Home

Service & Maintenance Manual

1. 1 Sequence Cable Adjust Nut 4 Mast Section 3 T Check Mast Stowed Height 10 Chain Lock Nut 2 Mast Section 1 5 Mast Section 4 8 Chain Anchor Plate 11 Threaded Chain End 3 Mast Section 2 6 Mast Section 5 9 Chain Adjust Nut 3121231 JLG Lift 5 3 SECTION 5 MAST COMPONENTS 9 3 SEQUENCE CABLE REPLACEMENT KIT A sequence cable replacement kit is available from the JLG Parts Department to service broken or worn sequence cables This kit consists of a replacement sequence cable with the threaded top end attached same as the top end of the factory cable Also included is a clamp drum socket type to secure the bottom end of the cable Use the following procedure to install the replacement cable and clamp kit Remove Old Cable 1 Remove the locking nut from the threaded end of the cable at the top of the mast and then remove the spring cap spring and spacer washers if installed 2 Slide the threaded top end out of the upper anchor bracket then at the bottom end pull the cable out though the sheave pulley ancho
2. Mast Assembly Installation 1 Mast Mounting Column 2 Mounting Bolt Washer Nut Locations a Notes a Apply Loctite 271 to bolt threads on final assembly JLG Lift 5 15 SECTION 5 MAST COMPONENTS 5 7 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES The MVL MSP lift mast sections are constructed of extruded aluminum protected with an anodized surface finish The mast sections are interlocked into each other when assembled by internally mounted slide pads at the top and bottom of each mast section These slide pads run up and down in slide pad channels on each side of the mast The MVL MSP model mast assembly contains a different number of mast sections as shown following Table 5 1 MVL MSP Mast Component Features Model No of Mast Extend Retract Sections Device MVL Series amp MSP 5 Chain Assembly procedures for all mast sections is basically the same carefully slide the mast sections together until mast ends are even When sliding the mast sections together be careful not to scratch the anodized surface Assemble the hardware to the bottom of mast section first slide this section out the top of previous section and assemble hardware to the top of mast Always install slide pad shims with slide pads inserted into the slide pad channels ends of mast
3. Figure 4 1 Control Components Location MVL MSP 1 Pump Motor Tank Assembly 2 Alarm 3 Horn 3121231 4 Batteries 2 12V standard 7 Platform Control Console 5 Traction Control Module 8 Obstruction Sensor System MSP Option 6 Ground Control Module JLG Lift 4 1 SECTION 4 CONTROL COMPONENTS 4 2 CONTROLS COVER INSTALLATION Battery Cover Doors Optional Hinged 1 Left Side Cover 2 Mast Support Column 1 Right Side Cover 2 Mast Support Column Center Left and Right Lower Covers Lower Left Cover Front View Center Cover Lower Left and Right Covers Rear View Lower Right Cover Front View Note Center Cover requires unplugging the Charger AC Receptacle and LED Indicator wires when removing 4 2 JLG Lift 3121231 SECTION 4 CONTROL COMPONENTS 4 3 CONTROL COMPONENTS INSTALLATION NOTICE BEFORE REMOVING ANY COMPONENT FROM THE ELECTRICAL SYSTEM DISCONNECT THE POSITIVE
4. 1 1 INA N Mast Section 2 Chain Anchor Block Sheave Wheel Assembly 1 Support Bar Screws a 4 Sheave Wheel Assy 2 Pin Support Bars 5 Sheave Pin 3 Narrow Washers 6 Square Keys Note a Apply Loctite 242 to threads 21 Remove the cylinder mount cap shoulder screws and apply Loctite 242 to the threads Install the screws and torque to 85 ft Ibs 22 Tighten the center lift cylinder mount screw this screw keeps the cylinder assembly from rotating in the mount 23 Slide mast section 2 back into section 1 until top JLG Lift and bottom ends are even 5 21 SECTION 5 MAST COMPONENTS Mast Section 3 Assembly NOTE 24 25 NOTE 26 27 28 29 30 31 32 33 34 35 5 22 When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 3 into section 2 until ends are even Insert slide pads into the top end mast rails between section 2 and 3 one on each side of the mast with beveled surface facing inward towards section 3 Before fastening and shimming the slide pad on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt throug
5. STEP ACTION SPEC YES NO 1 Check resistance across the positive and negative studs onthe SeeTable 6 2 Replace Ground RepairorReplace pump motor Control Module Pump Motor or Motor Brushes Code 15 Lift Down Valve Disconnected Check For These Obvious Conditions First Inspect wire terminals on the lift down valve at the base of the lift cylinder for tight and secure connection Table 6 19 Code 15 Lift Down Valve Disconnected STEP ACTION SPEC YES NO 1 Checkvoltage atthe P1 connector on the Ground Control Module between 2 4VDC Replace Ground Goto Step 2 pin 10 and pin 3 Is reading within spec Control Module 2 Checkresistance betweenthe terminals on the lift down valve located at 6 Ohms Repair or Replace Replace the the base ofthe lift cylinder Is reading within spec Wiring Harness Lift Down Valve from Ground Solenoid Control Module 3 Withtheterminals still removed from the lift down valve coil check continu 00 Ohms Repair or Replace ity ofthe wires from pins 10 and 3 onthe P1 connectorto the lift down valve Wiring 6 24 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING Code 16 Lift Down Valve Short Circuit Check For These Obvious Conditions First Damaged wiring in the lift down valve wiring harness or a damaged lift down valve coil Table 6 20 Code 16 Lift Down Valve Short Circuit STEP
6. 6 19 6 8 Code 03 Right PHP Bar UP iod e eese RE E eus 6 19 6 9 Code 04 Tilt Condition 6 20 6 10 Code 06 Drive Motor Brush Wear Warning 6 21 6 11 Code 07 Left Drive Motor Disconnected 6 21 6 12 Code 08 Right Drive Motor Disconnected 6 22 6 13 Code 09 Left Brake Disconnected 6 22 6 14 Code 10 Right Brake 6 22 6 15 Code 11 Left Drive Motor Short 6 23 6 16 Code 12 Right Drive Motor Short Circuit 6 23 6 17 Code 13 Traction Module In Fold 6 23 6 18 Code 14 Pump Motor Disconnected 6 24 6 19 Code 15 Lift Down Valve 6 24 6 20 Code 16 Lift Down Valve Short 6 25 6 21 Code 17 Ground Control Module In Fold 6 25 6 22 Code 18 Alarm Short 1 0
7. STEP ACTION SPEC YES NO 1 Recycle machine power 5 times allowing a 10 second interval between Done Goto Step 2 each power recycle Does fault clear 2 Which code numberis displaying Code 103 Goto Step 3 Replace Ground Control Code 119 Goto Step 5 Module 3 Confirm that both installed batteries are 12 Volt DC 12VDC Goto Step 4 Replace with proper Batteries 4 Check battery voltage while charger is operating Is voltage within specifi Maximum of Replace Repair or Replace cation 31 Volts DC Ground Control Battery Charger Module 5 Remove the communications cable P5 connector at the Ground Control Goto Step 6 Repair or Replace Module and round connector atthe Traction Control Module Check conti Wire s nuity of all three 3 wires inthe communications cable from end to end P5 Pins 2 3 and 4 6 With communications cable still disconnected at both ends check for con Repair or Replace Goto Step 7 tinuity between Pins 2 3 and 4 atthe P5 connector end Wires 7 Plug the communications cable onthe Traction Control Module to the round Done Replace socket on the opposite end of the module Does this fix problem Ground Control Module 6 36 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING Codes 200 299 Platform Control Console Fault Condition Check For These Obvious Conditions First Damage to Platform Control Console wiring harness Secure harness co
8. 2 5 1 5 2 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT 5 2 Mast Chain Cable 5 2 Sequencing Cable 5 2 5 3 SEQUENCE CABLE 5 4 Hemove Old Cable x sack RE Ee edie ice E Y HAM RIO EUER REA CS 5 4 Replacement Cable Installation llis 5 4 Clamp Installation Drum Socket Type 5 4 5 4 HYDRAULIC LINE DISCONNECT SPECIAL 5 7 Tool Use In Line Style 0 5 7 Tool Use Angled Style Fittings 5 8 5 5 HYDRAULIC LIFT CYLINDER REMOVAL INSPECTION AND REBUILD 5 9 Lift Cylinder Removal eis ie VEREMOS Rub RR Rer Ire ae ee 5 9 Cylinder Disassembly 5 12 Lift Cylinder Component 5 12 Cylinder Assembly See Figure 5 4 5 13 Cylinder Installation 20 oc epee ee d aw be PE ee Se AND ee 5 13 5 6 MAST ASSEMBLY INSTALLATION
9. SEHEN BORE STROKE ROD DIA 15MVL 15MSP 1 63 41 50 1 375 Lift Cylinder 4 10 105 4 3 49 20MVL 20MSP 1 63 54 0 1 375 Lift Cylinder 4 10 137 1 3 49 JLG Lift 1 6 SERIAL NUMBER LOCATIONS For machine identification a serial number plate is affixed to the machine The plate is located on the back of the mast just above the mast support column 1 7 TORQUE REQUIREMENTS When maintenance becomes necessary or a fastener has loosened refer to the applicable Torque Charts in this sec tion of the manual to determine proper torque values for different size fasteners 3121231 SECTION 1 MACHINE SPECIFICATIONS Table 1 7 Lubrication Intervals for Various Components INTERVAL 9 LUBE METHOD COMMENTS LUBE POINTS 3 6 1 2 MONTHS MONTHS YEAR YEARS 1 FillToLineon HO Check Hyd Oil Checkfluid level every day 9 Hydraulic Oil Reservoir Level Change hydraulic oil every 2 5 Qt Reservoir Change Hyd Oil years 2 2 Per Section Chain Lube Brush or Inspect lubricate i
10. STEP ACTION SPEC YES NO 1 Using a digital level checkthe actuallevel ofthe machines resting surface in 1 59 Goto Step 2 Drive Machine to both the X and the Y directions Does surface check within machine specifi X and Y Direction Level Surface cation 2 Atthe Ground Control Module enter the programming mode See Ground 1 5 Replace Ground Goto Step 3 Control Programming Section 3 of Service Manual and checkthetiltsen Xand Y Direction Control Module sorXandY readings Are readings within machine specification 3 Zero Tilt Sensor on a surface checked to within 0 0 degrees with a digital level in both the X and Y directions See Ground Control Programming Sec tion 3 of Service Manual NOTE If frequent calibration of the internal Tilt Sensor is required replace the Ground Control Module Code 05 Reserved JLG Lift 3121231 6 20 SECTION 6 TROUBLESHOOTING Code 06 Drive Motor Brush Wear Warning Indicator Check For These Obvious Conditions First Did the Brush Wear Indication relay get wet If so dry the relay and wire terminals and reset the Brush Wear Warning Timer Program Ground Control Station module to reset the Brush Wear Warning Timer see Section 4 6 Ground Control Mod ule Programming If machine has accumulated a lot of hours in service since new or the last brush replacement check the Drive Motor Brushes see Section 3 Replacing Drive Moto
11. 2 5 Generals sea petere te ue ated dese C qoe o depu pe oce 2 5 Safety and Workmanship 2 5 Cleanliness i kn VER PRI Sr pide dered 2 5 Components Removal and Installation 2 5 Component Disassembly and Reassembly 2 5 Pressure Fit Parts eR la RE RU EUER MER EP 2 5 Bearings ioen EE 2 5 Cc cp 2 5 Bolt Usage and Torque Application 1 2 5 Hydraulic Lines and Electrical Wiring 2 6 3121231 JLG Lift TABLE OF CONTENTS Hydraulic System is uot DERE ded cte gk vane p Redes 2 6 Lubrication and Servicing 2 6 eee RNA Pe is SA ee Ae ee oe a epee ds 2 6 Mast Chain Inspection 2 6 2 4 LUBRICATION INFORMATION 1 2 2 8 Hydra lic Systetm s ecco ies ED ela le 2 8 Hydraulic ut Se ews rr eV uei wee a Be nube Sia eRe IU NUI 2 8 Changing Hydraulic Qil ERR GRE RUE eed hace EX 2 8 Lubrication Specifications 1 2 8 SECTION 3 BASE COMPONENTS 3 1 BASE A
