Service and Maintenance Manual

Models
X17JP - X500AJ
X20JP - X600AJ
X26JP - X770AJ

3121623

March 14, 2022 - Rev F

 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-
nel pay strict attention to these warnings and precautions FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SEC-
to avoid possible injury to themselves or others, or dam- TION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR
age to the equipment. A maintenance program must be DEATH AND IS A SAFETY VIOLATION.
followed to ensure that the machine is safe to operate.
• ENSURE REPLACEMENT PARTS OR COMPONENTS ARE
IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR
COMPONENTS.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM
• NO SMOKING IS MANDATORY. NEVER REFUEL DURING
SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANU-
ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS
FACTURER.
CLOSED AND SECURE AT ALL OTHER TIMES.
The specific precautions to be observed during mainte-
nance are inserted at the appropriate point in the manual. • REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN
These precautions are, for the most part, those that apply PERFORMING ANY MAINTENANCE.
when servicing hydraulic and larger machine component • DO NOT WEAR LONG HAIR UNRESTRAINED, OR
parts. LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE
Your safety, and that of others, is the first consideration APT TO BECOME CAUGHT ON OR ENTANGLED IN
when engaging in the maintenance of equipment. Always EQUIPMENT.
be conscious of weight. Never attempt to move heavy
parts without the aid of a mechanical device. Do not allow • OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS
heavy objects to rest in an unstable position. When raising ON MACHINE AND IN SERVICEMANUAL.
a portion of the equipment, ensure that adequate support
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STAND-
is provided.
ING SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED
COOLANT SYSTEM.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER
THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA IS • NEVER WORK UNDER AN ELEVATED BOOM UNTIL
THE RESPONSIBILITY OF THE OWNER/OPERATOR. BOOM HAS BEEN SAFELY RESTRAINED FROM ANY
MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR
BOOM SAFETY PROP HAS BEEN ENGAGED.
HYDRAULIC SYSTEM SAFETY
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
It should be noted that the machines hydraulic systems PERFORMING ANY OTHER MAINTENANCE, SHUT OFF
operate at extremely high potentially dangerous pres- ALL POWER CONTROLS.
sures. Every effort should be made to relieve any system
pressure prior to disconnecting or removing any portion • BATTERY SHOULD ALWAYS BE DISCONNECTEDDUR-
of the system. ING REPLACEMENT OF ELECTRICAL COMPONENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS
STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.

3121623 – JLG Lift – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

REVISON LOG

Original Issue A - October 21, 2013

Revised B - November 3, 2016

Revised C - March 29, 2017

Revised D - March 27, 2018

Revised E - June 29, 2018

Revised F - March 14, 2022

b – JLG Lift – 3121623

 TABLE OF CONTENTS

TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-A
HYDRAULIC SYSTEM SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-A
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-A

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 TRACK SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Honda Engine iGX390 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Honda Engine iGX440 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Hatz Engine 1B40 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Perkins Engine 402D Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Kubota Engine D902-E3B Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4 SPECIFICATIONS AND PERFORMANCE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Reach Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Function Speed Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Machine Orientation When Performing Speed Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.5 HYDRAULIC PRESSURE SETTINGS - PSI (BAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.6 MAJOR COMPONENT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.7 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.8 SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.9 FASTENER TORQUE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
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 GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Pressure-Fit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 LUBRICATION AND INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

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Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 CYLINDER DRIFT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.6 WELDING ON JLG EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
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 & TURNTABLE

3.1 RUBBER TRACK MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Checking Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Operations For Loosening/tightening The Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Checking The Rubber Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Replacing The Rubber Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installing The Rubber Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Checking tightness of nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2 UNDERCARRIGE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Replacement roller lower wheel and tracks adjuster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Replacement sprocket and Gear Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Sprocket remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Gear motor remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Gear motor installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Sprocket installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 AXLE EXTENSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.4 FINAL DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5 SWING DRIVE (IMO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Technical 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 The Slew Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Inspecting The Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.6 HONDA ENGINE IGX440 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Engines & Controls Adjustments And Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Engine Harness By-Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Fuel System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Fuel Tank Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Replacement Of Engine ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.7 HATZ ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Model: HATZ 1B40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Description Of The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Engine Type Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

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Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.8 PERKINS ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Model: 402D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Fuel Filter Base - Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.9 KUBOTA DIESEL ENGINE MODEL D902 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Engine Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Engine Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Speed Sensor Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Diesel Engine RPM control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
All Diesel Actuator Rod Travel Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.10 THERMIC ENGINE REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.11 ELECTRIC MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.12 LITHIUM MACHINE WITH 76V LITHIUM BATTERY SYSTEM - X26JP - X770AJ
(S/N C170001340 TO PRESENT)3-43
Charge Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Lithium Cells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
DC-DC Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
RPM Regulation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
RPM Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Temperature Ongoings (Heaters And Fans) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Diagnostics And Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

SECTION 4 - BOOM & PLATFORM

4.1 BOOM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Removal of the Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Disassembly of the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Assembly of the Main Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Installation of the Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2 BOOM DISASSEMBLY X20JP - X600AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Checking Wear And Deformation Of Ropes And Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Installation To Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Three month inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.4 WIRE ROPE TENSION ADJUSTMENT PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.5 ROTARY ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
ARP Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Installing Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.6 BOOM ROTATION SENSOR ASSEMBLY - X26JP - X770AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.7 PROXIMITY SENSOR ADJUSTMENT (X17JP-X500AJ – X20JP-X600AJ) . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.8 PLATFORM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Platform Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.9 LOAD CELL AND FOOTSWITCH REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Removing Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Installing Load Cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Removing Footswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Installing Footswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

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4.10 SKYGUARD INSTALLATION - ONE PERSON PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Procedure:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Installation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Skyguard System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4.11 SKYGUARD INSTALLATION - TWO PERSON PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Options/Accessories Prohibited When Installing This Kit: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Tools & Equipment Required:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Personnel Required: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Procedure:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Installation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Skyguard System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

SECTION 5 - HYDRAULICS

5.1 MAIN COMPONENTS IDENTIFICATION AND LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

X17JP-X500AJ and X20JP-X600AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
X26JP-X770AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 HYDRAULIC SYSTEM PUMP AND PRESSURE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3 GROUND COMPONENT HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.4 OUTRIGGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.5 DRIVE GEAR MOTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.6 TRACKS WIDENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.7 BOOM COMPONENT HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
First And Second Booms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Third Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Telescope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Jib. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Basket Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Basket Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Turret Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Emergency Gravity Descent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Hydraulic System Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.8 CYLINDER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Specification - Cylinders Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Hydraulic Cylinders Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Equipment And Product List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Cylinder With Sensor - General Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Cleanness And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Magnetic Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Threaded Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
General Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Cylinder Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Cylinder Repair Without Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Piston With Nut Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Seals Head Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Bushing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Cylinders Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5.9 REPLACEMENT HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Pump removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Pump installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5.10 HYDRAULIC PUMP REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Seal Kit Replacement Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
External Components Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Components disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Second Section Components Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Second Section Seals Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

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Second Section Seals Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

First Section Seals Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
First Section Seals Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
First Section Seals Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Cover Seals Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Second Section Components Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
First Section Components Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Components Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Final Assembly And Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
5.11 HYDRAULIC COMPONENT START-UP PROCEDURES AND RECOMMENDATIONS . . . . . . . . . . . . . 5-41
5.12 PRESSURE SETTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Control Valve (Chassis functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Automatic Reductions Drive Speed (X17JP-X500AJ and X26JP-X770AJ Only) . . . . . . . . . . 5-43
Control Valve Turntable Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5.13 OUTRIGGERS AUTO-RETRACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

SECTION 6 - JLG CONTROL SYSTEM

6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 MACHINE IGNITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 PLATFORM - REMOTE CONTROL STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
LCD Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
LCD Display Icon Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Lithium Only Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Tilt Conditions Drive Cut-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Speed Control Possible Conditions On The X17JP - X500AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Speed Control Possible Conditions on the X20JP - X600AJ. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Speed Control Possible Conditions on the X26JP - X770AJ. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Speed Control Conditions On X Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.4 CANBUS COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Can Bus Device Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
CAN-BUS Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
CAN Timeout Menu’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Software Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
CAN BUS Devices And Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
X17JP - X20JP - X500AJ - X600AJ - CAN BUS Device Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Resistence Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
X26JP - X770AJ - CAN BUS Device Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Electronic Module LED Flashing Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6.5 SENSORS AND DEVICES NOT COMMUNICATING THROUGH CAN-BUS. . . . . . . . . . . . . . . . . . . . . . . 6-30
Electrical System Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Inclination Sensor System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Load Cell System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Rotation Sensor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Electric Motor (Not For Lithium Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
12 Volt Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Battery Charge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6.6 CALIBRATION REQUIREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
6.7 PLATFORM REMOTE CONTROL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Service Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Using The Service Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Input Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Language Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Errors Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
RAMP Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
CURRENT Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65

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Working Hours Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67

Joystick Menu
X26JP - X770AJ (S/N C170001340 to Present) 6-70
6.8 MACHINE SETUP MENU X26JP - X770AJ
(PRIOR TO S/N C170001340)6-71
Setup 1 - ACCELER - (Calibrating Tilt Sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
Setup 2 - VERSION - Model Number - Engine Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
Setup 3 - EXTRA - Machine Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Setup 4 - CALIBRATION SWING SENSOR (X26JP - X770AJ Only). . . . . . . . . . . . . . . . . . . . . . . . 6-85
Setup 5 - LOAD SENSING SYSTEM (LSS CALIBRATION) X17JP - X500AJ & X20JP - X600AJ
(Prior to S/N C170000892) 6-87
Setup 5 - LOAD SENSING SYSTEM (LSS CALIBRATION) X17JP - X500AJ & X20JP - X600AJ
(S/N C170000893 to Present) 6-89
Setup 6 - TIME Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
Setup 7 - DATE Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
6.9 MACHINE SETUP MENU X26JP - X770AJ
(S/N C170001340 TO PRESENT)6-91
Setup - Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
Setup - Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
Setup - Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
Setup - Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
Setup - Load Cell Board (ECM3) Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93
Setup - Acceler (Calibrating Tilt Sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93
Setup - Extra . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94
6.10 JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99
6.11 CALIBRATING JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-100

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Resistance Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Continuity Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Current Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Continuity Measurement Over Long Distances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Requirements: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 ELECTRICAL SCHEMATICS MANUALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4 X17JP-X500AJ AND X20JP-X600AJ - HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.5 X26JP-X770AJ - HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

6 3121623
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SECTION 1. SPECIFICATIONS
1.1 CAPACITIES

Table 1-1. Drive Hub Capacities

Machine Type Drive Hub Drive Capacities
BONFIGLIOLI AUTO
X17JP / X500AJ 0.10 gal (0,4 L)
700C2K I:32 + MAG12 VP 2 SPEED
BONFIGLIOLI AUTO
X20JP / X600AJ 0,09 gal (0,35 L)
700-2 C2K+ MAG16VP 2 SPEED
BONFIGLIOLI AUTO
X26JP / X770AJ 0.16 gal (0,6 L)
701 C2K + MAG18VP 2 SPEED

Table 1-2. Hydraulic & Fuel Tank Capacities

FUEL TANK X17JP - X500AJ & FUEL TANK X17JP - X500AJ & X20JP -
HYDRAULIC OIL TANK X20JP - X600AJ (Prior to S/N- C170000892) X600AJ (S/N-C170000893 to Present)
MACHINE
CAPACITY
GASOLINE DIESEL GASOLINE DIESEL
X17JP / X500AJ 10.56 gal (40L) 1.55 gal (5,9L) 1.3 gal (5L) 1.6 gal (6,1L) 1.3 gal (5L)
X20JP / X600AJ 10.56 gal (40L) 1.55 gal (5,9L) 2.6 gal (10L) 1.6 gal (6,1L) 2.6 gal (10L)
X26JP / X770AJ 15.85 gal (60L) — 10.56 gal (25L) — 10.56 gal (25L)

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 SECTION 1 - SPECIFICATIONS

1.2 TRACK SPECIFICATIONS

Table 1-3. Track Specifications

RUBBER BELT TRACK

MACHINE
MODEL PART
TYPE DIMENSIONS DRAWING
NUMBER

LOW
PROFILE
053715L0
BLACK
COLOR

X17JP Cm
X500AJ 180 X 37 X 72
LOW
PROFILE
053715LB
NON-MARK-
ING

LOW
PROFILE 257215L0
BLACK COLOR

X20JP Cm
X600AJ 200 X 48 X 66
LOW
PROFILE
257215LB
NON- MARK-
ING

HI PROFILE
27589900
BLACK COLOR

X26JP Cm
X770AJ 230 X 26 X 96
HI PROFILE
NON-MARK- 2758990B
ING

1-2 3121623
 SECTION 1 - SPECIFICATIONS

Table 1-4. Ground Bearing Pressure

PRESSURES AND REACTIONS TO THE GROUND

ON TRACKS ON OUTRIGGER
MODEL Maximum
*Ground Bearing Pressure Maximum
Ground Bearing Pressure
[daN/cm²] - [PSI] Ground Bearing Pressure
On Each Pad
* Average values on hard surface [daN/cm²] - [PSI]
[daN] - [lbf]
X17JP-X500AJ 0,67 daN/cm² 9.7 PSI 1731 daN 3892 lbf 2,45 daN/cm² 35.5 PSI
X20JP-X600AJ 0,64 daN/cm² 9.2 PSI 2150 daN 4833 lbf 3,04 daN/cm² 45 PSI
2
X26JP-X770AJ 0,53 daN/cm 7.6 PSI 3124 daN 7023 lbf 4,42 daN/cm2 65 PSI

1.3 POWER SOURCE

Table 1-5. Power Configurations

X17JP - X500AJ X20JP - X600AJ X26JP - X770AJ

Gasoline Engine
Honda iGX440
X17JP - X500AJ & X20JP - X600AJ N/A
12.7 hp (9,5 kW) / 3600 RPM
(Prior to C170000892)
Gasoline Engine Honda iGX440
Honda iGX390
X17JP - X500AJ & X20JP - X600AJ 12.7 hp (9,5 kW) / 3600 RPM N/A
11,7 hp (8,7 kW) / 3600 rpm
(C170000893 to Present)
Hatz 1B40 Perkins 402.05 Kubota D902
Diesel Engine
10 hp (7.46 kW) 14 hp (10.44 Kw) 21.6 hp (16,1 Kw)
Lithium 90 or 100Ah 72V 90 or 100Ah 72V 100 Ah 83V
AC Electric Motor 110V 50 Hz (2,2 KW)
120V 60 Hz (1.2 kW)
230V 50 Hz (2.2 kW)
230V 60 Hz (2.2 kW)
NOTE: RPM Tolerances are ± 50.

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 SECTION 1 - SPECIFICATIONS

Honda Engine iGX390 Specifications

Table 1-6. Specifications Honda Engine iGX390
Model iGX390
Air cooled 4-stroke OHV petrol engine,
Engine type 25° inclined cylinder, horizontal shaft, cast
iron sleeve
Bore x stroke 88 x 64 mm
Displacement 389 cm3
Compression ratio 8.2 : 1
6.4 kW (8,6 HP) / 3 000 rpm
Net power
7.0 kW (9.4 HP) / 3 600 rpm
Max. net torque 26.5 Nm / 2.7 kgfm / 2 500 rpm
Ignition system Digital CDI with variable ignition timing
Recoil starter,
Starting system
Electric starter
Choke Automatic
Fuel tank capacity 6.1 l
Fuel cons. at cont. rated power 3.5 L/hr - 3 600 rpm
Engine oil capacity 1.1 l
Dimensions (L x W x H) 409 x 484 x 448 mm
Dry weight 37,0 kg

Honda Engine iGX440 Specifications

Table 1-7. Specifications Honda Engine iGX440

Model iGX440U
Description code GCAWK
Type 4-stroke, overhead camshaft, single cylinder, inclined by 15°
Displacement 438 cm3 (26.7cu-in)
Bore x stroke 88.0 x 72.1 mm (3.46 x 2.84 in)
Maximum horsepower 11.2 kW (15.2 HP) / 3,600 min-1 (rpm)
Recommended maximum operation bhp 8.0 kW (10.8 HP) / 3,600 min-1 (rpm)
Maximum torque 29.8 N·m (3.0 kgf·m, 22 lbf·ft)/2,500 min-1 (rpm)
Compression ratio 8.1 : 1
Minimum fuel consumption 328 g/kW·h (241 g/HP·h, 0.53 lb/HP·h)
Ignition system CDI
Ignition timing (at no load) 10° B.T.D.C./1,400 min-1 (rpm)
13° B.T.D.C./3,600 min-1 (rpm)
Spark plug BKR7E-E (NGK), K22PR-UR (DENSO)
Lubrication system Forced splash type
Oil capacity 1.10 l (1.16 US qt, 0.97 lmp qt)
Cooling system Forced air
Starting system Recoil and starter motor
Stopping system Ignition primary circuit open
Carburetor Horizontal type batter fly valve

1-4 3121623
 SECTION 1 - SPECIFICATIONS

Table 1-7. Specifications Honda Engine iGX440

Model iGX440U
Air cleaner Dual element type
Governor STR (Self Tuning Regulator) governor
Fuel used Unleaded gasoline with a pump octane rating 86 or higher

Hatz Engine 1B40 Specifications

Table 1-8. Specifications Hatz Engine 1B40

Type 1B40
Design Air-cooled four-stroke diesel engine
Combustion system Direct injection
Number of cylinders 1
Bore / stroke 88 / 76 mm
Displacement 462 cm3
Lubricating oil capacity without oil sump: 1.5 1) l, approx.
with oil sump: 3.2 1) l, approx.
Difference between “max” and “min” levels without oil sump: 0.8 1) l, approx.
with oil sump: 2.2 1) l, approx.
Lubricating oil consumption (after running in) 1% of fuel consumption at full load max.)
Lubricating oil pressure (oil temperature 100 °C) 2.5 bars at 3000 r.p.m. (approx.)
Direction of rotation, power take-off end anti-clockwise
0.10 mm
Valve clearance 10 - 30 ° C - Inlet and exhaust valve
or automatically 2)
Max. tilt angle in operation, in direction Flywheel 25° down 3) all other directions 35°3)
Weight (incl. fuel tank, air-cleaner, exhaust silencer, recoil starter
55 kg approx.
and electric starter)
Battery capacity max. 12 V / 60 Amp/h

Perkins Engine 402D Specifications

Table 1-9. Specifications Perkins Engine 402D

Type 402D-05 Engine

Maximum Operating Speed (rpm) 3600 rpm
Cylinders and Arrangement In-Line two cylinder
Bore 67 mm (2.64 inch)
Stroke 72 mm (2.83 inch)
Displacement 0.507 L (30.939 in3)
Aspiration NA(1)
Compression Ratio 23.5:1
Firing Order 1-2
Rotation that is viewed from the flywheel Counterclockwise
Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)
Valve Lash Setting (Exhaust) 0.20 mm (0.008 inch)
Injection Indirect

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 SECTION 1 - SPECIFICATIONS

Kubota Engine D902-E3B Specifications

Table 1-10. Specifications Kubota Engine D902-E3B

Model D902-E3B
Emission Regulation Tier 4
Vertical 4-cycle Liquid
Type
Cooled Diesel
Number of Cylinders 3
Bore mm (in) 72 (2,83)
Stroke mm (in) 73,6 (2,9)
Displacement L (cu.in) 0,898 (54,80)
Compustion System IDI
Intake System Naturally Aspirated
Maximum Speed rpm 3200
Output:
KW 16.1
Gross Intermittent
hp 21.6
ps 21.9
Direction of Rotation Counterclockwise viewed on flywheel
Oil Pan Capacity L (gal) 3,7 (0,98)
Starter Capacity V-KW 12-1,2
Alternator Capacity V-A 12-40
Lenght mm (in) 467,1 (18,40)
Width mm (in) 420,5 (16,6)
Height (1) mm (in) 544,1 (21,42)
Height (2) mm (in) 204,0 (8,03)
Dry Weight KG (lb) 72,0 (158,8)

1-6 3121623
 SECTION 1 - SPECIFICATIONS

1.4 SPECIFICATIONS AND PERFORMANCE DATA

Reach Specifications
Table 1-11. Machine Reach Specifications
X17JP X500AJ X20JP X600AJ X26JP X770AJ
CE ANSI CE ANSI CE ANSI
Working Height 17.06 m N/A 20,15 m N/A 25,70 m N/A
Platform Height 14,96 m 49,08 ft 18,05 m 59,21 ft 23,60 m 77,42 ft
Horizontal Outreach 7,50 m 24,60 ft 9,70 m 31,82 ft 13,75 m 45,11 ft
Up & Over Height 7.80 m 25,59 ft 8,20 m 26,90 ft 10,1 m 33,13 ft
Swing (non - continuous) 360°
Max gradeability allowed in drive 16° / 28,7% 16° / 28,7% 16° / 28,7%
Max gradeability stabilization 12° 15° 16°
Max Approach /Depart angles 20°/26° 20°/21° 22°

Dimensional Data
Table 1-12. Machine Dimensional Data
X17JP / X500AJ X20JP / X600AJ X26JP / X770AJ
Platform size (standard 2 persons) 27.16 in. x 52.56 in. (690 mm x 1335 mm)
Stowed width (with std. 2P platform) 52.56 in. (1335 mm)
Stowed width (without platform) 30.70 in. (780 mm) 30.70 in. (780 mm) 38.98 in. (990 mm)
Stowed height (on tracks) 76.66 in. (1998 mm) 76.66 in. (1998 mm) 78 in. (1981 mm)
Stowed length (on tracks) 178.3 in. (4529 mm) 197.28 in. (5011 mm) 250 in. (6347 mm)
113.54 in. x 113.74 in. 115 in. x 115.16 in. 160.59 in. x 156.61 in.
Outrigger footprint (Between Center Plate )
(2884 x 2889 mm) (2922 x 2925 mm) (4079 x 3978 mm)
Outrigger footprint reduced stabilization area (Between 214.61 in. x 98.50 in.
NA NA
Center Plate ) (5451 x 2502 mm)
Machine weight (with standard platform )
Gasoline: 4916 lb. (2230 Kg) 6261 lb. (2840 Kg) NA
Diesel: 4916 lb. (2230 Kg) 6482 lb. (2940 Kg) 9623 lb. (4365 Kg)
Lithium Battery: 5071 lb. (2300 Kg) 6504 lb. (2950 Kg) 9665 lb. (4384 Kg)

3121623 1-7
 SECTION 1 - SPECIFICATIONS

Function Speed Data

Table 1-13. Function Speed
FUNCTIONS SPEED RANGE
MACHINE MODEL X17JP / X500AJ X20JP / X600AJ X26JP / X770AJ
POWER SYSTEM Engine Lithium Engine Lithium Engine Lithium
FUNCTION TIME Sec TIME Sec TIME Sec
TELESCOPE EXTEND 15" - 20" 35'' - 45'' 21" - 28" 35'' - 41'' 21" - 30" 45'' - 60''
TELESCOPE RETRACT 16" - 22" 35'' - 43'' 16" - 20" 21'' - 25'' 21" - 30" 40'' - 50''

TOWER BOOM UP 21" - 24" 38'' - 46'' 30" - 35" 35'' - 43'' 36'' - 42'' 45'' - 60''
TOWER BOOM DOWN 19" - 22" 41'' - 49'' 30" - 35" 37'' - 45'' 36'' - 45'' 50'' - 65''

UPPER BOOM UP 25" - 29" 34'' - 42'' 35" - 40" 38'' - 48'' 41'' - 52'' 50'' - 70''
UPPER BOOM DOWN 24" - 30" 35'' - 43'' 35" - 40" 38'' - 44'' 41'' - 52'' 50'' - 70''

BASKET ROTATE RIGHT 7" - 10" 7,5'' - 11'' 7" - 10" 6,5'' - 11'' 7'' - 15'' 7'' - 15''
BASKET ROTATE LEFT 7" - 10" 7,5'' - 11'' 7" - 10" 6,5'' - 11'' 7'' - 15'' 7'' - 15''

SWING LEFT 40" - 45" 47'' - 57'' 45" - 50" 48'' - 59'' 55'' - 65'' 60'' - 80''
SWING RIGHT 40" - 45" 47'' - 57'' 45" - 50" 48'' - 59'' 55'' - 65'' 60'' - 80''

JIB UP 7" - 10" 17'' - 24'' 7" - 10" 13'' - 17'' 7" - 15" 10'' - 20''
JIB DOWN 7" - 10" 11'' - 15'' 7" - 10" 9,5'' - 11'' 7" - 15" 10'' - 15''

BASKET LEVEL UP 40" - 58" 41'' - 64'' 33" - 55" 29'' - 61'' 33" - 55" 33'' - 55''
BASKET LEVEL DOWN 35" - 52" 40'' - 57'' 37" - 50" 34'' - 57'' 37" - 50" 40'' - 65''

0.43/1.12/2.24 mph 0.25/0.50/0.99 mph 0.31/0.81/1.55 mph 0.52/0.99 mph 0.68/1.24 mph 0.43/0.75 mph
DRIVE SPEED
(0,7/1,8/3,6 Km/h) (0,4/0,8/1,6 Km/h) (0,5/1,3/2,5 Km/h) (0,83/1,6 Km/h) (1,1/2 Km/h) (0,7/1,2 Km/h)

Machine Orientation When Performing Speed Tests • Articulating Jib: Platform level and centered with the
boom. Start with the Jib down. Jib Up, Record Time.
• Lift: Boom Retracted. Telescope Retracted. Lift Up, Jib Down, Record Time.
Record Time, Lift Down, Record Time. • Lower Lift: Upper Boom horizontal. Telescoped In.
• Swing: Machine stabilized, upper Boom at Full Eleva- Lower Lift Up, Record Time. Lower Lift Down, Record
tion. Telescope Retracted. Swing the Turntable to the Time.
end stop. Swing the Opposite Direction, Record Time. Test Notes:
• Telescope: Boom at Full Elevation; Telescope 1. Stop watch should be started with the function,
Retracted; Telescope Out, Record Time. Telescope In, not with the controller or switch.
Record Time.
2. All speed tests are run from ground with remote
• Drive: Test to be done on a smooth level surface. control connected on the basket.
Drive Select Switch should be set at 2WD High Engine. 3. Function speeds may vary due to cold, thick
Start approximately 25 ft. (7.62 m) from starting point hydraulic oil. Test should be run with the oil tem-
so that the unit is at maximum speed when starting perature above 100° F (38° C).
the test.
• Platform Rotate: Platform level and completely
rotated one direction. Rotate the opposite direction,
Record Time. Rotate the other direction, Record Time.

1-8 3121623
 SECTION 1 - SPECIFICATIONS

1.5 HYDRAULIC PRESSURE SETTINGS - PSI (BAR)

Table 1-14. Pressure Settings Table 1-15. Reduction Drive Speed Pressure Settings

UNDERCARRIAGE AUTOMATIC REDUCTIONS DRIVE SPEED

TOWER
Left and Right MODEL
MODEL Control Valve
Control Valve BAR PSI
BAR PSI BAR PSI X17JP - X500AJ 26 380
X17JP - X500AJ 165 2393 185 2045 X20JP - X600AJ NA NA
X20JP - X600AJ 165 2393 210 3045 X26JP - X770AJ 26 380
X26JP - X770AJ 200 2900 200 2900

1.6 MAJOR COMPONENT WEIGHTS

Table 1-16. Major Component Weights
MACHINE X17JP - X500AJ X20JP - X600AJ X26JP - X770AJ
DESCRIPTION KG LBS KG LBS KG LBS
Basket with Remote Control 43 94.7 36 79.3 43.0 94.7
Basket A-Frame Assembled 33 72.7 31 68.3 31 68.3
Basket Level Cylinder 8 17.6 8 17.6 8 17.6
Basket Rotator 20 44 17 37.4 17 37.4
Cylinder JIB 12 26.4 12 26.4 12 26.4
Upper JIB Link 10 22 10 22 10 22
Lower JIB Link 15 33 15 33 15 33
Arms JIB 24 52.9 24 52.9 24 52.9
Upper Boom 92 202.8 158 348.3 218.3 481.2
Telescope Cylinder 52 114.6 61.5 135.5 94.8 209
Upper Upright 60 132.2 92 202.8 83.3 183.6
Master Cylinder 7 15.4 7 15.4 7 15.4
Upper Lift Cylinder 38 83.7 53.3 117.5 69.7 153.6
Upper Boom Link 61 134.4 128 282.1 204 449.7
Upper Tower Boom 105 231.4 149.5 329.5 283.1 624.1
Upper Tower Cylinder 38 83.7 53 116.8 89.4 197
Lower Boom Link 14 30.8 28.5 62.8 27 59.5
Lower Upright 57 125.6 84 185.1 126.3 278.4
Tower Link 35 77.1 86 189.5 141 310.8
Lower Tower Boom 71 156.5 98.5 217.1 194.3 428.3
Tower 218 480.6 268 590 217.9 480.3
Undercarriage Assembled 1119 2466.9 1271 2802 2137.2 4711.7

3121623 1-9
 SECTION 1 - SPECIFICATIONS

1.7 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
-5°C/+50°C TELLUS S3V ISO46 EP EXTRA
46 V.I.160 (P/N 7527700) ISO 32 V.I.160 HYDRAULIC
-9°C/+40°C MobilEAL / SHELL EP EXTRA
EnvirosynH46 TELLUS S3V ISO 22 V.I.180
(P/N2300029) 32 V.I.160 / SHELL
-15°C/+30°C TELLUS S3V
22 V.I.180
-24°C/+20°C

Figure 1-1. Hydraulic Oil Temperature Operating Range

FLUID PROPERTIES TYPE CLASSIFICATIONS

Viscosity at 40°C (cst,Typical)

Readily Biodegradable*
Synthetic Polyol Esters

Virtually Non-toxic**

Fire Resistant***
DESCRIPTION
Viscosity Index

Vegetable Oils
Mineral Oils

Synthetic

Pakelo Hydraulic EP Extra ISO 68 68 180 X

Pakelo Hydraulic EP Extra ISO 46 46 160 X
GeolubeECO HydraulicISO 46 (P/N 17527700) 47.3 144 X X
Pakelo Hydraulic EP Extra ISO 32 32 160 X
Pakelo Hydraulic EP Extra ISO 22 22 180 X
SHELL TELLUS S3V 68 68 180 X
SHELL TELLUS S3V 46 46 160 X
MobilEAL EnvirosynH46 (P/N2300029) X X
SHELL TELLUS S3V 32 32 160 X
SHELL TELLUS S3V 22 22 180 X
Table 1-17. Hydraulic Oil Specifications
* Readily biodegradable classification indicates one of the following: CO2 Conversion > 60% per EPA 560/6-82-003 / CO2
Conversion > 80% per CEC-L-33-A-93
** Virtually Non-toxic classification indicates an LC50 > 5000 per OECD 203
*** Fire Resistant classification indicates Factory Mutual Research Corp. (FMRC) Approval
Flash point (C.O.C) for 68-46-32-22: 210°C

1-10 3121623
 SECTION 1 - SPECIFICATIONS

1.8 SERIAL NUMBER LOCATION

A serial number plate is affixed on to the frame a frame.
The following illustration showing the position.

Figure 1-3. X26JP / X770AJ Serial Number Plate Location

(on side of chassis rear compartment cover)

Figure 1-2. Serial Number Plate

Figure 1-4. X17JP/X20JP - X500AJ/X600AJ - Serial Number Plate Location

3121623 1-11
 SECTION 1 - SPECIFICATIONS

1.9 FASTENER TORQUE CHARTS

Figure 1-5. Torque Chart - Sheet 1 of 5 - (SAE Fasteners)

1-12 3121623
 SECTION 1 - SPECIFICATIONS

Figure 1-6. Torque Chart - Sheet 2 of 5 - (SAE Fasteners)

3121623 1-13
 SECTION 1 - SPECIFICATIONS

Figure 1-7. Torque Chart - Sheet 3 of 5 - (SAE Fasteners)

1-14 3121623
 SECTION 1 - SPECIFICATIONS

Figure 1-8. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)

3121623 1-15
 SECTION 1 - SPECIFICATIONS

Figure 1-9. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)

1-16 3121623
 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
General Form and the Inspection and Preventative Maintenance
Schedule for items requiring inspection during the per-
This section provides the necessary information needed formance of these inspections. Reference the appropri-
by those personnel that are responsible to place the ate areas of this manual for servicing and maintenance
machine in operation readiness and maintain its safe procedures.
operating condition. For maximum service life and safe
operation, ensure that all the necessary inspections and Annual Machine Inspection
maintenance have been completed before placing the
machine into service. With proper care, maintenance The Annual Machine Inspection must be performed by a
and inspections performed per JLG's recommendations Factory-Certified Service Technician on an annual basis,
with any and all discrepancies corrected, this product no later than thirteen (13) months from the date of the
will be fit for continued use. prior Annual Machine Inspection. JLG Industries, Inc.
recognizes a Factory-Certified Service Technician as a
Preparation, Inspection, and Maintenance person who has successfully completed the JLG Service
Training School for the subject JLG product model. Ref-
It is important to establish and conform to a compre- erence the machine Service and Maintenance Manual
hensive inspection and preventive maintenance pro- and appropriate JLG inspection form for performance of
gram. The following table outlines the periodic machine this inspection.
inspections and maintenance recommended by JLG
Industries, Inc. Consult your national, regional, or local Reference the JLG Annual Machine Inspection Form and
regulations for further requirements for aerial work plat- the Inspection and Preventative Maintenance Schedule
forms. The frequency of inspections and maintenance for items requiring inspection during the performance
must be increased as environment, severity and fre- of this inspection. Reference the appropriate areas of
quency of usage requires. this manual for servicing and maintenance procedures.

