JLG Boom Lift X13SJP - X13SJN Service & Maintenance Manual 31220629 2025

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JLG Boom Lift X13SJP - X13SJN Service & Maintenance Manual 31220629 2025
Size: 11.11 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Service & Maintenance Manual, Hydraulic Diagram
Model: JLG X13SJP - X13SJN Boom Lift
Part Number: 31220629
Publication Date: 2025
Number of Pages: 115 Pages

Contents:
Section 1. SPECIFICATIONS

1.1 Capacities​

1.2 CAPACITIES Track specifications​

1.3 POWER SOURCE​

1.4 Specifications and Performance Data​

Reach Specifications​

Dimensional Data​

Function Speed Data​

Machine Orientation When Performing Speed Tests​

1. Stop watch should be started with the function, not with the controller or switch.​

2. All speed tests are run from ground with remote control connected on the platform.​

3. Function speeds may vary due to cold, thick hydraulic oil. Test should be run with the oil temperature above 100° F (38° C).​

1.5 Hydraulic PRESSURE SETTINGS - PSI (BAR)​

1.6 Lubrication​

Hydraulic Oil​

1.7 SERIAL NUMBER LOCATION​

1.8 Fastener Torque Charts​

Section 2. GENERAL

2.1 Machine Preparation, Inspection, and Maintenance​

General​

Preparation, Inspection, and Maintenance​

Pre-Start Inspection​

Pre-Delivery Inspection and Frequent Inspection​

Annual Machine Inspection​

Preventive Maintenance​

2.2 Service and Guidelines​

General​

The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this book.​

Safety and Workmanship​

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in ...​

Cleanliness​

1. The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provi...​

2. At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter.​

3. Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their co...​

Components Removal and Installation​

1. Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be parallel to each other and as near perpendicular as possible to top of part being lifted.​

2. Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90 degrees.​

3. If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., have been removed and that no adjacent parts are interfering.​

Component Disassembly and Reassembly​

When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any ...​

Pressure-Fit Parts​

When assembling pressure-fit parts, use an anti-seize or molybdenum disulphide base compound to lubricate the mating surface.​

Bearings​

1. When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing.​

2. Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.​

3. If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearings until they are ready to install.​

4. Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race.​

Gaskets​

Bolt Usage and Torque Application​

1. Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only t...​

2. Unless specific torque requirements are given within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in accordance with recommended shop practices. (See Torque Chart Section 1.)​

Hydraulic Lines and Electrical Wiring​

Hydraulic System​

1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system.​

2. Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate components, as required, to aid assembly.​

Lubrication​

Battery​

Lubrication and Servicing​

2.3 Lubrication and Information​

Hydraulic System​

1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenanc...​

2. The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty opera...​

3. Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil.​

4. It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is...​

Hydraulic Oil​

Changing Hydraulic Oil​

1. Filter elements must be changed after the first 50 hours of operation and every 300 hours (unless specified otherwise) thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this ...​

2. Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to clean all possible contaminants from the service container. Always clean the mesh element of the filter and replac...​

3. While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service.​

Lubrication Specifications​

Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose grease requirements.​

2.4 Cylinder Drift Test​

Cylinder Drift​

2.5 Pins and Composite Bearing Repair Guidelines​

2.6 Welding on JLG Equipment​

Do the Following When Welding on JLG Equipment​

Do NOT Do the Following When Welding on JLG Equipment​

Section 3. CHASSIS & TURNTABLE

3.1 RUBBER TRACK MAINTENANCE/REPLACEMENT​

Checking Track Tension​

Tensioning Rubber Track​

Removing Rubber Track​

1. To loosen the track, slowly unscrew grease release valve (1) counterclockwise for no more than a turn. If the grease does not start drain, slowly rotate the track. If also in this case the grease not emerges repeat the rotation of a lap of the val...​

2. Use a pry bar (4) of adequate length to force a tooth of the central wheel out of the idler, then rotate the track slowly (5) using the pry bar to help it out, if necessary. Force (6) sideways to slide the track and lift it from the idler.​

Installing Rubber Track​

1. Starting with the machine undercarriage raised in conditions of safety provided of suitable supports stable below the undercarriage frame to support the machine.​