12. o Ll 1 Hydraulic Oil Filter 3 Pressure Gauge Assembly 2 T Fitting 4 Extend Line Pump Motor Tank Assembly Installation Figure 4 8 Typical Hydraulic Pressure Gauge 1 Pump Motor Tank Assembly 3 Detach and Cap Extend Installation After Hydraulic Filter 2 Attach Screws Washers and Return Lines Note See Figure 4 2 for wiring connection instructions 4 22 JLG Lift 3121231 SECTION 4 CONTROL COMPONENTS General Installation and Disassembly FENNER BRAND PUMP Brush Replacement The following is a complete disassembly assembly of the MVL MSP machines pump motor assembly No internal parts to the hydraulic pump are serviced by JLG except for a pump installation seal kit Also the only parts service able internal to the pump electric motor is the motor brush kit Motor Cap Motor Installation NOTE During reassembly of the pump motor assembly apply a liberal coat of JLG recommended hyaraulic fluid to all seals and o rings Also keep all internal metal parts clean and coated with hydraulic fluid to prevent surface corrosion JLG recommends replacing all seals and o rings when disassembling and reassembling the pump motor unit The motor and motor brushes can be serviced without removing the complete pump motor unit However com ponents on the bottom end of the unit will require removal of the complete pump motor unit See Pump Motor Tank Installation ins
13. 6 28 Code 25 Auxiliary 1 Circuit lt 6 29 Code 26 Auxiliary 2 Short 6 29 Code 27 Auxiliary 2 6 30 Code 28 Reserved vx Er e re ERRARE eb OR Y e E usu Ecce 6 30 Gode 29 Reserved oru uerba RT cei Dea a Vale e parts 6 30 Code 30 Traction Module No Communication with Ground Control Module 6 30 Code 31 Platform Control Console No Communication with Ground Control Module 6 31 Code 32 Pump Motor Over 4 6 31 Code 33 Both PHP 6 32 Code 34 P2 Auxiliary 1 Inhibit 6 32 Code 35 P2 Auxiliary 1 Tie 6 32 Code 38 Battery Voltage Low Warning Level 2 Two 2 LED LCDs lit 6 33 3121231 JLG Lift V TABLE OF CONTENTS Code 39 Battery Voltage Low Warning Level One 1 LED LCDs lit 6 33 Code 40 Obstruction Sensor System No Communication with Ground Control Module 6 34 Codes 41 thru 46 OSS Sensor 1 through 6 Fault Condition 6 35 Codes 100 199 Ground Control Module Fault Condition 6 36 Codes 200 2
14. Proximity Switch Wire Harness Routing PLUG INTO PLATFORM AUX 1 LOCATED ON MAST HEADER PY eo z _ NO NO 2 Proximity Switch Wiring 1 Connector 3 Proximity Switches 2 Splice 3121231 Proximity Switch Location 1 Platform Vertical Rail 3 Lower Gate Stop 2 Left Platform Gate 4 Proximity Switch a NOTE a There are two proximity switches one on each gate mounted in the lower gate stop Platform Junction Box 1 Platform Upper Rail 3 Platform Junction Box 2 Mast Header 4 AUX 1 Connector JLG Lift 5 29 SECTION 5 MAST COMPONENTS 5 12 MAST 14 FT HEIGHT LIMITING SWITCH 15MSP OPTION Ground Control Module Programming settings required Set Ancillary 2 POL to HIGH Up Arrow Location of Proximity Switch and Target Right side of mast from rear 1 Proximity Switch 2 Target Plate 5 30 Proximity Switch Installation 1 Mounting Screws Nuts and Washers 2 Switch Shim 3 Prox
15. 3 16 Main Gear Box Sub Assembly Inspect seal surface of Spindle Sub Assembly Remove any debris or burrs that may be present Apply a coating of grease to the Lip Seal not shown in the Hub Sub Assembly Place Spindle G1 Sub Assembly on table with car rier side up Carefully install the Hub Subassembly seal side down onto the Spindle Sub Assembly This instal lation should be a slip fit and takes place in 3 stages Stage 1 The hub slides together until the gear teeth of the hub hit the gear teeth of the 3 Output Planet Gears G9 Stage 2 Find the Output Planet Gear G9 that is tight and turn it until you feel it go into mesh with the hub gear teeth apply slight downward pressure to the hub and then find the next gear that is tight and do the same Stage 3 Once all the Output Planet Gears G9 are in mesh apply pressure to the hub it should push on the rest of the way Install Retaining Ring G27 into the groove on the OD of the Spindle G1 carrier This is a Spiral Retaining Ring so it will not require pliers You will need to pull the Retaining Ring G27 apart and work it into the groove Using the appropriate pressing tool T 174356 press in the Input Ring Gear G3 into the bore of Hub Subassembly NOTE NOTE NOTE JLG Lift Do not use excessive pressing force because it will be reacted by the main wheel bearings Install the Input Carrier Subassembly into mesh The
16. 2 WP i x s MN 4 oL Brush Carrier Assembly Remove Install 1 Stator Brush Carrier Screws Pump Rear 2 Stator Brush Carrier Screws Pump Front a 3 Mark Brush Carrier Position on Motor Housing 4 Brush Carrier Assembly NOTE a Removed previously with motor cover disassembly shown for reference only Brush Assembly Remove Install az Brush Assembly Remove Install 4 Brush Terminal Screw 5 Brush Attach Terminal 1 Brush Assembly a 2 Brush Carrier Socket 3 Brush Tab Slot NOTE a Slide brush assembly into socket until tab is in slot at rear of socket 3121231 JLG Lift 4 27 SECTION 4 CONTROL COMPONENTS Tank Installation Pump Installation Tank Installation 1 Tank Assembly 3 O Ring Seal 2 Tank Screws 4 4 Use Screwdriver to pry tank away from pump head Filter Screen Installation V Filter Screen Installation 1 Filter Screen 2 Pump Pick Up Tube 4 28 Pump Installation 1 Pump Asse
17. 4 22 Motor Brush Installation lee II 4 23 Brush Housing Final Assembly 4 24 MONARCH BRAND PUMP Brush 4 25 Motor Assembly Remove Install Reference 4 25 Motor Brush Cover 1 4 25 Brush Carrier Assembly 4 26 Brush Assembly 1 4 26 Tank Installation xol em MR 4 27 Filter Screen Installation 4 27 P rmp Irstallatlor scm um etd ED Re s REA p eU Set 4 27 Pressure Adjust Valve 1 4 28 Pressure Check Valve 1 4 28 3121231 JLG Lift iii TABLE OF CONTENTS 4 9 OBSTRUCTION SENSOR SYSTEM SERVICE PROCEDURE MSP 4 29 General Jesena e tut rund ERREUR eek dies PRESA 4 29 Transducer Sensor 20 4 30 OSS Component 5 4 31 SECTION 5 MAST COMPONENTS 5 1 MAST COMPONENTS OVERVIEW
18. 111 or TITE 7437 140 18 0 15 In Sq In LB IN LB N m IN LB N m IN LB N m 4 40 0 1120 0 00604 sc oo 1 E 6 32 01380 0099 D T T 10 oso oos T T ToS 8 32 0140 00400 D f 0640 001474 1320 43 5 10 24 01900 0 01750 1880 60 7 L 1 32 0190 0 02000 100 68 8 V4 20 Sa 18 FB Nm Nm FB Nm 25 25 38 16 03750 0 0775 700 45 60 445 5 35 50 50 70 20 04375 0 1187 10700 80 no 70 9 60 80 12 13 110 120 155 a p 839 328 185 28 318 175 210 285 190 220 240 325 215 245 375 510 340 380 420 570 380 430 7 8 0 8750 0 4620 41600 605 825 545 740 455 620 875 1015 1310 1475 1855 2055 2430 2760 3225 3625 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS NO ie REV J 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER Figure 1 2 Torque Chart SAE Fasteners Sheet 2 of 7 JLG Lift 1 7 SECTION 1 MACHINE SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating Ref 4150701 Torque TM TM Torque size Tensile Clamp Load E E Loctite 2627 Stress Area See Note 4 ipra TITE 111 oF or Vibra TITE
19. 6 25 6 23 Code 19 Alarm 6 26 6 24 Code 20 Beacon Short Circuit 6 26 6 25 Code 21 Beacon Short Disconnected 6 27 6 26 Code 22 Horn Short Circuit 4 6 27 6 27 Code 23 Horn Disconnected 6 28 6 28 Code 24 Auxiliary 1 Circuit Short 6 28 6 29 Code 25 Auxiliary 1 Circuit 6 29 6 30 Code 26 Auxiliary 2 Short 6 29 6 31 Code 27 Auxiliary 2 6 30 6 32 Code 30 Traction Module No Communication with Ground Control Module 6 30 6 33 Code 31 Platform Control Console No Communication with Ground Control Module 6 31 6 34 Code 32 Pump Motor Over 6 31 6 35 Code 33 Both PHP 6 32 6 36 Code 34 P2 Auxiliary 1 7 6 32 6 37 Code 35 P2 Auxiliary 1 Tie
20. 6 32 6 38 Code 40 OSS No Communication with Ground Control Module 6 34 6 39 Codes 41 thru 46 OSS Sensor 1 through 6 Fault 6 35 viii JLG Lift 3121231 TABLE OF CONTENTS 6 40 6 41 6 42 6 43 6 44 6 45 6 46 6 47 6 48 6 49 6 50 6 51 6 52 6 53 6 54 6 55 3121231 Codes 100 199 Ground Control Module Fault Condition 6 36 Code 200 299 Platform Control Console Fault 6 37 Codes 300 399 Traction Control Module Fault 6 38 Machine Will Not Power 1 244 0 6 39 Platform Will Not Lower Manually 6 40 Platform Lift Up and Down Jerky 6 40 Mast Noisy when Lifting and Lowering 6 41 Platform Mast Won t Stay 6 42 Platform Mast Descends 6 42 Hydraulic Leak Troubleshooting 0 ccc eects 6 43 Caster Wheels Not Operating 2 6 44 Pot Hole Protection PHP Bars will not Lower 6 44 Won t Climb Grad
21. STEP ACTION SPEC YES NO 1 Checkto see of the platform will lower from the Ground Control Station in Repair or Replace Goto Step 2 Ground Control Mode the Manual Descent Control Valve 2 Checkto see if the lift down valve is opening completely Goto Step 3 Replace the Lift Down Valve 3 Check the flow valve in the lift cylinder for a restriction Clean or Replace Consult Factory Flow Valve Platform Lift Up And Down Jerky Overview Of Procedure The following procedure suggests areas on the machine which might attribute to erratic movement of the platform during lift up and down Check For These Obvious Conditions First If mast is not running smooth or has tight and rough spots refer to the Mast Section Rebuild Hyaraulic oil level in reservoir tank at full level Hydraulic oil is not milky presence of water or foamy full of air Table 6 45 Platform Lift Up and Down Jerky STEP ACTION SPEC YES NO CONTROLS ELECTRICAL 1 Isplatform control console platform enable up or down pad defective or Replace pad Goto Step 2 worn out 2 Looseconnections ground and power Repair Goto Step 3 connection 3 Valve solenoid keeps opening and closing Repair Connection Goto Step 4 or Replace Valve 4 Problem internal to the Ground Control Module Replace Module Goto Step 5 HYDRAULIC 5 Isthe hydraulic valve working properly Goto
22. ses 45 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED AB Figure 1 6 Torque Chart METRIC Fasteners Sheet 6 of 7 3121231 JLG Lift 1 11 SECTION 1 MACHINE SPECIFICATIONS Magni Coating Ref 4150701 CLASS 12 9 SOCKET HEAD CAP SCREWS M6 AND ABOVE Torque Lub OR Loctite amp 1 5 BUCH Clamp Load Dry or Loctite 242 or 271 Loctite 262 Area 999 Note 4 OR Vibra TITE OR Ec or 140 15 678 78 8 78 14 20 12 5 wo 2 2 Lus saso ss as sm seo em NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 8 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10
23. 7 8 9 0 8750 0 4620 41600 605 825 545 740 455 620 1000 06630 59 70 95 1355 895 125 75 015 _ ps 3750 13150 118100 2705 3680 2435 3310 2030 2760 NO 5000059 REV J 8 i 12 7 5 6 s 2 6 i NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 8 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 4 Torque Chart SAE Fasteners Sheet 4 of 7 3121231 JLG Lift 1 9 SECTION 1 MACHINE SPECIFICATIONS Tensile Size Stress Area Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 8 8 METRIC BOLTS CLASS 8 METRIC NUTS Torque Loctite amp Torque Dry or Loctite Torque Loctite 262 242 or 271 2637 Lub OR Vibra OR Vibra TITE 131 TITE 111 or 140 14 23 34 08 1420 6 18 68 e 1 san n 84 12 19 8 125 36601 159 15 5800 252 55 12 175 8430 307 66 w w 154 241 331 469 22 303 581 436 523 639 24 353 737 553 663 811 27 459 1080 81
24. 5 15 Mast Removal deep eR RI aad whee eee A ee Led eed PRADA 5 15 Mast Installation leer Er eR ERU ee MR HER e EROR MER Pe En 5 15 5 7 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES 5 16 Mast Disassembly 5 16 Mast Assembly 0 5 19 5 8 MSP STOCKPICKER PLATFORM 5 27 5 9 MSP STOCKPICKER PLATFORM MID GATE INTERLOCK INSTALLATION 5 28 5 10 MAST BEACON 2 1 5 28 5 11 GATE ALARM INSTALLATION OPTION FOR SIDE ENTRY W FOLDING MATERIAL TRAY PLATFORM 5 29 Switches and Wiring oie eek are ER tee ee ER e eae 5 29 5 12 MAST 14 FT HEIGHT LIMITING SWITCH 15MSP OPTION 5 30 SECTION 6 TROUBLESHOOTING 6L GENERALS DES IR eR M PP Ne ae Du Ner ue 6 1 6 2 TROUBLESHOOTING INFORMATION 1 6 1 6 3 HYDRAULIC CIRCUIT 1 6 1 6 4 ELECTRICAL CIRCUIT 2 6 1 General src AIR EIE EE CGU ER due UPS 6 1 6 5 MULTIMETER BAS