Pre-Start Inspection For the purpose of receiving safety-related bulletins, it is

important that JLG Industries, Inc. has updated owner-
It is the User’s or Operator’s primary responsibility to ship information for each machine. When performing
perform a Pre-Start Inspection of the machine prior to each Annual Machine Inspection, notify JLG Industries,
use daily or at each change of operator. Reference the Inc. of the current machine ownership.
Operator’s and Safety Manual for completion proce-
dures for the Pre-Start Inspection. The Operator and Preventative Maintenance
Safety Manual must be read in its entirety and under- In conjunction with the specified inspections, mainte-
stood prior to performing the Pre-Start Inspection. nance shall be performed by a qualified JLG equipment
Pre-Delivery Inspection and Frequent Inspection mechanic. JLG Industries, Inc. recognizes a qualified JLG
equipment mechanic as a person who, by possession of
The Pre-Delivery Inspection and Frequent Inspection a recognized degree, certificate, extensive knowledge,
shall be performed by a qualified JLG equipment training, or experience, has successfully demonstrated
mechanic. JLG Industries, Inc. recognizes a qualified JLG the ability and proficiency to service, repair, and main-
equipment mechanic as a person who, by possession of tain the subject JLG product model.
a recognized degree, certificate, extensive knowledge,
training, or experience, has successfully demonstrated Reference the Preventative Maintenance Schedule and
the ability and proficiency to service, repair, and main- the appropriate areas of this manual for servicing and
tain the subject JLG product model. maintenance procedures. The frequency of service and
maintenance must be increased as environment, sever-
The Pre-Delivery Inspection and Frequent Inspection ity and frequency of usage requires.
procedures are performed in the same manner, but at
different times. The Pre-Delivery Inspection shall be per-
formed prior to each sale, lease, or rental delivery. The
Frequent Inspection shall be accomplished 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

3121623 2-1
 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 Operator and Safety Manual
Inspection At each Operator change.
Service and Maintenance Man-
Pre-Delivery Inspec- Prior to each sale, lease, or Qualified JLG
Owner, Dealer, or User ual and applicable JLG inspec-
tion rental delivery. Mechanic
tion form.
In service for 3 months or 150 hours, whichever
comes first; or Service and Maintenance Man-
Frequent Qualified JLG
Out of service for a period of more than 3 Owner, Dealer, or User ual and applicable JLG inspec-
Inspection Mechanic
months; or tion form.
Purchased used.
Service and Maintenance Man-
Annual Machine Annually, no later than 13 months from the Factory-Certified Ser-
Owner, Dealer, or User ual and applicable JLG inspec-
Inspection date of the prior inspection. vice Technician
tion form.
Preventative At intervals as specified in the Service and Qualified JLG Service and Maintenance Man-
Owner, Dealer, or User
Maintenance Maintenance Manual. Mechanic ual

2.2 SERVICE AND GUIDELINES them clean. Be sure all parts are clean before they
are installed. New parts should remain in their con-
General tainers until they are ready to be used.
The following information is provided to assist you in Components Removal and Installation
the use and application of servicing and maintenance
1. Use adjustable lifting devices, whenever possible, if
procedures contained in this book.
mechanical assistance is required. All slings (chains,
cables, etc.) should be parallel to each other and as
Safety and Workmanship near perpendicular as possible to top of part being
Your safety, and that of others, is the first consideration lifted.
when engaging in the maintenance of equipment. 2. Should it be necessary to remove a component on
Always be conscious of weight. Never attempt to move an angle, keep in mind that the capacity of an eye-
heavy parts without the aid of a mechanical device. Do bolt or similar bracket lessens, as the angle
not allow heavy objects to rest in an unstable position. between the supporting structure and the compo-
When raising a portion of the equipment, ensure that nent becomes less than 90 degrees.
adequate support is provided. 3. If a part resists removal, check to see whether all
nuts, bolts, cables, brackets, wiring, etc., have been
Cleanliness removed and that no adjacent parts are interfering.
1. The most important single item in preserving the Component Disassembly and Reassembly
long service life of a machine is to keep dirt and
foreign materials out of the vital components. Pre- When disassembling or reassembling a component,
cautions have been taken to safeguard against complete the procedural steps in sequence. Do not par-
this. Shields, covers, seals, and filters are provided tially disassemble or assemble one part, then start on
to keep air, fuel, and oil supplies clean; however, another. Always recheck your work to assure that noth-
these items must be maintained on a scheduled ing has been overlooked. Do not make any adjustments,
basis in order to function properly. other than those recommended, without obtaining
proper approval.
2. At any time when air, fuel, or oil lines are discon-
nected, clear adjacent areas as well as the openings Pressure-Fit Parts
and fittings themselves. As soon as a line or compo-
nent is disconnected, cap or cover all openings to When assembling pressure-fit parts, use an anti-seize or
prevent entry of foreign matter. molybdenum disulfide base compound to lubricate the
3. Clean and inspect all parts during servicing or mating surface.
maintenance, and assure that all passages and
openings are unobstructed. Cover all parts to keep

2-2 3121623
 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. Compressed the specified intervals. When recommended lubricants
air can be used but do not spin the bearing. are not available, consult your local supplier for an
2. Discard bearings if the races and balls (or rollers) equivalent that meets or exceeds the specifications
are pitted, scored, or burned. listed.
3. If bearing is found to be serviceable, apply a light Battery
coat of oil and wrap it in clean (waxed) paper. Do
not unwrap reusable or new bearings until they are Clean battery, using a non-metallic brush and a solution
ready to install. of baking soda and water. Rinse with clean water. After
cleaning, thoroughly dry battery and coat terminals
4. Lubricate new or used serviceable bearings before with an anti corrosion compound.
installation. When pressing a bearing into a retainer
or bore, apply pressure to the outer race. If the Lubrication and Servicing
bearing is to be installed on a shaft, apply pressure
to the inner race. Components and assemblies requiring lubrication and
servicing are shown in the Lubrication Chart in Section
Gaskets 1.
Check that holes in gaskets align with openings in the 2.3 LUBRICATION AND INFORMATION
mating parts. If it becomes necessary to hand-fabricate
a gasket, use gasket material or stock of equivalent Hydraulic System
material and thickness. Be sure to cut holes in the right
location, as blank gaskets can cause serious system 1. The primary enemy of a hydraulic system is con-
damage. tamination. Contaminants enter the system by vari-
ous means, e.g., using inadequate hydraulic oil,
Bolt Usage and Torque Application allowing moisture, grease, filings, sealing compo-
1. Use bolts of proper length. A bolt which is too long nents, sand, etc., to enter when performing mainte-
will bottom before the head is tight against its nance, or by permitting the pump to cavitate due
related part. If a bolt is too short, there will not be to insufficient system warm-up or leaks in the
enough thread area to engage and hold the part pump supply (suction) lines.
properly. When replacing bolts, use only those hav- 2. The design and manufacturing tolerances of the
ing the same specifications of the original, or one component working parts are very close, therefore,
which is equivalent. even the smallest amount of dirt or foreign matter
2. Unless specific torque requirements are given entering a system can cause wear or damage to the
within the text, standard torque values should be components and generally results in faulty opera-
used on heat-treated bolts, studs, and steel nuts, in tion. Every precaution must be taken to keep
accordance with recommended shop practices. hydraulic oil clean, including reserve oil in storage.
(See Torque Chart Section 1.) Hydraulic system filters should be checked,
cleaned, and/or replaced as necessary, at the speci-
Hydraulic Lines and Electrical Wiring fied intervals required in the Lubrication Chart in
Section 1. Always examine filters for evidence of
Clearly mark or tag hydraulic lines and electrical wiring, metal particles.
as well as their receptacles, when disconnecting or
removing them from the unit. This will assure that they 3. Cloudy oils indicate a high moisture content which
are correctly reinstalled. permits organic growth, resulting in oxidation or
corrosion. If this condition occurs, the system must
Hydraulic System be drained, flushed, and refilled with clean oil.
1. Keep the system clean. If evidence of metal or rub- 4. It is not advisable to mix oils of different brands or
ber particles are found in the hydraulic system, types, as they may not contain the same required
drain and flush the entire system. additives or be of comparable viscosities. Good
grade mineral oils, with viscosities suited to the
2. Disassemble and reassemble parts on clean work ambient temperatures in which the machine is
surface. Clean all metal parts with non-flammable operating, are recommended for use.
cleaning solvent. Lubricate components, as
required, to aid assembly. NOTE: Metal particles may appear in the oil or filters of new
machines due to the wear-in of meshing compo-
nents.

3121623 2-3
 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. Cylinder Drift
specified otherwise) thereafter. If it is necessary to
change the oil, use only those oils meeting or MAX ACCEPTABLE DRIFT
CYLINDER BORE DIAMETER
exceeding the specifications appearing in this IN 1 MINUTE
manual. If unable to obtain the same type of oil INCHES MM INCHES MM
supplied with the machine, consult local supplier
2.1 55 0.02 0.53
for assistance in selecting the proper equivalent.
Avoid mixing petroleum and synthetic base oils. 2.3 60 0.021 0.54
JLG Industries recommends changing the hydrau- 2.5 65 0.013 0.35
lic oil annually.
2.7 70 0.026 0.68
2. Use every precaution to keep the hydraulic oil 2.9 75 0.013 0.35
clean. If the oil must be poured from the original
container into another, be sure to clean all possible 3.1 80 0.011 0.29
contaminants from the service container. Always 3.7 95 0.009 0.23
clean the mesh element of the filter and replace the
3.9 100 0.007 0.2
cartridge any time the system oil is changed.
3. While the unit is shut down, a good preventive 4.5 115 0.005 0.15
maintenance measure is to make a thorough 4.9 125 0.004 0.12
inspection of all hydraulic components, lines, fit- 6.1 155 0.002 0.07
tings, etc., as well as a functional check of each sys-
tem, before placing the machine back in service. Drift is to be measured at the cylinder rod with a cali-
Lubrication Specifications brated dial indicator. The cylinder oil must be at ambi-
ent temperature and temperature stabilized.
Specified lubricants, as recommended by the compo-
nent manufacturers, are always the best choice, how- The cylinder must have the normal load, which is the
ever, multi-purpose greases usually have the qualities normal platform load applied.
which meet a variety of single purpose grease require-
ments. Should any question arise, regarding the use of If the cylinder passes this test, it is acceptable.
greases in maintenance stock, consult your local sup-
plier for evaluation. Refer to Section 1 for an explanation
of the lubricant key designations appearing in the Lubri-
cation Chart.

2-4 3121623
 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
Filament wound bearings. the machine and to welding performed from the
machine on an external structure, or component,
1. Pinned joints should be disassembled and
inspected if the following occurs: Do the Following When Welding on JLG Equipment
a. Excessive sloppiness in joints. • Disconnect the battery.
b. Noise originating from the joint during opera- • Disconnect the moment pin connection (where fitted)
tion. • 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. Cracked or damaged liner backing. • Ground on frame and weld on any other area than the
c. Bearings that have moved or spun in their chassis.
housing. • Ground on turntable and weld on any other area than the
d. Debris embedded in liner surface. turntable.
3. Pins should be replaced if any of the following is • Ground on the platform/support and weld on any other
observed (pin should be properly cleaned prior to area than the platform/support.
inspection):
• Ground on a specific boom section and weld on any other
a. Detectable wear in the bearing area. area than that specific boom section.
b. Flaking, pealing, scoring, or scratches on the
• Allow pins, wear pads, wire ropes, bearings, gearing, seals,
pin surface.
valves, electrical wiring, or hoses to be between the
c. Rusting of the pin in the bearing area. grounding position and the welded area.
4. Re-assembly of pinned joints using filament wound
bearings. NOTICE
a. Housing should be blown out to remove all FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY RESULT
dirt and debris...bearings and bearing hous- IN COMPONENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEAR-
ings must be free of all contamination. ING, COLLECTOR RING, BOOM WIRE ROPES ETC.)
b. Bearing / pins should be cleaned with a sol-
vent to remove all grease and oil...filament
wound bearing are a dry joint and should not
be lubricated unless otherwise instructed (i.e.
sheave pins).
c. Pins should be inspected to ensure it is free of
burrs, nicks, and scratches which would dam-
age the bearing during installation and opera-
tion.

3121623 2-5
 SECTION 2 - GENERAL

NOTES:

2-6 3121623
 SECTION 3 - CHASSIS & TURNTABLE

SECTION 3. CHASSIS & TURNTABLE

3.1 RUBBER TRACK MAINTENANCE 4. When correct track tension has been obtained,
turn valve (1) in a clockwise direction and
Checking Track Tension tighten it. Clean all traces of grease.

Stop the machine on firm, level surface. Lift the machine

into safe conditions and place stable supports under the
under-carriage frame for total support. Parallel with the
central roller of the under-carriage, measure distance (A)
from the bottom of the roller to the rigid inside of the rub-
ber belt. Track tension is normal if measurement (A) is
between 10 and 15 mm.
If track tension is not within the measurements specified
above, loose or too taught, follow the procedures illus-
trated in the paragraph below.

A
Figure 3-1. Figure 3-2.
5. To tighten the track, connect a grease gun to
Operations For Loosening/tightening The Track greaser (2) and add grease until belt tension is
The grease contained in the hydraulic track is pressurised. within the specified values.
For this reason, do not loosen the greasing valve (1) by
more than 1 turn; if the valve is loosened too much, it risks DANGER
being expelled under the effect of the pressure of the IT IS NOT NORMAL IF THE TRACK REMAINS TAUGHT AFTER HAVING
grease, putting the safety of the operator at risk. Never TURNED VALVE (1) IN AN ANTI-CLOCKWISE DIRECTION OR IF THE
loosen greaser (2). TRACK IS STILL LOOSE AFTER HAVING PUT GREASE INTO GREASER (2).
When gravel or mud are blocked between the toothed NEVER TRY TO REMOVE THE TRACKS OR DISASSEMBLE THE TRACK-
wheel and the track links, remove it before loosening. TENSIONED CYLINDER BECAUSE THE GREASE PRESSURE INSIDE THE
TRACK IS VERY DANGEROUS.
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 grease does not start to drain, turn the
track slowly.

3121623 3-1
 SECTION 3 - CHASSIS & TURNTABLE

Checking The Rubber Tracks

g

PATTERN

WORN PARTS
Figure 3-4.

SPROCKET
STEEL WIRE HOLE 3. Separation of the metal cores
WHEEL SIDE a. The metal core acts as a type of adhesive of
METAL CORE the rubber between the core itself and the
steel ropes. Separation may be caused by
excessive tension as breakage of the ropes
Figure 3-3. Rubber Track Structure for the following reasons:
The structure of the rubber track is illustrated in Figure 3-3.
The steel ropes and the metal core are imbedded into the b. The metal cores have been wound by the
rubber. The carved profiles are used to give traction when worn toothed wheel as indicated in the fig-
moving over loose land. They are situated in the lower ur e. W he n t h i s w ea r an d a b r as i on i s
part resting on the ground, while the wheel guides situ- detec ted, the toot hed wheel must be
ated inside the track, prevent the track from escaping replaced as soon as possible.
from the guide rollers. c. If it breaks, as stated in item 2, "Wear and
breakage of the metal cores", the track must
CAUSES OF DAMAGE be replaced because this damage leads to a
1. Breakage of the steel ropes complete loss of functions.
Excessive tension causes the steel ropes to break 4. Abrasion and fatigue cracks
in the following conditions: a. The cracks at the base of the carved profile
a. when stones or foreign bodies accumulate occur due to bending fatigue of the rubber
between the track and the under-carriage caused by the toothed wheel and the track-
frame; tensioning wheel.
b. when the track escapes from its guide; b. The cracks and bends on the edge of the
rubber are due to manoeuvres with the
c. in the case of strong friction such as rapid track in presence of cement kerbs and
direction changes. edges.
2. Wear and breakage of the metal cores
As for breakage of the steel ropes, stated above,
excessive tension may cause the metal cores to
bend or break, as may the following causes:
a. incorrect contact between toothed wheel
and track; CRACK

b. breakage of internal rollers; Figure 3-5.

c. functioning on sandy land. c. The cracks and abrasions in the rubber on
the tracks of the roller guide originate from
fatigue from the compression of the rubber
by the weight of the wheel, together with
functioning on sandy land, or repeated and
abrupt changes of direction.
d. Abrasion of the carved profiles may occur
especially if slewing on concrete surfaces or
on gravel or hard surfaces are carried out.

3-2 3121623
 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. One turn of valve 1 is sufficient to loosen
ual and progressive damage, they allow the the track.
track to continue working. The develop- 4. If the grease does not start to drain, turn the
ment of the damage indicated in point 3 track slowly.
leads to the exposure of the metal cores and
if they are exposed for more than half of the 5. Insert three steel pipes (4) inside the track in the
track circumference, it means that it is time space between the rollers. Turn the driving
to replace them. It can however still be used. wheel backwards (5) in a way that the steel pipes
proceed with the track and engage on the track-
5. Cracks due to external factors tensioning wheel. Apply force (6) laterally to
Cracks on external track surfaces (those in con- allow the track to run and lift it from the track-
tact with the ground) are often due to contact tensioning wheel.
with gravel, sharp stones, sharp materials, nails,
glass, which cause cuts. From the rubber proper- 5
ties point of view, this is inevitable although it
does depend on service conditions. Cracks on
the internal surface of the circumference and on
the edge of the rubber originate from contact of
the belt with the structure of the undercarriage
52
02
02
BH
19

or with sharp concrete edges. The increase in

cracks is relatively small. Even if it does not
appear to be in good condition the track can be
used in heavy duty conditions.

Replacing The Rubber Tracks

4
DANGER 6
THE GREASE CONTAINED IN THE HYDRAULIC TRACK IS PRESSURISED.
Figure 3-7.
FOR THIS REASON, DO NOT LOOSEN THE GREASING VALVE (1) BY
MORE THAN 1 TURN; IF THE VALVE IS LOOSENED TOO MUCH, IT RISKS
BEING EXPELLED UNDER THE EFFECT OF THE PRESSURE OF THE Installing The Rubber Track
GREASE, PUTTING THE SAFETY OF THE OPERATOR AT RISK. NEVER
LOOSEN GREASER (2). DANGER
ENSURE SAFE CONDITIONS WITH THE MACHINE LIFTED TO PROCEED
When gravel or mud are blocked between the toothed WITH MOUNTING THE TRACKS.
wheel and the track links, remove it before loosening.
Removing The Rubber Track
1. Check that the grease contained in the hydraulic
1. Stop the machine on solid, level land, lift it and cylinder has been removed.
support it in safe conditions, using the outrig- 2. Engage the track links with the toothed wheel
gers. and position the other end of the track on the
track-tensioning wheel.
3. Turn the driving wheel in reverse (7) pushing the
track plate inside the frame (8).
4. Position the track using a steel pipe and turn the
driving wheel again.
5. Ensure that the track links are correctly engaged
in the toothed wheel and in the track-tensioning
wheel.
6. Adjust track tension (see paragraph -Operations
Figure 3-6. for loosening/tightening the track).
2. Remove the screws and take of adjustment 7. Rest the tracked under-carriage on the ground.
access lid 3.

3121623 3-3
 SECTION 3 - CHASSIS & TURNTABLE

3.2 UNDERCARRIGE COMPONENTS

7
a. Fully extend the undercarriage.
b. Remove the tracks (see sub-section 3.1).
c. Remove the key ignition, and a tag with
52
02
02
BH
19 warning do not start the machine.

Figure 3-8.

Checking tightness of nuts and bolts

Depending on the use of the platform, it is indispensable Figure 3-9.
to check the parts and the nuts and bolts in general, which
are subject to loosening. Replacement roller lower wheel and tracks
Pay particular attention to the frame components, such as adjuster
track-tensioning wheels, traversing geared motors, driving
wheels and guide rollers. Check that they are tightened
sufficiently as indicated in the following table. 5
The values indicated are to be applied unless otherwise 4
stated in this manual.
ilize the machine on level ground.

Figure 3-10.

Disassembly
1. Remove the nuts 2 on the lower roller.
2. Remove the lower roller 3.
3. Remove the front idler 5.
4. Remove the tracks adjuster 4.

Assembly
1. Fit the tracks adjuster 4.
2. Instal the front idler 5.
3. Instal the lower roller 3.
4. Apply loctite 243 and torque the nuts 2 on the
lower roller at 125Nm.

3-4 3121623
 SECTION 3 - CHASSIS & TURNTABLE

Replacement sprocket and Gear Motor Gear motor installation

1. Fix the screws 11.
12 2. Instal the valve 10.
11
3. Connect the Hydraulic hoses
10
4. Instal the cover 9.

12
11
8 10

1 9
11
12
7 8
6 9
1
11
Figure 3-11. 12
7
Sprocket remove
6
1. Fully extend the undercarriage.
Figure 3-12.
2. Remove the tracks (see paragraph 3.1).
3. Remove the key ignition, and a tag with warning Sprocket installation
do not start the machine.
1. Instal the sprocket
4. Remove screws 6.
2. Instal the screws 6
5. Remove the sprocket 7.

Gear motor remove

1. Remove cover 9.
2. Disconnect and tag the hydraulic hoses from the
gearmotor.
3. Remove the valve 10 to access all the screws 11
(on single speed versions only).
4. Remove the screws 11.
5. Remove the gearmotor 12.

Table 3-1. Final Drive Torque Valves

SPROCKET SCREW N. 6 FINAL DRIVE SCREW N. 11
MACHINE MODEL
TORQUE VALUES TORQUE VALUES
X17JP - X500AJ M10x18 - Nm 50 M10x25 - Nm 50
X20JP - X600AJ M10x25 - Nm 70 M10x30 - Nm 70
X26JP - X770AJ M12x18 - Nm 86 M12x30 - Nm 86

3121623 3-5
 SECTION 3 - CHASSIS & TURNTABLE

3.3 AXLE EXTENSION REMOVAL 8. Using a suitable lifting device (minimum 441 lb.
(200kg) capacity) to remove the track frame.

6 5

3 4
Figure 3-16.
Figure 3-13. 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.
3. Turn engine and key off.
4. Remove the key ignition, and a tag with warning

5.
do not start the machine.
Open the hydraulic cap, and operate the func-
9
tion undercarriage extend/retract to discharge
any residual pressure in the system.

8 9
2 7
Figure 3-17.
12. Remove the cylinder.

1 NOTE: Before to install the undercarriage frame inspect the

slide guides 9.
a. Unscrew the screws 7.
Figure 3-14.
b. Remove the stop slide guides 8.
6. Remove the cotter pin 1 - (figure 3-13) c. Remove the slide guides 9.
7. Remove the pin 2 d. Check the thickness of slide guides, if less
.
than 3.5 mm, damage, with deep scratches
or with deformation, replace its. Otherwise
clean them and install by adding Grease GR
MU EP1 before to install the track guides.
e. Use medium strength Loctite (Loctite 243)
on screws 7 and tightening torque of 10 Nm.

Figure 3-15.

3-6 3121623
 SECTION 3 - CHASSIS & TURNTABLE

3.4 FINAL DRIVE Information

For all enquiries regarding general information on the
Table 3-2. Final Drive Models product, spare parts, assistance etc, always give the identi-
MACHINE TYPE SPEED fication data stamped on the ID plate.
X17JP - X500AJ 700C2K I:32 + MAG12 AUTO TWO SPEED The gearmotor has two ID plates, one gives data on the
gearbox and the other data on the hydraulic motor.
X20JP - X600AJ 700-2C2K MAG16VP AUTO TWO SPEED
The plates must not be removed or damaged during the
X26JP - X770AJ 701C2K+MAG18 AUTO TWO SPEED life of the product. The following illustration shows how
the data is set out.
Product Identification
NOTE: Note Refer to the supplier final drive applicable Ser-
The data to identify the product are shown on the identifi- vice Manual - Bonfiglioli Trasmital MAN_serie
cation plate attached to it. 700CK_IS.doc. Rev17

3121623 3-7
 SECTION 3 - CHASSIS & TURNTABLE

3.5 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. 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 3-18. Type plate

The type plate is on the housing and contains the follow-

ing information:
• Manufacturer
• Drawing no./type
• Identification code consisting of:
• Order number, year of manufacture and consecutive
number
Figure 3-19. Slew drive WD-L
• Module
• Web address
1. Connection for options: Potentiometer, perma-
nent brake or front-end brake
2. Worm shaft
3. Lubricating nipple
4. Ball slewing ring
5. Option: Drive motor
6. Bolted unions for the mounting structure
7. Housing
8. Lubricating nipple

3-8 3121623
 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.
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
Figure 3-20. Use suitable lifting gear/never transport product
charged with point load so that it is offset by 90°
vertically
relative to the main load-carrying zone. The
main load- carrying zone is in the main slewing
Unpacked slew drives can be transported with lifting gear range.
when using eye bolts under the following conditions
• The lifting gear must be configured appropriately for CAUTION
the weight of the transport units. THE HARDNESS GAP OR THE FILLING PLUG IN A SLEWING RING CON-
• The ring bolts must be configured appropriately for STITUTE A ZONE OF DECREASED LOAD-CARRYING CAPACITY. THE SER-
the weight of the transport unit. VICE-LIFE OF THE SLEW DRIVE WILL BE REDUCED SIGNIFICANTLY, IF
THE HARDNESS GAP IS IN THE MAIN SLEWING RANGE. FRACTURE OF
• The slew drive shall only be transported by itself, with-
out attached parts. BEARING RING FOR EXAMPLE MAY CAUSE SLEW DRIVE FAILURE. CON-
SEQUENTLY PLACE THIS MARKED POINT IN A REDUCED LOAD ZONE IF
• Maintain the insertion depth prescribed by the manu- POSSIBLE.
facturer.
3. Use a feeler gauge to check whether the support
• If insertion depth is not prescribed, then a minimum surface of the slew drive is completely sup-
insertion depth of 1.5 x the bolt diameter must be
selected. ported by the mounting structure. If this is not
the case, the support surface of the mounting
• Transport within the company shall only be executed structure must be reworked.
horizontally.

Figure 3-22. Check the support surface

Figure 3-21. Always use the full length of the thread

3121623 3-9
 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- FM 1)
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 kN lbs
MATERIAL DAMAGE. M24 282 63396
M27 367 82505
NOTICE
M30 448 100714
MOUNT THE SLEW DRIVE IN UNSTRESSED STATE.
M33 554 124544
Strictly comply with the procedure specified below to M36 653 146800
avoid impermissible deviations between the bolt tighten-
ing forces: M42 896 201429
M45 1043 234476
NOTICE
M48 1177 264600
FIRST FASTEN THE HOUSING, THEN FASTEN THE TOOTHED BEARING
M52 1405 315857
RING!
M56 1622 364640
1. Use medium strength Loctite (Loctite 243) on
screws. M60 1887 424215
2. Pretension the bolts, with washers if required, M64 2138 480642
crosswise in 3 steps, 30%, 80%, and 100% of the M68 2441 548759
tightening torque, or the hydraulically applied
pretension force. 1)FM for hydraulic bolt-tensioning cylinder pretension to
3. In this process turn the unscrewed ring several
85% of yield strength.
times. Repeat the procedure for the bearing ring
that has not yet been bolted.
Table 3-4.
If using a hydraulic bolt-tensioning cylinder the tension-
ing forces for the bolt pretension should not exceed 90% MOUNTING PRETENSION FORCE
of yield strength. MOUNTING BOLT
FM 1)
DIMENSIONS
STRENGTH CLASS 10.9 in
kN lbs
1 – 8 UNC 301 67668
1 1/8 – 7 UNC 379 85203
1 1/4 – 7 UNC 481 108133
1 3/8 – 6 UNC 573 128816
1 1/2 – 6 UNC 697 156692
1 5/8 – 6 UNC 832 187041
1 3/4 – 5 UNC 942 211770

1)
FM for hydraulic bolt-tensioning cylinder pretension to
85% of yield strength.

Figure 3-23. Tighten crosswise

3-10 3121623
 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.

INTERVAL MAINTENANCE TASK TO BE EXECUTED BY

Weekly Check seal Qualified person
After 250 Operating Hours Check tighten bolts Qualified person
Check tilting clearance Qualified person
After Every Additional Check tighten bolts Qualified person
500 Operating Hours Or At Least Reduce the inspection interval if there is heavy wear or continuous operation.
Every 6 Months Check tilting clearance Qualified person
Reduce the inspection interval to 200 operating hours if the detected increase in tilting clearance
is approximately 75% of the permissible tilting clearance increase.
After further increase reduce the interval between inspections to 50 - 100 hours.
Check circumferential backlash Qualified person
Reduce the inspection interval to 200 operating hours if the detected increase in circumferential
backlash is approximately 75% of the permissible circumferential backlash increase.
After further increase reduce the interval between inspections to 50 - 100 hours.

Lubrication The specified values are valid for the following conditions:
General re-lubrication of slew drives: • Operating temperature on the slew drive < 70° C (158°
F).
• After each cleaning
• Circumferential speed < 0.5 m/s (1.64 ft/sec) for SP
• Before and after longer periods of standstill, e.g. for slew drives.
cranes and construction machines during the winter
months. • Output speed < 5 rpm for WD slew drives.
• Low to moderate load.
NOTICE
THE MAIN CAUSE FOR SLEWING RING FAILURE IS INADEQUATE LUBRI- NOTICE
CATION. THE LUBRICATION INTERVALS ESSENTIALLY DEPEND ON COMPLY WITH THE INSTRUCTIONS IN THE OPERATING MANUAL PRO-
EXISTING WORKING AND ENVIRONMENTAL CONDITIONS, AS WELL AS VIDED BY THE MANUFACTURER, FOR LUBRICATION OF OPTIONAL
THE VERSION OF THE SLEW DRIVE. PRECISE LUBRICATION INTERVALS INTERMEDIATE GEAR UNITS, BRAKES, AND MOTORS.
CAN ONLY BE DETERMINED BY TESTS UNDER NORMAL OPERATING
CONDITIONS. NOTICE
IF NECESSARY RE-LUBRICATE PERMANENT BRAKES. FOR THIS ONLY
USE THE SPECIAL GREASE SHELL RETINAX HDX2.
If comparable results are not available, the following table can be used as a guide value:

WORK CONDITIONS LUBRICATING INTERVAL TO BE EXECUTED BY

Dry and clean workshop hall (rotary tables, robots, etc.) Approx. every 300 operating hours, at least every 6 months Specialist
Severe conditions on open terrain (cranes, excavators, etc.) Approx. every 100 to 200 operating hours, at least every 4 months Specialist
Aggressive climatic conditions, (ocean, desert, arctic climate, Every 50 operating hours, at least every Specialist
extremely polluted environment, ≥70 operating hours per week 2 months
Extreme conditions (tunnel boring machines, steel works, wind tur- Continuous lubrication (through central lubrication or grease cups) Specialist
bines)

3121623 3-11
 SECTION 3 - CHASSIS & TURNTABLE

Maintenance Tasks
Inspecting The Mounting Bolts 1. Detached bolt

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
BE EXECUTED WITHOUT EXERTING ADDITIONAL EXTERNAL STRESS ON Torque wrench
THE BOLTED UNION. 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 AS SPECIFIED FOR INSTALLATION OF THE SLEW
DRIVE WHEN CHECKING THE BOLTED UNION.

Figure 3-24. Inspecting the mounting bolts

3-12 3121623
 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. THE STANDARD LUBRICANTS USED ARE
"R.TECC NORPLEX LKP2" FROM RHENUS, OR THE GREASE "OPTIMOL
LONGTIME PD0" FROM CASTROL. IF IN DOUBT, OR IF THERE IS NO
SPECIFICATION ON THE DRAWING, CONSULT WITH OUR CUSTOMER
SERVICE. USING THE WRONG LUBRICANT MAY CAUSE DAMAGE TO THE
SLEW DRIVES AND REDUCE THE SERVICE LIFE. IN THIS CASE, ANY
WARRANTY SHALL BE EXCLUDED. COMPLY WITH THE INSTRUCTIONS Figure 3-25. Lubricating the slew drive
PROVIDED BY THE LUBRICANT MANUFACTURER!
• If possible use a central lubrication system to lubricate 1. Fresh lubricant
the raceway system. In this regard ensure that the 2. Lubricating nipple, bearing ring
hoses are filled with grease at commissioning and
that the storage tanks are regularly topped up with 3. Lubricating ring housing
grease. 4. In succession, press grease into all lubricating
• An automatic re-lubricating system significantly facili- nipples while simultaneously turning the slew
tates re-lubrication for the raceway system and the drive all the way through, until a continuous col-
toothing. Functional safety as well as wear behavior lar of grease forms under at least one seal.
are improved. 5. Ensure that old lubricant can escape without
• Comply with the instructions in the operating manual obstruction.
provided by the respective manufacturer for lubrica-
tion of optional intermediate gear units, brakes, and Inspecting The Seals
motors.
• If it is evident that moisture has penetrated into the NOTICE
slew drive, or has been absorbed by the grease, you DAMAGED SEALS MUST BE REPLACED IMMEDIATELY. IF THERE IS COR-
must re-lubricate more intensively. ROSION DAMAGE OR FUNCTIONAL IMPAIRMENT A CONSEQUENCE OF
DAMAGED SEALS NOT BEING REPLACED AT THE PROPER TIME, ANY
WARRANTY SHALL BE EXCLUDED. PENETRATING MOISTURE MAY
QUICKLY CAUSE CORROSION IN THE BEARING RING AND IMPAIRS
SAFE OPERATION. NOTE THAT THE FACTORY-INSTALLED SEAL ONLY
OFFERS PROTECTION AGAINST DUST AND SPLASHING WATER.
If damage is detected on a seal, contact the customer ser-
vice organization without delay.

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 SECTION 3 - CHASSIS & TURNTABLE

3.6 HONDA ENGINE IGX440 Serial Number Location

NOTE: Refer to the supplier Engine applicable Honda Ser- The engine serial number is stamped on the cylinder
vice Manual. barrel. Refer to this when ordering parts or making tech-
nical inquiries.

ENGINE SERIAL NUMBER

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 SECTION 3 - CHASSIS & TURNTABLE

Specifications
Dimensions And Weight

MODEL iGX440U
PTO types S Q V
Overall length 407 mm (16.0 in) 433 mm (17.0 in) 450 mm (17.7 in)
Overall width 505 mm (19.9 in)
Overall height 454 mm (17.9 in)
Maximum angle of inclination 20°
Dry weight 39 kg (86 lbs)
Operating weight 45 kg (99 lbs)

Engine

MODEL iGX440U
Description code GCAWK
Type 4-stroke, overhead camshaft, single cylinder, inclined by 15°
Displacement 438 cm3 (26.7cu-in)
Bore x stroke 88.0 x 72.1 mm (3.46 x 2.84 in)
Maximum horsepower 11.2 kW (15.2 PS) / 3,600 min-1 (rpm)
Recommended maximum operation bhp 8.0 kW (10.8 PS) / 3,600 min-1 (rpm)
Maximum torque 29.8 N·m (3.0 kgf·m, 22 lbf·ft)/2,500 min-1 (rpm)
Compression ratio 8.1 : 1
Minimum fuel consumption 328 g/kW·h (241 g/PS·h, 0.53 lb/PS·h)
Ignition system CDI
Ignition timing (at no load) 10° B.T.D.C./1,400 min-1 (rpm)
13° B.T.D.C./3,600 min-1 (rpm)
Spark plug BKR7E-E (NGK), K22PR-UR (DENSO)
Lubrication system Forced splash type
Oil capacity 1.10 l (1.16 US qt, 0.97 lmp qt)
Cooling system Forced air
Starting system Recoil and starter motor
Stopping system Ignition primary circuit open
Carburetor Horizontal type batter fly valve
Air cleaner Dual element type
Governor STR (Self Tuning Regulator) governor
Fuel used Unleaded gasoline with a pump octane rating 86 or higher
Fuel tank capacity 6.5 l (1.72 US gal, 1.43 lmp gal)

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 SECTION 3 - CHASSIS & TURNTABLE

Wiring Diagrams
With starter motor and charge coil (20A) type

3-16 3121623
 SECTION 3 - CHASSIS & TURNTABLE

Engines & Controls Adjustments And

Troubleshooting • LED OFF
Battery or key switch malfunction
Experience of engine doesn’t start or not run correctly, fol- Fuse 3A or 30A blown
lowing this procedure to recognize an engine trouble, or a Wires harness failure
machine control system problem. ECM failure.
The electrical test requires disconnecting the engine har- • LED ON
ness from the machine harness system and then start the Fuel; or Spark issue
engine isolate from the machine. (See Fuel or Spark Plug Check procedure).
As well if the engine starts then need inspecting the • LED 2 Flashes
machine system, otherwise refer to the Engine Service Not enough oil
manual for the troubleshooting or contact the local Oil level switch or wire harness short circuit
engine service. ECM Failure.
Other than further the suggestion of the engine controls. • LED 4 Flashes
Engine temperature sensor or harness short circuit;
These instructions are valid for engines with and with no ECM Failure.
key start switch. • LED 6 Flashes
If the engine is not cranking, go to the instructions Power coil or harness short circuit
“Engine Harness By-Pass”. ECM Failure.
• LED 8 Flashes
ECM Software failure

Figure 3-26.
Check the status of the LED on the carburetor control unit.
Figure 3-28.
Position of the Fuses 3Amp and 30Amp

Figure 3-27.
Led on ECM carburetor Figure 3-29.
Location of the Engine temperature sensor

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 SECTION 3 - CHASSIS & TURNTABLE

Figure 3-30.
Location of the Engine oil level sensor
For additional instruction refer to the Engine Service Man-
Figure 3-32.
ual for a complete troubleshooting.
Disconnect the white plugs of the engine harness from
the machine harness.
Engine Harness By-Pass
With these Instructions the engine harness is discon-
nected from the machine harness.

Figure 3-33.
Connect together the two white plugs of engine harness.

Figure 3-31.
On engine left side removes the two bolts and the gray
plate to access to the harness, and recognize the wires
with white plug connectors.

Figure 3-34.
Start the engine with the manual rope recoil starter.

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 SECTION 3 - CHASSIS & TURNTABLE

Fuel System Check

Follow these Instructions to check the fuel flow into the
carburetor float bowl.

Figure 3-35.
On engines with the key switch, it should be possible to
try and start also by the key switch.

Figure 3-37.
a. Place a container below the carburetor.
b. Unscrew the drain tap and check if gasoline flows out.
In the event that gasoline does not flow out proceed with
the test below.

Figure 3-36.
To shut down the engine with no key switch, disconnect
the white plugs

Figure 3-38.
With the drain tap unscrewed pull the manual rope recoil
starter at least 3 times , and check if gasoline flows out.
In gasoline does not flow out; replace the filter in the fuel
tank, if gasoline does flow out, proceed with the spark
test.

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 SECTION 3 - CHASSIS & TURNTABLE

Fuel Tank Inspection Unscrew the two lock nuts and remove the bottom plate
Replace the fuel filter if not dirt free.

Figure 3-41.
Figure 3-39. Disconnect the hose
Unscrew the four bolts and lift the tank

Figure 3-42.
Figure 3-40. Unscrew and remove and clean or replace the filter.