2. Check that the grease contained in the hydraulic cylinder has been removed.​

3. Mesh the track links with the track teeth of sprocket wheel and place the other end of the track on the idler.​

4. Rotate the drive wheel to reverse slowly (7) pushing into the frame. If necessary, help yourself with a pry bar (8), especially to “walk” the first teeth in past the idler.​

5. Make sure that the track links are properly meshed in the sprocket and idler.​

6. Adjust the track tensioning “Tensioning rubber track".​

7. Lower the undercarriage down to the ground.​

3.2 UNDERCARRIGE COMPONENTS​

Machine Positioning​

1. Stabilize the machine on level ground.​

2. Fully extend the undercarriage.​

3. Remove the tracks (see sub-section 3.1).​

4. Remove the key ignition, and a tag with warning do no start the machine.​

Replacement Roller Lower Wheel and Tracks Adjuster​

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. Install the front idler 5.​

3. Install the lower roller 3.​

4. Apply loctite 243 and torque the nuts 2 on the lower roller at 125 Nm (92 ft. lbs.).​

Replacement Sprocket and Gear Motor​

Sprocket Removal​

1. Fully extend the undercarriage.​

2. Remove the tracks (see sub-section 3.1).​

3. Remove the key ignition, and a tag with warning do not start the machine.​

4. Remove screws 6.​

5. Remove the sprocket 7.​

Gear Motor Removal​

1. Remove cover 9.​

2. Disconnect and tag the hydraulic hoses from the gear motor.​

3. Remove the valve 10 to access all the screws 11 (on single speed versions only).​

4. Remove the screws 11.​

5. Remove the motor 12.​

Gear Motor Installation​

1. Fix the screws 11.​

2. Instal the valve 10.​

3. Connect the Hydraulic hoses.​

4. Instal the cover 9.​

Sprocket Installation​

1. Instal the sprocket.​

2. Instal the screws 6.​

3.3 Tracks EXTENSION REMOVAL​

3.4 Track Drive​

Product Identification​

3.5 Swing Drive (imo)​

Technical Data – Type Plate​

Structure and Function​

1. Connection for options: Potentiometer, permanent 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​

Structure and Function​

Maintenance Tasks​

1. Detached bolt​

Lubricating The Slew Drive​

1. Fresh lubricant.​

2. Lubricating nipple, bearing ring.​

3. Lubricating ring housing.​

4. In succession, press grease into all lubricating nipples while simultaneously turning the slew drive all the way through, until a continuous collar of grease forms under at least one seal.​

5. Ensure that old lubricant can escape without obstruction.​

3.6 Power System X13SJP - X13SJN​

Lithium Powered Units​

48V Lithium Battery System​

System Function​

Lithium Cells​

Battery Charger​

DC-DC Transformer​

Electric Motor​

Electric Motor Three-Phase Control Speed System​

Temperature Ongoings (Heaters and Fans)​

Diagnostics and Fault Codes​

Lithium System Components Location​

Section 4. BOOM & PLATFORM

4.1 BOOM MAINTENANCE​

Removal of the Boom Assembly​

1. Remove the platform and platform support as follows:​

2. Remove the boom from the turntable (turret) as follows:​

Disassembly of the Main Boom​

1. Loosen jam nuts on aft end of fly boom wear pad adjustment and loosen adjustments.​

2. Using a portable power source, attach hose to telescope cylinder port block. Using all applicable safety precautions, activate hydraulic system and extend cylinder to gain access to cylinder rod retaining pin. Shut down hydraulic system.​

3. Carefully disconnect hydraulic hose from retract port of cylinder. There will be initial weeping of hydraulic fluid which can be caught in a suitable container. After initial discharge, there should be no further leakage from the retract port.​

4. Remove hardware securing telescope cylinder to the fly boom section, then remove pin from fly.​

5. Remove hardware securing telescope cylinder to the base boom section.​

6. Using a suitable lifting device, remove telescope cylinder from boom sections.​

7. Using a piece of tape, mark the length of hoses and wires from front of fly boom and bottom of base boom for reassembly.​

8. Remove hardware securing the front wear pads on base boom section, remove wear pads.​

9. Remove hardware securing the powertrack to the aft end of the fly boom section.​

10. Using a suitable lifting device, remove fly boom from boom section.​

11. Remove hydraulic lines and electrical cables from powertrack.​

12. Remove hardware securing powertrack to the base boom section. Remove powertrack.​

Inspection​

1. Inspect all boom pivot pins for wear, scoring or other damage, and for tapering or roundness. Replace pins as necessary.​

