, by this page it's possible to set the SETTING maximum charging current, after having inserted the rele- vant password “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.

  • Page 150: 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 151: 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 cuits and missing connections to the valve coils, further- main machine software it is able to install the software in more monitoring the circuit load.
  • Page 152 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 NOTE: By CODE MENU, not all the DEVICEs signed with an Here follows the list of the main DEVICEs that could ERROR and “ACTIVE YES”...
  • Page 153 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 Basket right rotation valve coil Basket left rotation valve coil Aerial part proportional valve coil...
  • Page 154 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 NOTE: Some different indications on CODE menu could part movement will not be carried out and the icon FAIL occur depending on the machine conditions (stabi-...
  • Page 155 SECTION 6 - JLG CONTROL SYSTEM COIL CONNECTION ERROR EXAMPLE DEVICE CODE ERROR CODE ACTIVE EXAMPLE OF MACHINE WITH A COIL CONNECTION vated, except for the third boom lowering that will be re- ERROR AFTER KEY RESET activated only after its coil anomaly is restored. From the software release 2.0, resetting the machine by the main key the aerial part movements will be re-acti- COIL CONNECTION ERROR AFTER KEY RESET EXAMPLE...
  • Page 156 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 157: General Electrical Information & Schematics

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS SECTION 7. GENERAL ELECTRICAL INFORMATION & SCHEMATICS avoid damaging the seal around the wire. It is best to use probes or probe tips specifically designed for this THIS MACHINE IS POWERED BY AN 76VDC (NOMINAL) ELECTRICAL technique, especially on sealed connectors.

  • Page 158: Min/Max

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Min/Max the device under test correctly. Also check that the lead on the "COM" port goes to the ground or negative side Use of the "Min/Max" recording feature of some meters of the signal and the lead on the other port goes to the can help when taking measurements of intermittent positive side of the signal.

  • Page 159: 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 160: Continuity Measurement Over Long Distances

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Over Long Distances 3. On one side, jumper from contact of wire #1 and wire When trying to determine continuity of a harness or 4. Measure continuity between wire #1 and wire #2. If wire, longer than the reach of standard instrument there is continuity, both wires are good and can be leads, is possible to perform the check without exces-...
  • Page 161 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

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