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Spark Test
Use these Instructions to check the condition of the spark
plug and if spark occurs.

Figure 3-45.
Connect the wire plug to the spark plug.
Keeping the spark plug against the engine, pull the man-
ual rope recoil starter to see if a spark occurs.
Figure 3-43.
In the event of no or pour spark, with a spark plug in a
Pull the wire plug from the spark plug and with a tool good condition, refer to the OEM SM for the troubleshoot-
unlock the spark plug ing or contact the local Honda service.

Figure 3-44.
Gently and carefully remove the spark plug.

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 SECTION 3 - CHASSIS & TURNTABLE

Replacement Of Engine ECU

The engine ECU has specific software for the machine
arrangement. Install or replace ECM programmed only,
orderable on JLG spare part system, otherwise contact
Honda servicers.

Figure 3-48.
Gently take out the ECM and disconnect the two plugs
harness.

Figure 3-46.
Unscrew and remove the air filter support

Figure 3-49.
Gently disconnect the white connector on the ECM

Figure 3-47.
Unscrew the three screws on top of the ECM

Figure 3-50.
Replace the carburator ECM. Install the ECM following the
steps of the procedure on the contrary.

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3.7 HATZ ENGINE

Model: HATZ 1B40

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 SECTION 3 - CHASSIS & TURNTABLE

Description Of The Engine

2 1 22 21 20 19

3 18

4 17

5 16

6 15

7 8 9 10 9 11 12 13 14

1. Type plate 12. Engine mountings

2. Cylinder head cover 13. Ignition key
3. Exhaust silencer 14. LED display
4. Exhaust mesh insert 15. Intake opening for cooling and combustion air
5. Oil pressure switch 16. Oil filler pipe and dipstick
6. Starter motor 17. Recoil starter
7. Voltage regulator 18. Engine shutdown pin
8. Crankshaft - power take-off 19. Dry-type air cleaner
9. Oil drain plug 20. Lifting lug
10. Speed adjustment lever 21. Fuel tank cap
11. Oil filter 22. Noise insulating hood

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Technical data

Type 1B40
Design Air-cooled four-stroke diesel engine
Combustion system Direct injection
Number of cylinders 1
Bore / stroke mm 88 / 76
Displacement cm3 462
Lubricating oil capacity without oil sump with oil sump l, approx. 1.5 1)
l, approx.
3.2 1)
Difference between “max” and “min” levels without oil sump with oil sump l, approx. 0.8 1)
l, approx.
2.2 1)
Lubricating oil consumption (after running in) max. 1% of fuel consumption at full
load
Lubricating oil pressure (oil temperature 100 °C) approx. 2.5 bars at 3000 r.p.m.
Direction of rotation, power take-off end anti-clockwise
Valve clearance 10 - 30 °C mm 0.10
Inlet and exhaust valve
or automatically 2)
Max. tilt angle in operation, in direction Flywheel 25° down 3) all other directions 35°3)
Weight kg, approx. 55
(incl. fuel tank, air-cleaner, exhaust silencer, recoil starter and electric starter)
Battery capacity Amp/h max. 12 V / 60 Amp/h

1) These values are intended as an approximate guide. The max. marking on the dipstick is the deter-mining factor.

2)
Depending on model (see maintenance charts).
3)
Exceeding these limits causes engine breakdown.

Tightening torques

Item Nm
Oil drain plug 50

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 SECTION 3 - CHASSIS & TURNTABLE

Engine Type Plate

MOTORENFABRIK HATZGMBH
+CO KG
D-94099 RUHSTORF
TYP KENNZ.

MOTOR / FABRIK NO. ABE /AUSF.

MIN-1 NH PV CM 3

MADE IN GERMANY

The type plate is placed on the noise insulating hood and Engine serial number on crankcase
includes the following engine information:
1. engine type
2. code (only for special equipment)
3. engine number (also stamped on crankcase)
4. max. engine speed
For any offer as well as spare parts orders it is necessary to
mention these data (also see spare parts list).

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 SECTION 3 - CHASSIS & TURNTABLE

Operation When adding oil or checking the oil level, the engine must
be horizontal.
Engine Oil - Oil Quality
Qualified are all trademark oils which fulfil at least one of
the following specifications:
ACEA – B2 / E2 or more significant
API – CD / CE / CF / CF-4 / CG-4or more significant.
If engine oil of a poorer quality is used, reduce oil change
intervals to 150 hours of operation.

Oil Viscosity
y
°F °C OIL: SAE...
122 50

104 40

86 30
10W/40
15W/40

40
5W/40

10W/30

30
5W/30

68 20

50 10
10W

32 0 Remove oil filler screw and add engine oil.

14 -10 Lubricating oil capacity: see Chapter Technical data.
-4 -20

-22 -30

-40 -40

Select the viscosity class according to the ambient tem-

perature for cold starts.

max.

To check the oil level, remove the dipstick, clean it - then

screw it back in and finally remove it again.
Check the oil level on the dipstick and, if necessary, top up
to the max.level.

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 SECTION 3 - CHASSIS & TURNTABLE

Troubleshooting
These instructions are valid for engines with the key
start switch only.

Figure 3-53.
On engine harness plug connector make a bridge
between PIN 1 and PIN 2.
Figure 3-51.
Identify behind the engine the harness plug that connect-
ing the engine and the machine system.

Figure 3-52.
Figure 3-54.
Disconnect the plug X51.
Attempt to start the engine by key switch

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 SECTION 3 - CHASSIS & TURNTABLE

Those instructions are valid for engines with no key

switch.

Figure 3-57.
Figure 3-55. LED’s On when Pin 12 feed with 12 Volt.
On engine right side access to the harness, and disconnect
To turn off the engine remove the supply voltage to Pin
the engine harness plug. 12

Figure 3-56.
On female connector jump the following wires:

• Pin12 (12 Volt supply) battery positive terminal.

• Pin 5 (Starter) for a moment utilize hook up this pin as
key starter.

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 SECTION 3 - CHASSIS & TURNTABLE

3.8 PERKINS ENGINE Engine Identification

Perkins engines are identified by a serial number. This
Model: 402D number is shown on a serial number plate that is mounted
above the fuel injection pump on the right hand side of
the engine block.
An example of an engine number is
GP*****U000001M.

GP ________________________________Type of engine
U ______________________Built in the United Kingdom
*****__________________ The list number of the engine
000001 _______ _______________Engine Serial Number
M ____________________________ Year of Manufacture

Perkins dealers or Perkins distributors need all of these

numbers in order to determine the components that were
included with the engine. This permits accurate identifica-
tion of replacement part numbers.

Serial Number Plate

Specifications
Table 3-5.
402D-05 Engine
Maximum Operating Speed (rpm) 3600 rpm
Cylinders and Arrangement In-Line two cylinder
Bore 67 mm (2.64 inch)
Stroke 72 mm (2.83 inch)
Displacement 0.507 L (30.939 in3)
Aspiration Naturally Aspirated
Compression Ratio 23.5:1
Firing Order 1-2
Rotation that is viewed Counterclockwise
from the flywheel
Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)
Valve Lash Setting 0.20 mm (0.008 inch)
(Exhaust)
Injection Indirect

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 SECTION 3 - CHASSIS & TURNTABLE

Fuel Filter Base - Remove and Install 4. Remove bolt (1) and remove fuel filter base (2)
from the mounting bracket.
Removal Procedure
Installation Procedure
NOTICE
NOTICE
DO NOT ALLOW DIRT TO ENTER THE FUEL SYSTEM. THOROUGHLY
CLEAN THE AREA AROUND A FUEL SYSTEM COMPONENT THAT WILL BE KEEP ALL PARTS CLEAN FROM CONTAMINANTS. CONTAMINANTS MAY
DISCONNECTED. FIT A SUITABLE COVER OVER DISCONNECTED FUEL CAUSE RAPID WEAR AND SHORTENED COMPONENT LIFE.
SYSTEM COMPONENT.

NOTICE
CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CONTAINED
DURING PERFORMANCE OF INSPECTION, MAINTENANCE, TESTING,
ADJUSTING AND REPAIR OF THE PRODUCT. BE PREPARED TO COLLECT
THE FLUID WITH SUITABLE CONTAINERS BEFORE OPENING ANY COM-
PARTMENT OR DISASSEMBLING ANY COMPONENT CONTAINING FLU-
IDS. DISPOSE OF ALL FLUIDS ACCORDING TO LOCAL REGULATIONS
AND MANDATES.

NOTICE
KEEP ALL PARTS CLEAN FROM CONTAMINANTS. CONTAMINANTS MAY
CAUSE RAPID WEAR AND SHORTENED COMPONENT LIFE.
NOTE: Place identification marks on all hoses for installa-
tion purposes. Plug all hoses and all the ports in the
fuel filter base. This helps prevent fluid loss, and this
helps to keep contaminants from entering the sys-
tem. 1. Ensure that the fuel filter base is clean and free
from damage. If necessary, replace the fuel filter
base.
2. Align fuel filter base (2) with the mounting
bracket. Install bolt (1). Tighten the bolt to a
torque of 25 N·m (18 lb ft).
3. If necessary, install a new fuel filter element (6)
to fuel filter base (2). Refer to Operation and
Maintenance Manual, “Fuel System Filter -
Replace”.
4. Connect hoses (4) and tighten hose clamps (3).
NOTE: Ensure that the hoses do not contact any other
engine components.
5. Turn the fuel supply to the ON position.
6. Remove the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel Sys-
tem - Prime”.

1. Turn the fuel supply to the OFF position.

2. Loosen hose clamps (3) and disconnect hoses
(4).
3. If necessary, remove fuel filter element (5). Refer
to Operations and Maintenance Manual, “Fuel
System Filter - Replace”.

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 SECTION 3 - CHASSIS & TURNTABLE

Troubleshooting
These Instructions are valid for machines with the
engine the key switch.

Figure 3-60.
On grey connector make a wire to connect the pin 1 to the
positive terminal of the battery and another at pin 2 to
ground or battery.

Figure 3-58.
Identify the plug X-51 that feed the fuel pump shutoff to
the machine system.

Figure 3-61.
Attempt to start the engine by key switch

Figure 3-59.
Disconnect the plug X-51.

Figure 3-62.
To shutdown the engine disconnect the wires.

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 SECTION 3 - CHASSIS & TURNTABLE

These Instructions are valid for machines with no engine

key switch.

Figure 3-65.
On Female connector jump the follows wires:

• Pin12 (12 Volt supply) battery positive terminal.

Figure 3-63. • Pin 7 (Glow plugs) hook up if necessary for few second
Remove the engine hood to access to the harness and only.
engine left side, to identify the wires with plug connectors. • Pin 5
• (Starter) for a moment utilize hook up this pin as key
starter.

Figure 3-64.
Disconnect the plug circled.

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 SECTION 3 - CHASSIS & TURNTABLE

3.9 KUBOTA DIESEL ENGINE MODEL D902

 

Type Vertical 4-Cycle Liquid Cooled Diesel

Combustion System IDI
Intake System Naturally Aspirated
Diesel fuel intake system Electric Pump
Number of cylinders 3
Power 16,1 Kw (21,6 Hp) / 3200 rpm
Max rpm 3200 rpm
Direction of rotation Counter clockwise Viewed on Flywheel
Max torque 56 Nm / 2400 rpm
Displacement 898 cm³
Bore 72 mm (2,83 in)
Stroke 73,6 mm (2,9 in)
Fuel tank capacity 40 litres
Emission Regulation Tier 4 F
Dry Weight (according to Kubota's standards) 72 Kg (158,8 Lbs)

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 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.

3121623 3-35
 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.

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 SECTION 3 - CHASSIS & TURNTABLE

Troubleshooting
Those Instructions valid for all machines serial number

Figure 3-68. Female Connector

On Female connector jump the follows wires:
Figure 3-66. • Pin 16 (Ground) to battery negative terminal.
On engine left side remove the engine hood and cut the • Pin 10 (fuel pump) to battery positive terminal.
strap to access to the harness, plug. • Pin 6 (Glow plugs) hook up if necessary 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 wills contimue to run for a while untile it ends the
fuel on the line.

Figure 3-67.
Disconnect the plug harness

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 SECTION 3 - CHASSIS & TURNTABLE

Engine Speed Sensor

A sensor in the diesel engine detects the engine rpm’s and
communicates this data to the master controller.

Figure 3-71.
Speed Sensor on Kubota D902

Figure 3-69.
Speed Sensor Installation and Adjustment
Speed Sensor Hatz 1B40

Figure 3-72.
1. Install the speed sensor into the housing until it
Figure 3-70. contacts the flywheel.
2. Back the sensor out 1 turn.
Speed Sensor on Perkins 402.05
3. Tight the nut.

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 SECTION 3 - CHASSIS & TURNTABLE

Diesel Engine RPM control

On Diesel powered units a throttle actuator controls the
fuel to manage the engine speed based on operating con-
ditions.

Figure 3-75.
Speed Sensor Hatz 1B40

All Diesel Actuator Rod Travel Adjustment

Figure 3-73.
Throttle actuator on Perkins 402.05

Figure 3-76.
With the control linkage pushed against the idle stop,
Figure 3-74. adjust the lock nut.
Throttle actuator on Kubota D902

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 SECTION 3 - CHASSIS & TURNTABLE

3.10 THERMIC ENGINE REPLACEMENT

1. Place and stabilize 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 3-78. Image 2

Figure 3-77. Engine cover

4. Disconnect, tag and isolate the wires from the
engine.
NOTE: On X20JP-X600AJ – X26JP-X770AJ diesel, disconnect
the oil pipes and cooling lines, then drain the 2 cir- Figure 3-79. Image 3
cuities.
1. Remove the screws (items 13 and 5 - image 2).
2. Remove the engine, remove the joint (items 8
and 9 - Image 2) .
3. Remove the muffler (item 6 - Image 2).
4. Replace the engine and tighten the screws
(items 13 and 5 - Image 2). Torque screws to 16.2
ft. lb. (22N-m) and 18.5 ft. lb. (25Nm) respec-
tively.
5. Connect the wires to the motor.
6. Replace guard on motor (1) and test the
machine.

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 SECTION 3 - CHASSIS & TURNTABLE

3.11 ELECTRIC MOTOR REPLACEMENT 4. Open the cover of the electrical box (7), label and
disconnect the wires attached to the electrical
1. Place and stabilize the machine on a flat and motor and isolate the wires end
level surface; for the models X17JP/X500AJ and 5. Remove the four bolts that attach the pumps
X20JP/X600AJ rotate the turret 90° (Figure 3-80.), adapter to the electrical motor.
while for X26JP and X770AJ, keep the machine
in stowed position 6. Remove the four mounts bolts (2) that attach the
electrical motor to the frame.
2. Turn machine OFF and remove the Key switch,
make sure that plug connector is disconnect, 7. Carefully lift, remove the electrical motor and
and the machine is isolate from any electrical separate from the pumps adapter.
power supply. 8. After the electrical motor has been removed,
3. Remove the cover. loosen the screw (3) and pull off the coupler (4)

Figure 3-82.
9. For the electrical motor installation follow the
Figure 3-80. Cover position engine X17JP/X500AJ X20JP/X600AJ 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 (6) of the pumps adapter to 16.23 ft. lb.
(22N-m).
11. Reattach the previously labelled electrical wires
to the electrical motor and close the cover of the
electrical box (item 7).

Figure 3-81. Cover position engine X26JP/X770AJ

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 SECTION 3 - CHASSIS & TURNTABLE

Figure 3-83.
12. Energize the system and start the electrical
motor
13. Check from the fan side, if the electrical motor
run in correct CW direction, otherwise swap the
wires connected as shown on (Figure 3-84.).

Figure 3-84.

14. Install cover and test the machine.

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3.12 LITHIUM MACHINE WITH 76V LITHIUM Battery Charger

BATTERY SYSTEM - X26JP - X770AJ The on-board battery charged is activated when its
(S/N C170001340 TO PRESENT) plugged, if present it has to be used the plug fitted on the
lithium pack, otherwise the one close to the magneto-
thermic switch.
Charge Information
The level of charge of the lithium pack is shown by the DC-DC Transformer
icon on the right lower corner of the display, or more in A part for Lithium system that works at 76 nominal Volt,
detail by the input SOC (State Of Charge). the rest of the machine electronic boards and compo-
When Lithium pack State of Charge (SOC) is lower than nents still work at 12 / 5 Volt, so Lithium system includes a
21%, remote control beeper is activated to inform the DC-DC transformer that convert the 76 Volt into 12 Volt.
operator that machine need to be charged. Machine is equipped with 12 Volt battery necessary to
When SOC is lower than 11%, inverter feeds electric motor switch ON Lithium system.
with an half of the standard speed.
When SOC is lower than 6%, inverter feeds electric motor Electric Motor
with an extra low speed, and the following icon are dis- Type Three-phase
played.
Nominal tension 80 Volt

"EXTRA LOW SPEED" ICON Nominal Power 3500 Watt

Electric motor is fed through an inverter that convert the

lithium pack direct current (DC) into alternative three-
"CONNECT TO THE ELECTRIC" ICON phase current.

RPM Regulation System

When SOC is 0%, machine could not be moved and the RPM regulation is carried out by the following compo-
icon “CONNECT TO THE ELECTRIC NETWORK” is displayed nents:
in the middle of the display.
• Master board (ECM1)
Lithium Cells • Inverter
Number of cells in the battery 48 cells, 24 couples of cells connected • Electric motor
pack in series Inverter is parameterized to feed the electric motor with a
pre-determinate selection of frequencies, corresponding
Nominal voltage of each cell 3 Volt
to a nominal rpm configurations, in case of inverter
Capacity of one cell 50 Amps/h replacement is required a new parameterization.
Nominal features of the com- NOTE: The set-point rpm could be different from the nomi-
76 Volt –100 Amps/h
plete pack nal rpm configuration depending on the electric
Max cell nominal voltage 3,7 Volt load.
Min cell operating voltage 2,5 Volt RPM Setting
DOD 90% ECM1 through its internal contacts communicates the
Charge cycles 3000 full cycles required rpm selection to the inverter, which will feed the
electric motor with the relevant frequency in order to
Memory effect NO achieve the nominal rpm selected, the actual rpm
depends also on the machine working conditions.
Lithium cells are managed by BMS (Battery Management
System) that continuously manages charge and discharge
operations, monitors cells parameters including their ten-
sions and their temperatures, and in case of failure opens
the internal contactor insulating the Lithium pack.

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 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-
LITHIUM SYSTEM RPM SETTING itive lithium battery level (SOC>0), is possible over -10°C.
TURTLE NORMAL/ HARE MOVEMENT (*) In cold environmental temperature (not lower than -25°C),
the on-board electric heaters automatically warm up the
1500 + double
1500 1st and 2nd booms UP cells, they are activated by the BMS when the minimum
pump
cell temperature goes down 0°C, they are automatically
900 1950 1st and 2nd booms DOWN switched off when the minimum cell temperature raises
900 1950 3rd boom UP over the 2°C.
In case of battery charger is connected, till 0°C it supplies
900 1500 3rd boom DOWN
only 5A in order to surely feeds only the heaters, waiting
1950 + double positive temperatures to recharge the cells.
1500 Telescope OUT
pump In cold environmental temperature (from -25°C to 0°C),
1500 1950 Telescope IN with null lithium battery level (SOC = 0), the heaters work
only while the cable is plugged to the electric network
900 1050 Turret rotation
(battery charger activated).
900 900 Basket rotation While heaters are working on the display will appear the
900 900 Basket levelling icon batteries cold, and machine could be moved only in
lower speed (turtle).
900 1050 Jib UP
900 900 Jib DOWN
"BATTERY COLD/HEATER ACTIVATED"
1500 3000 Tracks forward or backward ICON
1500 3000 Tracks opening or closing
Auto stabilization with maximum one In hot environmental temperature, the fans system auto-
3000 3000 matically cool down the cells, they are automatically acti-
outrigger on the ground
vated by the BMS when cells temperature raises over 37°C,
Auto stabilization with two or three out- they are automatically switched off when cells tempera-
1500 1500
riggers on the ground ture goes down the 35°C.
Auto stabilization with all outrigger on
3000 3000
the ground Diagnostics And Fault Codes
Outriggers Auto retraction with all out- The main devices composing the lithium batteries system
3000 3000 are able to carry out self-diagnosis informing the operator
rigger lifted from the ground
by the remote control display, in particular they eventually
Outriggers Auto retraction with at least display informative icons and provide fault codes.
1500 1500
one outrigger on the ground
Self-diagnosis is carry out by:
NOTE: Outriggers rpm depends on the machine condition. • BMS (Battery Management System)
• Battery charger
NOTE: Tracks opposite rotation is carry out with lower
speed. • Inverter
NOTE: Aerial contemporary movements including jib, bas- Further information about Lithium system, fault codes and
ket leveling or rotation are carry ion at minimum diagnose are detailed by Lithium system specific training.
rpm.
NOTE: Double pump valve is not activated with move-
ments together.

3-44 3121623
 SECTION 4 - BOOM & PLATFORM

SECTION 4. BOOM & PLATFORM

4.1 BOOM MAINTENANCE f. Remove hardware securing the lower boom
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 and lower to ground or suitable supported
REMOVED FIRST. FAILURE TO DO SO WILL RESULT IN SEVERE DAMAGE work surface.
TO THE BOOM.
Disassembly of the Main Boom
Removal of the Boom Assembly
1. Remove the platform and platform support as 1. Loosen jam nuts on aft end of fly boom wear pad
follows: adjustment and loosen adjustments.
a. Disconnect electrical cable from control 2. Using a portable power source, attach hose to
console. telescope cylinder port block. Using all applica-
ble safety precautions, activate hydraulic system
b. Tag and disconnect the hydraulic lines run- and extend cylinder to gain access to cylinder
ning to the rotate cylinders. Cap the hydrau- rod retaining pin. Shut down hydraulic system.
lic lines and ports.
3. Carefully disconnect hydraulic hose from retract
c. Using an overhead crane or suitable lifting port of cylinder. There will be initial weeping of
device, use nylon support straps to support hydraulic fluid which can be caught in a suitable
the platform/support. container. After initial discharge, there should be
NOTE: When removing the retaining pin from the rod end no further leakage from the retract port.
of the level cylinder, make sure the cylinder is prop- 4. Remove hardware securing telescope cylinder to
erly supported. the fly boom section, then remove pin from fly.
d. Remove bolts and keeper pins that secures 5. Remove hardware securing telescope cylinder to
the retaining pins. Using a suitable brass the base boom section.
drift and hammer, remove the retaining pins
from the platform support. NOTICE
2. Remove the boom from the turntable as follows: WHEN REMOVING TELESCOPE CYLINDER FROM BOOM SECTIONS.
a. Disconnect wiring harness from ground CARE SHOULD BE TAKEN NOT TO LEAVE CYLINDER REST ON POWER-
control harness connector. TRACK WHICH COULD CAUSE DAMAGE TO POWERTRACK.
6. Using a suitable lifting device, remove telescope
NOTICE cylinder from boom sections.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY 7. Using a piece of tape, mark the length of hoses
AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS and wires from front of fly boom and bottom of
INTO SYSTEM. base boom for reassembly.
b. Tag and disconnect hydraulic lines from 8. Remove hardware securing the front wear pads
boom to control valve. Use a suitable con- on base boom section, remove wear pads.
tainer to retain any residual hydraulic fluid. 9. Remove hardware securing the powertrack to
Cap all hydraulic lines and ports. the aft end of the fly boom section.
c. Using a suitable lifting equipment, ade- 10. Using a suitable lifting device, remove fly boom
quately support boom weight along entire from boom section.
length.
11. Remove hydraulic lines and electrical cables
d. Remove the bolts and keeper pins securing from powertrack.
the lift cylinder pivot pin. Using a suitable
12. Remove hardware securing powertrack to the
brass drift and hammer, remove the pivot
base boom section. Remove powertrack.
pin from the lower boom.
e. Remove hardware securing the level link
pivot pin. Using a suitable brass drift and
hammer, remove the pin from the level link
and turntable.

3121623 4-1
 SECTION 4 - BOOM & PLATFORM

Figure 4-1. Position pins X17JP - X500AJ

Figure 4-2. Position pins X20JP - X600AJ

4-2 3121623
 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 ovality. MUST BE TAKEN NOT TO DAMAGE THE POWER TRACK ASSEMBLY.
Replace pins as necessary. 11. Slowly slide the telescope cylinder into boom
2. Inspect lift cylinder pins for wear, scoring or assembly, align rod end with attach point in fly
other damage, and for tapering or ovality. section. Insert pin and secure with retaining ring.
Ensure pin surfaces are protected prior to instal- 12. Slowly slide the telescope cylinder into boom
lation. Replace pins as necessary. assembly, align barrel end with attach point in
3. Inspect telescope cylinder rod attach pin for fly section. Insert pin and secure with retaining
wear, scoring or other damage. Replace pin as ring.
necessary. 13. Install wear pads at front of base boom section.
4. Inspect inner diameter of boom pivot bushings Adjust the wear pads to zero clearance.
for scoring, distortion, wear or other damage.
Replace bushings as necessary.
5. Inspect wear pads for wear.
6. Inspect all threaded components for damage
such as stretching, thread deformation, or twist-
ing. Replace as necessary.
7. Inspect structural units of boom assembly for
bending, cracking, separation of welds, or other
damage. Replace boom sections as necessary.

Assembly of the Main Boom

1. Install power track to the attach point on the
base boom section. Secure power track with the
attaching hardware.
2. Install hydraulic lines and electrical cables into
the power track.
3. Install wear pads to the aft end of the fly section.
4. Using suitable lifting equipment, slide fly section 14. Adjust pads alternately side to side, so that fly
into the base section until power track attach boom section is centered in base boom section
point aligns with holes in side of base section. (lower wear pad with 1 mm gap).
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. Connect a suitable auxiliary hydraulic power
source to the telescope cylinder port block.
9. Extend the telescope cylinder the distance of the
two attach points.
10. Secure the sling and lifting device at the tele-
scope cylinder’s approximate center of gravity,
and lift the cylinder to the aft end of the boom
assembly.

3121623 4-3
 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.
3. Using all applicable safety precautions, operate
lifting equipment in order to position boom lift
cylinder and level link so that holes in cylinder
rod end and level link are aligned with the one in
the turntable. Insert cylinder pins.
4. If necessary, gently tap pins 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 the boom assembly.
7. Connect all hosing and wiring at platform con-
trol station.
16. Disconnect auxiliary power source from tele- 8. Using all safety precautions, operate machine
scope cylinder. systems and extend and retract boom for four or
five cycles.
Installation of the Boom Assembly 9. Shut down machine systems and check for leak-
age.
1. Using suitable lifting equipment, position boom
assembly on turntable so that boom pivot holes
in both boom and turntable are aligned.

Figure 4-3.

4-4 3121623
 SECTION 4 - BOOM & PLATFORM

4.2 BOOM DISASSEMBLY X20JP - X600AJ

NOTE: The following procedure assumes the boom is
removed from the machine.
1. Extend the boom approximately 2 feet (0.6 m).
This will enable access to the bolts that secure
the cable mount block to the boom fly section.
2. Remove hardware securing the telescope cylin-
der.

Figure 4-6.
6. Remove the four bolts, shims, and mounting
blocks that secure the telescope cylinder rod to
the boom base section.

Figure 4-4.
NOTE: Do not allow wire rope to rotate. This may damage
the wire rope.
3. Clamp both threaded ends of wire rope to pre-
vent rotation. Note: Do not clamp on threads.
Remove jam nuts and nuts which secure the wire
rope adjustments to the bottom front of the
base boom section.
4. Using a M6 drive extension approximately 4 feet
(1.2 m) long, remove the bolts and washers
securing the cable mount block to the boom fly
section.

Figure 4-7.

NOTICE
WHEN REMOVING THE TELESCOPE CYLINDER FROM THE BOOM, IT
MAY BE NECESSARY AT SOME POINT TO TURN THE CYLINDER SLIGHTLY
IN ORDER TO CLEAR ASSEMBLIES MOUNTED WITHIN THE BOOM. CARE
MUST BE TAKEN TO MOVE THE CYLINDER SLOWLY FROM THE BOOM.
Figure 4-5. DAMAGE TO COMPONENTS MAY RESULT FROM FORCIBLE IMPACT
5. Remove the four bolts, shims, and attachment WITH THESE ASSEMBLIES.
blocks that secure the telescope cylinder barrel NOTE: The telescope cylinder weighs approximately 600
to the boom mid section. lbs. (275 kg).

3121623 4-5
 SECTION 4 - BOOM & PLATFORM

1. Using overhead cranes or other suitable lifting/ porting devices will have to be repositioned to
supporting devices, carefully pull the telescope support the weight of the cylinder as it is drawn
cylinder out from the back of the boom. At the out of the boom.
same time, also pull the cable mount block out
so the extension cables come out with the tele-
scope cylinder and do not bind. The lifting/sup-

14

10
12
6
9

Figure 4-8.

4-6 3121623
 SECTION 4 - BOOM & PLATFORM

1
13
2
4 3
8
5
7 11
Figure 4-9.
1. Base Boom 8. ExTend Cable
2. Mid Boom 9. Retract Cable
3. Fly Boom 10. Extend Cable Adjustment
4. Telescope Cylinder 11. Retract Cable Adjustment
5. Extend Sheave 12. Proximity Switch
6. Retract Sheave 13. Wear Pad
7. Sheave Block 14. Wear Pad

8. Carefully remove the telescope cylinder and

sheave assembly. Place telescope cylinder on a
suitable trestle.
a. Remove hardware from the wear pads;
remove wear pads from cylinder.
b. Remove hardware from the wire rope guard;
remove guard from cylinder.
c. Remove hardware from the sheave pin;
remove pin and sheave from cylinder.

Figure 4-10.
9. Remove hardware which secures the wear pads
to the front of base boom section; remove wear

3121623 4-7
 SECTION 4 - BOOM & PLATFORM

pads from the top, sides and bottom of the base 4.3 INSPECTION
boom section.
10. Using an overhead crane or suitable lifting Checking Wear And Deformation Of Ropes And
device, remove mid and fly boom sections from
base section. Note: When removing mid and fly Pulleys
boom sections from base boom section, retract
If only one of the following situations is detected the
wire rope must be dragged along with boom
ropes or pulleys must be replaced.
sections.
11. Remove hardware which secures the wear pads 1. Check that there are no broken threads on the
to the rear end of mid boom section; remove the surface of the rope, in the internal area or in cor-
wear pads from the top, sides and bottom of the respondence with the cable socket.
mid boom section.
12. Remove hardware which secures the sheave
guards and sheave assemblies to mid boom sec-
tion, remove sheave assemblies from mid boom
section.
13. Remove hardware which secures the wear pads
to the front of mid boom section; remove wear Figure 4-12.
pads from the top, sides and bottom of the mid 2. Check that there are no signs of corrosion on the
boom section. rope.
14. Using an overhead crane or suitable lifting 3. Check that there are no signs of kinking, crush-
device, remove fly boom section from mid sec- ing or deformations of any type on the rope.
tion. Note: When removing fly boom section
from mid boom section, retract wire rope must
be dragged along with fly boom section.
15. Remove hardware which secures the wear pads
to the rear end of fly boom section; remove wear
pads from the top, sides and bottom of the fly
boom section.
Figure 4-13.
16. When removing wire rope from fly boom sec-
tion, push the cable into fly boom. Route wire 4. Check the condition of the fixing pins of the out-
rope back through holes in the side of the fly let pulley and extensions return.
boom section. 5. Check the wear of the pulley grooving using a
profile comparator. As indicated in the figure it is
necessary to check that the outline of the com-
parator corresponds with the base of the groov-
ing.

Figure 4-14.
6. Check that there are no signs of ovalisation, wear
or any other type of deformation on the pulleys.
Figure 4-11.

4-8 3121623
 SECTION 4 - BOOM & PLATFORM

Assembly pins and secure them with mounting hardware.

Position retract wire ropes onto the sheaves.
NOTE: When installing fly section wear pads, install same 9. Install sheave guards to rear end of mid boom
number and thickness of shims as were removed section and secure with mounting hardware.
during disassembly.
10. Slide mid boom section into the base boom sec-
1. Measure inside dimensions of the base and mid tion. Allow the retraction wire ropes to trail
sections to determine the number of shims between the bottom surfaces of boom sections.
required for proper lift. Adjust boom, if necessary, for a total of 1/16 inch
2. Measure inside dimensions of the mid section to (0.062) clearance.
determine the number of shims required for 11. Install wear pads into the forward position of the
proper lift. base boom section. Adjust boom, if necessary,
3. Install side, top and bottom wear pads to the for a total of 2/10 inch (0.20) clearance.
rear end of fly section; shim evenly to the mea- 12. Install sheave block to bottom of base boom sec-
surements of the inside of mid section. tion and adjust block so that retract wire ropes
4. Install retract wire ropes into rear end of fly sec- do not come into contact with boom surfaces.
tion, route wire ropes thru holes in side of fly 13. Install wire rope threaded ends thru attachment
boom section and pull into slot. holes in the bottom of base boom section.
Loosely install nuts and jam nuts onto the
threaded ends of wire ropes.
14. Pull the boom sections out to approximately
where they were extended to for telescope cylin-
der removal.
15. Install a new extend sheave on the end of the
telescope cylinder.
16. Route new extend cables around the telescope
cylinder. Loosely fasten the threaded end of the
cables to the rod end of the telescope cylinder
with the adjusting nuts and lock nuts. Install the
opposite end of the cables in the cable mount
block.
17. Use tape or tie straps to fasten the cables to the
telescope cylinder assembly. It is important that
the tape or straps be strong enough to hold the
cable in place yet weak enough to break and fall
away when the cables are adjusted.
Figure 4-15.
NOTICE
5. Install side, top and bottom wear pads to the
rear end of mid section. WHEN PUSHING THE TELESCOPE CYLINDER INTO THE BOOM, IT MAY
BE NECESSARY AT SOME POINT TO TURN THE CYLINDER SLIGHTLY IN
NOTICE ORDER TO CLEAR ASSEMBLIES MOUNTED WITHIN THE BOOM. CARE
MUST BE TAKEN TO MOVE THE CYLINDER SLOWLY INTO THE BOOM.
WHEN ASSEMBLING BOOM SECTIONS, ENSURE THAT THE BOOM SLID- DAMAGE TO COMPONENTS MAY RESULT FROM FORCIBLE IMPACT
ING TRAJECTORIES HAVE BEEN CLEARED OF CHAINS, TOOLS, AND WITH THESE ASSEMBLIES.
OTHER OBSTRUCTIONS.
6. Slid fly boom section into the mid boom section. NOTE: The telescope cylinder weighs approximately 600
Adjust boom, if necessary, for a total of 1/16 inch lbs. (275 kg).
(0.062) clearance. 18. Using adequate lifting equipment, carefully
7. Install wear pads into the forward position of the push the telescope cylinder assembly and cables
mid boom section. Adjust boom, if necessary, for back into the boom.
a total of 2/10 inch (5.08mm) clearance.
8. Properly position the retraction wire rope
sheaves assemblies at the rear end of the mid
boom section; ensure all sheave-to-mounting
block attachment holes align. Install the sheave

3121623 4-9
 SECTION 4 - BOOM & PLATFORM

19. Apply Loctite #242 to the bolts and fasten the

telescope cylinder rod to the boom base section
with the bolts, shims, mounting blocks.

Figure 4-18.
22. Connect all the hydraulic lines to the cylinder as
tagged during the removal procedure.
23. Adjust the boom cables as outlined under Sec-
tion 4.4, ROPES TENSION ADJUSTMENT PROCE-
DURE.