2. Inspect lift cylinder pins for wear, scoring or other damage, and for tapering or roundness. Ensure pin surfaces are protected prior to installation. Replace pins as necessary.​

3. Inspect telescope cylinder rod attach pin for wear, scoring or other damage. Replace pin as necessary.​

4. Inspect inner diameter of boom pivot bushings 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 twisting. 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. Ins tall powertrack to the attach point on the base boom section. Secure powertrack with the attaching hardware.​

2. Install hydraulic lines and electrical cables into the powertrack.​

3. Install wear pads to the aft end of the fly section.​

4. Using suitable lifting equipment, slide fly section into the base section until powertrack attach point aligns with holes in side of base section.​

5. Attach the powertrack to the aft end of fly boom section. Secure powertrack with the attaching hardware.​

6. Using suitable lifting equipment, slide fly boom section out to gain access to telescope 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 section.​

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 telescope cylinder’s approximate center of gravity, and lift the cylinder to the aft end of the boom assembly.​

11. Slowly slide the telescope cylinder into boom assembly, align rod end with attach point in fly section. Insert pin and secure with retaining ring.​

12. Slowly slide the telescope cylinder into boom assembly, align barrel end with attach point in fly section. Insert pin and secure with retaining ring.​

13. Install wear pads at front of base boom section. Adjust the wear pads to zero clearance.​

14. Adjust pads alternately side to side, so that fly boom section is centered in base boom section (lower wear pad with 1 mm gap).​

15. Turn the wear pad to expose the groove on the head to insert the cotter.​

16. Disconnect auxiliary power source from telescope cylinder.​

Installation of the Boom Assembly​

1. Using suitable lifting equipment, position boom assembly on turntable so that boom pivot holes in both boom and turntable are aligned.​

2. Install boom pivot pin, ensuring that location of 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 structure. 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 control station.​

8. Using all safety precautions, operate machine systems and extend and retract boom for four or five cycles.​

9. Shut down machine systems and check for leakage.​

4.2 Wire Rope and Pulleys​

Inspection​

1. Inspect ropes for broken wires, particularly valley wire breaks and breaks at end terminations.​

2. Inspect wire ropes for corrosion.​

3. Inspect wire ropes for kinks or abuse.​

4. Inspect sheaves for condition of bearing/pins.​

5. Inspect sheaves for condition of flanges.​

6. Inspect sheaves with a groove wearout gauge for excessive wear.​

7. Wire ropes passing inspection should be lubricated with wire rope lubricant prior to assembly.​

Three Month Inspection​

1. Remove all protection sumps from the third arm and the two extensions. Use a flashlight 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 millimeters.​

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 all rope fixing nuts and the respective rocker arms; recommended torque 7.4 ft-lbs (10 Nm).​

Seven Year or 3000 Hours Replacement​

4.3 Ropes Tension Adjustment Procedure​

4.4 PROXIMITY SENSOR ADJUSTMENT​

4.5 PLATFORM REMOVAL/INSTALLATION​

Removal​

1. Remove the platform/remote control box from the mounting support.​

2. Loosen and remove the aluminium caps that secure the platform to the jib platform mounting posts.​

3. Lift the platform off the mounting posts in an upward direction. Place platform aside for later installation.​

Installation​

1. Lift the platform and align the platform mounts with the jib mounting posts and lower until seated.​

2. Secure the platform to the jib mounting posts with the aluminum threaded caps. Do not overtighten.​

3. Re-install the platform/remote control box into the mounting support on the platform.​

4.6 SKYGUARD INSTALLATION - ONE PERSON PLATFORM​

Options/Accessories Prohibited When Installing This Kit:​

Tools & Equipment Required:​

Personnel Required:​

Parts List:​

Procedure:​

1. Park the machine on the firm level surface, fully retract & lower the boom.​

2. Extend all the four outriggers, set them to the auto levelling mode and set the machine to rest position.​

3. Remove the key and shut the engine OFF.​

4. Allow the machine and system fluids to cool.​

5. Disconnect the battery power from the machine.​

For Reference:​

Installation:​

1. Install the SkyGuard Support Bracket (8) onto the welded mounts on platform rails. Secure the support bracket using four Bolts (2), relevant Washers (7) and Nuts (3). See Figure 4-25.​