25. 3 Complete the following steps to determine shim stock thickness required for section 5 NOTE Always use the an even amount of shim material behind slide pads on both sides of the mast rails This will keep mast sections centered in rail chan nels and prevent any distortion of the section a Use two shim pieces per slide pad a thick one and a thin one b Start with a total thickness of approximately 035 and 075 thick shim stock c Attach shim stock and slide pads to both sides of mast section 5 using five 5 1 4 20UNC x 1 1 4 long hex head cap screws per side with flatwasher under each bolt head Assemble shim stock and slide pad to mast section rail with shim stock against rail and slide pad with bev eled side out d Carefully thread the slide pad mounting bolts with flat washers through slide pads and shim stock into threads in mast section 5 Be certain there are no air gaps between shims shim and mast or shim and slide pad when tightened NOTE Mast section 5 into section 4 fit should be very snug but still be able to be pushed together by hand If too tight remove section 5 disassemble slide pad and reduce thickness of shim stock e Begin sliding top of mast section 5 with closed rail down engaging the slide pads into slide pad channels at bottom of mast section 4 s open rail Continue to push section 5 into section 4 until BOTTOM ends of mast sections are even f Check mast section for s
26. 3121231 ete le Wek OF OF OW ADAMO AGO 2 SIGNAL QUT bui SECURITY Lock OPTIONAL SIGNAL IN 8 ANALOGUE INPUT BRUSH WEAR INDICATION J 2 WHT RED 57 1 a 81 i EME ag ru SEE 5 8 DRIVE MEEEE MOTOR S 17159 VOLTAGE HIGH REF Res ZONE 8 6 ge WHT RED 57 2 2 E TILT SWITCH RETURN CINHIBITS LIFT DRIVE 5 B TILT SWITCH S B POWER E 5 B AUX 2 SIGNAL C AUX 2 RETURN CIL LET 2 B AUX SIGNAL INHIBITS DRIVE 8 AUX RETURN a ri a In CHARGER On PLUGGED IN B i 158 NOTE gl B Se AUX 2 INPUT MAY BE USED FOR HEIGHT LIMITERS 25 CUTBACK SWITCH ELEVATED OPEN AUX INPUT MAY BE USED FOR GATE INTERLOCK m 4 m WE denm REV E AUSTRALIA ONLY Removed platform module keyswitch 802 9 Be Ha C3 connector and replaced ground module key switch with BE ce REFIERE non keyed switch A LIMIT SWITCH 09 BAR UP OPEN 1870202 F Figure 6 3 Electrical Diagram MVL MSP JLG Lift 6 51 SECTION 6 TROUBLESHOOTING CYLINDER jo ger 6 i PUMP i 1 Tank 5 Pressure Adjust Valve 2 Filter Screen 6 Extend Line 3 Pump 7 Hydra
27. N gt 8 39 E me w2 75 0 5625 0 1820 11600 110 149 18 0 5625 02030 12960 120 163 0 6250 0 2560 16300 170 230 353 0 8750 0 4620 29400 430 583 637 1 0000 0 6630 42200 700 949 735 1000 633 858 1085 813 1 2500 0 9690 53800 1120 1518 1139 1175 1598 1009 1368 1681 1247 1978 1491 2278 1708 2630 1979 12 1 5000 1 5800 87700 2200 2983 2224 2300 3128 1974 2676 NO 5000059 REV J N NIO 9 16 w N Az NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND 0100011 242 121 Medium Strength Blue 0100019 271 Vibra TITE 140 High Strength Red 0100071 262 Vibra TITE 131 Medium High Strength Red Figure 1 1 Torque Chart SAE Fasteners Sheet 1 of 7 1 6 JLG Lift 3121231 SECTION 1 MACHINE SPECIFICATIONS 3121231 Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS Tomus Torque Torque H n TM TM TM Size TPI Bolt Dia Tensile Clamp Load Dry or Loctite 263 eet 242 271 Loctite amp 20 or Vibra Stress Area K 0 20 OR
28. Input Carrier Disassembly 1 NOTE Do not overstress these Retaining Rings when Input Carrier Disassembly Remove Retaining Rings G18 from each of the 9 Remove the three Planet Shafts G6 from the Input three Planet Shafts G6 Carrier NOTE The Planet Shafts G6 are held in with a press fit removing them To avoid damage to the parts use an arbor or hydraulic press to remove the Planet Shafts G6 2 Remove Thrust Plate G23 3 Remove Thrust Washer G25 from each Planet Shaft G6 4 Slide each Input Planet Gear G5 off the Planet Shaft G6 5 Press out Bushing G26 from the bore of each Planet Gear G5 Bushings cannot be reused when removed 6 Remove the other Thrust Washer G25 from each Planet Shaft G6 7 Remove Retaining Ring G24 from Output Sun Gear G8 8 Slide Output Sun Gear G8 out from the center of 3 10 the Input Carrier G7 JLG Lift 3121231 SECTION 3 BASE COMPONENTS Hub Disassembly Hub Disassembly 1 Remove Main Wheel Bearing G14 2 Remove main Lip Seal G16 NOTE This part is held in the hub with a press fit To NOTE This Lip Seal G16 is also held in with a press fit remove have the hub setting seal side up Use a Remove the Lip Seal only if the hub or seal needs to plate or rod with a large enough diameter push in the be replaced The Lip Seal will most likely become inner race of the bea
29. Before fastening and shimming the slide pad on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in outside rail on top of mast section 2 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Insert slide pads into the bottom end mast rails between section 2 and 3 one on each side of the mast with beveled surface facing out towards sec tion 2 Same as Figure 5 7 on page 5 19 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes on inside rail on bottom end of mast section 3 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Slide section 4 out the bottom of section 3 approxi mately one 1 foot Locate one 1 of the chain bottom anchor plates one with threaded holes horizontally aligned to cen ter of bracket Attach using holes in bottom of mast section 4 with four 4 1 4 20UNC x 3 4 long bolts place a flatwasher under head of each bolt 5 23 SECTION 5 MAST COMPONENTS 1 Chain Anchor Bracket 2 Mast Section 4 Note 10 11 12 5 24 Mas
30. OBSTRUCTION BELOU 4 lt p PLATFORN 4 mmm X 00000 0 055 Sensor LCD Display Mode 1 Detection Indicator Yes No 2 Sensor numbers 3 Object distance from sensor 4 Signal strength Note This screen can be viewed while another person performs the transducer sensor check see Section 4 9 1 FP WO 2700200 SSSSSMEMIL 5 222222 2 2222 222221 49 22222221 C1 2 22222292 22222229 9 2222222 9 72222222 4 SS S 55 222222 3 oL o AN IM S 20 2 Transducer Sensor Locations 1 Transducer Sensors 1 through 6 2 Underside of MSP Platform JLG Lift 4 81 SECTION 4 CONTROL COMPONENTS 0 Component Installation NOTICE THE FOLLOWING ILLUSTRATIONS PROVIDE KEY INSTALLATION INSTRUCTIONS FOR THE OSS TO OPERATE PROPERLY The OSS Control Module must be electrically isolated from the mast see installation instructions below The sensor shield tubes attached to the platform s under sides must be properly installed and undamage
31. 131 140 OR Precoat 85 4 40 070 oo00000 48 0120 e 32 01380 000909 o oeo oono e eeo 32 0 1640 0 01400 36 0 1640 0 01474 10 24 0 1900 0 01750 32 0100 0 02000 1 o 20 0 2500 00318 2 1 14 4 1 65 0 0364 3 139 6 L 15 1 5 16 0 3125 0 0524 4720 20 25 20 25 20 25 0 3125 0 0580 5220 35 3 8 6 0 3750 0 0775 7000 50 35 50 35 50 78 976 58 3 4 78 9 08750 04620 41600 515 700 485 60 455 620 1 8 1000 06060 51500 730 995 685 930 645 875 11 8 7 11250 1 9760 seno 105 340 100 14m 5965 31 11 4 7 13 8 12 1 23750 1 3150 118100 2300 3130 2165 2945 2030 2760 11 2 EZB 2690 3660 2530 3440 2370 3225 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS NO 5000059 REV J 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 3 Torque Chart SAE Fasteners Sheet 3 of 7 1 8 JLG Lift 3121231 SECTION
32. 20 sec 22 5 sec Platform Down 15 21 sec 21 26sec 15 21 sec 21 26 sec 2 2351b 2 235 Ib 2 280 Ib 2 280 Ib Gross Machine Weight Platform Empty 955 kg 955 kg 975 kg 975kg NOTE 1 Standard unless equipped with 14 ft limiter circuit 3121231 JLG Lift 14 SECTION 1 MACHINE SPECIFICATIONS 1 1 CAPACITIES System Voltage All Models 24 Volt DC Hydraulic System All Models 5 qts U S 4 7 L Drive Motor GearBox gear oil Models 10 oz 296cc 1 2 COMPONENT DATA Hydraulic Pump Pump Motor Assembly Pump Motor 24 Volt DC motor Standard Duty Pump Displacement MVL MSP 098 cu 1 6cc rev Pump Output Max MVL MSP 1 20 gpm 2200 psi 9 23 5 volts and 105 amps 45 centistrokes 200 SSU Reservoir Capacity MVL MSP 1 Gallon 3 78 L Rear Wheel Drive Motors Drive Motors 24 Volt DC Variable Gear Box 3500 in Ib 395 5 Nm Continuous Output 7000 in Ib 791 Nm Intermittent Output 30 68 1 Gear Ratio Brakes Friction Disk Spring Applied Electrically Released Batteries Battery Charger JLG MACHINES EQUIPPED WITH DELTA BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FAC TORY APPROVED BATTERIES APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG S AFTERMARKET PARTS DISTRIBUTION CEN TERS OR JLG S AFTERMARKET PROGRAMS FOR ASSISTANCE WITH PROPER BATTERY REPLACEMENT PLEASE CO
33. 3121231 Horn Button Switch Install Remove Qu Platform Console Horn Switch Installation 1 Horn Button Switch a 3 Nut 2 Lock Washer Nole a Remove rear cover unplug wire remove nut and lock washer then slide switch out of console Key Switch Install Remove No key switch on Australian specification machines Platform Console Key Switch Installation 1 Key Switch a 3 Attach Nut 2 Notch 4 Key Note a Remove mounting bracket on bottom of console to gain access to the key switch assembly JLG Lift 4 19 SECTION 4 CONTROL COMPONENTS E Stop ShutDown Switch Install Remove Joystick Assembly Install Remove Platform Console E Stop Switch Installation 1 Loosen Switch Set Screw 5 Barrel Seal 2 Turn Switch 90 6 Switch to Body Retainer 3 Pull Spring Loaded Release Hooks a Lever Out 7 Switch Retainer Slots 4 Remove Barrel Assembly Note a Use a small straight blade screwdriver to extend the spring loaded retainer hooks 6 out and release the switch from the body 4 20 JLG Lift Platform Console Joystick Installation 4 Rubber Boot Gasket 5 Install Remove through the Access Hole in Bottom of Housing a b 1 Joystick Assembly 2 Attach Screws 01 4 3 Nylon Washers Qty 4 Note a Remove the console mounting bracket b Remove the key switch and e st
34. 4 6 4 7 4 4 Ground Control Module 42 1 4 8 4 5 Platform Control Console 4 16 4 6 Hydraulic Pressure Adjustment Screw Machine Rear Covers 4 20 4 7 Typical Hydraulic Pressure Gauge Installation Hydraulic Filter 4 20 4 8 Typical Hydraulic Pressure Gauge Installation After Hydraulic 4 21 4 9 Obstruction Sensor System Components Platform Cutaway 4 29 5 1 Mast Components 4 5 1 5 2 MVL MSP Mast Chain and Sequence Cable Adjustment 5 3 5 3 Machine Positioned for Cylinder 1 5 9 5 4 Lift Cylinder Component Cross Section 5 13 5 5 Mast Section Assembly Reference 5 16 5 6 Mast Chain Routing Diagram 5 18 5 7 Mast Bottom End Slide Pad 1 5 5 19 5 8 MSP StockPicker Platform 2 1 5 27 6 1 Voltage Measuremen
35. 6 49 SECTION 6 TROUBLESHOOTING Australia Spec Key Switch Removed UNCTION ES OUT YELLOW BLACK BOX ES IN YELLOW SHIELD B BLACK 2 854856 BLUE 5485 ORANGE AUX 1 SIGNAL B RED BLACK AUX 1 RETURN BLUE BLACK 0 5 5 SUPPLY 24V DC RED 0 5 5 DIGITAL RETURN BROWN SPARE ORANGE BLACK SPARE BROWN BLACK SPARE BLACK RED JOYSTICK MODULE HORN BOARD DIGITAL RETURN SUPPLY 24V DC 4 FUNCTION i 4 SELECT a gt 5 20 i HEN C9 EQUIPPED 2 W LSS 9 01 LSS SWITCH OPEN OVERLOAD UNUSED
36. HIGH Level 3 Operator Level Settings NO X LOW LEVEL PROGRAMMABLE ITEM FACTORY PRESET SETTING RANGE 2 Ancillary 1 Anti Tie down 0 0 1 2 Ancillary 2 Anti Tie down 0 0 1 2 Mode Select Delay active before time out 5 Sec 0 60 Seconds 2 Invert Lift Direction NO YES NO 2 Lift Lock Delay 5 Sec 0 60 Seconds 2 Acceleration platform lowered 80 1 100 2 Deceleration platform lowered 80 1 100 2 Turn Acceleration platform lowered 50 1 100 2 Turn Deceleration platform lowered 50 1 100 2 Maximum Forward Speed platform lowered 100 1 100 2 Minimum Forward Speed platform lowered 40 1 100 2 Maximum Reverse Speed platform lowered 50 1 100 2 Minimum Reverse Speed platform lowered 20 1 100 2 Maximum Turn Speed platform lowered 20 1 100 2 Minimum Turn Speed platform lowered 15 1 100 2 Minimum Forward Speed platform elevated 13 1 100 2 Minimum Reverse Speed platform elevated 13 1 100 2 Minimum Turn Speed platform elevated 5 1 100 2 Motor Compensation 50 mOhms 0 500 mOhms 2 EPPROM Reset Resets GCM to default factory settings Notes a MSP Models equipped with stock picker platform and mid gate interlock drive inhibit switch are factory preset to HIGH b MSP Models equipped with 12 ft or 14 ft lift limit switch option are factory preset to HIGH 4 16 JLG Lift 3121231 SECTION 4 CONTROL COMPONENTS 4 7 PLATFORM CONTROL CONSOLE SERVICE PROCEDURES General NOTICE DO NOT