Installation To Machine
Figure 4-16.
1. Using a suitable lifting device, position boom
20. Apply Loctite #242 to the bolts and fasten the assembly on upright so that the pivot holes in
telescope cylinder barrel to the boom mid sec- both boom and upright are aligned.
tion with the bolts, shims, mounting blocks.
2. Install boom pivot pin, ensuring that location of
hole in pin is aligned with attach point on
upright.
3. If necessary, gently tap pin into position with
soft headed mallet. Secure pin mounting hard-
ware.
4. Connect all wiring to the ground control box.
5. Connect all hydraulic lines running along side of
boom assembly.
6. Using all applicable safety precautions, operate
lifting device in order to position boom lift cylin-
der so that holes in the cylinder rod end and
boom structure are aligned. Insert the lift cylin-
der pin, ensuring that location of hole in pin is
aligned with attach point on boom.
7. Align holes in boom structure with hole in mas-
ter cylinder. Insert the master cylinder pin,
ensuring that location of hole in pin is aligned
with attach point on boom.
8. Adjust retract and extend cables to the proper
Figure 4-17. torque. Refer to Section 4.4, ROPES TENSION
21. Using a 3/8 drive extension approximately 4 feet ADJUSTMENT PROCEDURE.
(1.2 m) long, install the bolts and washers secur- 9. Using all applicable safety precautions, operate
ing the cable mount block to the boom fly sec- machine systems and raise and extend boom
tion. Tape the bolts to the socket at the end of fully, noting the performance of the extension
the extension to prevent it from coming out of cycle.
the socket before it engages the mounting
threads. 10. Retract and lower boom, noting the perfor-
mance of the retraction cycle.

4-10 3121623
 SECTION 4 - BOOM & PLATFORM

Three month inspection 4.4 WIRE ROPE TENSION ADJUSTMENT PROCEDURE

1. Remove all protection sumps from the third arm NOTE: Do not clamp on threads.
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 phase the
return ropes are sufficiently in traction in a way
not to allow relative contact with the third arm.
4. Vice versa in the extension return phase, check
that the outlet ropes are subject to a tension that
allows them not to come into contact with the
second extension or the cylinder.
5. Use a torque wrench to check the correct torque
of al rope fixing nuts and the respective rocker C
arms; recommended torque 10 Nm. Figure 4-19. Clamping Wire Ropes
If the tension of the ropes should not be adequate the 1. Loosen the register counter-nuts by a few turns,
conditions for use must be restored by scrupulously fol- position them in a way to access the adjustment
lowing the Ropes Tension Adjustment procedure reported nuts in order to make the adjustment. (two nuts
following. with relative counter-nut for extend ropes and
one nut with relative counter-nut for retract
ropes rocker arm).
2. Completely retract both extendible arms and
make them escape for 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 4-20. 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

3121623 4-11
 SECTION 4 - BOOM & PLATFORM

keep the ropes blocked to prevent them turning

with the nuts. Make use of the relevant seat for
the wrench on the cable socket.

Figure 4-23.
6. Activate the movement of the extendible arms
several times and check that the residual loads
on the ropes are 10Nm.
7. This procedure could require several attempts
before it is completed correctly.
8. The adjustment is correct when the ropes do not
emit any noise during extension or return and
the torque value prescribed is reached on all of
the ropes.
Figure 4-21. Nuts for exit cables stop 9. Once calibration has been concluded, tighten
the counter-nuts and re-mount the sump.

Figure 4-22. Terminal with seat for anti-rotation key

4-12 3121623
 SECTION 4 - BOOM & PLATFORM

4.5 ROTARY ACTUATOR Technical Data

ARP Series

a
b

c
d

a. Rotary actuator model.

b. Construction year.
c. Serial number. Please refer to this number in
order to obtain every further details from
our technical department.
d. Max working pressure.

Actuator Model
Technical Data
RP.17/L25H1D2VPH
Rotation Angle 124°
Displacement (cm3) ~ 81
Weight (kg) ~ 16
Ports ¼G
Working temperature (°C) - 20 / + 80
Max. torque at 210bar (Nm) 505
Max. working pressure (bar) 210
Max. Capacity straddle mount / cantile- 2800 / 1400
ver mount (Nm)
Max. capacity: thrust / radial (N) 5000 / 14000

For more information and other details see technical

drawing.

3121623 4-13
 SECTION 4 - BOOM & PLATFORM

Figure 4-24.

4-14 3121623
 SECTION 4 - BOOM & PLATFORM

H.987/124DC01/C – H.987/124DC07/C
POS. QTY DEFINITION
SPECIAL INTERNAL PRODUCTION MOVECO
A 1 TOOTHED SHAFT D85/D40X187,5 THROUGH HOLE
C 1 WELDED BODY CYLINDER ASSEMBLY X ...DC01/C
1 WELDED BODY CYLINDER ASSEMBLY X ...DC07/C
2 BUSHING D28XD20X40 X H.987/124DC01/C
2 BOX SUPPORT
4 HEX.HEAD SCREW M6X20
4 FLAT WASHER D6XD18X2
4 SELF LOCKING NUT M6
F 1 REAR FLANGE D84,4X35,5-124°
G 1 TOOTHED GEAR RING
M* 2 WIPER RING D101XD81X7,5
P 1 TOOTH PISTON D75XD40X86
S* 3 PIN D6X12
V 1 DOUBLE OVERCENTER VALVE
SEALS KIT (includes the particulars marked by * )
NOTE: Units (A, C, F, P) are exchangeable only by MOVECO
SPARE-PARTS
1* 2 BONDED SEAL D5
2 2 HEX.HEAD SCREW M5X8
3 4 PIN D6X24 - UNI 6364 A
4 4 THRUST RING D60XD85X1
5 2 THRUST BEARING D60XD85X3
6* 1 INT.PTFE SEAL D40
7* 1 EXT.PTFE SEAL D75 - 0750/A
8* 1 SEAL RING OP D40XD35,5X4,5
9* 2 GUIDE RING I 80/E85X14.8 RF
10* 2 EXT.PTFE SEAL D85 PROF. B

3121623 4-15
 SECTION 4 - BOOM & PLATFORM

Disassembly

CAUTION
THE SEALS MUST BE REMOVED USING APPOSITE TOOLS, SEALING SUR-
FACES MUST NOT BE DAMAGED.
1. After disassembly all parts must be cleaned and
degreased.
2. Clean all parts with compressed air.
3. Lubricate all sealing surfaces.
4. Make sure that the seals are not damaged during
disassembly and assembly.

NOTICE
10. Now carefully remove bearing 5 and thrust ring
REMOVE ONLY WHEN THE ACTUATOR IS UNINSTALLED FROM THE 4.
MACHINE/EQUIPMENT.
5. Fix the actuator to the bench.
6. Remove valve V, plugs and any bleeder screws
on the body (eg 1, 2).
NOTE: Place a suitable container below the actuator to col-
lect oil.
7. Remove protection ring M.
8. Remove the locking pins S.
9. Loosen flange F from shaft A using hole Ø6 and
using an appropriate wrench. We recommend
make equipment to facilitate the operation.
NOTE: Before unscrewing, make a reference between shaft
and flange and measure the gap between them on
side A. 11. Using holes Ø6 on the head of shaft and using a
proper wrench, rotate shaft A clockwise to bring
piston P to touche against the stop on body C.
12. With the piston stop, rotate the shaft anti-clock-
wise and this will march by the body.
NOTE: On gear teeth of shaft and piston (before disengag-
ing the same) make a reference, marking a tooth for
every detail on which engages with reciprocal.

Detail 8, remove before removing shaft!

4-16 3121623
 SECTION 4 - BOOM & PLATFORM

13. Now carefully remove shaft A,bearing 5 and

thrust ring 4.
14. Make a reference between actuator body C and
gear ring G (on side A), so as to reposition it
properly during assembly.

16. Remove all elements sealing by the particular.

CAUTION
THE SEALS MUST BE REMOVED USING APPOSITE TOOLS, SEALING SUR-
FACES MUST NOT BE DAMAGED.
17. After disassembly all parts must be cleaned and
degreased.
15. Push piston toward the side A, when it is stop- 18. Clean all parts with compressed air.
ping on gear ring G, make an effort to remove it 19. Lubricate all sealing surfaces.
from mounting pins 3, push out the two details 20. Make sure that the seals are not damaged during
from actuator body and remove pins. disassembly and assembly.
NOTE: On gear teeth of piston and gear ring (before disen-
gaging the same) make a reference, marking a
tooth for every detail on which engages with recip-
rocal.

3121623 4-17
 SECTION 4 - BOOM & PLATFORM

Assembly NOTE: During this operation pay attention to the sealing

elements between the shaft A and piston P.
1. Fix the actuator in a proper way to the bench
8. Place bearing 5 and thrust ring 4 (4+5+4) on side
2. Reinstall all sealing elements on their particulars A.
paying attention to mounting direction (see
9. Screw flange F, with seal 10 and guide rings 9,
drawing). If you have difficulty use appropriate
until the reference and the gap between shaft
bushings cone.
and flange do not match (clamp the shaft using
NOTE: For easy mounting, it is recommended to heat up the holes Ø6 on the head).
the elements of PTFE details 6, 7 and 10 in hot water 10. Put the pins S.
at 70/80 ° C.
11. Install any plugs and bleeder screws on the body
3. Put piston P, complete with seals 6 and 7 in actu- (eg: 1, 2).
ator body C. 12. Install valve V and details M.
4. Engage gear ring G with piston P referring to the 13. Check that there isn’t air inside the actuator. To
previously marked position. get out any internal air put the actuator in hori-
5. Turn gear ring G and match references between zontal position with the axis of rotation, with the
this and body (made during removal) and insert attacks facing up and make several rotations (10/
mounting pins 3 until it is under the level of gear 20).
ring. 14. To assure the oil exchange within the system
6. Place bearing 5 and thrust ring 4 (4+5+4) on side during the work the volume of the connecting
B. pipes must be lower than the actuator displace-
ment.
NOTE: Lubricate with grease the bearing and thrust ring.
Use grease EP 0 (NLGI consistency 0; soap type Lith- 15. Align the fixing holes of structure/machine to
ium; base oil Mineral). those of structure/actuator flange and lock this
position by pins/screws of suitable torque.
7. Insert shaft A from side B, complete with seals 8
and 10 and guide ring 9, engage it with piston P 16. Connect the rotary actuator as per layout on the
by referring to previously marked tooth. drawing.

4-18 3121623
 SECTION 4 - BOOM & PLATFORM

Installing 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 4-25., Rotator Counterbalance Valve. valve. Loctite #242 should be applied to the
1. Make sure the surface of the actuator is clean, shank of the three bolts at the time of installa-
free of any contamination and foreign debris tion.
including old Loctite. 4. Torque the 1/4-inch bolts 110 to 120 inch
2. Make sure the new valve has the O-rings in the pounds (12.4 to 13.5 Nm). Do not torque over
counter bores of the valve to seal it to the actua- 125 inch pounds (14.1 Nm). Torque the 5/16-inch
tor housing. bolts 140 inch pounds (15.8 Nm). Do not torque
over 145 inch pounds (16.3 Nm).

Figure 4-25. Rotator Counterbalance Valve

3121623 4-19
 SECTION 4 - BOOM & PLATFORM

4.6 BOOM ROTATION SENSOR ASSEMBLY - X26JP -

X770AJ
1. Assemble the end couplings (p/n-26741500)
using the hex galvanized screws (p/n-BV013000)
to the extension pipe (p/n-06745900).

Figure 4-28.
4. Route the rotation sensor electrical cable inside
the frame as shown below.

Figure 4-26.
2. Locate the rotation sensor (encoder) (p/n-
0660400) and encoder coupling (p/n-26741500).

Figure 4-29.
5. Install a coupling onto the rotation sensor shaft
using 1 - 3x12M screw (p/n-BV013000).
Figure 4-27.
3. Mount the rotation sensor (encoder) to the
crossmember under the turntable bearing using
3 - 6 x 12M screws with threadlocker. Connect
the rotation sensor electrical connector to the
connector coming from the electrical box.
See Figure 4-28.

Figure 4-30.
6. Install the protective cover over the rotation sen-
sor assembly using 3-6x16M TE screws and
washers. Install cover with the open slot facing
the engine end of the machine. See Figure 4-31.

4-20 3121623
 SECTION 4 - BOOM & PLATFORM

9. Make the difference between this distance and

the rotation marker size (15mm), then add at
least 0.02 in. (0,5mm) to have an interference fit
(but not more than 0.06 in. (1,5mm). Adjust to
the right measure shifting the two couplings on
the pipe to achieve 0.63 in. (16mm).
(Example 18,29-16= 2,29mm)
In this case it’s necessary to elongate the dis-
tance between the two couplings to 0.09 in.
(2,29mm).

Figure 4-31.
7. Install the sensor extension pipe with couplings
assembled in step 1, onto the sensor coupling at
the bottom of the protective cover. Install a rub-
ber coupling (blue arrow) into the metal cou-
pling (red arrow) at each end of the extension
pipe (green arrow) before installing.

Figure 4-34.

Figure 4-32.
8. Measure with a caliber the distance between the
coupling top and the surface of the first boom
support where the rotation marker will be
mounted. See Figure 4-33.
Figure 4-35.

Figure 4-33.

3121623 4-21
 SECTION 4 - BOOM & PLATFORM

4.7 PROXIMITY SENSOR ADJUSTMENT (X17JP-

X500AJ – X20JP-X600AJ)

Adjust the proximity sensor in order to obtain a gap of 2

mm between the sensor and the undercarriage ring
plate.

Figure 4-36.

4-22 3121623
 SECTION 4 - BOOM & PLATFORM

4.8 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
the mounting support. 2. Secure the platform to the jib mounting posts
with the aluminum threaded caps. Do not over-
2. Loosen and remove the aluminium caps that
tighten.
secure the platform to the jib platform mounting
posts. 3. Re-install the platform/remote control box into
the mounting support on the platform.
3. Lift the platform off the mounting posts in an
upward direction. Place platform aside for later
installation.

1 3

Figure 4-37.

3121623 4-23
 SECTION 4 - BOOM & PLATFORM

4.9 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
1. Turn the machine off and unplugged from the paragraph basket removal).
power supply. 3. Remove screws (5) securing support footswitch (6).
2. Remove the basket of the 4. Loosen the fixing screw foot (1).
machine (see dismantling basket). 5. Remove the footswitch (1) disconnecting
3. Remove screws (2) and remove cover (3). the wiring from ECM3.
4. Remove the load cell (4) by disconnecting
the wiring from ECM3.
Installing Footswitch
1. Fit and secure with screw the the footswitch
Installing Load Cell (1) to the support footswitch (6).
1. Install the load cell (4) and stop with cover 2. Secure with screws (5) footswitch support (6) to
(3) and secure with screws (2). the basket support(7).
2. Remount the load cell (4) connecting 3. Connect the wiring to ECM3.
the electrical wiring to ECM3. 4. Reinstall the basket. (See
3. Reinstall the paragraph basket installation).
basket. (See section basket installation)

Figure 4-38.

4-24 3121623
 SECTION 4 - BOOM & PLATFORM

4.10 SKYGUARD INSTALLATION - ONE PERSON Options/Accessories Prohibited When Installing This
Kit:
PLATFORM
• None
The purpose of this instruction is to install a SkyGuard sys-
Tools & Equipment Required:
tem on JLG Compact Crawler Boom (platform capacity of
one person) models listed below and with below pictured • Standard mechanic tools including 5/16” & 7/32”
SkyGuard Bracket. Allen Wrenches
• Tie Straps
Personnel Required:
• Qualified JLG equipment mechanic
Welded
Mount
Parts List:
ITEM PART NUMBER DESCRIPTION QTY
1 0641414 Bolt, 1/4-20 x 1 3/4 LG 2
2 0700812 Bolt (Metric), 8 x 25 LG 4
3 3290801 Nut, M8 x 1.25 4
4 3300430 Nut, Acorn 1/4- 20 2
5 3931424 Bolt, 1/4-20x1 1/2 LG 2
6 4711400 Washer, 1/4 DIA Plain Steel, Narrow 4
7 4811902 Washer, 8mm LG OD 4
8 37675400 Bracket, Skyguard Support 1
9 1001186517 Cover, Platform Sensor 2
10 1001188889 Support, Shear Block 2
11 1001213890 Switch, Skyguard 1
12 1001213891 Mount, Platform Sensor 1
Figure 4-39. SkyGuard Bracket with Mount
Procedure:
It is recommended that you read and thoroughly under-
stand these instructions before starting this procedure. 1. Park the machine on the firm level surface, fully
retract & lower the boom.
NOTICE 2. Extend all the four outriggers, set them to the
Use all applicable Safety precautions while working on, around or auto levelling mode and set the machine to rest
under any machinery. position.
3. Remove the key and shut the engine OFF.
Models Affected: 4. Allow the machine and system fluids to cool.
NOTE: This can only be installed on below machines 5. Disconnect the battery power from the machine.
“With a single person basket”.
• X500AJ (S/N C170000893 to Present)
• X600AJ (S/N C170000893 to Present)
• X770AJ
• X17J Plus (S/N C170000893 to Present)
• X20J Plus (S/N C170000893 to Present)
• X26J Plus

3121623 4-25
 SECTION 4 - BOOM & PLATFORM

For Reference: Installation:

1. Install the SkyGuard Support Bracket (8) onto
SkyGuard Switch the welded mounts on platform rails. Secure the
Assembly support bracket using four Bolts (2), relevant
Washers (7) and Nuts (3). See Figure 4-41.

2
8

SkyGuard
Bracket

Figure 4-40. SkyGuard Bracket with SkyGuard

Figure 4-41.
2. Align and attach Platform Sensor Mount (12)
onto the SkyGuard Switch (11) as shown in Fig-
ure 4-42.
3. Attach Platform Sensor Covers (9) to SkyGuard
switch assembly at both ends. See Figure 4-42.

12

11

Figure 4-42.
4. Position SkyGuard switch assembly with sensor
cover onto the SkyGuard Support Bracket (8) as
shown in Figure 4-43..

4-26 3121623
 SECTION 4 - BOOM & PLATFORM

5. Insert a Shear Block Support (10) through shear 9. Route the SkyGuard switch harness along Sky-
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. Secure the harness using
43. tie straps. See Figure 4-44.
NOTE: Ensure the correct position of Shear Block Support
(10) before installation. SkyGuard Switch
6. Secure the shear block on welded mount of Sky- Assembly
Guard support bracket using Bolt (1), relevant
Washer (6) and Acorn Nut (4) as shown in Figure
4-43.
7. Secure the SkyGuard switch assembly using Bolt
(5) and relevant Washer (6) on platform sensor
mount. See Figure 4-43.
NOTE: Tighten the Bolt (5) using appropriate allen wrench.
8. Repeat Steps 4 through 7 to secure SkyGuard
switch assembly on the other side of the Sky- Tie Strap
Guard support bracket ensuring correct position
of the shear block support before installation.

11 12
9
9
SkyGuard Switch
Harness
1
10
5 6
4-Pin Female
Connector
Figure 4-44.
8
6 10. Connect Sky Guard connector to the one on the
4 machine located under load cell box. See Figure
4-45..

Figure 4-43.

Figure 4-45.

3121623 4-27
 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 4-46.
• 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 4-46.
Asterisk must show next
12. Connect connector X603 to connector X605. See
Figure 4-47. to the ON position

Figure 4-48.

• Press button 9 (esc)

• Press button 9 (esc)
• Press button 9 (esc)
• Press button 9 (esc)
• Remote control screen should be on main icon
page

NOTICE
IF PLATFORM REMOVAL WILL BE NECESSARY, SKY GUARD EXTERNAL
CONNECTOR HAS TO BE DISCONNECTED. THEN RECONNECTED WHEN
Figure 4-47. THE PLATFORM IS INSTALLED ON THE MACHINE.

CAUTION
WHEN THE SKYGUARD IS PUSHED WITH EXCESSIVE FORCE THE SEN-
SOR SUPPORTS (ITEM 10 - FIGURE 4-43.) WILL BREAK. REPLACE WITH
NEW SENSOR SUPPORTS BEFORE CONTINUING OPERATION OF THE
MACHINE.
13. Reconnect the battery power to the machine.
14. Check for the proper functioning of SkyGuard
system.

Figure 4-49.

4-28 3121623
 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.

 
Main Lift     Tele  
Main Main Tele Main Drive   Drive    
Tower Lift  
Tower Lift Basket  Basket  Jib
(3 Boom) Up (Extension) In (Extension) Out  
Swing Forward Reverse (1 Boom) Up (1 Boom) Down Level Rotate Lift

R C R R C C R C C C C
R= Indicates Reversal is Activated
C= Indicates Cutout is Activated

Figure 4-50. SkyGuard Function Table

3121623 4-29
4-30
SECTION 4 - BOOM & PLATFORM

Figure 4-51. Pedal - Sky Guard System Schematic

3121623
 SECTION 4 - BOOM & PLATFORM

4.11 SKYGUARD INSTALLATION - TWO PERSON Options/Accessories Prohibited When Installing

PLATFORM This Kit:
The purpose of this instruction is to install a SkyGuard sys- • None
tem on JLG Compact Crawler Boom (capacity of two per-
son) models listed below and with below pictured Tools & Equipment Required:
SkyGuard Bracket.
• Standard mechanic tools including 5/16” & 7/32”
Allen Wrenches
• Tie Straps

Personnel Required:
• Qualified JLG equipment mechanic

Dual Side Entry Platform Parts List:

ITEM PART NUMBER DESCRIPTION QTY
1 38302200 Support, Left 1
Figure 4-52. : Dual Side Entry Platform SkyLine and Bracket
2 38302300 Support, Right 1
3 08310700 Cover, Right 1
4 08310800 Cover, left 1
5 08309700 Bar, Threaded 1
6 08132300 Bar, Fiberglass 1
7 3311601 Nut 1
8 18310600 Microswitch 1
Welded 9 383036Y1 Support, Bar 1
Mount
Parts List:
ITEM PART NUMBER DESCRIPTION QTY
1 0641414 Bolt, 1/4-20 x 1 3/4 LG 2
2 0700812 Bolt (Metric), 8 x 25 LG 4
3 3290801 Nut, M8 x 1.25 4
4 3300430 Nut, Acorn 1/4- 20 2
5 3931424 Bolt, 1/4-20x1 1/2 LG 2
6 4711400 Washer, 1/4 DIA Plain Steel, Narrow 4
7 4811902 Washer, 8mm LG OD 4
8 37609800 Bracket, Skyguard Support 1
Figure 4-53. SkyGuard Bracket with Mount 9 1001186517 Cover, Platform Sensor 2
10 1001188889 Support, Shear Block 2
It is recommended that you read and thoroughly under-
stand these instructions before starting this procedure. 11 1001213890 Switch, Skyguard 1
12 1001213891 Mount, Platform Sensor 1
NOTICE
USE ALL APPLICABLE SAFETY PRECAUTIONS WHILE WORKING ON, Procedure:
AROUND OR UNDER ANY MACHINERY.
1. Park the machine on the firm level surface, fully
retract & lower the boom.

3121623 4-31
 SECTION 4 - BOOM & PLATFORM

2. Extend all the four outriggers, set them to the For Reference:
auto levelling mode and set the machine to rest
position.
3. Remove the key and shut the engine OFF. SkyGuard Switch
4. Allow the machine and system fluids to cool. Assembly
5. Disconnect the battery power from the machine.

SkyGuard
Bracket

Figure 4-54. SkyGuard Bracket with SkyGuard

4-32 3121623
 SECTION 4 - BOOM & PLATFORM

Installation: 5. Insert a Shear Block Support (10) through shear

block housing on the SkyGuard support bracket
1. Install the SkyGuard Support Bracket (8) onto and into the platform sensor mount. See Figure 4-
the welded mounts on platform rails, secure the 57.
support bracket using four Bolts (2), relevant
NOTE: Ensure the correct position of Shear Block Support
Washers (7) and Nuts (3). See Figure 4-55.
(10) before installation.
6. Secure the shear block on welded mount of Sky-
Guard support bracket using Bolt (1), relevant
Washer (6) and Acorn Nut (4) as shown in Figure
4-57.
7
7. Secure the SkyGuard switch assembly using Bolt
(5) and relevant Washer (6) on platform sensor
3 mount. See Figure 4-57.
NOTE: Tighten the Bolt (5) using appropriate allen wrench.
8. Repeat Steps 4 through 7 to secure SkyGuard
switch assembly on the other side of the Sky-
Guard support bracket ensuring correct position
2 of the shear block support before installation.
8
11 12
9
9

1
10
5 6

Figure 4-55. 8
2. Align and attach Platform Sensor Mount (12) 6
onto the SkyGuard Switch (11) as shown in Fig- 4
ure 4-56.
3. Attach Platform Sensor Covers (9) to SkyGuard
switch assembly at both ends. See Figure 4-56.

12

9 Figure 4-57.

11

Figure 4-56.
4. Position SkyGuard switch assembly with sensor
cover onto the SkyGuard Support Bracket (8) as
shown in Figure 4-55.

3121623 4-33
 SECTION 4 - BOOM & PLATFORM

9. Route the SkyGuard switch harness along Sky- 11. Open load cell board (ECM3) box, locate connec-
Guard support bracket (right side) and under the tors X604 and X603, then disconnect them. See
platform control box. Secure the harness using Figure 4-60.
tie straps. See Figure 4-58.

SkyGuard Switch
Assembly

Figure 4-60.
Tie Strap 12. Connect connector X603 to connector X605. See
Figure 4-61.

SkyGuard Switch
Harness

4-Pin Female
Connecor
Figure 4-58.
10. Connect Sky Guard connector to the one on the
machine located under load cell box. See Figure
4-59.

Figure 4-61.

CAUTION
WHEN THE SKYGUARD IS PUSHED WITH EXCESSIVE FORCE THE SEN-
SOR SUPPORTS (ITEM 10 - FIGURE 4-57.) WILL BREAK. REPLACE WITH
NEW SENSOR SUPPORTS BEFORE CONTINUING OPERATION OF THE
MACHINE.

13. Reconnect the battery power to the machine.

14. Check for the proper functioning of SkyGuard
system.

Figure 4-59.

4-34 3121623
 SECTION 4 - BOOM & PLATFORM

15. POWER ON the machine.

NOTICE
• Press button 6 (service) on the remote control
IF PLATFORM REMOVAL WILL BE NECESSARY, SKY GUARD EXTERNAL
• Press button 7 (set up) CONNECTOR HAS TO BE DISCONNECTED. THEN RECONNECTED WHEN
• Press button 5 (password) THE PLATFORM IS INSTALLED ON THE MACHINE.
• 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)

Asterisk must show next

to the ON position
Figure 4-63.
NOTE: If further information is required, please contact the
JLG Service Department.

Skyguard System
When the SkyGuard sensor is activated, functions that
Figure 4-62. were in use at the time of actuation will reverse or cutout.
The table below outlines these functions.
• Press button 9 (esc)
• Press button 9 (esc)
• Press button 9 (esc)
• Press button 9 (esc)
• Remote control screen should be on main icon
page

 
Main Lift     Tele  
Main Main Tele Main Drive   Drive    
Tower Lift  
Tower Lift Basket  Basket  Jib
(3 Boom) Up (Extension) In (Extension) Out  
Swing Forward Reverse (1 Boom) Up (1 Boom) Down Level Rotate Lift

R C R R C C R C C C C
R= Indicates Reversal is Activated
C= Indicates Cutout is Activated

Figure 4-64. SkyGuard Function Table

3121623 4-35
4-36
SECTION 4 - BOOM & PLATFORM

Figure 4-65. Pedal - Sky Guard System Schematic

3121623
 SECTION 5 - HYDRAULICS

SECTION 5. HYDRAULICS
5.1 MAIN COMPONENTS IDENTIFICATION AND LOCATION
X17JP-X500AJ and X20JP-X600AJ

3121623 5-1
 SECTION 5 - HYDRAULICS

X26JP-X770AJ
The ground control box located on the right side of the machine contains the aerial part valveblock.
The hydraulic components compartment on the right side inside the bonnet contains the ground valveblocks, the hydrau-
lic manifold, the deviator valve, the double pump valve and the hand pump.
Together with hydraulic components is indicated in brackets the relevant number on hydraulic diagram.

5-2 3121623
 SECTION 5 - HYDRAULICS

3121623 5-3
 SECTION 5 - HYDRAULICS

5.2 HYDRAULIC SYSTEM PUMP AND PRESSURE NOTE: Lithium machine are equipped only with n.2 pumps
unit, one connected to the electric motor with n.2
LINES pumps 3,15 cc/rev each and the hand pump.
The machine hydraulic system is powered by n.3 pumps All of the pump unit pressure lines are conveyed through
units: the hydraulic manifold into two pressure lines A and B. Six
• Pumps unit connected to the diesel engine, n.2 one-way valves avoid oil under pressure to flow back to
pumps 6,67cc/rev each, diesel engine is calibrated at the tank through an unused pump unit.
maximum 3200 rpm Every time that hydraulic oil tank is opened (depressur-
• Pumps unit connected to the electric motor, n.2 ized), such as in case of hydr. oil filter replacement, it must
pumps 2,15 cc/rev each, electric motor is calibrated at be pressurized again (with cork screwed) at minimum
1500 rpm rpm, to avoid cavitation.

• Emergency hand pump, this has only one outlet line

but it’s equipped with a deviator to select which one
of the two lines should be fed

5-4 3121623
 SECTION 5 - HYDRAULICS

"A" pressure line sends oil under pressure to the deviator While "N" or "RABBIT" speed are selected, when some
valve, this valve is commanded directly by the control boom manifold movement is in progress, double pump
module to feed right side ground valve-block or to aerial valve is fed by the control module in order to feed also
part valve-block. with the second pump the boom manifold valve-block,
Deviator valve normally (when not fed) send oil to aerial increasing the movement speed even without increasing
part valve-block, so that it feeds right side ground valve- the RPM.
block only when its coil is energized. Which movement are speed up by this way depends on
Its coil is not energized (oil to the aerial part) only when which power system is used on that moment, diesel
machine is OFF or when machine is stabilized. engine, electric motor or lithium electric motor for lithium
machines, they are those movements that are better per-
"B" pressure line sends oil under pressure to the double formed with an higher oil rate, for instance telescope
pump valve that normally feeds the left side ground valve- opening is always carried out with both the pumps.
block.
Double pump valve is not fed with contemporaneously
Double pump valve normally (when not fed) sends oil to movements and is not fed at minimum speed "TURTLE".
left side ground valve-block, so that it send oil to the devi-
ator only when its coil is energized.

From the three valve-blocks the outgoing oil is collected by the blow-off manifold to the tank filter.

3121623 5-5
 SECTION 5 - HYDRAULICS

5.3 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 two hydraulic valve-blocks (right side and left side), both equipped with one
maximum pressure valve, one proportional valve and an ON-OFF valve for each ground control movement.

RIGHT
SIDE
VALVE
BLOCK

LEFT-
SIDE
VALVE
BLOCK 

MAX PROPORTIONAL ON-

PRESSURE VALVE OFF
VALVE

5-6 3121623
 SECTION 5 - HYDRAULICS

On each ground manifold oil rate is controlled through the 5.4 OUTRIGGERS
proportional valve managed by the control module.
Depending on the movement required, proportional valve Outrigger cylinders are controlled by the cylinder valves
will open accordingly regulating the oil rate, at the same block that is screwed on the cylinder. When machine is
time the relevant ON-OFF valves (one each movement) setup on outriggers, oil is kept under pressure on the cyl-
will open feeding the relevant cylinder or drive gear inder bottom side, against machine weight, by two
motor. piloted one-way valves installed in series on the cylinder
valves block.
Ground manifold maximum pressure valve has to be cali-
brated as indicated on use and maintenance manual, at Another piloted one-way valve is installed on the stem
200 bar with Diesel engine or 180 bar with electric motor side.
(185 bar for lithium machine). While cylinder movements are in progress the opposite/s
When the proportional valve coil is not energized, oil flows one-way valves is/are piloted to open letting oil flow back
back to the tank. to the valveblock.
Left side ground valve-block controls the two left side out-
riggers (n.1 and n.2), the left track drive gear motor and
the tracks widening cylinders.
Right side ground valve-block controls the two right side
outriggers (n.3 and n.4) and the right track drive gear
motor.

3121623 5-7
 SECTION 5 - HYDRAULICS

5.5 DRIVE GEAR MOTORS The second speed block contains the coil in charge to acti-
vate the second speed, selecting RABBIT from remote con-
Each drive gear motors runs forward or backward inde- trol button the control module will energize that coil.
pendently, it's so possible to turn the machine. Drive gear When that coil is energized oil is sent to both drive gear
motors are controlled by the ground valve-blocks and motors to move their plate so that their chamber capacity
each one is equipped with an automatic brake that is will be reduce.
hydraulically deactivated only while it runs.
With reduced capacity the gear rate is increased so that
Drive gear motors are equipped with a second speed sys- the tracks speed is increased too.
tem, indeed they are variable capacity so that they can
perform two different hydraulic speeds in order to change
tracks speeds further that rpm regulation.

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.

5-8 3121623
 SECTION 5 - HYDRAULICS

SMALLER CHAMBER: BIGGER CHAMBER:

 FASTER SPEED  SLOWER SPEED
 SMALLER TORQUE  HIGHER TORQUE

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.

SECOND
SPEED
MANIFOLD

3121623 5-9
 SECTION 5 - HYDRAULICS

5.6 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.

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.

5-10 3121623
 SECTION 5 - HYDRAULICS

5.7 BOOM COMPONENT HYDRAULIC SYSTEM

The boom components controlled by the boom control manifold valve are, 1st/2nd boom cylinder, 3rd boom cylinder,
telescope cylinder, jib cylinder, platform rotator, and platform leveling cylinders.
The boom components are controlled by an hydraulic manifold valve equipped with one maximum pressure valve, one
proportional valve and an ON-OFF valve for each aerial part movement.

MAX
PROPORTIONAL ON-OFF
PRESSURE
VALVE VALVES
VALVE

AERIAL PART
VALVEBLOCK

3121623 5-11
 SECTION 5 - HYDRAULICS

Boom component manifold valves are fed by pressure line "A" through deviator valve and oil rate is controlled through the
proportional valve managed by the control module.
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).
Through boom component manifold valves feed the turret rotation motor, the cylinder for moving 1st and 2nd booms, the
cylinder for moving the 3rd boom, the telescope cylinder, the jib cylinder, the basket rotation actuator and the basket lev-
elling circuit.
On each cylinder an actuator is installed a couple of calibrated valves, one each direction, when movement is in progress
on one direction the opposite valve is piloted to open letting oil flow back to the manifold valve block.
When these valves are not piloted oil flow is avoided so that they keep the cylinder and actuator position against external
forces or in case of an hose damage.

COUPLE OF
CALIBRATED
VALVES

First And Second Booms

1st and 2nd booms are moved together by one cylinder through the connection rod designed to obtain a double parallel-
ogram system, this cylinder is equipped with an internal sensor that measures its opening position.

5-12 3121623
 SECTION 5 - HYDRAULICS

Third Boom
Third boom is moved by one cylinder, this cylinder is equipped with an internal sensor that measures its opening position.
While lifting third boom, when it's going to reach its end of the stroke, in order to achieve a smoother machine handling,
movement is automatically hydraulically decelerate by reducing the opening of proportional valve.

Telescope
Telescope system is composed by three parts, the third boom that contains a first telescope and a second telescope, they
are all opened or closed together by an unique internal cylinder and a system of ropes and pulleys.
A microswitch is in charge to detect an eventual anomalies about the ropes positions.
More details about ropes system and their maintenance are indicate on use and maintenance manual.

Jib
Jib is moved by one cylinder, while moving jib the basket is kept level thanks to the parallelogram system.

Basket Leveling
Basket levelling close circuit is composed by two cylinders, one on the basket and one on the third boom connection rod,
basket is automatically kept levelled while third boom is moving because of the basket cylinder is moved by connection
rod cylinder.
In particular, while third boom is opening, the connection rod cylinder will be closing so that its oil will be send to the bas-
ket cylinder achieving the automatic basket levelling.
Of course is possible to adjust basket levelling acting on its joystick.

Basket Rotation
Basket rotation is carried out by the basket rotation actuator composed by two chambers, the maximum rotation possible
is 62° on both directions achieving a total of 124°.
Two black arrows show the basket aligned position.

Turret Rotation
Turret rotation is carried out by a rotation hydraulic motor moved by a worm screw on a bearing ring.
Turret could be rotated 180° each side till a mechanical block, achieving a total rotation.

3121623 5-13
 SECTION 5 - HYDRAULICS

Emergency Gravity Descent System

Cylinders for 1st and 2nd booms, 3rd boom and jib are equipped with a coil valve for gravity emergency descent, they are
controlled by the control module when the remote control button "gravity emergency descent" is pressed.
When they are fed they open a calibrated passage and under the gravity effect (weight) they will allow oil to get out from
the bottom of the cylinder flowing back to the tank (through the ON-OFF valves), so that booms will slow down.
The coil valve for gravity emergency descent has a blue cap.