2. Align and attach Platform Sensor Mount (12) onto the SkyGuard Switch (11) as shown in Figure 4-26.​

3. Attach Platform Sensor Covers (9) to SkyGuard switch assembly at both ends. See Figure 4-26.​

4. Position SkyGuard switch assembly with sensor cover onto the SkyGuard Support Bracket (8) as shown in Figure 4-27.​

5. Insert a Shear Block Support (10) through shear block housing on the SkyGuard support bracket and into the platform sensor mount. See Figure 4-27.​

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 4-27.​

7. Secure the SkyGuard switch assembly using Bolt (5) and relevant Washer (6) on platform sensor mount. See Figure 4-27.​

8. Repeat Steps 4 through 7 to secure SkyGuard switch assembly on the other side of the Sky- Guard support bracket ensuring correct position of the shear block support before installation.​

9. Route the SkyGuard switch harness along Sky- Guard support bracket (right side) and under the platform control box. Secure the harness using tie straps. See Figure 4-28.​

10. Connect Sky Guard connector to the one on the machine located under load cell box. See Figure 4-29.​

11. POWER ON the machine.​

12. Check for the proper functioning of SkyGuard system.​

SkyGuard System​

Section 5. HYDRAULICS

5.1 General​

5.2 Chassis Hydraulic System​

1. Front Left Outrigger​

2. Rear Left Outrigger​

3. Tracks Widening System​

4. Front Right Outrigger​

5. Rear Right Outrigger​

D1. Right side and main boom​

D2. Left side and aerial section​

D3. Pump sum (feeds D2 line when energized)​

Outriggers​

Tracks Widening​

5.3 Boom, Platform & Turntable Hydraulic System​

5.4 cylinder Repair​

Specification - Cylinders Overview​

Hydraulic Cylinders Torque Specifications​

Screws Torque Specifications​

Cylinder Assembling​

1. Screw the head into the cylinder barrel and tighten with a spanner wrench. Refer to “Hydraulic Cylinder Torque Specifications” for tightening guidelines for the head.​

2. Thread the counterbalance valve into the block on the cylinder barrel.​

Cylinder Repair Without Sensor​

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 equipment if possible.​

3. Remove the counterbalance valve from the side of the cylinder barrel.​

4. When the cylinder has been emptied pull out the rod ~ 15mm and loosen the head until ~ 15mm.​

Piston With Nut Disassembling​

1. Fix the rod into the vice.​

2. Avoid overheating, or the parts may become distorted or damaged.​

3. Remove the piston head from the rod and carefully slide the head gland off the end of the rod.​

Cylinder Assembly​

1. Use the proper tools for specific installation tasks. Clean tools are required for assembly.​

2. Install new seals, backup 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 Cylinder Torque Specifications” for tightening gui...​

Seals Head Replacing​

1. Remove all seals, backup rings and o-rings from the piston head and all seals, backup rings and o-rings.​

2. Install new seals, backup rings and o-rings on the piston and the head using the proper tool.​

Cylinder Inspection​

1. Inspect internal surfaces and all parts for wear, damage, etc. If the inner surface of the tube does not display a smooth finish, or is scored or damaged 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.​

4. Install the piston on to the end of the cylinder rod. Loctite® 270TM.​

Bushes Replacement​

1. Carefully grind the bush with a milling cutter for plastic.​

2. After that the bushing has been removed inspect the internal surface.​

3. Replace the bush with a new one and put it inside with a press.​

Emptying Of The Cylinder​

Vent Valve​

Purge screw​

5.5 REPLACEMENT HYDRAULIC PUMP​

Pump Removal​

1. Open the top cap of the hydraulic oil tank.​

2. Tag & disconnect the hoses from the pump 15.​

3. Loose screws 16.​

4. Remove from the pump 15 from the adapter 12.​

5. Loosen nut 10 and remove the coupling 11 and plate 14 from the pump shaft 15.​

6. Move the new pump the particular 14.​

Pump Installation​

1. Install the 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.​

5.6 Hydraulic Diagram​

Section 6. JLG CONTROL SYSTEM

6.1 Introduction​

6.2 Platform - Remote Control Station​

LCD Display Screen​

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:​

Only Lithium Icons​

6.3 Diagnostic By Service Menu​

Menu Input​

Only Lithium Input​

Language Menu​

Error Menu​

Working Hours Menu​

1. Press button 7 “SETUP”.​

2. Press button 5 “PASSWORD”.​

3. Press button 9 “ESC” two times.​

4. Press button 6"W:HOURS”.​

5. Press button 9 ESC 3 times to escape.​

Joystick Menu​

6.4 Machine Setup Menu​

Setup - Version​

Setup - Time​

Setup - Password​

Setup - Date​

Setup - Load Cell Board (ECM3) Calibration​

1. Turn ON the main key and stay out from the platform with remote control on hands.​

2. Press button n.6 (SERVICE) and then press button 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 page here below:​