37. Inspection Schedule and the appropriate areas of this manual for servicing and maintenance procedures The frequency of service and maintenance must be increased as environment severity and frequency of usage requires JLG Lift 2 1 SECTION 2 GENERAL Table 2 1 Inspection and Maintenance Type Frequenc F r samle Reference quency Responsibility Qualification Pre Start Prior to use each day or User or Operator User or Operator Operator and Safety Manual Inspection Ateach Operator change Pre Delivery Priorto each sale lease or Owner Dealer or User Qualified JLG Service and Maintenance Man Inspection rental delivery Mechanic ual and applicable JLG inspec tion form Frequent In service for 3 months or Out of service Owner Dealer or User Qualified JLG Service and Maintenance Man Inspection fora period of more than 3 months or Pur Mechanic ual and applicable JLG inspec chased used tion form Annual Annually no laterthan 13 months fromthe Owner Dealer or User Qualified JLG Service and Maintenance Man Machine date of the prior inspection Mechanic ual and applicable JLG inspec Inspection tion form Preventative Atintervals as specified in the Service and Owner Dealer or User Qualified JLG Service and Maintenance Man Maintenance Maintenance Manual Mechanic ual 2 2 JLG Lift 2 2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE See Table 2 2
38. Isthe electrical signal and amperage draw to the drive motors equal Check See Table 6 3 Recheck Steps Goto Step 6 with machine on level surface 1thru5 6 Checkthe drive motor brushes do they need replaced Replace per Goto Step 7 procedure in this Service Manual 7 Inside the drive motor gear box check if the drive shaft is excessively loose Repair Replace gear box amp condition of drive shaft bearings components per procedure inthis Service Are any gears broken or gear teeth excessively worn Manual 3121231 JLG Lift 6 47 SECTION 6 TROUBLESHOOTING PROGRAMMABLE SECURITY PUMP C 2 EAD CUR LOCK MOTOR lI STATION OPTION AUX 1 225 OUTPUT POWER mns OUTPUT m BEACON LIGHT MAST OPTION LIGHT BASE DVSP Figure 6 6 Overview of Electrical System Components MVL MSP Sheet 1 of 2 6 48 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING BATTERY CHARGER BATTERY L E D BATTERY DR 2 CHARGER E gU RECEPTACLE o SPARE 4 Ry NNPUT g amp INPUT PLATFORM NHIBITS iu AUX LIFT DRIVE SN J D PHP SWITCHES Poza p j ACCESSORY RECEPTACLE MAST gt 2 EN ELEVATION a se dE Se PLATFORM LIFT SWITCH OBSTRUCTION ELECTRONICS BOX OPTION OBSTRUCTION SENSORS Figure 6 2 Overview of Electrical System Components MVL MSP Sheet 2 of 2 3121231 JLG Lift
39. JLG Lift NOTE Figure 5 7 Mast Bottom End Slide Pad Installation Typical 1 Slide Pads 2 Shim Stock 3 Slide Pad Bolts Washers a Note Apply Loctite 242 to threads 6 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in mast section 2 inside rail into the slide pad inserts Thread in enough to hold pad in place Shim slide pads using the following steps Always use the an even amount of shim material behind slide pads on both sides of the mast rails This will keep mast sections centered in rail chan nels and prevent any distortion of the mast section a Start with a 036 thick shim and a 075 thick shim per side at each slide pad Slide shims into place between slide pad and mast rail Tighten the slide pad mounting bolts be sure there are no air gaps between shims shim and mast or shim and slide pad when tight ened 5 19 SECTION 5 MAST COMPONENTS 8 NOTE c Check mast section for side play If play exists add 015 shims dividing the thickness equally between both sides of mast Insert shims until the shims cannot be inserted halfway by hand with the mast pulled to the opposite side d When mast slide pads are shimmed properly there should be no side to side movement of slide pad in rail channel Mast sections should be snug in channels but still be able to slide in channel by
40. Regulated Lead Acid batteries using the instruc tions of the battery tester manufacturer 2 If an appropriate battery tester is unavailable the batteries can be tested by fully charging them with the charger that is installed on the machine Then check the battery voltage of each battery 4 hours after charging is complete Batteries less than 12 72 volts should be replaced NOTE If a faulty charger is suspected the batteries can be charged using a charger that supplies 2 45 volts cell Charging should be terminated when the charge cur rent drops below 1 amp Battery Disconnect Option If equipped the optional battery disconnect loop is located on the left side of the mast assembly just above the rear cover assembly Battery electrical power to the machine is disconnected when the upper half of the con nector is separated from the fixed lower half connector Use the wire handle provided on the front of the upper half connector to disconnect it from the lower half A lanyard keeps the upper half attached to the machine when dis connected Battery Disconnect Option 1 Upper Half of Disconnect 3 Upper Half Pull Handle 2 Lower Half of Disconnect JLG Lift 4 5 SECTION 4 CONTROL COMPONENTS Battery Installation 2 12V Batteries To gain access to the batteries requires opening or removal of the upper ha
41. Remove the charger cover from the machine located under the platform see Section 3 2 on page 3 2 2 Disconnect the positive battery cable at the left side battery under the left rear upper cover 3 Disconnect the AC input LED Status Indicator Drive Cut Out Interlock and DC Voltage Output to battery wiring connectors from the top and bottom of the charger assembly 4 Remove the two 2 screws and washers from the top bracket securing the charger to the frame mount Only loosen the two 2 screws on the bot tom of the bracket of the charger enough to slide the charger out Move the charger to a suitable work surface O JLG Lift MVL MSP Battery Charger Removal 1 Battery Charger Assembly 2 Attach Screws Top 3 Attach Screws Bottom a 4 120 220 AC Voltage Input Cable 5 Charger LED Status Indicator harness 6 Drive Cut Out Interlock Harness P2 T DC Voltage Output to Battery Posts NOTE a The mounting bracket is slotted under these Screws loosen only 3121231 SECTION 4 CONTROL COMPONENTS SECTION 4 CONTROL COMPONENTS 4 1 CONTROL COMPONENTS OVERVIEW
42. SlideBar Front StockPicker SideEntry w Folding Material Tray Platform Tray Combined 1 EEG Model Capacity Capacity Capacity 15MSP 300b 150 Ib 450 Ib ANSI 136 kg 70 kg 206 kg CSA 20MSP 300lb 1501b 45010 136 70 kg 206 20MVL 250 Ib 100 Ib 350 Ib 115kg 45 kg 160 kg 15MVL 350 Ib 150 Ib 500 Ib 160k 70k 230k AUS 160 kg 70 kg 230 kg 20MVL 250 Ib 10016 350b 115kg 45 kg 160 kg 1 This platform is only available on models shown NOTE Distribute weight evenly in platform when loading Reference the capacity decal on the machines decal billboard mounted on mast 3121231 SECTION 1 MACHINE SPECIFICATIONS Platform Size Oversized Standard 26 in W x 28 in L 66cm x 71cm Stockpicker 28 in W x 48 in L 71cm x 122cm Extendible 26 in W x 49 in L 66cm x 124cm Plat w Mat Tray 27 W x 23 in L 68cm x 58cm Plat w Folding Tray 26 in W x 30 in L 66cm x 76cm Machine Height platform stowed MVL MSP 78 in 198cm height Machine Ground Clearance PHP Retracted 2 in 5 1 PHP Extended 0 75 in 1 9cm Base Footprint MVL MSP 29 25 in W x 52 in L 74cm x 132cm Table 1 2 15MVL MSP Machine Maximum Wheel Loads Lb and PSI Per Wheel 15MVL 15MSP TERMINA Average Maximum Average Maximum Capacity W
43. The preventive maintenance and inspection checks are listed and defined in the following table This table is divided into two basic parts the AREA to be inspected and the INTERVAL at which the inspection is to take place Under the AREA portion of the table the various systems along with the components that make up that system are listed The INTERVAL portion of the table is divided into five columns representing the various inspec tion time periods The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive Variances in interval times may occur due to climate and or conditions and depend ing on the location and use of the machine 3121231 SECTION 2 GENERAL Table 2 2 MVL MSP Preventive Maintenance amp Inspection Schedule INTERVAL AREA ON MACHINE PRE START a 3 MONTH 6 MONTH PRE DELIVERY b ANNUAL d INSPECTION PREVENTATIVE PREVENTATIVE OR FREQUENT YEARLY MAINTENANCE MAINTENANCE INSPECTION INSPECTION MAST ASSEMBLY 7 Mast Sections 2 5 2 9 Chain Systems 14 3 14 14 25 Sequence Cable Syst
44. aa 6 45 Machine Drives in Opposite 6 45 Machine Won t Drive 7 6 46 Noise From Drive Assembly 2 6 47 vi JLG Lift 3121231 TABLE OF CONTENTS LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Torque Chart SAE Fasteners Sheet 1 7 1 6 1 2 Torque Chart SAE Fasteners Sheet 2 7 1 7 1 3 Torque Chart SAE Fasteners Sheet 3 7 1 8 1 4 Torque Chart SAE Fasteners Sheet 4 7 1 9 1 5 Torque Chart METRIC Fasteners Sheet 5 7 1 10 1 6 Torque Chart METRIC Fasteners Sheet 6 7 1 11 1 7 Torque Chart METRIC Fasteners Sheet 7 7 1 12 3 1 Base Components e cae b i or PERI Re and Sa 3 1 3 2 Wheel Lug Nut Tightening 3 3 4 1 Control Components Location 4 1 4 2 Component Electrical Connections 2 12V Batteries 4 6 4 3 Battery Cable to Battery Terminal Connections
45. batteries must be charged until 8 bars are lit on the ground station LCD display to clear the fault code Failure to do so will result in a fault code 39 Code 39 Battery Voltage Low Warning Level 3 One 1 LED LCDs lit To maximize battery life it is recommended that the factory supplied batteries be charged continuously for a minimum of 4 hours or until 8 bars are lit on the ground station LCD Display before operating the machine When drained to Warning Level 1 batteries must be charged until 8 bars are lit on the ground station LCD display to clear the fault code 3121231 JLG Lift 6 33 SECTION 6 TROUBLESHOOTING Code 40 Obstruction Sensor System No Communication with Ground Control Module Check For These Obvious Conditions First s machine equipped with an Obstruction Sensor System Are the electrical harness connectors from the OSS Module through the Platform Junction Box to the Ground Control Module tight and undamaged Table 6 38 Code 40 OSS No Communication with Ground Control Module STEP ACTION SPEC YES NO 1 Is machine equipped with an OSS system Gotto Step 4 Goto Step 2 2 Atthe Ground Control Module enter programming mode and view if OSS is X No Goto Step 3 Replace Ground enabled Is OSS enabled Control Module 3 InService Level Programming mode Disable Obstruction Senor System X No 4 With machine powered up