Hydraulic System Sections

The hoses that start from the boom component manifold valves and go through the booms are sectionized with fittings
inside the second boom where is indicated by the blue arrow here below.
Other sectioning points are on the catenary, at the beginning and at the end of the rigid pipes and are attached to the
hoses coming from the lower booms and the hoses going to the jib arm.

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 SECTION 5 - HYDRAULICS

5.8 CYLINDER REPAIR

Specification - Cylinders Overview

Figure 5-1. Piston Thread

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 SECTION 5 - HYDRAULICS

Figure 5-2. Piston With Nut Thread

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 SECTION 5 - HYDRAULICS

Figure 5-3. Telescope Cylinder

3121623 5-17
 SECTION 5 - HYDRAULICS

Figure 5-4. Cylinder With Sensor

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 SECTION 5 - HYDRAULICS

Hydraulic Cylinders Torque Specifications Hose Connections Torque Specifications

Screws Torque Specifications
JUNCTION
CYLINDER SCREWS TORQUE VALUE Ø HOSE METRIC THREAD TORQUE VALUE (N/m)
DRILLED SCREW 3/8" 70N/m 6 M12x1.5 20
SCREW M8 25N/m 8 M14x1.5 25
SCREW M6 11N/m 10 M16x1.5 30
SCREW M4 3N/m 12 M18x1.5 40
CAP 1/4" 30N/m 15 M22x1.5 60
PURGE SCREW 8N/m 18 M26x1.5 90
GREASE NIPPLE 2N/m 22 M30x2 170
SENSOR SETSCREW 0.5N/m 28 M36x2 210
35 M45x2 360
42 M52x2 490
Cylinders Head Torque Specification

TIGHTENING TORQUE HEAD

TORQUE [Nm]
HEAD DIAMETER (mm)
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
160 550 600
170 550 600
180 550 600
190 550 600
200 600 650
210 600 650
220 600 650
230 600 650
240 600 650
250 700 750

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 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.

Cylinder With Sensor - General Cylinder 5. Remove 4 screws of the sensor

Disassembly

1. Clean the cylinder with a suitable cleaner before

disassembly. Remove all dirt, debris and grease 6. Unhook the connector from the base making
from the cylinder. pressure on 2 wing signed in the picture.
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 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
THE COUNTERBALANCE VALVE WITH A NEW PART.

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 SECTION 5 - HYDRAULICS

7. Push the connector inside the hole and fix the

plate again. 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.

8. Unscrew the setscrew and remove the pin. Use a

magnet to pull out the pin.

NOTICE
BE CAREFUL IN THIS OPERATION IN ORDER TO AVOID TO BREAK THE
WIRE OR DAMAGE THE SENSOR.

9. Secure the setscrew in order to keep the air pres-

sure.

10. Blow pressurized air with caution on the connec-

tion in order to push the sensor out of the hos-
ing.

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 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. Clean all metal parts with an approved cleaning

solvent such as trichlorethylene. Carefully clean
cavities, grooves, threads, etc. 4. Verify the integrity of the tube checking that the
surface doesn't present scratches.

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.

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 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.

2. Pull out the spacer.

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
3. Pull out the magnet. 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
4. Pull out the other spacer.
threads and other parts, which must be removed by
brushing with a soft brass wire brush prior to reassembly.

3121623 5-23
 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.
3. Fasten the rod eye in a soft-jawed vise, and place
a padded support under and near the threaded
end of the rod to prevent any damage to the rod.
4. Lubricate and slide the head over the cylinder
rod. Install the piston head on to the end of the
cylinder rod. Loctite® 243TM and install the set
screw in the piston head. Refer to “Hydraulic Cyl-
inder Torque Specifications,”for tightening
guidelines for the piston, head and the set Cylinder Mounting
screws. Cylinder Inspection
Seals Head Replacing 5. Inspect internal surfaces and all parts for wear,
Remove all seals, back-up rings and o-rings from the pis- damage, etc. If the inner surface of the tube does
ton head and all seals, back-up rings and orings. 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 400-600 grit
emery cloth. Use the emery cloth in a rotary
motion to polish out and blend the scratch(es)
into the surrounding surface.
7. Check the piston rod assembly for run-out. If the
rod is bent, it must be replaced.

8. Replace the seals on the piston. DO NOT

attempt to salvage cylinder seals, sealing rings
or o-rings. ALWAYS use a new, complete seal kit
N° DESCRIPTION Qty. when rebuilding hydraulic components. Consult
1 O-RING 2 the parts manual for ordering information.

2 BEARING 2
3 BACK UP RING 1
4 SEAL 2

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 SECTION 5 - HYDRAULICS

Mount the seals in the following order: Refer to “Hydraulic Cylinder Torque Specifications,” for
9. Seal tightening guidelines for the piston.
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. Clean the residue away
with a soft brass wire brush prior to reassembly, and
wipe clean before reinstallation.
12. Mount spacer with chamfer face outside.

13. Lubricate the o-ring

3121623 5-25
 SECTION 5 - HYDRAULICS

14. Joint the sensor pin with a guidance cable.

15. Insert sensor with a cable pass 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.

16. Use plastic tool to insert the sensor

17. Push the tool carefully

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 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. Clamp the barrel end of the cylinder in a soft-
jawed vise or other acceptable holding equip-
ment if possible.

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
1. Screw the head into the cylinder barrel and
tighten with a spanner wrench. Refer to “Hydrau- AVOID USING EXCESSIVE FORCE WHEN CLAMPING THE CYLINDER IN A
lic Cylinder Torque Specifications,” for tightening VISE. APPLY ONLY ENOUGH FORCE TO HOLD THE CYLINDER SECURELY.
guidelines for the head. EXCESSIVE FORCE CAN DAMAGE THE CYLINDER TUBE.
3. Remove the counterbalance valve from the side
of the cylinder barrel.

NOTICE
DO NOT TAMPER WITH OR ATTEMPT TO ADJUST THE COUNTERBAL-
ANCE VALVE CARTRIDGE. IF ADJUSTMENT IS NECESSARY, REPLACE
THE COUNTERBALANCE VALVE WITH A NEW PART.
NOTE: Cylinder can have residual pressure inside.
4. When the cylinder has been emptied pull out
the rod ~ 15mm and loosen the head until ~
2. Thread the counterbalance valve into the block 15mm.
on the cylinder barrel.
Refer to Section 3.2 “Hydraulic Cylinder Torque
Specifications”.

NOTICE
WHEN SLIDING THE ROD AND PISTON ASSEMBLY OUT OF THE TUBE,
PREVENT THE THREADED END OF THE TUBE FROM DAMAGING THE
NOTE: The following are general procedures that apply to PISTON. KEEP THE ROD CENTERED WITHIN THE TUBE TO HELP PRE-
all of the cylinders without sensor. Procedures that VENT BINDING.
apply to a specific cylinder will be so noted

3121623 5-27
 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.
1. Fix the rod into the vice.
NOTE: Before attempting to disassemble the piston
remove any accessible seals.

Cylinder Assembly
General Cylinder Assembly
1. Use the proper tools for specific installation
tasks. Clean tools are required for assembly.
NOTE: Apply heat to break the bond of the sealant
between the piston and the rod before the piston 2. Install new seals, back-up rings and o-rings on
can be removed. the piston and the head.
3. Fasten the rod eye in a soft-jawed vise, and place
CAUTION a padded support under and near the threaded
end of the rod to prevent any damage to the rod.
WARM THE SURFACE INDICATED MAX 300°C
4. Lubricate and slide the head over the cylinder
2. Avoid overheating, or the parts may become dis- rod. Install the piston head on to the end of the
torted or damaged. cylinder rod. Loctite® 243TM and install the set
screw in the piston head. Refer to "Hydraulic Cyl-
inder Torque Specifications” for tightening
guidelines for the piston, head and the set
screws.

Apply sufficient torque for removal while the parts are still
hot. The sealant often leaves a white, powdery residue on
threads and other parts, which must be removed by
brushing with a soft brass wire brush prior to reassembly.

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 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.
2. Remove light scratches on the piston, rod or
inner surface of the tube with a 400-600 grit
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
N° DESCRIPTION Qty. new, complete seal kit when rebuilding hydraulic compo-
nents. Consult the parts manual for ordering information.
1 O-RING 2
Mount the seals in the following order:
2 BEARING 2
4. Seal
3 BACK UP RING 1 5. Support bearing
4 SEAL 2 6. Bearing

2. Install new seals, back-up rings and o-rings on

the piston and the head using the proper tool.

NOTICE
PROTECT THE FINISH ON THE ROD AT ALL TIMES. DAMAGE TO THE
SURFACE OF THE ROD CAN CAUSE SEAL FAILURE.

3121623 5-29
 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
new, complete seal kit when rebuilding hydraulic compo- 1. Carefully grind the bush with a milling cutter for
nents. Consult the parts manual for ordering information. plastic.

7. 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. Clean the residue away
with a soft brass wire brush prior to reassembly, and
wipe clean before reinstallation.
2. After that the bushing has been removed
inspect the internal surface.

Refer to “Hydraulic Cylinder Torque Specifications,” for

tightening guidelines for the piston. 3. Replace the bush with a new one and put it
inside with a press.

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 SECTION 5 - HYDRAULICS

Cylinders Bleeding 5.9 REPLACEMENT HYDRAULIC PUMP

Vent Valve
Pump removal
Air inside the circuit has to be removed in order to avoid
vibration and irregular motion of the cylinder, vent valves 1. Open the top cap of the hydraulic oil tank.
are apply to make this kind of operation. 2. Tag & disconnect the hoses from the pump 15.
Failure to remove air from the circuit can cause diesel 3. Loose screws 16.
effect with consequent damage of the seals. 4. Remove from the pump 15 from the adapter 12.
Be sure that there is no presence of air inside the cylinder 5. Loosen nut 10 and remove the coupling 11 and
before it start working. plate 14 from the pump shaft 15.
Bleeder screw 6. Move the new pump the particular 14.

Pump installation
1. Install the plate 14, coupling 11, and the nut 10
on the pump.
2. Tighten the nut 10 at (15Nm).
3. Fit the pump 15 on the coupling 15 with screw
16.
4. Connect the hoses to the pump 15.

CAUTION
LOOSEN BLEEDER SCREW TO LET AIR ESCAPE RE-TIGHTENING TORQUE
6 FT. LB. (8 Nm).

Image 4

3121623 5-31
 SECTION 5 - HYDRAULICS

5.10 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
General Suggestions THE MACHINED SURFACES. PUT THE PUMP IN HORIZONTAL POSITION
AND BLOCK THE COVER IN THE VICE'S JAWS. LOOSEN THE BOLTS.
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.

Vice Vice

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 SECTION 5 - HYDRAULICS

1. Unscrew the nut and remove the nut and washer

(1).
2. Take out the shaft key (2).

3. Put the pump on the work bench and remove 3. Remove the rear cover.
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.

3121623 5-33
 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. Remove from the plate the back-up ring (1) and

the seal (2).

2. Remove the gears and the pressure plates.

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 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

2. Fit the new seal (1) and back-up ring (2) on the plate and the body. It will be used later during
plate. reassembly.

2 1
3. Remove the gears and the pressure plates.

3121623 5-35
 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
2. Remove from the plate the back-up ring (1) and plate.
the seal (2).

1
2
2
1
3. Remove from the plate the back-up ring (1) and 3. Fit the new seal (1) and back-up ring (2) on the
the seal (2). plate.

1
2 2
1

5-36 3121623
 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. 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
Cover Seals Replacement CASAPPA tool pn.06100091

7. Insert the back-up ring.

1. Put the cover on the working bench. 8. Using a mallet push all the way down the
2. Remove the snap ring (1). CASAPPA tool pn. 06100091.
3. Paying attention not to damage the seat remove
with a screw driver (flat head) the shaft seals.(2 -
3)
4. Put some clean grease into the seat seal.

1
2
3

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 SECTION 5 - HYDRAULICS

Second Section Components Reassembly First Section Components Reassembly

1. Reassemble the gears and the plates. Use as ref- Reassemble the gears and the plates. Use as reference
erence the mark made previously. the mark made previously.

2. Reassemble the rear cover.

Components Reassembly
1. Put back the flange and the pins. Put the con-
necting hub into the second section shaft.

5-38 3121623
 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.

3121623 5-39
 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. 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.

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 SECTION 5 - HYDRAULICS

5.11 HYDRAULIC COMPONENT START-UP that the pump is not being asked to draw an inlet
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. Fill the
tem start up is to put into functional operation, the hydro- housing by pouring filtered oil into the upper
static system in such a way as to preserve the designed life case drain port.
span of the system. The following start-up procedure
should be adhered to whenever a new pump or motor is NOTE: It is highly recommended to use the highest possible
initially installed into a machine, or a system is restarted case drain port, this ensures that the housing con-
after either a pump or motor has been removed and/or tains as much oil as possible and offers the greatest
replaced. amount of lubrication to the internal components.
NOTE: In initial start-up conditions, it may be convenient
to fill the housing, just prior to installing the case
THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO BE DIS- drain line. Component, (especially motor), location
ABLED (WHEELS RAISED OFF THE GROUND, WORK FUNCTIONS DIS- may be such that access to the case drain port after
CONNECTED, ETC.) WHILE PERFORMING THE PROCEDURE IN ORDER installation is not realistic.
TO PREVENT INJURY. TAKE NECESSARY SAFETY PRECAUTIONS BEFORE NOTE: Make certain that the oil being used to fill the com-
MOVING THE VEHICLE/MACHINE. ponent housing is as clean as possible, and store the
Prior to installing the pump and/or motor, inspect the fill container in such a way as to prevent it from
unit(s) for damage that may have been incurred during becoming contaminated.
shipping and handling. Make certain that all system com- 4. Install a 60 bar (or 1000 psi) pressure gauge in
ponents (reservoir, hoses, valves, fittings, heat exchanger, the charge pressure gauge port in order to mon-
etc.) are clean prior to filling with fluid. itor the charge pressure during start-up.
5. It is recommended that the external control
1. Fill the reservoir with recommended hydraulic
input signal, (electrical connections for EDC), be
fluid. This fluid should be passed through a 10
disconnected at the pump control until after ini-
micron (nominal, no bypass) filter prior to enter-
tial start-up. This will ensure that the pump
ing the reservoir. The use of contaminated fluid
remains in its neutral position.
will cause damage to the components, which
may result in unexpected vehicle/machine
movement.
DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRAL POSI-
NOTE: If a pump or motor is being replaced due to internal- TION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAUTIONS TO PRE-
damage, the remaining units (pump or motors) VENT MACHINE MOVEMENT IN CASE PUMP IS ACTUATED DURING
need to be inspected for damage and contamina- INITIAL START-UP.
tion, and the entire hydraulic system will need to be
flushed and the fluid replaced. Failure to do so may 6. "Jog" or slowly rotate the engine until charge
cause considerable damage to the entire system. pressure starts to rise. Start the engine and run
at the lowest possible RPM until charge pressure
2. The inlet line leading from the reservoir to the has been established. Excess air should be bled
pump must be filled prior to start-up. Check the from the system lines as close to the motors as
inlet line for property tightened fittings and possible.
make sure it is free of restrictions and air leaks.
NOTE: With the engine on low idle, "crack", (loosen-don't
NOTE: In most cases, the reservoir is above the pump inlet remove), the system lines at the motor(s). Continue
so that the pressure head created by the higher oil to run the engine at low idle and tighten the system
level helps to keep the inlet pressures within an lines as soon as oil is observed to leak from them.
acceptable range and prevent high vacuum levels. When oil is observed to "leak" at the motor the line is
However, due to hose routing or low reservoir loca- full, the air has been purged, and the system hoses
tions, there may be air trapped within this line. It is should be retightened to their specified torque.
important to assure that the air is bled from this
line.This can be accomplished by loosening the hose 7. Once charge pressure has been established,
at the fitting closest the pump. When oil begins to increase speed to normal operating RPM. Charge
flow, the line is full, the air has been purged, and the pressure should be as indicated in the pump
fitting can be retightened to its specified torque. If model code. If charge pressure is inadequate,
the tank needs to be pressurized in order to start the shut down and determine the cause for
flow of oil, a vacuum reading should be taken at the improper pressure.
inlet of the pump during operation in order to verify

3121623 5-41
 SECTION 5 - HYDRAULICS

5.12 PRESSURE SETTING PROCEDURE

INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERATOR'S ABIL- Cold temperatures have a significant impact on pressure
ITY TO CONTROL THE MACHINE. readings. JLG Industries Inc. recommends operating the
machine until the hydraulic system has warmed to normal
8.
Shut down the engine and connect the external operating temperatures prior to checking pressures. JLG
control input signal. Also reconnect the machine Industries Inc. also recommends the use of a calibrated
function(s), if disconnected earlier. gauge. Pressure readings are acceptable if they are within
9. Start the engine, checking to be certain the ± 5% of specified pressures.
pump remains in neutral. With the engine at nor-
mal operating RPM, slowly check for forward and Control Valve (Chassis functions)
reverse machine operation.
1. Machine completely closed.
10. Charge pressure may slightly decrease during
forward or reverse operation. Continue to cycle
slowly between forward and reverse for at least
five minutes.
11. Shut down engine, remove gauges, and plug
ports. Check reservoir level and add filtered fluid
if needed. A 2,0
TSOP_OIGGOPPA

2,3
The machine is now ready for operation.
B B

2. Install the pressure gauge at the port marked

MA.
3. Activate the function outrigger IN on remote
control.
4. Verify that the pressure is as on Table below.

CONTROL VALVE LEFT SIDE (CHASSIS FUNCTIONS)

PRESSURE SETTING
MODEL PRESSURE PORT
BAR PSI
X17JP / X500AJ
165 2400
X20JP / X600AJ MA
X26JP / X770AJ 200 2900
Figure 5-5.

To adjust the relief valve, turn clockwise to increase, turn

counterclockwise to decrease the pressure.

5-42 3121623
 SECTION 5 - HYDRAULICS

Automatic Reductions Drive Speed (X17JP-X500AJ Control Valve Turntable Functions

and X26JP-X770AJ Only) 1. Machine with outrigger fully extended.
Adjust pressure reducing valve (only X17JP - X500AJ)
1. Adjust the pressure when the machine is
completely closed.

TSOP_OIGGOPPA

A 2,0

2,3
B B

2. Install the pressure gauge at the port 5. 2. Install the pressure gauge at the port marked
3. Activate the function outrigger IN on remote MB.
control 1. 3. Activate the function Telescope IN on remote
4. Verify that the pressure is as on Table below. control.
5. Pressure adjust on relief valve point 6 NOTE: The calibration must be made with oil hot and
speed setting to RABBIT.
4. Verify that the pressure is as on Table below.
AUTOMATIC REDUCTIONS DRIVE SPEED

PRESSURE PRESSURE SETTING

MODEL FUNCTION CONTROL VALVE TURNTABLE FUNCTIONS
PORT BAR PSI
X17JP / X500AJ Function PRESSURE PRESSURE SETTING
MA 26 380 MODEL FUNCTION
X26JP / X770AJ Outrigger IN PORT BAR PSI
X17JP / X500AJ 185 2683

X20JP / X600AJ MB Telescope IN 210 3050

X26JP / X770AJ 200 2900

Figure 5-6.

3121623 5-43
 SECTION 5 - HYDRAULICS

5.13 OUTRIGGERS AUTO-RETRACTION To achieve the stowed condition outriggers must be com-
pletely lifted up till the end of their stroke and have to be
To be able to automatically retract the outriggers the manually rotated while unlocked with their pivot.
machine must be closed and aligned and outriggers must The machine is equipped with two pressure switches on
be all opened as the previous paragraph describes. the hydraulic manifold, one for the right side and one for
To automatically retract the outriggers you have to press the left side. When both the same side outriggers are at
and hold remote control button n.1 "AUTOMATIC OUTRIG- end of the stroke, the hydraulic oil pressure reaches the
GERS RETRACTION", the display will shows "DEST". maximum value so that the pressure switch informs the
ECM1-2 that outriggers are completely lifted up. When
AUTO DEST ECM1-2 senses that all the four outriggers are completely
lifted up starts to feed one side outriggers at a time, this
will help when outriggers need more power to be lifted
up, for instance in case of cold hydraulic oil.
DEST.
NOTE: During the intermediate steps of auto-stabilization
and outriggers auto-retraction, while two or three
outriggers are touching the ground, the engine
Figure 5-7. Outriggers Auto-Retraction In Progress automatically runs at minimum RPM to ensure
smooth movements.
It's possible to keep automatic outriggers retraction run-
ning till outriggers are completely lifted up.

5-44 3121623
 SECTION 6 - JLG CONTROL SYSTEM

SECTION 6. JLG CONTROL SYSTEM

6.1 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,
WHEN INSTALLING ANY NEW MODULE CONTROLLER ON THE
creep, min speed, and max.-speed for all boom, and drive
MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CONTROLLER
functions.
FOR THE PROPER MACHINE CONFIGURATION, INCLUDING OPTIONS
AND PROPERLY CALIBRATE THE TILT SENSOR. The main lift, swing, and drive are controlled by individual
Joysticks. To activate Drive, Lift, and Swing move the joy-
NOTICE stick into the direction desired.
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ The control system will control the voltage output to the
ELECTRONIC COMPONENTS. SHOULD PRESSUREWASHING BE UTI- valves, as programmed for smooth operation and maxi-
LIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COM- mum cycle time.
PONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM The JLG Remote Control has a built in Display and by a
PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 push buttons, could show any present faults.
INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/
ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE The Remote Control is connected by cable on the follow-
DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURA- ing models:
TION. CE - X17JP - X20JP - X26JP
The JLG Control System is a 12 volt based control unit ANSI - X500AJ - X600AJ - X770AJ
installed on the compact crawlers boom lift.
The system can be accessed for troubleshooting even by
the analyzer RamHino; kit JLG part no.17162400.

3121623 6-1
 SECTION 6 - JLG CONTROL SYSTEM

6.2 MACHINE IGNITION

To start up the machine, the battery cutter that is under the ground bonnet must be active, both the emergency stop but-
tons (on the remote control and on the ground control box) must be released, than the main key on ground control box
has to be turned ON.
In case of need to restart the machine, main key must be turned ON again after at least 10 seconds from the switching OFF.

SWITCH

Once remote control display will switch ON, to ignite diesel engine press remote control "diesel engine" button, to start
the electric motor press "electric motor" button.
To switch OFF diesel engine or electric motor it's possible to press an emergency stop button or to press once again
respectively the "diesel engine" button or "electric motor" button.
Diesel engine and electric motor cannot be ignited together and the system avoids it.

With cold temperatures it's recommended to press the "preheating button" before to ignite diesel engine to warm it up by
the plugs and ignite it when the plugs icon will disappear from the display.

PREHEAT BUTTON  PLUGS ICON 

6-2 3121623
 SECTION 6 - JLG CONTROL SYSTEM

The display shows always in position 3 the motor selected and in case it's OFF the icon will be marked with an "X".

DIESEL ENGINE 

ELECTRIC MOTOR 

If the operator tries to start up the machine with a stop button pressed, the "ERROR STOP" message will appear as illus-
trated here below.

ERROR  IGNITION NOT

POSSIBLE
ERROR, STOP
PRESSED 

After machine has been used it must be switched OFF by the main key on ground control box.
When engine and electric motor are switched OFF with machine closed and aligned, remote control will emit an intermit-
tent acoustic signal to notify the operator that the main key is still turned ON.

3121623 6-3
 SECTION 6 - JLG CONTROL SYSTEM

6.3 PLATFORM - REMOTE CONTROL STATION

1 2 3 4 5 6 7 8

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.
The remote control is made up of buttons, joysticks, a key
selector switch and a display.
The display is used to view the status of the machine and
the operating information necessary or useful for the
operator.
When the machine’s main control board is powered via
the engine key, the information to be shown on the dis-
play is sent to the remote control.
This operation has a variable duration. Normally a few sec-
onds are sufficient, however the following screen may
appear on the display:

6-4 3121623
 SECTION 6 - JLG CONTROL SYSTEM

Icon position diagram:

Figure 6-2.
Figure 6-4.
In this case about 5-10 minutes are needed to send all the
information from the main board to the remote control. POSITION 3:
The machine cannot work during this period. Position 3 displays the engine/motor selection and the
Do not stop the machine or operate it during this period. engine status
NOTE: The numbers shown above DOWNLOAD are the
data transferred. The Download will be completed
when about more that 24000 steps are transferred.

LCD Display Screen

Figure 6-5. Petrol/diesel engine
When the machine is started, the main screen is displayed,
giving a general overview of the machine status. For the
sake of simplicity and clarity a layout is provided with 8
icon display positions.
Example of the main screen:

Figure 6-6. Electric motor

An X on the icon indicates that the engine/motor is off, no

X indicates that it is on.

POSITION 4:
Position 4 displays the selected speed or the reduced
speed for the Lithium:

Figure 6-3.

Figure 6-7. Slow

3121623 6-5
 SECTION 6 - JLG CONTROL SYSTEM

the audible warning is activated, then the overload icon

appears in position 5 in place of the icon enabling the
overhead movements.

Figure 6-8. Normal

Figure 6-9. Fast

Figure 6-13. Overload error display

POSITION 6:
Figure 6-10. Reduced Position 6 displays the icon confirming that track move-
ments (stabilizers, tracks, track extension) are enabled.
POSITION 5:
Position 5 displays the icon confirming that overhead
movements are enabled.

Figure 6-14.

This icon means that all conditions for operating the track
Figure 6-11. movements have been checked. No icon on means the
stabilizers cannot be used and the track cannot be
extended. The machine, however, can travel even when
This icon means that all conditions for using the overhead
the icon is off, as long as all 4 stabilizers are lifted from the
movements have been checked and the aerial part can be
ground.
lifted. No icon on means that the aerial part cannot be
lifted.
In place of this icon, the basket overload icon may be POSITION 7:
shown. Position 7 is used for functional signals:
Emergency STOP pressed

Figure 6-12.
Figure 6-15.
When the load sensor measures a load exceeding the
allowed work load - 230 kg - the main screen disappears
for three seconds, replaced by the overload error display, Signals that one of the emergency stop buttons on the
machine has not been released.

6-6 3121623
 SECTION 6 - JLG CONTROL SYSTEM

Battery Voltage Below Minimum Limit. POSITION 8:

Position 8 displays the battery charge status or the icon
indicating the battery is being recharged in the Lithium
version.

Figure 6-16.
Figure 6-21.

Indicates that the battery charge level is below the mini-

mum limit allowed. If this message appears, it is advisable
to recharge the battery, either by keeping the diesel or
petrol engine on, or by connecting to the network. Figure 6-22.

Position 8 is used to show the selection of the emergency

descent operation from the basket with solenoid valves
on the cylinders.

Figure 6-17.

Figure 6-23.
Figure 6-18.

In addition to the main screen described above, there are

Signals an error in the battery management system of
other functional displays that will be described succes-
Lithium version.
sively.
In this position also other functional signals can be dis-
played that are useful for machine diagnostics.

Figure 6-19.
The machine has a CANBUS line connection fault.

Figure 6-20.
A faulty or incorrect electronic board (card) has been
installed, or alternatively an incorrect software version has
been loaded.

3121623 6-7
 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.

Figure 6-24. LCD Display Icon Description

6-8 3121623
 SECTION 6 - JLG CONTROL SYSTEM

Lithium Only Icons

Joystick Controls
Using the joysticks the operator selects the movement to be performed, the direction and the speed. The direction of the
joystick determines the direction of the movement. The degree of movement of the joystick determines the speed. The
more the joystick is moved away from the central neutral position, the faster the movements obtained.
The following table shows the movement controlled and its direction depending on the joystick shifting direction.

Table 6-1.

3121623 6-9
 SECTION 6 - JLG CONTROL SYSTEM

Tilt Conditions Drive Cut-out The consequence of a stability emergency is, with increas-
ing severity:
X17JP-X500AJ X20JP-X600AJ X26JP-X770AJ are provided
with a special system that automatically reduces tracks a. Track speed reduction.
speed or stops the movement in case of stability risks. b. Tracks movement stopped,
This control depends automatically on different factors: display icon -->
• Weight in the basket
• Jib opened or closed Also the buzzer on the remote control could be activated.
• Tracks widened or not
• Slope inclination gradient in axles X and Y
TO MOVE THE TRACKS WHEN THE MACHINE IS STOPPED BY THOSE
CONDITIONS IT’S NECESSARY TO PRESS BUTTON 8 ON REMOTE CON-
TROL, A COUNTER-DOWN OF 10 SECONDS WILL BE ACTIVATE ON THE
DISPLAY AND IN THE MEANTIME TRACKS MOVEMENT IS ALLOWED IN
TURTLE SPEED WITH BEEPER ON. DURING THAT BY-PASS THE OPERA-
TOR CAN BRING MACHINE BACK TO STABILITY CONDITION.

X AXIS

Y AXIS

Speed Control Possible Conditions On The X17JP - X500AJ

X or Y >5° TURTLE
Y>7° TURTLE + BUZZER

BUZZER + MOVE-
Y>13° MENT STOPPED+
ALARM ICON

X>6° TURTLE + BUZZER

Not possible to
JIB OPEN
select HARE UNDERCARRIAGE CLOSED BUZZER + MOVE-
X>10° MENT STOPPED+
ALARM ICON

X>10° TURTLE + BUZZER

UNDERCARRIGE WIDENED BUZZER + MOVE-

X>15° MENT STOPPED+
ALARM ICON

6-10 3121623
 SECTION 6 - JLG CONTROL SYSTEM

X or Y >8° TURTLE
Y>10° TURTLE + BUZZER
BUZZER + MOVE-
Weight inside basket
Y>16° MENT STOPPED +
<=40kg
ALARM ICON

BUZZER + MOVE-
Weight inside basket
Y>13° MENT STOPPED +
Weight inside bas- >40kg<=120Kg
ALARM ICON
ket <=120Kg
Possible to select X>6° TURTLE + BUZZER
HARE
UNDERCARRIAGE CLOSED BUZZER + MOVE-
X>10° MENT STOPPED +
ALARM ICON
X>10° TURTLE + BUZZER

UNDERCARRIAGE OPEN BUZZER + MOVE-

X>15° MENT STOPPED +
ALARM ICON
JIB CLOSED
X or Y >5° TURTLE
Y>7° TURTLE + BUZZER
BUZZER + MOVE-
Y>13° MENT STOPPED +
ALARM ICON
Weight inside bas- X>6° TURTLE + BUZZER
ket >120<=230Kg
Not possible to UNDERCARRIAGE CLOSED BUZZER + MOVE-
select HARE X>10° MENT STOPPED +
ALARM ICON
X>10° TURTLE + BUZZER

UNDERCARRIAGE OPEN BUZZER + MOVE-

X>15° MENT STOPPED +
ALARM ICON
MAX WEIGHT
Weight inside bas-
ALARM + MOVE-
ket >230Kg
MENT STOPPED

3121623 6-11
 SECTION 6 - JLG CONTROL SYSTEM

Speed Control Possible Conditions on the X20JP - X600AJ

X or Y >6° TURTLE
Y>13° TURTLE + BEEPER

BEEPER + MOVE-
Y>20° BASKET DOWNSTREAM OR
MENT STOPPED+
Y>16° BASKET UPSTREAM
ALARM ICON

X>8° TURTLE + BEEPER

Not possible to
JIB OPEN BEEPER + MOVE-
select HARE UNDERCARRIAGE CLOSED
X>10° MENT STOPPED+
ALARM ICON

X>10° TURTLE + BEEPER

UNDERCARRIAGE WID- BEEPER + MOVE-
ENED X>15° MENT STOPPED+
ALARM ICON

X or Y >6° TURTLE
Y>13° TURTLE +BEEPER
BEEPER + MOVE-
Y>20° BASKET DOWNSTREAM OR
MENT STOPPED +
Y>16° BASKET UPSTREAM
ALARM ICON

Weight inside bas- X>8° TURTLE + BEEPER

ket <=120Kg Possi- BEEPER + MOVE-
ble to select HARE UNDERCARRIAGE CLOSED X>10° MENT STOPPED +
ALARM ICON
X>10° TURTLE + BEEPER

UNDERCARRIAGE OPEN BEEPER + MOVE-

X>15° MENT STOPPED +
ALARM ICON
X or Y >6° TURTLE
JIB CLOSED Y>10° TURTLE + BEEPER
BEEPER + MOVE-
Y>15° MENT STOPPED +
ALARM ICON
Weight inside bas- X>8° TURTLE + BEEPER
ket >120<=230Kg
Not possible to UNDERCARRIAGE CLOSED BEEPER + MOVE-
select HARE X>10° MENT STOPPED +
ALARM ICON
X>10° TURTLE + BEEPER

UNDERCARRIAGE OPEN BEEPER + MOVE-

X>15° MENT STOPPED +
ALARM ICON
MAX WEIGHT
Weight inside bas-
ALARM + MOVE-
ket >230Kg
MENT STOPPED

6-12 3121623
 SECTION 6 - JLG CONTROL SYSTEM

Speed Control Possible Conditions on the X26JP - X770AJ

Y>6°
TURTLE
BASKET ON LOWER SIDE
Y>13° TURTLE + BEEPER
JIB OPEN Y>20°
(HARE NOT AVAILABLE) BASKET ON LOWER SIDE
BEEPER + STOP + ALARM
ICON
Y>16°
BASKET ON UPPER SIDE
Y>6° BASKET
TURTLE
ON LOWER SIDE
Y>13° TURTLE + BEEPER
JIB CLOSED WITH <=120Kg Y>20°
BASKET ON LOWER SIDE
BEEPER + STOP + ALARM
ICON
Y>16°
BASKET ON UPPER SIDE
Y>6° TURTLE
JIB CLOSED WITH <=230Kg Y>10° TURTLE + BEEPER
(HARE NOT AVAILABLE) BEEPER + STOP + ALARM
Y>15°
ICON

Speed Control Conditions On X Axle

ALWAYS X>6° TURTLE

X>10° TURTLE+BEEPER
TRACKS NOT OPENED BEEPER + STOP + ALARM
X>13°
ICON
X>15° TURTLE+BEEPER
TRACKS OPENED BEEPER + STOP + ALARM
X>18°
ICON

3121623 6-13
 SECTION 6 - JLG CONTROL SYSTEM

Push Buttons BUTTON 4:

The buttons have a dual function: they can be used to
select machine functions or as numerical keys in the ser-
vice submenus.
They in fact feature an icon that represents their meaning
and a number for use as a numerical keypad.
An emergency STOP button is also available which, when Figure 6-28. Used to enable control of the emergency descent from
pressed, stops the motor and brings the machine to a the basket. Confirmation that the operation is enabled is displayed on
standstill. the screen in position 8.
The pressed position of the emergency STOP button is
represented on the display in position 7. BUTTON 5:
To make the machine operational again, the button must
be turned and released.
For the description of the individual functions, see para-
graph 6 Using the machine.

BUTTON 1: Figure 6-29. Used to select the travel speed and the engine/motor
speed.

There are three speeds available:

• SLOW: engine at idle for the operation of the aerial
part, at medium for the operation of the drive. Lowest
drive speed.
Figure 6-25. Used to automatically raise the stabilizers.
• NORMAL: variable rpm according to the selected
BUTTON 2: movement. Travel motors always with maximum dis-
placement, therefore medium travel speed
• FAST: variable rpm according to the selected move-
ment. Travel motors in automatic displacement varia-
tion mode, therefore maximum travel speed.
The three speeds are selected by pressing button 5 in
sequence, with a cyclical routine. The selected speed is
displayed on the screen in position 4.
Figure 6-26. Enters the menu for the manual movements of the
individual stabilizers.
BUTTON 6:
BUTTONS 3-9:

Figure 6-30. Enters the auto service menu

BUTTON 7:
Figure 6-27. Used to extend and narrow the tracked undercarriage.

Figure 6-31. Used to automatically lower the stabilizers.

6-14 3121623
 SECTION 6 - JLG CONTROL SYSTEM

BUTTON 10: BUTTON 12:

Figure 6-32. Preheating Figure 6-34. Allows the electric motor to be switched on/off. If the
button is pressed with the engine on, this will be stopped.
PETROL ENGINE
Allows the preheating of the petrol engine. One pressure If the start buttons are pressed with an emergency STOP
on the button sets the engine at 2200 rpm for 20 seconds, button pressed, starting will be impossible.
in order to heat the engine and improve the initial phases This condition is indicated by the icon STOP in position 7.
of use. If the operator attempts to start one of the two motors
DIESEL ENGINE while the other is already running, starting will be impossi-
Enables the activation of the sparking plugs preheating. ble and the icon showing the motor already on will appear
One pressure on the button causes a preheating equal to at the centre of the screen.
10 seconds. In case of anticipated starting, the preheating NOTE: Buttons 5 and 6 when pressed simultaneously also
ends when starting. activate the horn (optional).