6. With the platform unloaded from its support press button n.3 (CALIB) and verify that display indicates “OK”. In case of the platform is still loaded on its support this page will display “NOT READY” instead of “READY” and reset will no...​

7. Press button n.9 (ESC) and then turn OFF the main key.​

8. Turn ON again the main key and verify by INPUT "LOAD A" and "LOAD B" that calibration is correct by checking the variation at several platform loading condition, the difference between LOAD A and LOAD B values should be less than a certain value.​

Setup - Acceler (Calibrating Tilt Sensor)​

Do not calibrate the level sensor except with a machine levelled. Place the machine on outriggers, with booms in stowed position and aligned with the photocells and the platform empty. Engine and electrical motor must be switched OFF (avoiding vibrat...​

1. Turn ON the main key and wait for display switching ON.​

2. Press button n.6 (SERVICE) and then press button n.7 (SETUP).​

3. Press button n.5 (PASSWORD). The display will ask for the password.​

4. Inserting password 2857 the display will confirm with “OK”.​

5. Press button n.9 (EXIT) and then button n.8 (INCLIN.), the display will than visualize the page here below.​

6. Press button n.9 (ESC) and then turn OFF the main key.​

7. Turn ON again the main key and verify at INPUT "INCLIN. X" and "INCLIN. Y".​

Setup - Extra​

Setup - Extra - Modem​

Setup - Extra - GPS​

Optional (Page1)​

Optional (Page 2)​

Optional (Page 3)​

6.5 MASTER BOARD (ECM1) REPLACEMENT AND SETTING​

New Master Board​

1. Connect the remote control at its ground cable and select the control position accordingly by the control position selector switch.​

2. Turn ON the main key and select the correct machine model with button n.1 (VERSION), the display shows the machine model selected.​

3. In case of the engine model selected is not correct with button n.7 (MOTOR) select the correct one (for instance “D.RPM” is the diesel Hatz 1B40 and “G.13L” is the gasoline Honda iGX390).​

4. Press button n.3 (SAVE) to save the setting.​

5. Switch the main key OFF and ON again to restart it.​

6. Press and release the remote control emergency button to esc the SAFETY STATE.​

7. The display will show “LOAD CAL” and “INCL CAL”, following the procedures of appendixes 2 and 1 calibrate the load cell system and the tilt sensor.​

8. Following the relevant procedures set the other settings, as ramps and currents.​

Already Initialized Master Board​

Software Recovery By Modem​

6.6 CODE MENU​

Section 7. GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.1 General​

7.2 Multimeter Basics​

Grounding​

Backprobing​

Min/Max​

Polarity​

Scale​

Voltage Measurement​

Resistance Measurement​

Continuity Measurement​

Current Measurement​

Continuity Measurement Over Long Distances​

When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a p...​

Requirements:​

Procedure​

Test multimeter leads resistance. Subtract this value from the measured resistance of the wires to get a more accurate measurement.​

1. Disconnect all connections associated with the wire under test and the two additional wires. If harness is not completely isolated disconnect battery terminals also, as a precaution.​

2. Measure continuity between all three wires, the wire under test, wire #1 and wire #2. These should be open. If not, repair the shorted wires or replace the harness.​

3. On one side, jumper from contact of wire #1 and wire #2.​

4. Measure continuity between wire #1 and wire #2. If there is continuity, both wires are good and can be used for this test. If there is not continuity, either wire could be bad. Check connections and measurement setup. Redo measurement. If still no...​

5. Jumper from wire under test to wire #1.​

6. Measure continuity. If there is continuity, the wire under test is good. Resistance of a wire increases as the length increases and as the diameter decreases.​

7.3 ELECTRICAL SCHEMATICS MANUALS​