46. 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 Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion Refer to Section 1 in this Service Manual for an expla nation of the lubricant key designations appearing in the Lubrication Chart 3121231 SECTION 3 BASE COMPONENTS SECTION 3 BASE COMPONENTS 3 1 BASE ASSEMBLY COMPONENTS a Figure 3 1 Base Components 1 Base Mounted Beacon 5 Base Frame 9 Drive Motor Cover 2 Battery Charger Cover 6 Front Caster Wheel Assembly 10 Rear Tie Down Lug 3 Front Tie Down Lug T Left Drive Motor Assy 11 Right Drive Motor Assy 4 Battery Charger Assembly 8 Pot Hole Protection System 3121231 JLG Lift 3 1 SECTION 3 BASE COMPONENTS 3 2 BASE FRAME COVERS 3 3 DRIVE ELEVATION CUT OUT SWITCH Drive Motor Cover Installation INSTALLATION Drive Motor Cover Installation J _ _ Drive Elevation Switch Cut Out Switch Installation 1 Cover 3 Set Cover Tab on Lower 2 Screws and Wash
47. check if the RED LED is lit on the front of the OSS Goto Step 5 Goto Step 10 Module 5 Check continuity from pin 9 on the OSS module 9 pin connector to the Go To Step 6 Inspect Wiring platform junction box pin 2 4 pin connector and Harness Connectors 6 Checkcontinuity from platform junction box pin 2 4 pin connector to the Goto Step 7 Inspect Wiring Ground Control Module P 4 connector 7 and Harness Connectors 7 Checkcontinuity from pin 9 on OSS module 9 pin connector to the Goto Step 8 Inspect Ground Control Module P 4 connector 7 Connection atthe Platform Junction Box 8 Program the Ground Control Module to Disable the OSS System Does fault Replacethe Ground Goto Step 9 condition still appear Control Module 9 Replace the Obstruction Sensor System and check for fault Replace the Ground Control Module 10 Disconnect9 pin connector atthe OSS Module Place a positive lead 24V DC Replace the 055 Goto Step 11 onPin 1 and a negative lead on pin 5 Check for 24v DC Module 11 Checkthe wiring harness from the Platform Junction Box connector to the 24V DC Repair or Replace Goto Step 12 Ground Control Module positive lead on pin 1 to negative lead on OSSto Junction Box pin 4 Check for 24v DC Wire Harness 12 Atthe Ground Control Module P 4 connector check voltage between pin 8 24V DC RepairorReplace Replace Ground and pin 2 place positive lead on pin
48. position Inspect chains carefully after long time use and heavy loading for this type of crack If any cracks are dis covered replace all chains as seemingly sound plates 3121231 SECTION 2 GENERAL 3121231 on the verge of cracking Fatigue and ultimate strength failures on JLG Lifts are incurred as a result of severe abuse as design specs are well within the rated lift ing capacity of these chains Tight Joints joints in the leaf chain should flex freely On leaf chain tight joints are usually caused by rust corro sion or the inside plates walking off the bushing Limber up rusty corroded chains after inspecting care fully with a heavy application of oil preferably a hot oil dip Tap inside walking plates inward if walking persists replace the chain This type of problem is accelerated by poor lubrication maintenance practice and most tight joint chains have been operated with little or no lubrica tion Tight joints on leaf chain are generally caused by a Bent pins or plates b Rusty joints c Peened plate edges Oil rusty chains and replace chains with bent or peened chain components Keep chains lubricated TIGHT JOINTS QoS S Protruding or Turned Pins Chains operating with inade quate lube generate tremendous friction between the pin and plates pin and bushing on leaf chain In extreme cases this frictional torque can actually turn the pins in the outside press fit pla
49. 2 on connector P4 atthe Ground Control 24V DC Goto Step 5 Replace Ground Module Control Module 5 Check continuity of P4 connector pin 10 to Platform Junction Box pin 1 Repair or Replace Wires Also P4 connector pin 2 to Platform Junction Box pin 5 Code 32 Pump Motor Over Current Check For These Obvious Conditions First Platform overload condition Obstruction in mast system Pump Positive and Negative connections are secure and undamaged Crushed or kinked hydraulic lines Hydraulic leaks Table 6 34 Code 32 Pump Motor Over Current STEP ACTION SPEC YES NO 1 Checkcurrent draw of pump motor by elevating the platform to full height Lessthan Goto Step 2 Goto Step 3 and load pump by continuing to press the UP button 145 Amps Is reading within spec 2 Didunit give a 32 Fault Code while performing Step 1 Replace Ground Control Module 3 Isthe pump hydraulic pressure setting within specification as showin Sec See Section 1 6 Goto Step 4 Adjustto tion 1 6 of this Service Manual Specification 4 Check pump motor brushes and rotor commutator for abnormal wear Replace as Replace Required Pump Motor 3121231 JLG Lift 6 31 SECTION 6 TROUBLESHOOTING Code 33 Both PHP Bars UP Table 6 35 Code 33 Both PHP Bars UP STEP ACTION SPEC YES NO 1 Perform steps in Code 2 Left PHP Bar UP then Code 3 Right PHP Bar UP Done Goto Step 2 Do either of
50. 3 Checkthe PHP limit switch s at both sides of the machine for damage Replace Adjust or adjustment and for continuity through switch to ground when bars are Repair Wiring down 4 Code 03 Right PHP Bar UP Check For These Obvious Conditions First Obstruction under RIGHT pot hole bar Obstruction around the actuator assembly at the base of the mast Table 6 8 Code 03 Right PHP Bar UP STEP ACTION SPEC YES NO CHECK THE FOLLOWING WITH THE PLATFORM ELEVATED 3 TO 4 FEET 1 TO 1 5m 1 Gotothe 20 pin molex connector atthe Ground Control Module back probe Replace Ground Goto Step 2 to check for continuity of pin 9 BLK 9 wire with 19 ORG RED 49 2 Control Module wire Is there continuity 2 Checkthe actuator cables for adjustment or damage Adjust or Replace Goto Step 3 3 Checkthe PHP limit switch s at both sides of the machine for damage Replace Adjust or adjustment and for continuity through switch to ground when bars are Repair Wiring down 3121231 JLG Lift 6 19 SECTION 6 TROUBLESHOOTING Code 04 Tilt Condition Check For These Obvious Conditions First If machine is on a tilt of more than 1 5 in either or both the X or Y direction this is normal operation DRIVE and LIFT UP are disabled when tilt is detected Check if Ground Control Module is mounted securely to the mast support column Table 6 9 Code 04 Tilt Condition
51. 3 22 Battery Charger Removal Installation 3 22 SECTION 4 CONTROL COMPONENTS 4 14 CONTROL COMPONENTS OVERVIEW 2 4 1 4 2 CONTROLS COVER 4 2 Battery Cover Doors Optional Hinged 4 2 Center Left and Right Lower Covers 4 2 4 3 CONTROL COMPONENTS 4 3 Ground Control 4 3 ii JLG Lift 3121231 TABLE OF CONTENTS Traction Control Module 2 4 3 Platform Control Console Installation 4 4 Horn Installation cov pee I eee 4 4 Alarm Installation ster ER ELE Pa ER REP 4 4 4 4 BATTERIES SERVICE 4 5 Battery Condition Testing 4 5 Battery 2 4 4 0 4 5 Battery Disconnect Option 4 5 Battery Installation 2 12V 4 5 Battery Installation
52. 8 Junction Boxto Control Module Ground Control Module Wire Harness 6 34 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING Codes 41 thru 46 055 Sensor 1 through 6 Fault Condition Check For These Obvious Conditions First s there an obstruction under the sensor showing the fault s the faulted sensor mounted properly and securely to the platform base frame Table 6 39 Codes 41 thru 46 OSS Sensor 1 through 6 Fault Condition STEP ACTION SPEC YES NO 1 Is machine equipped with an OSS system Gotto Step 4 Goto Step 2 2 Atthe Ground Control Module enter programming mode and view if OSS is Goto Step 3 Replace Ground enabled Is OSS enabled Control Module 3 InService Level Programming mode Disable Obstruction Senor System X No Goto Step 4 4 Replace the sensor showing the fault Does this correct the problem Done Goto Step 5 5 Replace the complete OSS system module and sensors 3121231 JLG Lift 6 35 SECTION 6 TROUBLESHOOTING Codes 100 199 Ground Control Module Fault Condition Check For These Obvious Conditions First That all battery and harness connectors secure and undamaged on Ground Control Module Batteries have sufficient charge Confirm that the static ground strap attached under base frame is secure and undamaged Table 6 40 Codes 100 199 Ground Control Module Fault Condition
53. 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 7 Torque Chart METRIC Fasteners Sheet 7 of 7 1 12 JLG Lift 3121231 SECTION 2 GENERAL SECTION 2 GENERAL 2 1 MACHINE PREPARATION INSPECTION AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition For maximum service life and safe operation ensure that all the necessary inspections and maintenance have been completed before placing the machine into service Preparation Inspection and Maintenance It is important to establish and conform to a comprehen sive inspection and preventive maintenance program The following table outlines the periodic machine inspections and maintenance recommended by JLG Industries Inc Consult your national regional or local regulations for fur ther requirements for aerial work platforms The frequency of inspections and maintenance must be increased as environment severity and frequency of usage requires Pre Start Inspection It is the User s or Operator s primary responsibility to per form a Pre Start Inspection of the machine prior to use daily or at each change of operator Reference the Opera tor s and Safety Manual for completion procedures for the Pre Start Inspection The Operator and Safety
54. Box Main 2 3 9 Input Carrier 3 10 H b Bisassenibly anf soc URS 3 11 Spindle 3 12 Spindle Sub Assembly 3 13 5 uk wey gs 3 14 Input Carrier Sub Assembly 2 3 15 Main Gear Box 5 3 16 Motor Brake and Gear Box Assembly 3 17 3 6 POTHOLE PROTECTION 5 1 3 18 3 7 BATTERY CHARGER SERVICE 3 20 Battery Charger General Information 3 20 Battery Charger Maintenance Information 3 20 Battery Charge LED Indicator on Platform Control Console 3 20 Battery Low Voltage Warning 3 20 Battery Charging Status 3 21 Battery Charger Check Change Charging
55. Hydraulic Fluid 11 11 11 Electrical Connections 20 20 Instruments Gauges Switches Lights Horn 5 GENERAL Operator and Safety Manual in Storage Box 21 21 21 ANSI and EMI Manuals Handbooks Installed 21 21 21 Capacity Decals Installed Secure Legible 21 21 21 All Decals Placards Installed Secure Legible 21 21 21 Walk Around Inspection Performed 22 Annual Machine Inspection Due 21 No Unauthorized Modifications or Additions 21 21 All Relevant Safety Publications Incorporated 21 21 22 General Structural Condition and Welds 2 4 2 4 All Fasteners Pins Shields and Covers 1 2 Grease and Lubricate to Specifications 22 22 Function Test of All Systems 22 22 Paint and Appearance 7 7 Notify JLG of Change in Machine Ownership 22 Change only when serviced requires 10 oz 296cc s to fill Replace after system brush wear indicator warning is activated on Ground Control Station Drain and refill with fresh hydraulic fluid every two years Inspection and Maintenance Codes 16 No gouges excessive wear or cords showing 1 Check for proper and secure installation 17 Properly inflated and seated around rim 2 Visual inspection for damage cracks distortion or 18 Proper and authorized components excessive Weal 19 Fully charged Check for proper adjustment 20 Noloose connections corrosion or abrasions 4 Check for cracked or broken welds 21 Verify 5 Operates properly 22 Perform 6 Returns