BUTTON 11:

Figure 6-35.
Figure 6-33. Allows the engine to be switched on/off. If the button is
pressed with the engine on, this will be stopped.

3121623 6-15
 SECTION 6 - JLG CONTROL SYSTEM

6.4 CANBUS COMMUNICATIONS Each individual circuit from the modules is approximately
120 ohms.
The electrical system works with a CAN BUS system,
The GROUND MODULE ECM1-2 is the master system con-
where: troller.
CAN = Control Area Network Most functions are dispatched and coordinated from this
BUS = Channels for peripherals module, all other system modules; Remote Control; LSS
CANbus: CAN (Control Area Network) is a two wire differ- ECM3; Cylinders position sensors; Rham Modem.
ential serial link between the, Ground Module ECM1-2; the Fundamental characterized information (values) are
Remote Control; the LSS ECM3, the Cylinders position sen- stored into the ground module ECM 1-2 (i.e., Personalities
sors and the Rham Modem Module providing bi-direc- or Calibrations), while on the LSS ECM3 the basket load
tional communications. setting.
Two-wire: One wire (White; Black or Black with numbers) is Lift, Tele, Swing & Drive:
driven high (5v) and the other low (Gray; Brown or Black The GROUND MODULE ECM1-2 stores default values, han-
with number) (0v) to send a signal; both wires ”float” (2.5v) dles interlocks and calibration information.
when no signal is being sent.
Lift, Telescope Swing and Drive commands are dependent
Differential: Any electrical line noise can affect the high or
upon interlocks through out the machine that enables the
the low wires but never both, so communications is not
power supply of the ON -OFF proportional coils after veri-
corrupted.
fication of the safety conditions by handles interlocks.
Serial Link: Messages are being sent bit by bit along the
The safety control functioning ECM1 can be by - passed by
wires; the high bus speeds allow all modules to be con-
the key selector switch (spring return) “safety device by-
stantly updated around 20 times per second. Typical traffic
pass key”.
is 300 - 500 messages per second.
The circuit board ECM1 record any by-pass event by date,
A complete CANbus circuit is approximately 60 ohms,
time and duration of the “safety device by-pass key”
action.

6-16 3121623
 SECTION 6 - JLG CONTROL SYSTEM

Figure 6-36. Common Components And Canbus Links

3121623 6-17
 SECTION 6 - JLG CONTROL SYSTEM

Can Bus Device Positions

X17JP-X500AJ - X20JP-X600AJ

Figure 6-37. Control Module Location - X17JP-X500AJ - X20JP-X600AJ

6-18 3121623
 SECTION 6 - JLG CONTROL SYSTEM

X26JP-X770AJ

Figure 6-38. Control Module Location - X26JP-X770AJ

3121623 6-19
 SECTION 6 - JLG CONTROL SYSTEM

CAN-BUS Diagnostics
DISPLAYED ICONS
If an icon of the followings appears on the display check as
indicated here below.

THIS IS NOT A CAN-BUS ERROR

Control error menu: check from the display into the ERROR MENU push-
ing 6 – MENU and then 3 – ERRORS, then skipping the pages it will be
showed the devices error status, where there’s a NO means that the sig-
nal from two lines of that device are not according each other, so check it
and check its connections

Electronic board or software wrong: check if the platform’s devices are

compatibles with installed software, if necessary contact JLG with the
serial number and the release number of the installed software

CAN BUS signal missing: check the connection as indicated at the step 4
of the present procedure

2° cylinder sensor missing: check the connector of the position sensor on

3° arm cylinder and the sensor itself check also the battery charge level,
in case of low battery level let the engine run for some minutes, then
check if this alarm disappear.

Battery low charge alarm: it could appear especially after the engine
start, check the charge level and eventually recharge.

6-20 3121623
 SECTION 6 - JLG CONTROL SYSTEM

CAN Timeout Menu’ Software Check

As soon as you have CAN BUS error shown on the display, Only ff the problems occurred after a software updating,
check the error list on page 4, pushing the buttons 6 – check if the platform’s devices are compatibles with the
MENU --> 3 – ERRORS and then pushing 2 times NEXT till new software, in this case, if necessary contact JLG with
page 4 CAN TIMEOUT, the display will show the following the serial number and the release number of the software
screen on (left side) with the followings meaning (right install.
side).
CAN BUS Devices And Connections
If you didn’t fix the problem it’s requires going on with
CAN BUS devices and connections check that requires the
following schematics:
CAN TIMEOUT
1. CAN BUS DEVICES CONNECTIONS (here below).
2. CAN BUS DEVICES LAY-OUT (here below).
SAFETY OK
3. CAN NETWORK sheet on the electric wiring dia-
REMOTE OK gram (“E3”).
CIL1-2 OK Proceed step by step as follows:
CIL3 OK 4. DEVICES CHECK: Always with ignition switch
LOAD OK turned OFF and the battery cutter disconnected,
ROTA OK disconnect one by one every CAN BUS devices,
the blue lines indicated in the CAN BUS devices
connections here below, starting with the
1 PREV modem and continue with load cell board
2 NEXT (ECM3) on the jib arm and so on. Anytime that
you have disconnected one device, connecting
9 ESC the battery cutter and turning ON ignition
switch, check if CAN BUS error disappears. To
know which are the CAN BUS contacts on the
devices, consult the relative page on the electric
Figure 6-39. wiring diagrams
5. CONNECTIONS CHECK: Always with ignition
Table 6-2. CAN-Message switch turned OFF and the battery cutter dis-
connected, connect 2 external wires to create an
SAFETY Master board (ECM1-2) Safeties lines
alternative CAN BUS line from green connectors
REMOTE Remote control (example picture here below) of ECMs and dis-
1st and 2nd booms cylinder position sensor (X26JP- connect the original wires. To know which are
CIL 1-2
X770AJ Only) the CAN BUS contacts on the devices, consult
CIL 3 Third boom cylinder position sensor the relative page on the electric wiring dia-
grams.
LOAD Load cell board (ECM3)
ROTAT. Reduced area board (ECM4)

This page with OK indicates the correct presence of the

signals in the CAN BUS line of the different connected
devices. The indication shall always be OK, if the indication
is NO it means that the device is not communicating by
CAN BUS line and therefore it is not considered in function
by the other devices.
If it results some NO within this error page, try to check the
connection, afterward if it doesn’t fix the problem check
and eventually replace the device, if otherwise there are
only YES it’s requires to go on with a software check.

3121623 6-21
 SECTION 6 - JLG CONTROL SYSTEM

L
H

Figure 6-40.

Anytime that you have replaced a connection, connecting PROCEEDING EXAMPLE: Always changing the connections
the battery disconnect and turning ON ignition switch, configuration with battery disconnect disconnected, con-
check if CAN BUS error disappears. This operation is neces- nect two external wires (red lines here below) between
sary to check not only the continuity of the wires but also ECM1-2 and ECM3, disconnecting the original wires on
the status, because it could happen that a wire is this tract, then check the status: if with this configuration
scratched so even maintaining the continuity it introduces the error doesn’t disappear means that the failure is on a
a disturb into the signal device, otherwise if the error disappears it means that the
failure was in the original connections (it could be possi-
NOTE: Exchanging the wires H and L the system doesn’t
work, so it’s important to replace each connection ble that it appears “SEN 3 FAIL” 2nd cylinder sensor miss-
as was originally. ing). Then, in case we detected the problem on the
connection, replacing the original connections and substi-
tuting only the connection between ECM1-2 and the JIB
CONNECTOR SCHEDULE with and external couple of wires
(green lines here below), check the status, if the error
appear it means that the failure was on this tract original
connection, otherwise if the error disappear check the
other possible tracts.

6-22 3121623
 SECTION 6 - JLG CONTROL SYSTEM

X17JP - X20JP - X500AJ - X600AJ - CAN BUS Device Layout

Figure 6-41.

After checking, if the device is defective, change the Resistence Check

device, if the problem is the connection it’s required to
repair or replace the wires. WITHOUT FEEDING THE SYSTEM, looking into the electric
diagram of your platform (as the example here below),
NOTE: Evaluate that if you have already changed more check the remote control/receiver and ECM1-2 CAN BUS
than one spares of the same device, in this case the resistances (in the red round) on page CAN NETWORK
problem could be caused for example by water (page “E”), i.e. test the resistance measured within the
going inside the box, so take a look to possible cable H and L that should be about 120 Ohm with the
traces of oxidation on the contacts, in this case iso- device disconnected from the other and 60 Ohm with the
late better the box. Be careful that the jib box cover device connected each other, (always with FEED OFF)
has a direction to be assembled, if assembled in the
wrong direction water goes inside.

3121623 6-23
 SECTION 6 - JLG CONTROL SYSTEM

X26JP - X770AJ - CAN BUS Device Layout

Figure 6-42.

6-24 3121623
 SECTION 6 - JLG CONTROL SYSTEM

Figure 6-43.

3121623 6-25
 SECTION 6 - JLG CONTROL SYSTEM

Figure 6-44.

6-26 3121623
 SECTION 6 - JLG CONTROL SYSTEM

Electronic Module LED Flashing Codes

ECM (Master Board Modules) Led Code :
Master board (ECM1-2) is composed by two modules, the front module called ECM2 and the back module called ECM1.
 

MASTER BOARD BACK MASTER BOARD FRONT

MODULE (ECM1) MODULE (ECM2)

Figure 6-45.
ECM2 LED CODE
DL1 - green LED steady ON: Power +5V to MASTER BOARD FRONT MODULE CPU
DL2 - yellow LED steady ON: All the outriggers are lifted from the ground or machine is closed and aligned (photocells sig-
nal)
DL3 - yellow LED steady ON: All the outriggers are touching the ground or all the outriggers are lifted from the ground

DL1 
DL2 
DL3 

Figure 6-46.

3121623 6-27
 SECTION 6 - JLG CONTROL SYSTEM

ECM1 LED CODE

DL1 green steady LED ON: power +5V to safety channel "A" CPU
DL2 yellow steady LED ON: tracks safety relay for channel "A" CPU closed
DL3 yellow steady LED ON: aerial part safety relay channel "A" CPU closed
DL4 green steady LED ON: power +5V to safety channel "B" CPU
DL5 yellow steady LED ON: tracks safety relay channel "B" CPU closed
DL6 yellow steady LED ON: aerial part safety relay channel "B" CPU closed

DL4 
DL5 
DL6 

DL1 
DL2 
DL3 

Figure 6-47.

ECM3 and ECM4 LED CODE

LOAD CELL BOARD (ECM3) and REDUCED AREA BOARD (ECM4) are similar but not equal, they must not be confused.
DL1/DL3 and DL2/DL4 blinking green/red: board not calibrated
DL1-DL2 green LED steady ON: board calibration values are memorized, even it does not means that it is properly cali-
brated

 
DL1 
DL3 
DL2  DL4 

Figure 6-48.

6-28 3121623
 SECTION 6 - JLG CONTROL SYSTEM

MODEM LED CODE

DL1 green LED steady ON: power ON
DL2 blue LED flashing each 1 second: Network signal searching
DL2 blue LED flashing each 3 seconds: Line ready

DL1  DL2 

Figure 6-49.

3121623 6-29
 SECTION 6 - JLG CONTROL SYSTEM

6.5 SENSORS AND DEVICES NOT COMMUNICATING THROUGH CAN-BUS

6-30 3121623
 SECTION 6 - JLG CONTROL SYSTEM

The following devices not communicating through CAN BUS system are or directly connected to the ECM1-2 or indirectly
through ECM3 or ECM4 that communicate through CAN BUS their conditions.

Inclinometers: they are two accelerometers sensors (one each axles) welded on the  
ECM1-2. They detect the machine inclination on both axles, each one works with a double
line. EMC1-2 accelerometers have to be calibrated once it’s installed on the machine.

Load sensor: it’s an extensimeter sensor that sends a double electric signal to the ECM3.
These signals are compared and transduced by ECM3 that communicates the load mea-
sured through CAN BUS to the ECM1-2. EMC3 has to be calibrated with load cell sensor.

Turret rotation position sensor: it’s an encoder sensor that sends a double electric signal
to the ECM4. These signals are compared and transduced by ECM4 that communicates
the rotation angle measured through CAN BUS to the ECM1-2. EMC4 has to be calibrated
with turret rotation position sensor.

Photocells: they are installed on machine rear side interacting with the reflector installed
on the bottom of jib, when they receive back the reflector signal it means that machine is
closed and aligned. They are normally opened (NO) and are closed when the machine is
closed and aligned. They are directly connected to the ECM1-2 working in parallel as a
double line sensor.

Outriggers ground microswitches: they are four switches (one each outrigger) that
detect if the outrigger is touching the ground or not. They are normally closed (NC) and
are released when the outrigger is touching the ground. Each one is directly connected to
the ECM1-2 with a double line.

Outrigger reduced area microswitch (the upper one): they are four switches (one each
outrigger) that detect if the outrigger is opened (at least half-way) or closed. They are nor-
mally closed (NC) and are released when the outrigger is opened. Each one is connected
to the ECM4 with a double multiplex line (different frequencies).

3121623 6-31
 SECTION 6 - JLG CONTROL SYSTEM

Outrigger completely opened microswitch (the lower one): they are four switches (one
each outrigger) that detect if the relevant outrigger is completely opened or not. They are
normally closed (NC) and are released when the outrigger is completely opened. Each one
is directly connected to the ECM1-2 with a double line.

Pressure sensors: they are two pressure sensors installed on each hydraulic line that give
the signal to the ECM1-2 when an high pressure value is reached. They are normally
opened (NO), released when the pressure is lower than that value. They are directly con-
nected to the ECM1-2 as two single lines.

Pedal: it’s an OPTIONAL that could be activated by the service menu, if activated operator
must press it to move the machine from the basket, preventing unintentional movements.
It is normally opened (NO) and when is pressed it sends the signal to the ECM3 by a single
line.

Emergency stop button on the remote control: it’s a switch inside the remote control
that through ECM3 and ECM4 is connected to the ECM1-2 with a double line. It is normally
closed (NC) and it is released when the red button is released. When the remote control is
connected to the ground optional cable, its emergency stop button is directly connected
to the ECM1-2 with a single line.

Emergency stop button on the ground: it’s a red button switch installed on the ground
controls box directly connected to the ECM1-2 with a double line. It is normally closed
(NC) and it is released when the red button is released.

Jib microswitch: it’s used for the AUTOMATIC SPEED CONTROL function and it is installed
on the upper part of jib detecting if the jib is completely closed or not. It is normally
closed (NC) and is released when the jib is closed. It is connected to the ECM3 with a dou-
ble line.

Tracks widening sensor switches: they are two sensors used for the AUTOMATIC SPEED
CONTROL function. They are installed on the two tracks widening cylinders and detect the
position of tracks completely widened or not. They and normally opened (NO) and they
are connected in series directly to the ECM1-2.

6-32 3121623
 SECTION 6 - JLG CONTROL SYSTEM

Ropes sensor switch: It’s a microswitch installed inside the third boom bottom side that
detect the ropes integrity. It is normally closed (NC), it would be pressed in case of the
ropes will move. It is directly connected to the ECM1-2 with a single lines.

NOTE: Some other devices not listed here above, such as the ones for the emergency proce-
dures, are indicated by the wiring diagrams.

Electrical System Sections In case of an overcharge (more than 230 Kg for CE system,
more than 500 Lbs in ANSI system) or in case of anomalies
The cables that starting at the base going through the such as a discordance between the two lines machine will
booms are sectionized with connectors on the 1st and avoid the aerial part movements showing an error mes-
2nd booms cylinder inside the sock. sage.
ECM3 must be calibrated with the load cell sensor, in case
of one of these components need to be replaced the cali-
bration must be carried out as indicated by the APPENDIX
4.

Rotation Sensor System

The rotation sensor system, has two components, the
reduced area board (ECM4) and the turret rotation sensor.
The turret rotation sensor is installed in the centre of the
turret slew ring and it is an encoder sensor that sends a
double signal to the ECM4.
ECM4, located into the electric components compart-
Inclination Sensor System ment, elaborates that double signal translating it into a
The inclinometers system is composed by two sensors rotation angle and communicating it to the master board
(one each axles) welded on the master board (ECM1-2) (ECM1-2) through CAN-BUS line.
that gives a double signal each one translated into and "X" ECM4 also compares the double signal verifying their
inclination and "Y" inclination by the master board (ECM1- coherency (same values within a certain tolerance).
2). In case of turret rotation angle is not compatible with a
Each double signal and compared verifying their coher- machine safe condition concerning variable area system
ency (same values within a certain tolerance). and anti-collision system or in case of anomalies such as a
In same case, depending on the machine condition, if an discordance between the two lines, machine will act
inclination is exceeding the limit or in case of anomalies accordingly in case avoiding the aerial part movements
such as a discordance between the two lines machine will and showing an error message.
avoid the movements showing an error message. ECM4 must be calibrated with the rotation sensor, in case
EMC1-2 accelerometers must be calibrated once ECM1-2 is of one of these components need to be replaced the cali-
installed on the machine, the calibration must be carried bration must be carried out as indicated by the APPENDIX
out as indicated by the APPENDIX 2. 5.

Load Cell System

The load cell system has two components, load cell board
(ECM3) and the load cell sensor.
The load cell sensor is located under the basket and it is
has two extensimeters so that send a double signal to the
ECM3.
ECM3 is located into the jib arm box and it elaborates that
double signal communicating it translation in "Kg" or
"Lbs" to the master board (ECM1-2) through CAN-BUS line.
ECM3 also compares the double signal verifying their
coherency (same values within a certain tolerance).

3121623 6-33
 SECTION 6 - JLG CONTROL SYSTEM

Electric Motor (Not For Lithium Version) • start the motor by pressing the electric motor start
button (on the remote control or at the ground con-
Electric motor works only when the machine is connected trol box) so that its contactor is closed
to the electric network (110÷230 V). To start the electric
motor it is necessary to: Electric motor runs always at minimum speed 1500 rpm, it
is equipped with two capacitors in order to limit the
• connect the 110÷230V plug of the machine to the absorption during the motor starting.
electric network
• activate the circuit breaker

12 Volt Battery Battery Charge System

The machine electric system works at 12 Volt, the accumu- The battery charge is carried out by the electronic trans-
lation system is composed by an AGM start&stop battery former located under the base bonnet aside the electric
with a capacity of 70 Ah. motor.

12 Volt battery is feed by the engine generator while The output tension from the electronic transformer is
engine is running or by the battery charger described by fixed at 14 Volt DC and it does not depend on the electric
the following chapter while machine is plugged to the network tension or frequency.
electric network.
The output current is automatically regulated at a maxi-
mum of 19 Amp.

6-34 3121623
 SECTION 6 - JLG CONTROL SYSTEM

6.6 CALIBRATION REQUIREMENT Table 6-3. Calibration modules

This machine incorporates a variety of sensors and a high CALIBRATION PROCEDURE REASONS FOR RE-CALIBRATION
degree of function interaction. For safety and proper
machine functionality, the calibration procedures must be LOAD Cell LSS Module ECM3 replacement
repeated for any control module replacement, system cali- Calibration LSS Sensor removal or replacement
bration related fault, or removal or replacement of any Joystick Calibration Joystick replacement
sensors, valves, coils.
The chart below lists the calibrations required and poten- Chassis Tilt Calibration Master Board ECM1- ECM2 removal or
tial reasons for recalibrating. replacement
Tilt indication inaccuracy
All calibration procedures are menu driven through the
REMOTE CONTROL. Rotator Sensors Calibration X770AJ - X26JP Only
The user is prompted to exercise the machine in a specific Board ECM4 rotator sensor replacement
order to use the machines physical properties to consis- Rotator sensor removal or replacement
tently establish sensor response and the interaction of
valves, pumps, and motors.

NOTICE
A REPLACEMENT OF A NEW ECM 1-2 & 3 REQUIRE TO FLASH THE
PROPER MACHINE MODEL SOFTWARE AND TO ADJUST THE MACHINE
SETTINGS. A REPLACEMENT OF A NEW ECM 1-2 DO NOT REQUIRE THE
CALIBRATION OF THE ECM3 AND THE JOYSTICKS.

3121623 6-35
 SECTION 6 - JLG CONTROL SYSTEM

6.7 PLATFORM REMOTE CONTROL SERVICE The top level menus are as follows:

Service Button
A SERVICE button is present on the remote control which
allows to view the status of the machine parameters and is
an aid in the safety checks of the machine.
With machine power on, by pressing the SERVICE button a
numerical menu is displayed on the LCD display, each of
these menu items can be accessed by pressing the corre-
sponding platform/remote control buttons.
To navigate through the menu use the Buttons Numbered
1 Thru 9.

Figure 6-50. Menu Services

NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available or with dif-
ferent description depending upon machine configuration or language set-up.

6-36 3121623
 SECTION 6 - JLG CONTROL SYSTEM

Using The Service Program

MENU Selector SAVE

Button 1 Next Button 3

Button 2 Previous
Used to stored selected
Used to move between Top Level, values
Sub Level, and item menus

Display

VALUE Selector ESCAPE

Button 7 increase Button 9

Button 8 decrease
Used to return or access
Used to adjust values Previous menu

Figure 6-51. Service Mode Button Use

• To select a displayed menu item, press button 6 - SERVICE.

• To cancel a selected menu item, press button 9 - ESC, to escape.
• From the SERVICE menu use the buttons 1-2-3-7-8 to navigate through the menu, as noted in illustration above.
• From the SERVICE menu, use button selection “7 Setup”, the button “5 Password” then enter a proper password (by
using buttons 1 to 9) to advance to a lower level.
• Once OK is displayed, press button “9 ESC”, MENU should display and then press the button for proper MENU, which
will permit to change machine settings.

3121623 6-37
 SECTION 6 - JLG CONTROL SYSTEM

Figure 6-52. Password Use

NOTE: If NO is displayed, after digit the password, press button “9 Esc” to return to Menu, and repeat the procedure.
NOTE: Password will remain active if Key Switch is left ON, even if "9 - Esc" is pressed from the service menu.

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 SECTION 6 - JLG CONTROL SYSTEM

Input Menu
From the SERVICE menu, pressing button 1”INPUT” to accesses menu INPUT.

The menu INPUT allows you to visualize the status (or changes of status) of all the devices connected to the main control
module. Machine diagnostic devices status or values are shown on the display
Use the buttons 1 ”PREV.” and 2 ”NEXT” to choose the device.
Press button 9 ”ESC” to Esc from menu.

3121623 6-39
 SECTION 6 - JLG CONTROL SYSTEM

ANSI-SPEC - X500AJ - X600AJ

CE-SPEC - X17JP - X20JP

Press button
Service

Menu

Press button
1 - INP > OUT

ST1GND A FREE A7 TEMP.ALRM A PEDAL/SKGA INCLIN. Y

ST1 GND B FREE B7 TEMP.ALRM B SKYGUARD B LOAD A

FREE A1 BYPASAE A POS I ARM EM.BASK. A LOAD B

FREE B1 BYPASAE B TRACK OPEN EM.BASK. B FREE

ST2 GND A BYPASCB A FREE C0 FREE A POS. 3

ST2 GND B BYPASCB B EMRG. COMM. FREE B MOTOR RPM

FREE A3 EM.GRND A MICROROPES FREE A CURRENT A

FREE B3 EM.GRND B START M.TE FREE B CURRENT B

ST3 GND A FOTO A MOTOR TEMP FREE A CURRENT C

ST3 GND B FOTO B MOTOR PRES FREE B TEMPERAT.

FREE A5 PROXIMITY START M.EL FREE A SUPPLY (V)

FREE B5 EM. R. C. GND GND/BASKET FREE B BATTERY %

(Lithium only)

ST4 GND A ST12 CLOSED MICRJIB A R.C.BASKET

ST4 GND B ST 3-4 CLOSED MICRJIB B INCLIN. X

Figure 6-53. Input Menu Flow Chart

6-40 3121623
 SECTION 6 - JLG CONTROL SYSTEM

ANSI-SPEC - X770AJ
CE-SPEC - X26JP

Press button
Service

Menu

Press button
1 - INP -> OUT

ST1GND A ST4OPEN A TEMP.ALRM A PEDAL/SKGA INCLIN. Y

ST1 GND B ST4OPEN B TEMP.ALRM B SKYGUARD B LOAD A

ST1OPEN A BYPASS AE A FREE A17 EM.BASK. A LOAD B

ST1OPEN B BYPASS AE B TRACK OPEN EM.BASK. B POS. 1 E 2

ST2 GND A BYPASS CB A FREE C0 POSM1 A1 POS. 3

ST2 GND B BYPASS CB B EMRG. COMM. POSM1 B1 ROTATION A

ST2OPEN A EM.GRND A MICRO ROPES POSM2 A2 ROTATION B

ST2OPEN B EM.GRND B START M.TE POSM2 B2 MOTOR RPM

ST3 GND A FOTO A MOTOR TEMP POSM3 A3 CURRENT A

ST3 GND B FOTO B MOTOR PRES POSM3 B3 CURRENT B

ST3OPEN A FREE A14 START M.EL POSM4 A4 CURRENT C

ST3OPEN B EM. R. C. GND GND/BASKET A POSM4 B4 TEMPERAT.

ST4 GND A ST12 CLOSED MICRJIB A R.C.BASKET SUPPLY (V)

ST4 GND B ST 3-4 CLOSED MICRJIB B INCLIN. X BATTERY %

(Lithium only)

Figure 6-54. Input Menu Flow Chart

3121623 6-41
 SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. Input Menu Item - Explanation

X17JP - X20JP - X500AJ - X600AJ
ON Outrigger n.1 on the ground – the switch is released and A line is closed
ST1 GND A
OFF Outrigger n.1 lifted – the switch is pressed and A line is opened

ON Outrigger n.1 on the ground – the switch is released and B line is closed
ST1 GND B
OFF Outrigger n.1 lifted – the switch is pressed and B line is opened

ON DO NOT CONSIDER
FREE A1
OFF DO NOT CONSIDER

ON DO NOT CONSIDER
FREE B1
OFF DO NOT CONSIDER

ON Outrigger n.2 on the ground – the switch is released and A line is closed
ST2 GND A
OFF Outrigger n.2 lifted – the switch is pressed and A line is opened

ON Outrigger n.2 on the ground – the switch is released and B line is closed
ST2 GND B
OFF Outrigger n.2 lifted – the switch is pressed and B line is opened

ON DO NOT CONSIDER
FREE A3
OFF DO NOT CONSIDER

ON DO NOT CONSIDER
FREE B3
OFF DO NOT CONSIDER

ON Outrigger n.3 on the ground – the switch is released and A line is closed
ST3 GND A
OFF Outrigger n.3 lifted – the switch is pressed and A line is opened

ON Outrigger n.3 on the ground – the switch is released and B line is closed
ST3 GND B
OFF Outrigger n.3 lifted – the switch is pressed and B line is opened

ON DO NOT CONSIDER
FREE A5
OFF DO NOT CONSIDER

ON DO NOT CONSIDER
FREE B5
OFF DO NOT CONSIDER

ON Outrigger n.4 on the ground – the switch is released and A line is closed
ST4 GND A
OFF Outrigger n.4 lifted – the switch is pressed and A line is opened

ON Outrigger n.4 on the ground – the switch is released and B line is closed
ST4 GND B
OFF Outrigger n.4 lifted – the switch is pressed and B line is opened

ON DO NOT CONSIDER
FREE A7
OFF DO NOT CONSIDER

ON DO NOT CONSIDER
FREE B7
OFF DO NOT CONSIDER

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 SECTION 6 - JLG CONTROL SYSTEM

X17JP - X20JP - X500AJ - X600AJ

ON The aerial part safeties are deactivated through the safeties bypass key switch (emergency condition) – line “A”
of the aerial part safeties by-pass is closed
BYPASAE A
OFF The aerial part safeties are activated (normal working condition) – line “A” of the aerial part safeties by-pass is
opened

ON The aerial part safeties are deactivated through the safeties bypass key switch (emergency condition) – line
“B” of the aerial part safeties by-pass is closed
BYPASAE B
OFF The aerial part safeties are activated (normal working condition) – line “B” of the aerial part safeties by-pass is
opened

ON The ground part safeties are deactivated through the safeties bypass key switch (emergency condition) – line
“A” of the ground part safeties by-pass is closed
BYPASCB A
OFF The ground part safeties are activated (normal working condition) – line “A” of the ground part safeties by-
pass is opened

ON The ground part safeties are deactivated through the safeties bypass key switch (emergency condition) – line
“B” of the ground part safeties by-pass is closed
BYPASCB B
OFF The ground part safeties are activated (normal working condition) – line “B” of the ground part safeties by-
pass is opened

ON Stop button on the ground is released –“A” line of the stop button is closed
EM GRND A
OFF Stop button on the ground is pressed – “A” line of the stop button is opened

ON Stop button on the ground is released –“B” line of the stop button is closed
EM GRND B
OFF Stop button on the ground is pressed – “B” line of the stop button is opened

ON Photocell A receives the signal from the reflector (Aerial part closed and aligned)
FOTO A
OFF Photocell A does not receive the signal from the reflector (Aerial part opened)

ON Photocell B receives the signal from the reflector (Aerial part closed and aligned)
FOTO B
OFF Photocell B does not receive the signal from the reflector (Aerial part opened)

ON Turret is not almost completely rotated, contact is close, the 1st-2nd arm is not above
the engine
PROXIMITY
OFF Turret is almost completely rotated, contact is open, the 1st-2nd arm is above
the engine

ON The stop button on ground remote control is released

EM.R.C.GND OFF The stop button on ground remote control is pressed or the ground remote control is
disconnected

ON The pressure switch of outriggers 1 and 2 closes the contact – the outriggers are at end run and the max pres-
sure valve is opened
ST12 CLOSED
OFF The pressure switch contact of outriggers 1 and 2 is opened – the outriggers are open, partially open or already
closed

ON The pressure switch of outriggers 3 and 4 closes the contact – the outriggers are at end run and the max pres-
sure valve is opened
ST34 CLOSED
OFF The pressure switch contact of outriggers 3 and 4 is opened – the outriggers are open, partially open or already
closed

3121623 6-43
 SECTION 6 - JLG CONTROL SYSTEM

X17JP - X20JP - X500AJ - X600AJ

TEMP ALRM A ON The temperature external probe reached the maximum value – “A” line of the temperature probe is closed
Option reserved OFF The temperature external probe hasn’t reached the maximum value – “A” line of the temperature probe is open
for some markets

TEMP ALRM B ON The temperature external probe reached the maximum value – “B” line of the temperature probe is closed
Option reserved OFF The temperature external probe hasn’t reached the maximum value – “B” line of the temperature probe is
for some markets open

ON The switch of 1-2 arm position is released, contact is close, the 1st-2nd arm is open
POS.I ARM
OFF The switch of 1-2 arm position is pressed, contact is open, the 1st-2nd arm is closed

ON Tracks are in wide position. Widening cylinders switches are pressed, contact is
closed
TRACK OPEN
OFF Tracks are not in full wide position. Widening cylinders switches are released,
contact is open

FREE C0 DO NOT CONSIDER

ON The control position key selector for aerial part operation from the ground is activated
(emergency condition)
EMRG. COMM
OFF The control position key selector for aerial part operation is released
(normal working condition)

MICROROPES ON The cables of the extension are OK. The control switch of the cables on extension is released and the line is
To consider only closed (normal working condition)
for X20JP - OFF At list one cable on the extension is out of order. The control switch of the cables on extension is pressed and
X600AJ the line is open (emergency condition)

ON The ground button for engine start is pressed

START M.TE
OFF The ground button for engine start is released

MOTOR TEMP. To ON The engine reached the max functioning temperature (emergency condition – the engine
consider only for remains at min)
X20JP - X600AJ OFF The engine maintains the correct functioning temperature (normal working condition)

MOTOR PRES. To ON The engine oil pressure is inadequate (emergency condition – engine turns off)
consider only for OFF
X20JP - X600AJ The engine oil pressure is OK

ON The ground button for electric motor start is pressed

START M.EL
OFF The ground button for electric motor start is released

ON The control position key selector is positioned on “basket”

GND/BASKET
OFF The control position key selector is positioned on “ground”

ON The JIB is closed – the control switch is released and “A” line is closed
MICROJIB A
OFF The JIB is open – the control switch is pressed and “A” line is open

ON The JIB is closed – the control switch is released and “B” line is closed
MICROJIB B
OFF The JIB is open – the control switch is pressed and “B” line is open

6-44 3121623
 SECTION 6 - JLG CONTROL SYSTEM

X17JP - X20JP - X500AJ - X600AJ

ON The pedal is pressed and if Skyguard is installed its bar is pressed– the pedal electric line is closed and the Sky-
guard electric line A is closed
PEDAL / SKY A
OFF The pedal is released or if Skyguard is installed its bar is released – the pedal electric line is open or the Sky-
guard electric line A is open

ON If Skyguard is installed its bar is pressed– the Skyguard electric line B is closed
SKYGUARD B
OFF If Skyguard is installed its bar is released – the Skyguard electric line A is open

ON The stop button on remote control in basket is released – “A” line is closed
EM.BASK.A OFF The stop button on remote control in basket is pressed or the ground remote control is disconnected – “A” line
is open

ON The stop button on remote control in basket is released – “B” line is closed
EM.BASK. B OFF The stop button on remote control in basket is pressed or the ground remote control is disconnected – “B” line
is open

ON DO NOT CONSIDER
FREE A
OFF DO NOT CONSIDER

ON DO NOT CONSIDER
FREE B
OFF DO NOT CONSIDER

ON DO NOT CONSIDER
FREE A
OFF DO NOT CONSIDER

ON DO NOT CONSIDER
FREE B
OFF DO NOT CONSIDER

ON DO NOT CONSIDER
FREE A
OFF DO NOT CONSIDER

ON DO NOT CONSIDER
FREE B
OFF DO NOT CONSIDER

ON DO NOT CONSIDER
FREE A
OFF DO NOT CONSIDER

ON DO NOT CONSIDER
FREE B
OFF DO NOT CONSIDER

ON The remote control is in the support in basket

R.C. BASKET
OFF The remote control is not in the support in basket

0 Indicates the inclination of the machine on the X axis in tenth of degrees (accelerometer A)
INCLIN. X
0 Indicates the inclination of the machine on the X axis in tenth of degrees (accelerometer B)

0 Indicates the inclination of the machine on the Y axis in tenth of degrees (accelerometer A)
INCLIN. Y
0 Indicates the inclination of the machine on the Y axis in tenth of degrees (accelerometer B)

LOAD A 94 Indicates the weight in Kg in the basket on line A

LOAD B 95 Indicates the weight in Kg in the basket on line B

3121623 6-45
 SECTION 6 - JLG CONTROL SYSTEM

X17JP - X20JP - X500AJ - X600AJ

FREE 0 DO NOT CONSIDER

POS. 3 2398 Indicates the opening of the 3 arm cylinder in tenths of a millimeter

MOTOR RPM 2200 Only diesel version: Indicates the engine RPM read by rpm sensor

CURRENT A 0 DO NOT CONSIDER

CURRENT B 0 DO NOT CONSIDER

CURRENT C 0 DO NOT CONSIDER

TEMPERAT. 37.6 Indicates the temperature of the ECM1-2 in °C

SUPPLY (V) 12.1 Indicates the batteries voltage, or the output voltage from the battery charger

BATTERY % 100 Only for Lithium version: indicates the % level of charge of the pack

6-46 3121623
 SECTION 6 - JLG CONTROL SYSTEM

Table 6-5. Input Menu Item - Explanation

X26JP - X770AJ (Prior to S/N C170001340)
ST1 GND A ON Outrigger n.1 on the ground – the switch is released and A line is closed
OFF Outrigger n.1 lifted – the switch is pressed and A line is opened

ST1 GND B ON Outrigger n.1 on the ground – the switch is released and B line is closed
OFF Outrigger n.1 lifted – the switch is pressed and B line is opened