56. Indi cates charger has shutdown due to high internal temperature which typically indicates there is not sufficient airflow for cooling see step 1 of Installa tion Instructions Charger will restart and charge to completion if temperature is within accepted limits 6 FLASH Qui Q Fault Indicates that the batteries will not accept charge current or an internal fault has been detected in the charger This fault will nearly always be set within the first 30 seconds of operation Once it has been determined that the bat teries and connections are not faulty and Fault 6 is again displayed after interrupting AC power for at least 10 seconds the charger must be brought to a qualified service depot 3 21 SECTION 3 BASE COMPONENTS Battery Charger Check Change Charging Algorithm The charger comes pre loaded with nine algorithms for batteries as detailed in Table 3 3 If your specific battery model is not listed please contact JLG Each time AC power is applied with the battery pack NOT CONNECTED the charger enters an algorithm select dis play mode for approximately 11 seconds During this time the current Algorithm is indicated on the YELLOW CHARGING LED A single digit Algorithm is indicated by the number of blinks separated by a pause A two digit Algorithm is indicated by the number of blinks for the first digit followed by a short pause then the number of blinks for the second digit followed by a longer
57. Loctite 242 to threads before tightening b Tighten to 120 ft Ibs 534 N m JLG Lift SECTION 3 BASE COMPONENTS Wheel Drive Disassembly Main Components BRAKE CONTAINMENT HOLES Drive Motor Disassembly Main Components NOTE If possible remove the wheel drive assembly from 3 6 the machine frame Drain the oil from the Gearbox 1 by removing the cover plugs in the cover Remove the 2 Drive Motor Bolts 6 and slowly pull the Motor 2 out of the gearbox Obtain and install 2 bolts M5 x 0 8 20mm long into the brake containment holes This will keep the brake housing in one piece Cut the black wire tie not shown from the frame of the motor Remove the 3 Brake Bolts 7 6 NOTE JLG Lift Remove the Brake Housing B1 and the Spacers B4 The brake wires will have some silicone sealant at the slot through the motor flange It is okay to pull the wire out of the motor flange slot The slot will have to be re sealed during reassembly Remove the Brake Disc B2 from the splined motor shaft Remove the Brake Friction Plate B3 from the motor flange 3121231 SECTION 3 BASE COMPONENTS Replacing Drive Motor Brushes A CAUTION THE MOTOR MUST BE DISASSEMBLED FROM THE GEARBOX AND DISCONNECTED FROM THE MACHINE CONTROLLER BEFORE BEGINNING THIS PROCEDURE SEE WHEEL DRIVE ASSEMBLY REMOVAL FROM MACHINE AND WHEEL DRIVE D
58. Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart See Sec tion 1 Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants are not available consult your local supplier for an equiva lent that meets or exceeds the specifications listed Batteries Clean batteries using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroughly dry batteries and coat terminals with an anti corrosion compound 2 6 JLG Lift Mast Chain Inspection Procedure Inspect mast chains for the following conditions Wear Always inspect that segment of chain that operates over a sheave As the chain flexes over the sheaves joints and plate edges very gradually wear Chain stretch can be measured using a manufacturers wear scale or steel tape When chains have elongated 3 they must be removed and replaced Refer to Table 2 3 following for proper chain specifications and allowable stretch toler ances Peening and wear of chain plate edges are caused by sliding over a chain worn contact face of a sheave or unusually heavy loads All of the above require replace ment of the chain and correction of the cause Chain side wear noticeable when pin heads and outside plates show a definite wear pattern is caused by misalignment
59. Manual must be read in its entirety and understood prior to per forming the Pre Start Inspection Pre Delivery Inspection and Frequent Inspection The Pre Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic JLG Industries Inc recognizes a qualified JLG equipment mechanic as a person who by possession of a recog nized degree certificate extensive knowledge training or experience has successfully demonstrated the ability and proficiency to service repair and maintain the subject JLG product model The Pre Delivery Inspection and Frequent Inspection pro cedures are performed in the same manner but at differ ent times The Pre Delivery Inspection shall be performed prior to each sale lease or rental delivery The Frequent Inspection shall be accomplished for each machine in ser vice for 3 months out of service for a period of more than 3 months or when purchased used The frequency of this inspection must be increased as environment severity and frequency of usage requires 3121231 Reference the JLG Pre Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the perfor mance of these inspections Reference the appropriate areas of this manual for servicing and maintenance proce dures Annual Machine Inspection The Annual Machine Inspection must be performed by a qualified JLG equipment me
60. NO 1 Checkforthefollowing onthe drive assembly drive attachment weldments Repair Replace Goto Step 2 is bent has broken welds or loose hardware Tighten weldment 2 Check forthe following on the drive assembly drive motor mounting plates Repair Replace Goto Step 3 are bent are square with drive weldments or is hardware loose Tighten weldment 3 Check forthe following on the drive assembly drive motor hardware is Repair Replace Goto Step 4 hardware loose Tighten component 4 Checktheleftand right drive motor brakes for loose hardware amp not releas Tighten or Adjust Goto Step 5 ing properly per procedure inthis Service Manual 5 Isthe electrical signal and amperage draw to the drive motors equal Check See Table 6 3 Recheck Steps Goto Step 6 with machine on level surface 1thru5 6 Checkthe drive motor brushes do they need replaced Replace per Goto Step 7 procedure in this Service Manual 7 lsjoystick control defective Repair Replace Goto Step 8 If possible swap out with another platform control Platform control 8 lsthe Traction Control Module defective or connections not tight Tighten Connec Goto Step 9 If possible swap out with another Traction Control Module tions or Replace Traction Control Module 9 Inside the drive motor gear box check if the drive shaft is excessively loose Repair Replace gear box amp condition of drive shaft bearings components per procedure inthis
61. Output Sun Gear G8 portion of the Input Car rier Subassembly will mesh with the Output Planet Gears G9 and the Input Planet Gears G5 mounted on the Input Carrier Subassembly will mesh with the Input Ring Gear G3 Install the Input Sun Gear G4 into the area between the three Input Planet Gears G5 Apply a coating of grease to the Cover O ring G20 and install it into the o ring groove of the Hub Subassembly It may be helpful to stretch the o ring 620 out prior to assembly to avoid pinching or shearing when the Cover 611 is assembled Apply Loctite 380 or 480 glue to Cover Thrust Washer G21 and place it in the center counter bore of the Cover G11 so that the steel face of the washer is out of the bore Make sure that both the Cover Thrust Washer G21 and the Cover G11 have good clean surfaces for the Loctite to properly adhere Center the Cover G11 in the hub bore so that the JLG logo is up Push it into the bore Install the Cover Retaining Ring G19 into the groove of the Hub Sub assembly 3121231 SECTION 3 BASE COMPONENTS Motor Brake and Gear Box Assembly BRAKE CONTAINMENT HOLES Motor Brake and Gear Box Assembly Place the Motor 2 shaft up on the bench Place the Brake Friction Plate B3 onto face of the motor flange Line up the three holes of the Brake Friction Plate B3 with the tapped holes in the motor flange WHEN MOUNTING THE BRAKE FRICTION PLATE
62. Power Circuit 6 15 Mast Troubleshooting i srai e n RR ERE ee 6 15 Hydraulic Leak 2 2 22 2 6 15 Base Frame Components Troubleshooting 6 15 Drive System Troubleshooting 6 15 6 9 SPECIFICATIONS FOR VARIOUS 6 16 6 10 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS 6 16 6 11 FAULT CODE TROUBLESHOOTING TABLES 6 17 Machine in Drive Speed Cut Back Turtle Mode All The Time 6 17 Obstruction Sensor System Detection 6 18 Battery Voltage Low Warning Level Three 3 51 6 18 Code 02 Left PHP 6 19 Code 03 Right 6 19 Code 04 Tilt Condition cto HR Ges E He Ta aue e dos Y 6 20 Gode 05 Reserved nca denisa at epe ttn aei n o E RA OR Rer ela ae a Td 6 20 Code 06 Drive Motor Brush Wear Warning 6 21 Code 07 Left Drive Motor 6 21 Code 08 Right Dri
63. RESET position out Table 6 43 Machine Will Not Power UP STEP ACTION SPEC YES NO 1 Check for 24V DC atthe positive and negative main power cable 24V DC Goto Step 2 Replace the 175 connections on the Ground Control Module Amp Inline Fuse on the Positive power cable 2 Check continuity of the Emergency Stop wires running to the Platform Con Replacethe Ground Goto Step 3 trol Console pins 10 and 1 onthe P4 connector atthe Ground Control Mod Control Module ule 3 Removethe 9 pin Platform Control Console connector atthe Platform Goto Step 4 Replace the Junction Box and check continuity between pins 1 and 2 to the Emergency Platform Control Stop Switch in the Platform Control Console cable Console 4 Check continuity of the wires running from the P4 connector on Ground Replace Platform RepairorReplace Control Module to the Platform Junction Box Control Console Wiring P4 connector 1 to Junction Box Pin 2 and P4 connector Pin 10 to Junction Box Pin 1 3121231 JLG Lift 6 39 SECTION 6 TROUBLESHOOTING 6 13 MAST TROUBLESHOOTING Platform Will Not Lower Manually Check For These Obvious Conditions First s there an obstruction in the mast assembly s there a restricted hydraulic line smashed Are the mast slide pads shimmed properly not too tight per Mast Assembly procedure in Service Manual Table 6 44 Platform Will Not Lower Manually
64. Service Are any gears broken or gearteeth excessively worn Manual 6 46 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING Noise From Drive Assembly Overview Of Procedure The following procedure examines the drive motor assembly weldments attaching the drive motors to the base frame Also internal components of the drive motors gear box and a check of the components between the gear box and the drive wheels Check For These Obvious Conditions First Battery voltage 24 volts Fully charge batteries Nothing is lodged between one of the wheels and the base frame A caster wheel on the front of the machine is seized up creating resistance Table 6 55 Noise from Drive Assembly STEP ACTION SPEC YES NO 1 Checkforthe following onthe drive assembly drive attachment weldment Repair Replace Goto Step 2 is bent has broken welds orloose hardware Tighten weldment 2 Checkforthefollowing onthe drive assembly drive motor mounting plates Repair Replace Goto Step 3 are bent are square with drive weldments or is hardware loose Tighten weldment 3 Check forthe following on the drive assembly drive motor hardware is Repair Replace Goto Step 4 hardware loose Tighten Component 4 Checktheleftand right drive motor brakes for loose hardware amp not releas Tighten or Adjust Goto Step 5 ing properly per procedure inthis Service Manual 5
65. Step 6 Replace Valve 6 Pump drive cavatating Replace Pump Goto Step 7 7 Liftcylinder Rebuild or Replace Cylinder 6 40 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING Mast Noisy When Lifting And Lowering Overview Of Procedure This procedure examines components of the mast itself and as well as it s lifting components for dirt debris proper lubrica tion and operation Table 6 46 Mast Noisy when Lifting and Lowering STEP ACTION SPEC YES NO 1 Doslide pads and slide pad channels needto be cleaned of dust dirt or Clean Pads and Goto Step 2 other debris Channels 2 Domastchains need to be lubricated per JLG specification in the Service Lubricate as Goto Step 3 Manual Required 3 Arethechain cable sheave wheels dry and need lubrication Lubricate or Goto Step 4 Note Plastic wheels will howl on the sheave pin when they are dry Sheave Replace Sheave wheels may seize to the sheave pin and the pin may turn in the pin retainer Pins and Wheels blocks 4 Arethe sequence cables located on the side of mast chattering when the Clean Slide Pads Goto Step 5 springs are compressed Channels or Re Note This noise is normal atthe sequence cable sheave wheels when the shim Mast per Ser mastis completely lowered However if the sequence cable chattering is vice Manual happening no matter what position the mastis in it could be a result o
66. TERMINAL FROM THE LEFT SIDE BATTERY Ground Control Module The Ground Control Module is located under the center cover at the rear of the machine and is mounted on the mast support column All electrical components on the machine operate directly or indirectly through the Ground Control Module The module is currently programmed at the factory with the machines operating profile If replac ing a Ground Control Module the new module may require some programming to enable any optional equip ment See Section 4 6 Ground Control Module Program ming Ground Control Module Installation 1 Ground Control Module 2 Attach Screws Washers Note See Figure 4 2 for wiring connection instructions Traction Control Module The Traction Control Module is mounted below the Ground Control Module on the mast support column The traction module controls the voltage to the drive motors as regulated by the ground control module from signals received via the joystick controller located on the platform control module There are no internal parts serviced on this module Traction Control Module Installation 1 Traction Control Module 2 Attach Screws Washers Note See Figure 4 2 for wiring connection instructions 3121231 JLG Lift 4 3 SECTION 4 CONTROL COMPONENTS Platform Control Console Installation Horn Installation The platform control console is located i
67. TO THE MOTOR FLANGE CHECK THAT THE MOTOR HOUSING TO FLANGE MOUNTING BOLTS ARE NOT CONTACTING THE BRAKE FRIC TION PLATE UNDERNEATH CONTACT INTERFERENCE COULD CAUSE THE BRAKE FRICTION PLATE TO WARP WHEN TIGHT ENED DOWN 3 3121231 Place the Brake Disc B2 on the motor shaft Make sure the splines are properly lined up and the Brake Disc B2 is down against the Brake Friction Plate B3 Place the three Spacers B4 so that they line up with the three holes in the Brake Friction Plate B3 Carefully place the Brake Housing B1 onto the Spacers B4 so that the holes in the Brake Hous ing B1 line up with the holes in the Spacers B4 Make sure that the wire leads coming out of the Brake Housing B1 are lined up with the slot in the motor flange Install the three Brake Bolts 7 into the three holes in the Brake Housing B1 Tighten to 4 5 ft lbs Remove and discard the 2 bolts in the Brake Con tainment Holes 8 10 Pull the Brake Lead through the through the slot in the motor flange Make sure the leads are all the way in the bottom of the slot Install a wire tie around the brake leads and the motor housing Position the wire tie so that it is approximately 2 back from the motor flange If the Gearbox 1 is loose from the machine place it onto the bench with the cover side down If the Gearbox 1 is attached to the machine perform the next step with extreme caution BEFORE MOUNTING THE DRIVE MOT
68. TO USE ONLY THE LUG NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL Tighten the lug nuts to the proper torque to prevent wheels from coming loose Use a torque wrench to tighten the fasteners If you do not have a torque wrench tighten the fasteners with a lug wrench then immediately have a service garage or dealer tighten the lug nuts to the proper torque Over tightening will result in breaking the lug nuts or permanently deforming the mounting holes in the wheels The proper procedure for attaching wheels is as follows 1 Start all lug nuts by hand to prevent cross threading DO NOT use a lubricant on threads or nuts 2 Tighten lug nuts in the following sequence 3 The tightening of the lug nuts should be done in stages Following the recommended sequence tighten lug nuts per wheel torque Table 3 1 Wheel Torque Chart TORQUE SEQUENCE 1stStage 2nd Stage 3rd Stage 20 30 ftlbs 65 80 ftIbs 105 120ftlbs 28 42 Nm 91 112 Nm 142 163 Nm 4 Wheel lug nuts should be torqued after the first 50 hours of operation and after each wheel removal Check torque every 3 months or 150 hours of opera tion Caster Wheels Installation Caster Wheel Installation 1 Caster Wheel Assembly 3 Caster Shim b 2 Attach Screws and Wash ers Qty 4 a NOTE a On assembly apply Loctite 242 to threads b As required Place unit on a flat surface shim a caster wh
69. Wiring component Code 28 Reserved Code 29 Reserved Code 30 Traction Module No Communication with Ground Control Module Check For These Obvious Conditions First Check if the communications cable connections P5 connector on the Ground Control Module and round plug on the Traction Control Module are seated properly in their sockets at each end Check the Positive RED and Negative BLACK power cable connections from the Ground Control Module to the Traction Control Module are tight and secure at both ends Table 6 32 Code 30 Traction Module No Communication with Ground Control Module 6 30 JLG Lift STEP ACTION SPEC YES NO 1 Checkthe voltage reading at the main power Positive 4 Negative 24v DC Goto Step 2 Repair or Replace cable connection onthe Traction Control Module Positive or Negative Cable 2 Remove the communications cable P5 connector at the Ground Control Goto Step 3 Repair or Replace Module and round connector at Traction Control Module Check conti Wire s nuity of all three 3 wires in the communications cable from end to end P5 Pins 2 3 and 4 3 With communications cable disconnected at both ends check for continu Repair or Replace Goto Step 4 ity between Pins 2 3 and 4 of the P5 connector end Wires 4 Plugthe communications cable on the Traction Control Module to the round Done Replace Traction socket
70. and larger machine component parts Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of component weight and never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that ade quate support is provided A WARNING SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON TROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER OPERATOR B HYDRAULIC SYSTEM SAFETY 1 It should be particularly noted that the machines hydraulic systems operate at extremely high and potentially dangerous pressures Every effort should be made to relieve any system pressure prior to dis connecting or removing any portion of the system 2 Relieve system pressure by lowering the platform completely to direct any line pressure back into the return line to the reservoir Pressure feed lines to system components can then be disconnected with minimal fluid loss 3121231 JLG Lift REMOVE ALL RINGS WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE DO NOT WEAR LONG HAIR UNRESTRAINED OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT OBSERVE AND OBEY ALL DANGER WARNING CAU TION AND OTHER INSTRUCTIONS ON MACHINE AND IN SERVICE MANUAL KEEP STANDING SU
71. component becomes less than 90 degrees 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 com plete 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 adjustments other than those recommended without obtaining proper approval Pressure Fit Parts When assembling pressure fit parts use an anti seize or molybdenum disulfide base compound to lubricate the mating surface Bearings When bearing is removed cover it to keep out dirt and abrasives Clean bearings in nonflammable cleaning sol vent and allow to drip dry Compressed air can be used but do not spin the bearing Discard bearings if the races and balls or rollers are pit ted scored or burned 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 Lubricate new or used serviceable bearings before instal lation 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 Check that holes in gaskets a
72. debris which may stick to lubricated chains Slide mast section 3 out TOP of mast section 2 far enough to allow access to the chain sheave wheel assembly Remove countersunk flathead screws securing chain sheave wheel assembly attach bars on both side rails at TOP of mast section 3 and remove the sheave wheel assembly While mast section 3 is still extended from section 2 remove the pin attaching the chain anchor plate to the TOP of mast section 3 Remove chains When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels 16 Carefully slide mast section 3 out BOTTOM of sec tion 2 Remove slide pads and shims if necessary Mast Section 2 Removal 17 18 19 20 21 NOTE 22 Slide mast section 2 out TOP of mast section 1 far enough to allow access to the chain assembly anchor block sheave wheel assembly Remove countersunk flathead screws securing chain anchor block sheave wheel assembly attach bars on both side rails at TOP of mast section 2 Slide the chain anchor block sheave wheel assem bly and hydraulic cylinder out the TOP of mast sec tion 2 far enough to allow removal of the sheave wheel attach bars sheave wheels and sheave pin from chain assembly anchor block Remove the setscrew holding the hydraulic cylinder rod onto the chain assembly anchor block Lay chain assembly anchor block to side Remove the hydraulic cylinder throu
73. draining out of cylinder to avoid spillage onto work area Be careful not to nick or scour rod surface when extending and during installation Slide the lift cylinder into the closed rail side of mast section 2 and the cylinder mount into mast section 1 closed rail with the manual descent valve pointing down towards the back of the mast assembly Check the mount side to side clearance Use mount ing shims of equal thickness on each side to center the mount in the closed rail of section 1 if neces sary Install the cylinder mounting reinforcement plates 1 each side and secure the cylinder assembly to the mast using the cylinder mounting screws and wash ers Apply Loctite 242 to the screw threads before final tightening 3121231 SECTION 5 MAST COMPONENTS 15 16 17 18 19 Slide mast section 2 out of mast section 1 approxi mately 8 in 20cm Assemble one of the narrow chains sets 444 and to the small chain equalizer anchor plate using the pins washers and cotter keys Set aside Locate the chain anchor block and slide it onto the hydraulic cylinder rod end extending out the top of mast section 2 Lay out the chain 444 anchor plate assembly with anchor plate end towards mast be certain floor sur face is clean and free of any metal chip or debris which may stick to lubricated chains or lay chains in a clean bucket Assemble the chain anchor plate assembly and the chain anchor block to th
74. if possible If not possible keep in mind it may affect readings Access the terminals to the switch If the switch has two terminals a Measure resistance across the terminals b Change the switch position c Measure resistance again with the leads in the same positions If the meter was reading short it should read an open If the meter was reading open it should read short If the switch has more than two terminals consult the schematic or switch diagram to determine what terminals will be connected The test is similar to testing a switch with two terminals a Place one meter lead on the common contact and the other on a different contact in the same circuit b Cycle through all positions of the switch The meter should read short only when the switch connects the two termi nals and open otherwise c If the switch has more than one common contact repeat the process for that circuit Limit Switches Limit switches are used to control movement or indicate position Mechanical limit switches are just like manually operated switches except that the moving object operates the switch These switches can be tested the same way as a standard switch by manually operating the sensing arm Another type of limit switch used by JLG is the inductive proximity switch also referred to as a prox switch Inductive prox imity switches are actuated only by ferrous metal metal that contains Iron such as steel near the switch They do not re