ST1 OPEN A ON Outrigger n.1 is completely opened – the switch is released and A line is closed
OFF Outrigger n.1 is closed or only half-way opened– the switch is pressed and A line is opened

ST1 OPEN B ON Outrigger n.1 is completely opened – the switch is released and B line is closed
OFF Outrigger n.1 is closed or only half-way opened– the switch is pressed and B line is opened

ST2 GND A ON Outrigger n.2 on the ground – the switch is released and A line is closed
OFF Outrigger n.2 lifted – the switch is pressed and A line is opened

ST2 GND B ON Outrigger n.2 on the ground – the switch is released and B line is closed
OFF Outrigger n.2 lifted – the switch is pressed and B line is opened

ST2 OPEN A ON Outrigger n.2 is completely opened – the switch is released and A line is closed
OFF Outrigger n.2 is closed or only half-way opened– the switch is pressed and A line is opened

ST2 OPEN B ON Outrigger n.2 is completely opened – the switch is released and B line is closed
OFF Outrigger n.2 is closed or only half-way opened– the switch is pressed and B line is opened

ST3 GND A ON Outrigger n.3 on the ground – the switch is released and A line is closed
OFF Outrigger n.3 lifted – the switch is pressed and A line is opened

ST3 GND B ON Outrigger n.3 on the ground – the switch is released and B line is closed
OFF Outrigger n.3 lifted – the switch is pressed and B line is opened

ST3 OPEN A ON Outrigger n.3 is completely opened – the switch is released and A line is closed
OFF Outrigger n.3 is closed or only half-way opened– the switch is pressed and A line is opened

ST3 OPEN B ON Outrigger n.3 is opened (at least half-way) – the switch is released and B line is closed
OFF Outrigger n.3 is closed or only half-way opened– the switch is pressed and B line is opened

ST4 GND A ON Outrigger n.4 on the ground – the switch is released and A line is closed
OFF Outrigger n.4 lifted – the switch is pressed and A line is opened

ST4 GND B ON Outrigger n.4 on the ground – the switch is released and B line is closed
OFF Outrigger n.4 lifted – the switch is pressed and B line is opened

ST4 OPEN A ON Outrigger n.4 is opened (at least half-way) – the switch is released and A line is closed
OFF Outrigger n.4 is closed or only half-way opened– the switch is pressed and A line is opened

ST4 OPEN B ON Outrigger n.4 is opened (at least half-way) – the switch is released and B line is closed
OFF Outrigger n.4 is closed or only half-way opened– the switch is pressed and B line is opened

3121623 6-47
 SECTION 6 - JLG CONTROL SYSTEM

X26JP - X770AJ (Prior to S/N C170001340)

ON The aerial part safeties are deactivated through the safeties bypass key switch (emergency condition) – line “A” of
BYPASAE A
the aerial part safeties by-pass is closed
OFF The aerial part safeties are activated (normal working condition) – line “A” of the aerial part safeties by-pass is
opened

ON The aerial part safeties are deactivated through the safeties bypass key switch (emergency condition) – line “B” of
BYPASAE B
the aerial part safeties by-pass is closed
OFF The aerial part safeties are activated (normal working condition) – line “B” of the aerial part safeties by-pass is
opened

ON The ground part safeties are deactivated through the safeties bypass key switch (emergency condition) – line “A”
BYPASCB A
of the ground part safeties by-pass is closed
OFF The ground part safeties are activated (normal working condition) – line “A” of the ground part safeties by-pass is
opened

ON The ground part safeties are deactivated through the safeties bypass key switch (emergency condition) – line “B”
BYPASCB B
of the ground part safeties by-pass is closed
OFF The ground part safeties are activated (normal working condition) – line “B” of the ground part safeties by-pass is
opened

EM GRND A ON Stop button on the ground is released –“A” line of the stop button is closed
OFF Stop button on the ground is pressed – “A” line of the stop button is opened

EM GRND B ON Stop button on the ground is released –“B” line of the stop button is closed
OFF Stop button on the ground is pressed – “B” line of the stop button is opened

FOTO A ON Photocell A receives the signal from the reflector (Aerial part closed and aligned)
OFF Photocell A does not receive the signal from the reflector (Aerial part opened)

FOTO B ON Photocell B receives the signal from the reflector (Aerial part closed and aligned)
OFF Photocell B does not receive the signal from the reflector (Aerial part opened)

FREE 14 DO NOT CONSIDER

EM.R.C.GND ON The stop button on ground remote control is released

OFF The stop button on ground remote control is pressed or the ground remote control is
disconnected

ON The pressure switch of outriggers 1 and 2 closes the contact – the outriggers are at end run and the max pressure
ST12 CLOSED
valve is opened
OFF The pressure switch contact of outriggers 1 and 2 is opened – the outriggers are open, partially open or already
closed

ON The pressure switch of outriggers 3 and 4 closes the contact – the outriggers are at end run and the max pressure
ST34 CLOSED
valve is opened
OFF The pressure switch contact of outriggers 3 and 4 is opened – the outriggers are open, partially open or already
closed

TEMP ALRM A
Option reserved ON The temperature external probe reached the maximum value – “A” line of the temperature probe is closed
for some markets
OFF The temperature external probe hasn’t reached the maximum value – “A” line of the temperature probe is open

6-48 3121623
 SECTION 6 - JLG CONTROL SYSTEM

X26JP - X770AJ (Prior to S/N C170001340)

TEMP ALRM B
Option reserved ON The temperature external probe reached the maximum value – “B” line of the temperature probe is closed
for some markets
OFF The temperature external probe hasn’t reached the maximum value – “B” line of the temperature probe is open

FREE A17 DO NOT CONSIDER

TRACK OPEN ON Tracks are in wide position. Widening cylinders switches are pressed, contact is closed
OFF Tracks are not in full wide position. Widening cylinders switches are released, contact is open

FREE C0 DO NOT CONSIDER

EMRG. COMM ON The control position key selector for aerial part operation from the ground is activated (emergency condition)
OFF The control position key selector for aerial part operation is released (normal working condition)

ON The cables of the extension are OK. The control switch of the cables on extension is released and the line is closed
MICROROPES
(normal working condition)
OFF At list one cable on the extension is out of order. The control switch of the cables on extension is pressed and the
line is open (emergency condition)

START M.TE ON The ground button for engine start is pressed

OFF The ground button for engine start is released

MOTOR TEMP.
To consider only
ON The engine reached the max functioning temperature (emergency condition – the engine remains at min)
for Diesel
Machine
OFF The engine maintains the correct functioning temperature (normal working condition)

MOTOR PRES.
To consider only
ON The engine oil pressure is inadequate (emergency condition – engine turns off)
for Diesel
Machine
OFF The engine oil pressure is OK

START M.EL ON The ground button for electric motor start is pressed
OFF The ground button for electric motor start is released

GND/BASKET ON The control position key selector is positioned on “basket”

OFF The control position key selector is positioned on “ground”

MICROJIB A ON The JIB is closed – the control switch is released and “A” line is closed
OFF The JIB is open – the control switch is pressed and “A” line is open

MICROJIB B ON The JIB is closed – the control switch is released and “B” line is closed
OFF The JIB is open – the control switch is pressed and “B” line is open

ON The pedal is pressed and if Skyguard is installed its bar is pressed– the pedal electric line is closed and the Sky-
PEDAL / SKY A
guard electric line A is closed
OFF The pedal is released or if Skyguard is installed its bar is released – the pedal electric line is open or the Skyguard
electric line A is open

3121623 6-49
 SECTION 6 - JLG CONTROL SYSTEM

X26JP - X770AJ (Prior to S/N C170001340)

SKYGUARD B ON If Skyguard is installed its bar is pressed– the Skyguard electric line B is closed
OFF If Skyguard is installed its bar is released – the Skyguard electric line A is open

EM.BASK.A ON The stop button on remote control in basket is released – “A” line is closed
OFF The stop button on remote control in basket is pressed or the ground remote control is disconnected – “A” line is
open

EM.BASK. B ON The stop button on remote control in basket is released – “B” line is closed
OFF The stop button on remote control in basket is pressed or the ground remote control is disconnected – “B” line is
open

POSM1 A1 ON Outrigger n.1 is opened, half-way or completely – the switch is released and A line is closed
OFF Outrigger n.1 is closed – the switch is pressed and A line is opened

POSM1 B1 ON Outrigger n.1 is opened, half-way or completely – the switch is released and B line is closed
OFF Outrigger n.1 is closed – the switch is pressed and B line is opened

POSM2 A2 ON Outrigger n.2 is opened, half-way or completely – the switch is released and A line is closed
OFF Outrigger n.2 is closed – the switch is pressed and A line is ope

POSM2 B2 ON Outrigger n.2 is opened, half-way or completely – the switch is released and B line is closed
OFF Outrigger n.2 is closed – the switch is pressed and B line is opened

POSM3 A3 ON Outrigger n.3 is opened, half-way or completely – the switch is released and A line is closed
OFF Outrigger n.3 is closed – the switch is pressed and A line is opened

POSM3 B3 ON Outrigger n.3 is opened, half-way or completely – the switch is released and B line is closed
OFF Outrigger n.3 is closed – the switch is pressed and B line is opened

POSM4 A4 ON Outrigger n.4 is opened, half-way or completely – the switch is released and A line is closed
OFF Outrigger n.4 is closed – the switch is pressed and A line is opened

POSM4 B4 ON Outrigger n.4 is opened, half-way or completely – the switch is released and B line is closed
OFF Outrigger n.4 is closed – the switch is pressed and B line is opened

R.C. BASKET ON The remote control is in the support in basket

OFF The remote control is not in the support in basket

INCLIN. X 0 Indicates the inclination of the machine on the X axis in tenth of degrees (accelerometer A)
0 Indicates the inclination of the machine on the X axis in tenth of degrees (accelerometer B)

INCLIN. Y 0 Indicates the inclination of the machine on the Y axis in tenth of degrees (accelerometer A)
0 Indicates the inclination of the machine on the Y axis in tenth of degrees (accelerometer B)

LOAD A 94 Indicates the weight in Kg in the basket on line A

LOAD B 95 Indicates the weight in Kg in the basket on line B

POS. 1E2 2218 Indicates the opening of the 1st and 2nd booms cylinder in tenths of a millimetre

POS. 3 2398 Indicates the opening of the 3 arm cylinder in tenths of a millimeter

6-50 3121623
 SECTION 6 - JLG CONTROL SYSTEM

X26JP - X770AJ (Prior to S/N C170001340)

MOTOR RPM 2200 Only diesel version: Indicates the engine RPM read by rpm sensor

CURRENT A 0 DO NOT CONSIDER

CURRENT B 0 DO NOT CONSIDER

CURRENT C 0 DO NOT CONSIDER

TEMPERAT. 37.6 Indicates the temperature of the ECM1-2 in °C

SUPPLY (V) 12.1 Indicates the batteries voltage, or the output voltage from the battery charger

BATTERY % 100 Only for Lithium version: indicates the % level of charge of the pack

3121623 6-51
 SECTION 6 - JLG CONTROL SYSTEM

Table 6-6. Input Menu Item - Explanation

X26JP - X770AJ (S/N C170001340 to Present)
DOWN
ST1 GND AB Outrigger n.1 on the ground – the switch is released, line A is open and line B is closed
DOWN
Up
Outrigger n.1 lifted – the switch is pressed, line A is closed and line B is open
UP

ON
ST1 OPEN AB Outrigger n.1 is opened, half-way or completely - the switch is released, line A is open and line B is closed
ON
OFF
Outrigger n.1 is closed – the switch is pressed, line A is closed and line B is open
OFF

ON
ST1 TOT Outrigger n.1 is completely opened – the switch is released, line A is open and line B is closed
ON
OFF
Outrigger n.1 is closed or only half-way opened – the switch is pressed, line A is closed and line B is open
OFF

DOWN
ST2 GND AB Outrigger n.2 on the ground – the switch is released, line A is open and line B is closed
DOWN
Up
Outrigger n.2 lifted – the switch is pressed, line A is closed and line B is open
Up

ON
ST2 OPEN AB Outrigger n.2 is opened, half-way or completely - the switch is released, line A is open and line B is closed
ON
OFF
Outrigger n.2 is closed – the switch is pressed, line A is closed and line B is open
OFF

ON
ST2 TOT Outrigger n.2 is completely opened – the switch is released, line A is open and line B is closed
ON
OFF
Outrigger n.2 is closed or only half-way opened – the switch is pressed, line A is closed and line B is open
OFF

DOWN
ST3 GND AB Outrigger n.3 on the ground – the switch is released, line A is open and line B is closed
DOWN
UP
Outrigger n.3 lifted – the switch is pressed, line A is closed and line B is open
UP

ON
ST3 OPEN AB Outrigger n.3 is opened, half-way or completely - the switch is released, line A is open and line B is closed
ON
OFF
Outrigger n.3 is closed – the switch is pressed, line A is closed and line B is open
OFF

ON
ST3 TOT Outrigger n.3 is completely opened – the switch is released, line A is open and line B is closed
ON
OFF
Outrigger n.3 is closed or only half-way opened – the switch is pressed, line A is closed and line B is open
OFF

DOWN
ST4 GND AB Outrigger n.4 on the ground – the switch is released, line A is open and line B is closed
DOWN
Up
Outrigger n.4 lifted – the switch is pressed, line A is closed and line B is open
UP

6-52 3121623
 SECTION 6 - JLG CONTROL SYSTEM

X26JP - X770AJ (S/N C170001340 to Present)

ON
ST4 OPEN AB Outrigger n.4 is opened, half-way or completely - the switch is released, line A is open and line B is closed
ON
OFF
Outrigger n.4 is closed – the switch is pressed, line A is closed and line B is open
OFF

ON
ST4 TOT Outrigger n.4 is completely opened – the switch is released, line A is open and line B is closed
ON
OFF
Outrigger n.4 is closed or only half-way opened – the switch is pressed, line A is closed and line B is open
OFF

ON The aerial part safeties are deactivated through the safeties by-pass key switch (emergency condition) – line A is
BYPASAE AB
ON open and line B is closed
OFF
The aerial part safeties are activated (normal working condition) – line A is closed and line B is open
OFF

ON The track safeties are deactivated through the safeties by-pass key switch (emergency condition) – line A is open
BYPASTR AB
ON and line B is closed
OFF
The track safeties are activated (normal working condition) – line A is closed and line B is open
OFF

ON
STOP GND AB Stop button on the ground is pressed – line A is closed and line B is open
ON
OFF
Stop button on the ground is released – line A is open and line B is closed
OFF

ON Stop button on the remote control ground connected on the ground is pressed – lines A and B of the stop button
STOP RC DW
ON are open
OFF Stop button on the remote control ground connected on the ground is released – lines A and B of the stop button
OFF are closed

ON
STOP RC UP The stop button on remote control is pressed – lines A and B of the stop button are open
ON
OFF
The stop button on remote control is released – lines A and B of the stop button are closed
OFF

ON TPhotocells are aligned with the reflector (machine is closed and aligned) – Photocell A (the lower one) contact is
PHOTO AB
ON open and photocell B (the upper one) contact is closed
OFF Photocells are not aligned with the reflector (machine is not closed and aligned) – Photocell A (the lower one)
OFF contact is closed and photocell B (the upper one) contact is open

ON Pressure switch of outriggers n.1 and n.2 closes the contact – the outriggers are at end run and the max pressure
ST12 CLOSED
valve is opened
OFF Pressure switch contact of outriggers n.1 and n.2 is opened – the outriggers are open, partially open or already
closed

ON Pressure switch of outriggers n.3 and n.4 closes the contact – the outriggers are at end run and the max pressure
ST34 CLOSED
valve is opened
OFF Pressure switch contact of outriggers n.3 and n.4 is opened – the outriggers are open, partially open or already
closed

TEMP ALRM A ON Temperature external probe reached the maximum value, the temperature probe is closed
Option reserved OFF
for some markets Temperature external probe hasn’t reached the maximum value, the temperature probe is open

3121623 6-53
 SECTION 6 - JLG CONTROL SYSTEM

X26JP - X770AJ (S/N C170001340 to Present)

GENERATOR ON Engine is running
(Only for gasoline OFF
machine) Engine is not running

GND CTRL ON The control position selector for aerial part operation from the ground is activated (emergency condition)
OFF The control position selector for aerial part operation is released (normal working condition)

ON The cables of the extension are OK. The control switch of the cables on extension is released and the line is closed
ROPES
ON (normal working condition)
OFF At list one cable on the extension is out of order. The control switch of the cables on extension is pressed and the
OFF line is open (emergency condition)

ENGINE ON ON The ground button for engine start is pressed

OFF The ground button for engine start is released

ON The engine reached the max functioning temperature

MOTOR TEMP. (emergency condition)
(Only for Diesel
machine) OFF The engine maintains the correct functioning temperature
(normal working condition)

MOTOR PRES. ON The engine oil pressure is inadequate (emergency condition)

(Only for Diesel OFF
machine) The engine oil pressure is OK (normal working condition)

ELE MOT ON ON The ground button for electric motor start is pressed
OFF The ground button for electric motor start is released

RC UP CTRL ON The control position selector is positioned on “basket”

OFF The control position selector is positioned on “ground”

DOWN
MICROJIB AB The JIB is closed – the control switch is released, line A is open and line B is closed
DOWN
UP
The JIB is open – the control switch is pressed, line A is closed and line B is open
UP

PEDAL AB ON
The pedal is pressed– the pedal electric line A is open and line B is closed
(Option) ON
OFF
OFF The pedal is released – the pedal electric line A is closed and line B is open

RC BASKET ON The remote control is in the support in basket

OFF The remote control is not in the support in basket

TR.OPEN LFT ON Left track is fully widened. Widening cylinder of left track contact is closed
OFF Left track is not fully widened. Widening cylinder of left track contact is open

TR.OPEN RGT ON Right track is fully widened. Widening cylinder of right track contact is closed
OFF Right track is not fully widened. Widening cylinder of right track contact is open

INCLIN. X 0, 05 Indicates the inclination of the machine on the X axis in degrees

INCLIN. Y 0, 30 Indicates the inclination of the machine on the Y axis of degrees

6-54 3121623
 SECTION 6 - JLG CONTROL SYSTEM

X26JP - X770AJ (S/N C170001340 to Present)

133
LOAD AB Indicates the weight of the basket (about 50 Kg) plus the weight into the basket in Kg measured by A and B lines
134

SEN CYL 1-2 2073 Indicates the opening of the 1st-2nd boom cylinder in tenths of a millimetre

SEN CYL 3 2073 Indicates the opening of the 3rd boom cylinder in tenths of a millimetre

180
ROTATION AB Indicates the turret rotation angle (0°÷360°) measured by lines A and B, 180° indicates the aligned position
181

SKYGUARD ON Indicates that Skyguard bar has been pressed.

OFF Indicates that Skyguard bar has not been pressed.

MOTOR RPM.
(Only for Diesel 2220 Indicates the Diesel engine rpm
machine)

TEMP. 37, 62 Indicates the temperature of the ECM1 in °C

SUPPLY (V) 12, 15 Indicates the batteries voltage, or the output voltage from the battery charger

3317 Indicates the voltage at the lowest cell. When the cells are not under charge or under discharge, it tends to the
V HIGH CEL
nominal value that is around 3,3 Volt
2 Indicates the number of the lowest cell

Indicates the average voltage of the cell. When the cells are not under charge or under discharge, it tends to the
V AVG CELL 3316
nominal value that is around 3.3 Volt

3315 Indicates the voltage at the lowest cell. When the cells are not under charge or under discharge, it tends to the
V LOW CELL
nominal value that is around 3.3 Volt
12 Indicates the number of the lowest cell

Indicates the maximum current (Amp) that BMS requires to the battery charger (with lithium pack not fully
CHG SETUP 30
charge)

T HIGH CEL 23 Indicates the highest temperature (°C) detected among the cells
2 Indicates the number of the temperature sensor with the highest temperature detected

T AVG CEL 23 Indicates the average temperature (°C) detected among the cells

T LOW CEL 23 Indicates the lowest temperature (°C) detected among the cells
1 Indicates the number of the temperature sensor with the lowest temperature detected

T BMS 27 Indicates the temperature (°C) detected on the BMS

REM CAP AH 80 Indicates the remaining capacity (Ah)

R HIGH CELL 1 Indicates the highest resistance (mOhm) of the cells

1 Indicates the number of the cell with the highest resistance

R AVG CELL 1 Indicates the average resistance (mOhm) of the cells

R LOW CELL 1 Indicates the lowest resistance (mOhm) of the cells

1 Indicates the number of the cell with the lowest resistance

3121623 6-55
 SECTION 6 - JLG CONTROL SYSTEM

X26JP - X770AJ (S/N C170001340 to Present)

HOURS INV 27 It counts the working hours with engine running

0 Indicates the electric motor rpm read by the engine rpm sensor. At a certain rpm setting, the rpm read depends
RPM INV
also on the electric load

CONTACTOR ON Indicates that internal contactor is closed by bms (no error in progress)
OFF Indicates that internal contactor is opened by the bms

HEATER ON Indicates that lithium pack heaters are working to heat the cells, they are automatically activated
OFF Indicates that lithium pack heaters are off

ON Indicates that lithium pack fans of cooling system are running to cool the lithium pack, they are automatically acti-
COOLING
vated
OFF Indicates that lithium pack fans of cooling system are not running

SOC (%) 89 Indicates the charge level of the battery pack, 100 % is the maximum, 0 % is the minimum

79 IIndicates the total voltage of the lithium pack. When the cells are not under charge or under discharge, it tends to
BAT PACK V
the nominal value that is around 40 Volt, it doesn’t matter their charge status.

0 Indicates the value of the current (Amp) measured by the LEM sensor. With sign “–“ the current is going out from
CURRENT A
the battery pack (discharge), if there is no sign, the current is going inside the pack (charge)

BMS STATUS 1 Indicates the bms status (“1” is the nominal condition)

6-56 3121623
 SECTION 6 - JLG CONTROL SYSTEM

Language Menu
From the SERVICE menu, pressing button 2”LANGUAGE” to accesses menu language.

Using the buttons 1 to 4 to select the language desired.

Press button 9”ESC” to save the change.

The languages available are:

Button 1 - Italian
Button 2 - German
Button 3 - English
Button 4 - French
Button 5 - Spanish

3121623 6-57
 SECTION 6 - JLG CONTROL SYSTEM

Errors Menu
From the SERVICE menu, pressing button 3”ERROR” accesses the menu of errors to identification of malfunctioning of
some devices.

The faults highlighted by this list refer to devices with two safety lines, where the signal of the two lines is not coherent.
Errors menu underlines only the non-concordance between two safety lines (A and B) monitoring the same control, gives
OK or NO in the errors menu.

OK
• Indication the signals
agree.

NO
• Indication the signals
have a discordant value,
in this case the icon HELP
ERROR m ay automati-
cally appear on the dis-
play.

6-58 3121623
 SECTION 6 - JLG CONTROL SYSTEM

Table 6-7. Error Manu Flow Chart

Press button
Service

Menu

Press button
3 - ERRORS

ST1GND

ST1OPE EM.BAS ROTAT.

ST2GND POSM1 BATT.:

ST2OPE POSM2 INVER.:

ST3GND POSM3 CARIC.:

ST3OPE POSM4 BMS?:

ST4GND ACCEL. V MIN:

ST4OPE LOAD. T MIN:

BYPASA ROTA. V AVG:

BYPASC SAFETY

EM.GRN REMOTE

FOTO CIL1-2

TEMP.A CIL 3

MICRJI LOAD

3121623 6-59
 SECTION 6 - JLG CONTROL SYSTEM

Errors 1 - SCREEN

Errors 2 - SCREEN X26JP - X770AJ

(Prior to S/N C170001340)

Errors 2 - SCREEN X26JP - X770AJ

(S/N C170001340 to Present)

ERRORS
BYPASA OK BYPAS AE Aerial part safeties by - pass switch
BYPASTR OK BYPAS TR Ground part safeties by - pass switch
STOP GRN OK
STOP GRN Stop button on the ground
STOP RC UP OK
STOP RC DW OK STOP RC UP Remote control stop button on the basket
PHOTO OK STOP RC SW Remote control stop button on the ground
PEDAL OK
SKYGUARD OK PHOTO Photocells
1 PREV PEDAL Pedal
2 NEXT SKYGUARD Anti - entrapment system
9 ESC

6-60 3121623
 SECTION 6 - JLG CONTROL SYSTEM

Errors 3 - SCREEN X26JP - X770AJ

(Prior to S/N C170001340)

Errors 3 - SCREEN X26JP - X770AJ

(S/N C170001340 to Present)

ERRORS
MICR JIB Jib opening switch
MICR JIB OK
ST1 OK POSM1 Outrigger n.1 completely opened switch
ST2 OK POSM2 Outrigger n.2 completely opened switch
ST3 OK
ST4 OK POSM3 Outrigger n.3 completely opened switch
INCLIN. OK POSM4 Outrigger n.4 completely opened switch
LOAD OK
CODE OK INCLIN. Machine inclination sensors
1 PREV LOAD Basket load cell sensor
2 NEXT CODE Do not consider
9 ESC

CAN Message - SCREEN X26JP - X770AJ

(Prior to S/N C170001340)

3121623 6-61
 SECTION 6 - JLG CONTROL SYSTEM

CAN MESSAGE - SCREEN X26JP - X770AJ

(S/N C170001340 to Present)

CAN TIMOUT
RC BASK Remote control
RC BASK OK
SEN CYL 1-2 OK SEN CYL 1-2 1 st – 2 nd boom cylinder position sensor
SEN CYL 3 OK SEN CYL 3 3 RD boom cylinder position sensor
INCLIN. OK
ROTATION OK INCLIN. Machine inclination sensors
MODEM OK ROTATION Do not consider
LOAD OK
MODEM Modem
ROTATION OK
1 PREV LOAD Load cell board (ECM3)
2 NEXT ROTATION Reduced area board (ECM4)

Lithium Powered Model - SCREEN X26JP - X770AJ

(Prior to S/N C170001340)

The fifth page has to be considered only for Lithium machines, BATT, INVER and
CARIC are indicated as "0" otherwise it means there's a Lithium error in progress.
BMS ? = BMS generation, "1" means first gen., "2" means second gen.
V MIN = Cells minimum voltage
T MIN = Cells minimum temperature
V AVG = Cells average voltage
More information about those data are detailed on the manual section Lithium

Lithium Powered Model - SCREEN X26JP - X770AJ

(S/N C170001340 to Present)

LITH ERR
The fifth page has to be considered only for Lithium machines,
BMS : 0 BMS, INVERT and BAT CHAR are indicated as “0” otherwise it
means there’s a Lithium error in progress.
INVERT : 0 More information about those data are detailed on the Lithium
Training.
BAT CHAR : 0

1 PREV
2 NEXT
9 ESC

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 SECTION 6 - JLG CONTROL SYSTEM

RAMP Menu
From the SERVICE menu, pressing button 4”RAMP” accesses the menu RAMP to adjust the parameter settings in order to
achieved optimum machine performance.

1. Press button 7 “SETUP”.

2. Press button 5 “PASSWORD”.
Using the remote control buttons to enter the
password 1883.
NOTE: password permit to change all RAMP Settings.
Once the correct password is accepted the dis-
play shown “OK”.
3. Press button 9 “ESC” two times.
Repeat the above steps if “NO” appear on the
display.
4. Press button 4 “RAMP” to enter in menu ramps
setting.
Use buttons 1”PREV.” and 2”NEXT” to scroll the
various functions.
5. Use buttons 7”UP” and 8”DOWN” to adjust the
values.
6. Press button 3”SAVE” to save.

NOTE: Every time the ramp value gets modified button 3 to

save must be pressed, otherwise the modification is
not activated.

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 SECTION 6 - JLG CONTROL SYSTEM

Figure 6-55. RAMP Menu Flow Chart

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 SECTION 6 - JLG CONTROL SYSTEM

CURRENT Menu
From the SERVICE menu, pressing button 5 ”CURRENT” accesses the menu CURRENT to adjust the parameter settings in
order to achieved optimum machine performance.

1. Press button 7 “SETUP”. NOTE: Personality settings can be adjusted within the
2. Press button 5 “PASSWORD”. adjustment range in order to achieve optimum
Using the remote control buttons to enter the machine performance.
password 1883.
NOTE: password permit to change all CURRENT Settings.
Once the correct password is accepted the dis-
play shown “OK”.
3. Press button 9 “ESC” two times.
NOTE: Repeat the above steps if “NO” appear on the dis-
play.
4. Press button 5 “CURRENT” to enter in menu cur-
rent setting.
Use buttons 1 PREV. and 2 NEXT to scroll the var-
ious functions.
5. Use buttons 7 UP and 8 DOWN to adjust the val-
ues.
6. Press button 3 SAVE to save
NOTE: Every time the ramp value gets modified button 3 to NOTE: Refer to Table 6.8, Time range (sec) for recom-
save must be pressed; otherwise the modification is mended settings.
not activated.

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 SECTION 6 - JLG CONTROL SYSTEM

Figure 6-56. CURRENT Menu Flow Chart

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 SECTION 6 - JLG CONTROL SYSTEM

Working Hours Menu

From the SERVICE menu, pressing button 6 ”W.HOURS” accesses the menu Working Hours.
This menu allows viewing the working hours of the thermic engine and the electrical motor.
On lithium models, machine hours only.

To view the working hours of the Engine or Electrical motor.

Press button 6”W.HOURS”.

WORK. HOURS

ENGINE:
7
ELEC. MOT
2
KEY ON:
28
9 ESC

MAF00890

X26JP - X770AJ
X26JP - X770AJ (SN C170001340 to Present)
(Prior to SN C170001340)

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 SECTION 6 - JLG CONTROL SYSTEM

Figure 6-57. Working Hours Menu Flow Chart

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 SECTION 6 - JLG CONTROL SYSTEM

To change the working hours of the Engine or Electrical Motor.

KEEPING PRESSED the button 6 use the button
1”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 than button
3 to set zero the working hours of Engine and
Motor.
5. Press button 9 ESC 3 times to escape.
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.
X26JP - X770AJ
(Prior to SN C170001340)

WORK. HOURS

ENGINE:
7
ELEC. MOT
2
KEY ON:
28
9 ESC

MAF00890

X26JP - X770AJ
(SN C170001340 to Present)
1. Press button 7 “SETUP”.
2. Press button 5 “PASSWORD”.
Using the remote control buttons to enter the
password 7385.
NOTE: password allow to change the Working Hours of
Engine and Electrical Motor.
Once the correct password is accepted the dis-
play shown “OK”.
3. Press button 9 “ESC” two times.
NOTE: Repeat the above steps if “NO” appear on the dis-
play.
4. Press button 6“W:HOURS”.

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 SECTION 6 - JLG CONTROL SYSTEM

Joystick Menu
X26JP - X770AJ (S/N C170001340 to Present)
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
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.

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6.8 MACHINE SETUP MENU X26JP - X770AJ

(PRIOR TO S/N C170001340)
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 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.

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 SECTION 6 - JLG CONTROL SYSTEM

Figure 6-58. Machine Setup Flow Chart - 1 of 3

6-72 3121623
 SECTION 6 - JLG CONTROL SYSTEM

Figure 6-59. Machine Setup Flow Chart - 2 of 3

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 SECTION 6 - JLG CONTROL SYSTEM

Figure 6-60. Machine Setup Flow Chart - 3 of 3

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 SECTION 6 - JLG CONTROL SYSTEM

Setup 1 - ACCELER - (Calibrating Tilt Sensor) Once the correct password is accepted the dis-
play shown “OK”.
This menu allows the calibration of the tilt sensor.
6. Press button 9 “ESC”.
NOTICE Repeat the above steps if “NO” appear on the
A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE TIME display.
UNTIL THE FOLLOWING PROCEDURE IS PERFORMED. 7. Press button 1 “ACCELER” to enter in SETUP TILT
SENSOR.

DO NOT CALIBRATE THE LEVEL SENSOR EXCEPT WITH THE UNIT LEV- NOTE: If "ready" --> Go to point 8. If "not ready", mean one
ELED ON BOTH AXIS. CHECK THE BUBBLE LEVEL TO CONFIRM UNIT IS or more outrigger not tach the ground or photocell
LEVEL (BUBBLE IS IN THE 1° GREEN (CENTER) AREA). not aligned.
8. Press Button 1 to reset the TILT.
Check the values if both axle showed in the display
become zero, otherwise press button 1 again until both
values are zero.

NOTICE
EXTEND, AND ADJUST THE OUTRIGGERS UNTIL UNIT IS LEVEL (BUB-
BLE IS IN THE 1° GREEN (CENTER) AREA) AND THE TRACKS ARE RAISED
OF THE GROUND.

Press 3 times button 9 to Esc to escape.

NOTE: Using the password "Level 3" 4658 to read the values
only

Figure 6-61.
1. Engine OFF.
2. Engine Key Switch ON.
3. Press button 6 "SERVICE"
4. Press button 7 "SETUP“
5. Press button 5 “PASSWORD”
Using the remote control buttons to enter the
password "Level 2": 2857.
NOTE: Password above allow to calibrate the TILT SENSOR.

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 SECTION 6 - JLG CONTROL SYSTEM

Setup 2 - VERSION - Model Number - Engine Type Table 6-8.

This menu allows the setting of the machine model and PERSONALITY SETTING
the engine type. MODEL VERSION ENGINE
1. Press button 6 "SERVICE" D.STD
2. Press button 7 "SETUP “. D.RPM
3. Press button 5 “PASSWORD”.
X17JP B.13I
Using the remote control buttons to enter the LL1775
X500AJ B.15I
password "Level 2": 3684.
G.15I
NOTE: password above allow to choose machine number
and engine type. LITH.
Once the correct password is accepted the dis- D.STD
play shown “OK”. D.RPM
4. Press button 9 “ESC”. X20JP B.13I
LL2010
Repeat the above steps if “NO” appear on the X600AJ B.15I
display. G.15I
5. Press button 2 “VERSION” to enter in VERSION LITH.
SETUP.
X26JP D.RPM
6. Press Button 1 for machine number. LL2614
X770AJ LITH.
7. Press Button 7 for engine type.

Table 6-9.
ENGINE ID ENGINE IDENTIFICATIONS
D.STD Diesel RPM Manual Adjustment
D.RPM Diesel RPM Auto Adjustment
B.13I Gasoline RPM Auto Adjustment for
Engine Model iGX 390
B.15I Gasoline RPM Auto Adjustment for
Engine Model iGX 440
G.15I Gasoline RPM Auto Adjustment for
Engine Model iGX 440
X17JP - X500AJ & X20JP - X600AJ
Press button 9 ESC 3 times to escape. (Prior to S/N C170000892)
LITH. Engine Lithium Version
NOTE: Using the password "Level 3" 7715 to read the values
only

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 SECTION 6 - JLG CONTROL SYSTEM

Setup 3 - EXTRA - Machine Configuration

This menu allows the machine configuration.

Press button 1 to enter in menu “OPTIONAL”

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 SECTION 6 - JLG CONTROL SYSTEM

1 - FOOT PEDAL 2 - MOTION ALARM (BEEPER)

1. Press button 7 "SETUP". This menu allows the set ON or OFF of the motion alarm
2. Press button 5 "PASSWORD". with upper fame and undercarriage movements, or for
boom down only.
Using the remote control buttons to enter the
password “Level 2": 4771.
1. Press button 7 “SETUP“.
NOTE: password above allow to choose the options shown 2. Press button 5 “PASSWORD”.
on the screen.
Using the remote control buttons to enter the
Once the correct password is accepted the dis- password “Level 2": 8365.
play shown "OK".
NOTE: password above allow to choose the options shown
3. Press button 9 “ESC” on the screen.
Repeat the above steps if "NO" appear on the Once the correct password is accepted the dis-
display. play shown “OK”.
4. Press button 3 “EXTRA” 3. Press button 9 “ESC”.
5. Press button 1 “OPTIONAL”. Repeat the above steps if “NO” appear on the
6. Press button 1 “PEDAL”. display.
4. Press button 3 ”EXTRA”
5. Press button 1 “OPTIONAL”
6. Press button 2 “BEEPER”.

7. Press button 1 ON to activate the “PEDAL”.

8. Press button 2 "OFF to deactivate the Pedal”.
Press 4 times button 9 to Esc to escape.

7. Press button 1 ALL to activate all movements.

8. Press button 2 “FALL to activate the descent
movements only”.
9. Button 3 “WARN” spare (not available)

Press 5 times button 9 Esc to escape.

NOTE: Using the password “Level 3" 3336 to read the values
only

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 SECTION 6 - JLG CONTROL SYSTEM

3 - 2ND DRIVE SPEED 4 - SKYGUARD ACTIVATION

This menu allows to set ON or OFF of the high drive speed This menu allows to set ON or OFF the enable drive switch.
on models with this option. The enable drive switch (button 8) allow the drive function
with remote control off of the basket.
1. Press button 7 SETUP “.
2. Press button 5 “PASSWORD”. 1. Press button 7 "SETUP".
Using the remote control buttons to enter the 2. Press button 5 "PASSWORD".
password "Level 2": 5216. Using the remote control buttons to enter the
password 4771.
NOTE: password above allow to choose the options shown
on the screen. NOTE: password above allow to choose the options shown
on the screen.
Once the correct password is accepted the dis-
play shown “OK”. Once the correct password is accepted the dis-
play shown "OK".
3. Press button 9 “ESC”.
Repeat the above steps if “NO” appear on the 3. Press button 9 "ESC".
display. Repeat the above steps if "NO" appear on the
display.
4. Press button 3 ”EXTRA”.
5. Press button 1 "OPTIONAL" 4. Press button 3 "EXTRA"
6. Press button 3”D.SPEED”2 “. 5. Press button 1 "OPTIONAL".
6. Press button 4 "SKYGUARD"

7. Press button 1 ON to activate 2ND DRIVE SPEED. 7. Press button 1 ON to activate the function
8. Press button 2 OFF to deactivate the function
8. Press button 2 “OFF to deactivate the 2ND DRIVE
SPEED. Press 5 times button 9 to Esc to escape

Press 5 times button 9 Esc to escape.

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 SECTION 6 - JLG CONTROL SYSTEM

5 - ELECTRICAL MOTOR 6 - LAMPS on OUTRIGGER

1. Press button 7 "SETUP“. 1. Press button 7 "SETUP“.

2. Press button 5 “PASSWORD”. 2. Press button 5 “PASSWORD”.
Using the remote control buttons to enter the Using the remote control buttons to enter the
password "Level 2":3522. password 6661.
NOTE: Password above allow to choose the options shown NOTE: Password above allow to choose the options shown
on the screen. on the screen.
Once the correct password is accepted the dis- Once the correct password is accepted the dis-
play shown “OK”. play shown “OK”.
3. Press button 9 “ESC”. 3. Press button 9 “ESC”.
Repeat the above steps if “NO” appear on the Repeat the above steps if “NO” appear on the
display. display.
4. Press button 3 ”EXTRA” 4. Press button 3 ”EXTRA”
5. Press button 1 "OPTIONAL" 5. Press button 1 "OPTIONAL".
6. Press button 4 “EL.MOT”. 6. Press button 5 “LAMPS”.

7. Press button 1 2,2 KW for 220- 240 Volt 50HZ. 7. Press button 1 for Lamps continuously ON. Press
button 1 for lamps continuously ON with outrig-
8. Press button 2 1,2 KW” for 110 Volt 60HZ. ger on the ground and full work area active,
while blinking in restricted work area.
Press 5 times button 9 Esc to escape 8. Press button 2 for Lamps Blinking. Press button 2
for lamps blinking with outrigger on the ground
while lamps ON in restricted work area.

Press 5 times button 9 to Esc to escape

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 SECTION 6 - JLG CONTROL SYSTEM

7 - TILT DRIVE CUT-OUT FUNCTION (CHK INC) 1 - MACHINE SERVICE (SERVICE)

This menu allows to set ON or OFF the drive cut-out func- This menu allows to set ON or OFF the icon service func-
tion. tion, or to turn off the service required warning icon, when
the service is performed.
The drive function is reduce or stopped above certain
incline 1. Press button 7 "SETUP“.
1. Press button 7 "SETUP“. 2. Press button 5 “PASSWORD”.
2. Press button 5 “PASSWORD”. Using the remote control buttons to enter the
Using the remote control buttons to enter the password 4538.
password 6661.
NOTE: password above allow to choose the options shown
NOTE: password above allow to choose the options shown on the screen.
on the screen. Once the correct password is accepted the dis-
Once the correct password is accepted the dis- play shown “OK”.
play shown “OK”.
3. Press button 9 “ESC”.
3. Press button 9 “ESC”. Repeat the above steps if “NO” appear on the
Repeat the above steps if “NO” appear on the display.
display.
4. Press button 3 ”EXTRA”
4. Press button 3 ”EXTRA” 5. Press button 1 "OPTIONAL".
5. Press button 1 "OPTIONAL". 6. Press button 1 "SERVICE"
6. Press button 6 "CHK INC"

7. Press button 1 ON to activate the function

7. Press button 1 ON to activate the function 8. Press button 2 OFF to deactivate the function
8. Press button 2 OFF to deactivate the function 9. Press button 3 RESET to off the service required
warning icon
10. SET NEXT SERVICE INTERVAL:
Press 5 times button 9 to Esc to escape
While pressing and holding button 6, use the button 7 to
increase and button 8 to decrease the total hours until the
next service is required, once that hour setting is reached
a warning icon will appear on the display.
Press 5 times button 9 to Esc to escape

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 SECTION 6 - JLG CONTROL SYSTEM

2 - HI DRIVE SPEED LIMITATION (RC SPEE) 3 - ENABLE DRIVE SWITCH (RC MOV)
This menu allows to set ON or OFF the high drive speed This menu allows to set ON or OFF the enable drive switch.
with remote control off of the basket The enable drive switch (button 8) allow the drive function
with remote control off of the basket.
1. Press button 7 "SETUP“.
2. Press button 5 “PASSWORD”. 1. Press button 7 "SETUP“.
Using the remote control buttons to enter the 2. Press button 5 “PASSWORD”.
password 4771. Using the remote control buttons to enter the
NOTE: password above allow to choose the options shown password 4771.
on the screen. NOTE: Password above allow to choose the options shown
Once the correct password is accepted the dis- on the screen.
play shown “OK”. Once the correct password is accepted the dis-
3. Press button 9 “ESC”. play shown “OK”.
Repeat the above steps if “NO” appear on the 3. Press button 9 “ESC”.
display. Repeat the above steps if “NO” appear on the
4. Press button 3 ”EXTRA” display.
5. Press button 1 "OPTIONAL". 4. Press button 3 ”EXTRA”
6. Press button 2 "RC SPEE" 5. Press button 1 "OPTIONAL".
6. Press button 3 "RC MOV"

7. Press button 1 ON to activate the function

8. Press button 2 OFF to deactivate the function 7. Press button 1 ON to activate the function
9. Press button 3 RESET for reset the icon SERVICE 8. Press button 2 OFF to deactivate the function
Press 5 times button 9 to Esc to escape Press 5 times button 9 to Esc to escape

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 SECTION 6 - JLG CONTROL SYSTEM

4 - SOFTWARE UPDATE (FIRMWARE) 15. Press button 0 to "START"

This menu allow to flash a software on ECM 1-2, ECM 3 and 16. Press button 1 to "PROCEED" or press button 9 to
the MODEM. "ESC"
When on the ECM1-2 is uploaded a “new” software ver-
sion, different as of the currently installed one, on the
remote control display right-down corner it is visualized a AFTER PRESSED BUTTON 1 TO PROCEED, DON’T TURN OFF THE SYS-
unique icon, as follows. TEM UNTIL THE SOFTWARE UPGRADE
1. When the procedure ends the display will show
the screen with the icon

This function allow flash the software stored on the

modem to the ECM’s or on modem module.
9. Press button 7 "SETUP“.
10. Press button 5 “PASSWORD”.
Using the remote control buttons to enter the NOTE: The numbers shown above DOWNLOAD are the
password 1883 "Level 2". data transferred. The Download will be completed
when about more that 25000 steps are transferred.
NOTE: Password above allow to choose the options shown
on the screen.
Once the correct password is accepted the dis-
play shown “OK”.
11. Press button 9 “ESC”.
Repeat the above steps if “NO” appear on the
display.
12. Press button 3 ”EXTRA”
13. Press button 2 "FIRMWARE".
14. Press button 1,2,3,4,5,8 to select the modules to
update.

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 SECTION 6 - JLG CONTROL SYSTEM

5 - MODULES SERIAL NUMBER/SOFTWARE VERSION (CARDS) 6 - MODEM STATUS (MODEM)

This menu show the ECM’s modules serial number and the This menu show the status of the modem.
software revision.
6. Press button 7 "SETUP“.
1. Press button 7 "SETUP“. 7. Press button 3 ”EXTRA”
2. Press button 3 ”EXTRA” 8. Press button 4 "MODEM".
3. Press button 3 "CARDS".
4. Press button 1 or 2 to scroll through the screen STATUS: INIT. --> Initialization
to view the serial number and the software revi-
sion CAN TOUT --> Modem not connected
READY --> Active modem
SIM: NO --> Sim not present
OK --> Sim present
OPERATOR: Operator of the company rooming
RSSI: Signal strength
BER: Communication quality

5. Press 4 times button 9 to Esc to escape

9. Press 4 times button 9 to Esc to escape

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 SECTION 6 - JLG CONTROL SYSTEM

7 - GPS DATA (GPS) Setup 4 - CALIBRATION SWING SENSOR (X26JP -

This menu show the position GPS X770AJ Only)
10. Press button 7 "SETUP“. NOTICE
11. Press button 3 ”EXTRA” A NEW SWING SENSOR WILL ACT AS IF IT IS WITHOUT RESTRICTED
12. Press button 5 "GPS". AREA UNTIL THE FOLLOWING PROCEDURE IS PERFORMED. THE UPPER
FRAME COULD INTERFER WITH THE OUTRIGGERS.
This menu allows calibrating the swing sensor for proper
STATUS: INIT. --> Initialization
operating with outriggers on restricted work area.
CAN TOUT --> Modem not connected
1. Connect the remote control box to ground
READY --> Active modem cable.
SIM: NO --> Sim not present 2. Stabilize the machine (full work area).
OK --> Sim present 3. Lift up the lower boom almost 1m (to avoid con-
OPERATOR: Operator of the company rooming tacts with outrigger) for calibration position.
RSSI: Signal strength
BER: Communication quality

Figure 6-62.
4. Swing CW 180 degrees (centred over opposite
end of chassis) for Calibration Position.

13. Press 4 times button 9 to Esc to escape

Figure 6-63.
5. Stop the engine.

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 SECTION 6 - JLG CONTROL SYSTEM

6. With machine completely rotated on left side,

NOTICE hold the auxiliary reflector on the photocells
TO ENSURING THE SUCCESS OF THE CALIBRATION IT IS ESSENTIAL (icon "machine closed and aligned" has to
SWING THE UPPER FRAME ON CW DIRECTION ONLY, AND THE ROTA- appears on the display) in order to keep the sig-
TION HAS BEEN CARRIED OUT GAINST THE MECHANICAL STOP 1. nal always ON during the procedure, then press
and keep pressed for a couple of seconds button
n.1 (RESET) and check that the displayed values
become one "0" and the other "360" (360 is equal
to zero)

Figure 6-65.

Figure 6-64.

NOTICE
IN CASE OF REPLACING A NEW SWING SENSOR OR ECM4; THE SWING
FUNCTION COULD BE REVENTED TO MANUAL ROTATIE THE TURNTA-
BLE, ACTIVATE THE SWING CONTROL BY THE EMERGENCY PROCE-
DURE. Figure 6-66.
1. Press button 6 "SERVICE" Reflector in front of the photocells during the procedure.
2. Press button 7 "SET-UP". 7. Press 3 times button 9 to Esc to escape and then
3. Press button 5 "PASSWORD". turn OFF the main key. After at least 10 seconds
Using the remote control buttons to enter the turn ON again the main key
password 2857. 8. Press button 6 "SERVICE".
NOTE: password above allow to choose machine number 9. Press button 1 INP OUT.
and engine type. 10. Press button 2 "SUCC" until shown "ROTATION".
Once the correct password is accepted the dis- 11. Check by INPUT "ROTAT.A" and "ROTAT.B" that
play shown "OK". calibration is correct by checking the alignment
turret position that must be 180°, moving left-
4. Press button 9 "ESC". ward must decrease till about 0° (or 360°) and
Repeat the above steps if "NO" appear on the moving rightward must increase till 360° (or 0°)
display.
5. Press button 4 "ROTATION" to enter in ROTATION
SETUP.

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Setup 5 - LOAD SENSING SYSTEM (LSS CALIBRATION)

X17JP - X500AJ & X20JP - X600AJ
(Prior to S/N C170000892)
This menu allows the Calibration Menu is used with Plat-
form weight.

NOTICE
A NEW LOAD CELL OR A NEW LSS MODULE WILL ACT AS IF IT IS WITH-
OUT AREA UNTIL THE FOLLOWING PROCEDURE IS PERFORMED. THE
UPPER FRAME COULD INTERFER WITH THE OUTRIGGERS.
NOTICE
THE LOAD SENSING SYSTEM REQUIRES PERIODIC FUNCTION. VERIFI-
Figure 6-67. CATION.

If the value is different from 360 degrees repeat the proce-

dure. Empty the platform to allow the Load Sensing System to
record its weight during calibration.
NOTICE
MAKE SURE TO NOT LEAVE THE REFLECTOR ON THE PHOTOCELLS

Remove the remote control from the basket and keep it on

hand.

1. Press button 6 "SERVICE"

2. Press button 7 "SETUP“.
3. Press button 5 “PASSWORD”.
Using the remote control buttons to enter the
password "Level 2": 6138
Once the correct password is accepted the dis-
play shown “OK”.
4. Press button 9 “ESC”.
Repeat the above steps if “NO” appear on the
display.

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 SECTION 6 - JLG CONTROL SYSTEM

5. Press button 6 “LOADSENS” to enter in LOADS-

ENS SETUP.

8. Press 3 times button 9 to Esc to escape.

6.
Press button 1 “SET 0KG” and wait for about 5
seconds. NOTE: Using the password "Level 3" 5726 to read the values
only
Add weight of 200 kg (CE) / 440 Lb (ANSI) in the basket.

LSS VALIDATION
200KG OR 440LB ARE THE CORRECT WEIGHT FOR THE CALIBRATION
1. Stabilize the machine.
2. Press button 6 "SERVICE“.
3. Press button 1 INP OUT.
4. Press button 2 “SUCC” until shown “LOAD”.

Check that the value if is in reference to the weight on the

basket.

Wait for about 5 seconds.

If the values shown is almost greater than 10 kg, repeat
7. Press button 2 to SET 200KG. the procedure.

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Setup 5 - LOAD SENSING SYSTEM (LSS CALIBRATION)

X17JP - X500AJ & X20JP - X600AJ
(S/N C170000893 to Present)
This menu allows the Calibration Menu is used with Plat-
form weight.

NOTICE
A NEW LOAD CELL OR A NEW LSS MODULE WILL ACT AS IF IT IS WITH-
OUT AREA UNTIL THE FOLLOWING PROCEDURE IS PERFORMED. THE
UPPER FRAME COULD INTERFER WITH THE OUTRIGGERS.
THE LOAD SENSING SYSTEM REQUIRES PERIODIC FUNCTION. VERIFI-
CATION.

6. 6. Press button 1 "SET 0KG" and wait for about 5

seconds.
Press 3 times button 9 to Esc to escape.
NOTE: Using the password "Level 3" 5726 to read the values
Only

LSS VALIDATION
1. 1. Stabilize the machine.
2. 2. Press button 6 "SERVICE".
3. 3. Press button 1 INP OUT.
4. 4. Press button 2 "SUCC" until shown "LOAD".
Check that the value if is in reference to the weight on the
basket.

Remove the remote control from the basket and keep it on

hand.
1. 1. Press button 6 "SERVICE"
2. 2. Press button 7 "SETUP".
3. 3. Press button 5 "PASSWORD".
Using the remote control buttons to enter the
password "Level 2": 6138
Once the correct password is accepted the dis-
play shown "OK". If the values shown is almost greater than 10 kg, repeat
the procedure.
4. 4. Press button 9 "ESC".
Repeat the above steps if "NO" appear on the
display.
5. 5. Press button 6 "LOADSENS" to enter in LOADS-
ENS SETUP.

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 SECTION 6 - JLG CONTROL SYSTEM

Setup 6 - TIME Setup Setup 7 - DATE Setup

This menu allows the setting of the clock. This menu allows the setting of the data.

1. Press button 6 "SERVICE" 1. Press button 6 "SERVICE"

2. Press button 7 "SETUP“. 2. Press button 7 "SETUP“.
3. Press button 5 “PASSWORD”. 3. Press button 5 “PASSWORD”.
Using the remote control buttons to enter the Using the remote control buttons to enter the
password 1468. password 1468.
NOTE: Password above allow to change the time. NOTE: Password above allow to change the date.
Once the correct password is accepted the dis- Once the correct password is accepted the dis-
play shown “OK”. play shown “OK”.
4. Press button 9 “ESC”. 4. Press button 9 “ESC”.
Repeat the above steps if “NO” appear on the Repeat the above steps if “NO” appear on the
display. display.
5. Press button 7 “TIME” to enter in TIME SETUP. 5. Press button 8 “DATE” to enter in DATE SETUP.

6. Press buttons 1 Hours UP 6. Press buttons 1 Day UP

7. Press buttons 2 Hours Down 7. Press buttons 2 Month Down
8. Press buttons 3 Minutes UP 8. Press buttons 3 Year UP
9. Press buttons 4 Minutes Down 9. Press buttons 4 Year Down

Press 3 times button 9 to escape. Press 3 times button 9 to escape.

6-90 3121623
 SECTION 6 - JLG CONTROL SYSTEM

6.9 MACHINE SETUP MENU X26JP - X770AJ

(S/N C170001340 TO PRESENT)
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.
factory recommended setting.
NOTE: Refer to the following steps in this Service Manual
for the recommended factory settings.

3121623 6-91
 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
After having inserted the relevant password “3684” by this are dedicated to only one setting.
page it's possible to set machine model pressing button By PASSWORD page it's possible to insert the password
n.1, and to set power supply version pressing button n.7. required pressing the keyboard buttons, password are
After this setting machine need to be REBOOT by the main composed by 4 numbers, if password is accepted display
key reset will visualize an “OK”.

PASSWORD
VERSION
0
MODEL:
LL2614 0
ENGINE:
LITHIUM 0

0
1 MODEL
7 ENGINE 9 ESC
3 SAVE
9 ESC
MAF00660
MAF00640
Setup - Date
Setup - Time By this page is visualized the settled time, after having
By this page is visualized the settled time, after having inserted the relevant password “1468” it's possible to
inserted the relevant password “8262” it's possible to adjust it, pressing buttons n.1 to modify the day, buttons
choose the time-zone pressing buttons n.1 or n.2, ZONE: 0 n.2 to modify the month and n.3 or n.4 to modify the year.
is the time in meridian “0”.

DATE
TIME
5 11
8 : 34 : 05 2016

ZONE: 2
9 ESC
1 ZONE. +
7 ZONE. –
MAF00670

9 ESC
MAF00650

6-92 3121623
 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” of the load cell system, by it's necessary to calibrate the tilt levelling system.
this procedure the calibration parameters relevant to the
load cell sensor installed will be memorized on the ECM1. NOTE: Ensure the tilt switch is mounted at distance of 15
mm and securely attached on the bracket plate,
Being possible difference between one load cell sensor
with the screws 5x45 TCEI and Loctite.
and another it's necessary to calibrate ECM1 with the load
cell sensor installed on the machine and not with another.
The load sensor system reset must be done with the bas-
ket unloaded from its support.
The reset the load sensor system consist into saving the
value “0”, done without the basket, here follows the cali-
bration procedure:
1. Turn ON the main key and stay out from the bas-
ket with remote control on hands.
2. Press button n.6 (SERVICE) and then press but-
ton n.7 (SETUP).
3. Press button n.5 (PASSWORD). The display will
ask for the password.
4. Inserting password 6138 the display will confirm
with “OK”.
5. Press button n.9 (EXIT) and then button n.7
(LOAD SENS), the display will than visualize the NOTICE
page here below: A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE TIME
UNTIL THE FOLLOWING PROCEDURE IS PERFORMED.
LOAD SENS.
CALIBRATI ON
DO NOT CALIBRATE THE LEVEL SENSOR EXCEPT WITH A MACHINE LEV-
MACCHINA: NOT ELLED. PLACE THE MACHINE ON OUTRIGGERS, WITH BOOMS IN
READY STOWED POSITION AND ALIGNED WITH THE PHOTOCELLS AND THE
BASKET EMPTY. ENGINE AND ELECTRICAL MOTOR MUST BE SWITCHED
OFF (AVOIDING VIBRATIONS).
Start of the calibration procedure:
3 CALIB.
1. Turn ON the main key and wait for display
9 ESC switching ON.
MAF00680 2. Press button n.6 (SERVICE) and then press but-
6. With the basket unloaded from its support press ton n.7 (SETUP).
button n.3 (CALIB) and verify that display indi- 3. Press button n.5 (PASSWORD). The display will
cates “OK”. In case of the basket is still loaded on ask for the password.
its support this page will display “NOT READY” 4. Inserting password 2857 the display will confirm
instead of “READY” and reset will not be possi- with “OK”.
ble.
5. Press button n.9 (EXIT) and then button n.8
7. Press button n.9 (ESC) and then turn OFF the (INCLIN.), the display will than visualize the page
main key. here below.
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.

3121623 6-93
 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. --> Initialization, modem is not ready
READY to communicate.
3 CALIB. READY --> Modem is ready to communi-
cate
9 ESC
SIM: NO --> SIM CARD not present (STATUS will
MAF00690 be INIT.)
6. With machine perfectly levelled and motors OK --> SIM CARD present
switched OFF. Press button n.3 (CALIB) and verify
that display indicates “OK”. In case of outriggers OPERATOR: Shows the network operator, for instance
are not touching the ground, or photocells are TIM
not aligned, engine or electrical motor is
switched on, this display will show “NOT READY” RSSI: 0 - 100 --> SIM CARD operator signals,
instead of “READY” and reset will not be possi- need to be over 50 to have a good con-
ble. nection
7. Press button n.9 (ESC) and then turn OFF the BER: 0 - 100 --> network line signals
main key.
8. Turn ON again the main key and verify at INPUT GPRS: Ok --> GPRS signal available
"INCLIN. X" and "INCLIN. Y".
To verify the calibration is accurate, test out the
values at different machine gradient position. MODEM
STATUS :
Setup - Extra INITIALIZ
EXTRA menu gives the access to other settings and under SIM OK
menus. OPERATOR
The here aside picture shows the EXTRA menu display, I TIM
from EXTRA menu pressing button from n.1 to n.6 it's pos- RSSI : 22
sible to enter into further pages. Pressing button n.9 (ESC) BER : 10
brings back to the SETUP menu. GPRS: Ok

9 ESC
MAF00710
EXTRA
Setup - Extra - GPS
1 OPTIONAL
2 FIRMWARE This page shows RAHM references, the position availabil-
ity, latitude and longitude, date and hours references
3 CARDS
4 MODEM
5 GPS GPS

FIX: OK
9 ESC LATIT.:
45,20
LONGI.:
MAF00700 11,03

9 ESC

MAF00720

6-94 3121623
 SECTION 6 - JLG CONTROL SYSTEM

Optional (Page1) Beeper

OPTIONAL menu gives the access to other settings. By this page, if is installed the optional warning buzzer, it's
possible to set the motion alarm, after having inserted the
The here aside picture shows the OPTIONAL menu first relevant password "8365".
page display, from which pressing button from n.1 to n.6
it's possible to enter some settings. The motion alarm is activated depending on the BEEPER
menu setting.
Pressing button n.8 it's possible to enter into a second
page of settings, shown below. If it's selected ALL the warning buzzer is activated at all the
machine movements, both aerial part and ground part.
Pressing button n.9 (ESC) brings back to the EXTRA menu.
If it's selected FALL the warning buzzer is activated at the
aerial part lowering moment and telescope retraction.
OPTIONAL If it's selected WARN the warning buzzer is activated in the
same condition or the remote control beeper.
1 PEDAL
2 BEEPER
3 D SPEED BEEPER
4 EL MOT.
5 LAMPS
6 CHK INC 1 ALL *
2 FALL
7 PREV. 3 WARN
8 NEXT
9 ESC 9 ESC
MAF00730
MAF00750

Pedal
By this page it's possible to set the pedal, after having Second Speed
inserted the relevant password "4771", pressing button n.1 By this page it's possible to set the second speed (Hare),
“ON” pedal will be activated, pressing button n.2 “OFF” after having inserted the relevant password "5216", press-
pedal will be deactivated. ing button n.1 “ON” second speed will be activated, press-
ing button n.2 “OFF” second speed will be deactivated.

PEDAL
D SPEED

1 ON 1 ON *
2 OFF * 2 OFF

9 ESC
9 ESC
MAF00740

MAF00760

3121623 6-95
 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” machine will be set
for 2.2 KW electric motor, pressing button n.2 “1.2 KW” it Pressing button n.7 it's possible to come back to the first
will be set for 1.2 KW electric motor. page of settings.
The main difference between the two settings is in the Pressing button n.9 (ESC) brings back to the EXTRA menu.
auto-stabilization procedure steps timing.
OPTIONAL

EL MOT. 1 SERVICE
2 RC SPEE
3 RC MOV
4 AD TEST
1 2,2 KW *
5 AS TEST
6 SKYGUARD
2 1,2 KW
7 PREV.
9 ESC 8 NEXT
9 ESC
MAF00770
MAF00790

Lamps Service
By this page it's possible to set the outriggers lights, after By this page it's possible to set the service reminder, after
having inserted the relevant password “6661”, pressing having inserted the relevant password “4538”, pressing
button n.1 “ON” outriggers lights will be steady on while button n.1 “ON” service reminder will be activated, press-
they are touching the ground, pressing button n.2 ing button n.2 “OFF” it will be deactivated.
“FLASH” outriggers lights will be flashing while they are
touching the ground. The amount of hours considered is the sum of engine and
electric motor ones.
Pressing button n.3 “RESET” those hours counter is reset,
LAMPS keeping pressed button n.5 with buttons n.7 and n.8 it is
modified. Instead keeping pressed button n.6 with but-
tons n.7 and n.8 is modified the service hours amount.
1 ON

2 FLASH *
SERVICE
HOURS:
9 ESC
0
SERV:
50
MAF00780

0 1 ON
2 OFF
2 3 RESET
3
4 9 ESC
MAF00800

6-96 3121623
 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. certain movements.
After having inserted the relevant password “4771”, press- After having inserted the relevant password “4771”, press-
ing button n.1 “ON” second speed will be activated, press- ing button n.1 “ON” and restarting by the main key it will
ing button n.2 “OFF” it will be deactivated. be activated, pressing button n.2 “OFF” and restarting by
the main key it will be deactivated.
“REBOOT” indication means that the machine has to be
RC SPEED restarted by the main key to activate the function.

1 ON
2 OFF * SKYGUARD

1 ON
9 ESC
2 OFF *

MAF00810
REBOOT
REBOOT
RC Move
By this page it's possible to set the RC MOVE function,
when it is activated it binds the operator standing out 9 ESC
from the basket to press button n.8 to move tracks
MAF00830
After having inserted the relevant password "4771", press-
ing button n.1 "ON" second speed will be activated, press- Optional (Page 3)
ing button n.2 "OFF" it will be deactivated.
The here aside picture shows the OPTIONAL menu third
page display.
RC MOVE 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.
1 ON
2 OFF *
OPTIONAL

1 CHG SET
9 ESC 2 INV SET

MAF00820

7 PREV.
8 NEXT
AD Test
9 ESC
Not consider.
MAF00840

AS Test
Not consider.

3121623 6-97
 SECTION 6 - JLG CONTROL SYSTEM

CHG Set BMS TST

For a lithium machine, by this page it's possible to set the For a lithium machine, by this page it’s possible to test the
maximum charging current, after having inserted the rele- lithium cells heaters by pressing button n.1, and test the
vant password “1138”, pressing button n.1 it will be settled fans of cooling system by pressing button n.2, in both the
25 Amp, pressing button n.2 it will be settled 18 Amp. cases they will be working with a countdown of 30 sec-
This setting, considering the transformation rate, has to onds.
respect the maximum current available on local electric
plug.
BMS

CHG SETUP HEATER

1 OFF
1 STANDARD COOLING
2 1,2 KW 2 OFF

25 9 9 ESC
MAF00880
9 ESC

MAF00850
NOTE: Some pages are not accessible, or could not show
same information, if not after having inserted the
relevant password.
INV Set
For a lithium machine, by this page it's possible to setup
the rpm setting for a new inverter, pressing button n.1 the
rpm setting will be settled according to the machine
model settled by the relevant menu, check chapter
10.1.9.2.

INV SETUP

1 SETUP

9 ESC
MAF00860

BMS Set
For a lithium machine, by this page it’s possible to set the
bms serial number, it has to be done in case of bms
replacement.

BMS

S
000000000

8 9 ESC
MAF00870

6-98 3121623
 SECTION 6 - JLG CONTROL SYSTEM

6.10 JOYSTICK
From the SERVICE menu, pressing button 8 ”JOYSTICK” accesses the menu JOYSTICK to visualize the numeric values.

Engine Key Switch ON. Joystick Fully stroking (both direction)

Value = 127
USE Buttons 1 or 2 to choose the JOYSTICK.

Joystick Neutral position

Value = 0

3121623 6-99
 SECTION 6 - JLG CONTROL SYSTEM

6.11 CALIBRATING JOYSTICK 1. Turn Engine and Electrical Motor OFF.

This menu allows the calibration on Joystick replacement. 2. Press at the same time the 3 buttons below for at
least 7 seconds, until “JOY TEACH” appears.
NOTICE 3. Move each Joystick fully stroking on both direc-
A NEW JOYSTIC WILL ACT AS IT IS AWAITING UNTIL THE FOLLOWING tion.
PROCEDURE IS PERFORMED. 4. Press Button 7 to escape.

6-100 3121623
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

SECTION 7. GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.1 GENERAL presented in this section or which is not corrected by

listed corrective actions, technically qualified guidance
This section contains schematics to be used for locating should be obtained before proceeding with any mainte-
and correcting most of the operating problems which nance.
may develop. If a problem should develop which is not

IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH AREAS CON-
TAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF
12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR
BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.

7.2 MULTIMETER BASICS Min/Max

A wide variety of multimeters or Volt Ohm Meters Use of the "Min/Max" recording feature of some meters
(VOM) can be used for troubleshooting your equip- can help when taking measurements of intermittent
ment. A digital meter with reasonable accuracy (within conditions while alone. For example, you can read the
7%) is recommended for the measurements in these voltage applied to a solenoid when it is only operational
procedures. This section shows diagrams of a common, while a switch, far from the solenoid and meter, is held
digital VOM configured for several different circuit mea- down.
surements. Instructions for your VOM may vary. Please
consult the meter operator’s manual for more informa- Polarity
tion.
Finding a negative voltage or current reading when
Grounding expecting a positive reading frequently means the leads
are reversed. Check what reading is expected, the loca-
"Grounding the meter" means to take the black lead tion of the signal and that the leads are connected to
(which is connected to the COM (common) or negative the device under test correctly. Also check that the lead
port) and touch it to a good path to the negative side of on the "COM" port goes to the ground or negative side
the voltage source. of the signal and the lead on the other port goes to the
positive side of the signal.
Backprobing
Scale
To "backprobe" means to take the measurement by
accessing a connector’s contact on the same side as the M = Mega = 1,000,000 * (Displayed Number)
wires, the back of the connector. Readings can be done k = kilo = 1,000 * (Displayed Number)
while maintaining circuit continuity this way. If the con-
nector is the sealed type, great care must be taken to m = milli = (Displayed Number) / 1,000
avoid damaging the seal around the wire. It is best to
µ = micro = (Displayed Number) / 1,000,000
use probes or probe tips specifically designed for this
technique, especially on sealed connectors. Whenever Example: 1.2 k = 1200 
possible insert probes into the side of the connector
such that the test also checks both terminals of the con- Example: 50 mA = 0.05 A
nection. It is possible to inspect a connection within a
closed connector by backprobing both sides of a con-
nector terminal and measuring resistance. Do this after
giving each wire a gentle pull to ensure the wires are
still attached to the contact and contacts are seated in
the connector.

3121623 7-1
 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) Resistance should read a short circuit (very low resis-
• Use firm contact with meter leads tance)
• Circuit power must be turned OFF before testing resis-
tance
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
• Use firm contact with meter leads

7-2 3121623
 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 • Be sure to connect the meter leads to the correct jacks
• Circuit power must be turned OFF before testing con- for the current range you have selected
tinuity • If meter is not auto ranging, set it to the correct range
• Disconnect component from circuit before testing (See multi meter’s operation manual)
• Use firm contact with meter leads • Use firm contact with meter leads
• First test meter and leads by touching leads together.
Meter should produce an audible alarm, indicating
continuity

3121623 7-3
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Continuity Measurement Over Long Distances 3. On one side, jumper from contact of wire #1 and wire
#2.
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- used for this test. If there is not continuity, either wire
sively long leads. Using the other wires in the harness could be bad. Check connections and measurement
one can determine the condition of a particular wire in setup. Redo measurement. If still no continuity, repair
the harness. wires or consult schematic for other wires to use for
test.
Requirements:
5. Jumper from wire under test to wire #1.
• Harness with at least three separate wires including 6. Measure continuity. If there is continuity, the wire
the wire under test. under test is good. Resistance of a wire increases as
• These wires must be able to be isolated from other the length increases and as the diameter decreases.
wires, etc. One can find the continuity of two wires, here #1 and #2,
• Jumper or method to connect contacts on one side at once by following steps 1 through 4. If there is a prob-
of harness. lem the third wire is used to troubleshoot the other
• Meter that can measure resistance or continuity. wires. To find the problem, start at step 1 and use the
entire procedure.
Procedure
Test multimeter leads resistance. Subtract this value 7.3 ELECTRICAL SCHEMATICS MANUALS
from the measured resistance of the wires to get a more The electrical schematics manuals are separate from this
accurate measurement. manual. They are available online (Online Express or
Consult the circuit schematic to determine which wires www.jlg.com - Manuals) in the same folder where this
to use in addition to wire under test, here called wire #1 Service Manual was found.
and wire #2, and how to isolate these wires. These wires Here is a listing of the schematic manuals available:
should appear in the same connectors as the wire under
test or are within reach of the jumper. X17JP/X500AJ and X20JP/X600AJ -
Machines prior to S/N-C170000893. . . . . . . . . . 3121762
1. Disconnect all connections associated with the wire X17JP/X500AJ and X20JP/X600AJ -
under test and the two additional wires. If harness is Machines S/N-C170000893 to Present . . . . . . . 3121763
not completely isolated disconnect battery terminals
also, as a precaution. X26JP/X770AJ -
Machines prior to S/N-C170000944 . . . . . . . . . 3121764
2. Measure continuity between all three wires, the wire
under test, wire #1 and wire #2. These should be X26JP/X770AJ -
open. If not, repair the shorted wires or replace the Machines S/N-C170000944 to Present . . . . . . . 3121765
harness.

7-4 3121623
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.4 X17JP-X500AJ AND X20JP-X600AJ - HYDRAULIC SCHEMATICS

Figure 7-5. X17JP/X500AJ - X20JP/X600AJ - Hydraulic Schematic - 1 of 3

3121623 7-5
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-6. X17JP/X500AJ - X20JP/X600AJ - Hydraulic Schematic - 2 of 3

7-6 3121623
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-7. X17JP/X500AJ - X20JP/X600AJ - Hydraulic Schematic - 3 of 3

3121623 7-7
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.5 X26JP-X770AJ - HYDRAULIC SCHEMATICS

TO THE BOOM
COMPONENT
VALVEBLOCK

Figure 7-8. X26JP/X7700AJ - Hydraulic Schematic - 1 of 2

7-8 3121623
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

FROM THE
DEVIATOR VALVE

Figure 7-9. X26JP/X770AJ - Hydraulic Schematic - 2 of 2

3121623 7-9
 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

NOTES:

7-10 3121623
 Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533 USA
(717) 485-5161 (Corporate)
(877) 554-5438 (Customer Support)
(717) 485-6417

Visit our website for JLG Worldwide Locations.

www.jlg.com