75. of the sheave chain anchors and must be corrected promptly Do not repair chains if a section of chain is damaged replace the entire chain set of H Example H for a 1 chain 0 950 Maximum wear 5 of 0 950 0 047 Minimum plate depth 0 950 0 047 0 903 Rust and Corrosion Rust and corrosion will cause a major reduction in the load carrying capacity of the chain because these are primary reasons for side plate crack ing The initial lubrication at the factory is applied in a hot dip tank to assure full penetration into the joint Do not steam clean or degrease chains At time of chain installa tion factory lube must be supplemented by a mainte nance program to provide a film of oil on the chains at all times If chains are corroded they must be inspected especially the outside plates for cracks in line with the pins If cracks are found replace the chain if no cracks are discovered lubricate the chains by dipping in heated oil and reinstall on the machine Keep chains lubricated Table 2 3 Chain Stretch Tolerance Chain Size Allowable Stretch Measurement 50 pitch 12 or 24 pitches 24 in 12 in span 625 pitch 15 or 24 pitches 301 15 in span Fatigue Cracks Fatigue is a phenomenon that affects most metals and is the most common cause of chain plate failures Fatigue cracks are found through the link holes perpendicular 90 degrees from the pin in line
76. on the opposite end of the module Does this fix problem Control Module 5 Unplug the P5 connector atthe Ground Control Module Check voltage 4 5v DC Done Replace Ground between pins 2 lead in and 5 lead in Is voltage within spec Control Module 3121231 SECTION 6 TROUBLESHOOTING Code 31 Platform Control Console No Communication with Ground Control Module Check For These Obvious Conditions First Check the harness connection at the P4 connector on the Ground Control Module and the harness connection at the other end on the Platform Junction Box Table 6 33 Code 31 Platform Control Console No Communication with Ground Control Module STEP ACTION SPEC YES NO 1 Checkif LEDs are illuminated on the Platform Control Console Go To Step 2 Goto Step 3 2 Removethe 9 pin Platform Control Console connector from the side of the RepairorReplace RepairorReplace Platform Junction Box and the P4 connector at the Ground Control Module Platform Control Wiring Check continuity from the P4 connector pin 5 to Junction Box pin 3 and P4 Console pin 9 to Junction Box pin 4 3 Remove the 9 pin Platform Control Console connector from the side of the 24V DC Repair or Replace Go to Step 4 Platform Junction Box Check the voltage across pins 1 and 5 in the Junc Platform Control tion Box connector Console 4 Check voltage across pins 10 and
77. portion of Cover in Slot on 1 Mounting Screws a 3 Switch Mounting Block ers a Base Frame 2 Proximity Switch b 4 Frame Mounting Holes NOTE a Apply Loctite 242 to screw threads before tightening NOTE Elevate and block platform to gain access to switch a Apply Loctite 4242 to mounting screw Battery Charger Cover Installation threads on final assembly Batttery Charger Cover Installation 1 Charger Cover 3 Rear Attach Screws 2 Front Attach Screws and Washers Loosen and Washers Only Cover Slotted 3 2 JLG Lift 3121231 SECTION 3 BASE COMPONENTS 3 4 DRIVE AND CASTER WHEELS Tire Wear and Damage Inspect tires periodically for wear or damage Tires with worn edges or distorted profiles require replacement Tires with significant damage in the tread area or side wall require immediate evaluation before replacing the machine into service Wheel and Tire Replacement Replacement wheels must have the same diameter and profile as the original Replacement tires must be the same size and rating as the tire being replaced Wheel Installation It is extremely important to apply and maintain proper wheel mounting torque A WARNING WHEEL LUG NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS BROKEN LUG NUTS AND POSSIBLE SEPARATION OF WHEEL FROM THE AXLE BE SURE
78. power up check that both the Ground Control Module Emergency Stop Button and the Platform Control Console Emergency Stop Button are in the RESET position Also if machine is equipped with the PSL Program mable Security Lock option see Section 3 Pro grammable Security Lock in your Operators Manual for additional machine power up steps 3121231 SECTION 4 CONTROL COMPONENTS Entering Password Selecting Programmable Item to Adjust p 4 00000 OO SET SLEEP TIME 7 Entering Password 1 The Brake Release button 1 moves the box around digit from left to right to select which digit to change 2 Platform UP button 2 increases the numerical digit 3 Platform DOWN button 3 decreases the numerical digit 4 Change all five digits 4 to match password level then press the Brake Release button 1 again Programming Mode Selection RESET TIMERS Selecting Programmable Item to Adjust 1 Use the Platform UP DOWN buttons 1 to scroll through the list of programmable items available to your programming level 2 Once a programmable item to be adjusted is selected press the Brake Release button 2 to enter that set tings adjustment mode Adjusting Programmable Setting 5 9 3 NY 2 1 Programming Mode Selection
79. sections even Applying silicone spray onto the slide pads and slide pad channels before assembly will help mast sections slide easier after slide pads have been properly shimmed Mast Disassembly Procedure 1 After the mast assembly has been removed from the machine lay the mast assembly down on a suitable work table with the platform mounting section on top facing up 2 Remove the sequencing cables and hardware from the sides of the mast assembly Also remove the covers from the top of the mast assembly Mast Section 5 Removal 3 Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate lower on BOTTOM end of mast section 5 platform mounting section Push threaded ends of chain through anchor plate 4 At the TOP of mast section 5 pull chains out and allow to hang loose Be certain floor surface is clean and free of any metal chips or debris which may stick to lubricated chains NOTE When sliding mast sections apart be careful not to scratch or score the anodized surface in the slide pad channels CLOSED RAIL REFERS TO CLOSED RAIL BACK OF MAST SECTION REFERS TO TOP ENC OF MAST SECTION WHERE COVER AND SHEAVE WHEELS ARE ATTACHED REFERS TO BOTTOM END OF MAST SECTION WHICH SETS IN MACHINE S BASE FRAIVE Figure 5 5 Mast Section Assembly Reference 5 16 JLG Lift 3121231 SECTION 5 MAST COMPONENTS Carefully slide mast section
80. to neutral or off position when released 23 Sealed properly 7 Clean and free of debris 24 Overrides Platform controls 8 Interlocks function properly 25 Inspected per Service and Maintenance Manual 9 Check for signs of leakage Footnotes 10 Decals installed and legible a Prior to use each day or at each Operator change 11 Check for proper fluid level b Prior to each sale lease or delivery 12 Check for chafing and proper routing c In service for 3 months or Out of service for 3 months 13 Check for proper tolerances or more or Purchased used 14 Properly lubricated d Annually no later than 13 months from the date of the 15 Torqued to proper specification prior annual inspection JLG Lift 3121231 SECTION 2 GENERAL 2 3 SERVICING AND MAINTENANCE GUIDELINES General The following information is provided to assist you in the use and application of servicing and maintenance proce dures contained in this chapter Safety and Workmanship Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of component weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that ade quate support is provided A WARNING NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT FORM HAS BEEN SAFEL
81. 0 into the Spin dle G1 until it bottoms out Make sure the Output Planet Gear G9 spins freely after the Planet Shaft is pressed in Repeat Steps 5 11 for the other two Output Planet Gears G9 Turn the Spindle G1 over so that the carrier end is down Install Input Ball Bearing G15 into the Spindle G1 bore Using a flat plate or rod press the Motor Shaft Seal G17 into the center bore so that it is flush with the face of the Spindle G1 3 13 SECTION 3 BASE COMPONENTS Hub Sub Assembly NOTE 3 14 Hub Sub Assembly Put Hub G2 on a table with the tapped holes fac ing down Using a flat plate in conjunction with a pressing tool press in the Seal G16 so it is flush with the edge of the hub NOTE The Seal has a thin outer shell that can be easily damaged if not installed with care It is a good idea to start the Seal into the bore with a rubber mal let before pressing JLG Lift Flip the Hub G2 over Using the appropriate pressing tool T 174356 press the Main Bearing G14 into the bore until it bottoms out 3121231 SECTION 3 BASE COMPONENTS Input Carrier Sub Assembly e 3121231 Input Carrier Sub Assembly Use the Input Planet Shaft G6 as a pressing tool to install the Planet Bushing G26 into the bore of each Planet Gear G5 The shaft will help guide the bushing into the bore as well as prevent damage from the press
82. 0 970 1130 30 561 1460 1100 1320 1530 2090 2690 4290 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 5 Torque Chart METRIC Fasteners Sheet 5 of 7 JLG Lift 3121231 SECTION 1 MACHINE SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 10 9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12 9 SOCKET HEAD CAP SCREWS M3 M5 Torque Torque Lub OR Loctite Torque Tensile Clamp Dry or Loctite 242 or 271 OR Loctite 262 OR Size PITCH Stress 5 Load 2637 Vibra TITE 111 or Vibra TITE 131 K 0 20 140 K 0 15 K 0 18 ESEUSE AEA E 3 os s13 ee a oz sez 0 8 25 2 22 7 18 9 1 25 36 5 32 8 Emend a a M T mp 2 ws ne 200 1 1 1 2 ww ws ss 2 25 is 25 19 nos 43 395 35 24 3 2220 1065 90 80 561 2095 1885 1575 694 2855 2570 2140 3665 3300 2750 4s
83. 0W 30 and a viscosity index of 152 For cold weather applications i e when temperatures remain consistently below 20 F 7 C JLG recom mends using Mobil DTE 13 hydraulic oil Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not con tain the same required additives or be of comparable vis cosities If use of hydraulic oil other than Mobilfluid 424 is desired contact JLG Industries for proper recommenda tions Table 1 4 Hydraulic Oil Operating Range HYDRAULIC SYSTEM OPERATING SAE VISCOSITY TEMPERATURE RANGE GRADE 0 F to 180 F 10W 18 C to 83 C 0 F to 210 F 18 C to 99 C 50 F to 210 F 10 C to 99 C 10W 20 10W 30 20W 20 Lubrication Specifications Table 1 5 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 F Excellent water resistance and adhesive qual ities and being of extreme pressure type Timken OK 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API service classification GL 5 or MIL Spec MIL L 2105 HO Hydraulic Oil ISO Vg grade 32 46 CL ChainLube Use a good quality chain lubricant 1 5 CYLINDER SPECIFICATIONS NOTE All dimensions are given in inches in with the met ric equivalent centimeters cm given in parenthe Ses Table 1 6 Cylinder Specifications
84. 1 MACHINE SPECIFICATIONS T Bolt Dia PI 48 0 120 8 32 01880 40 01880 8 32 01640 36 0 1640 32 01900 28 02500 EE ERES RT O f a i oaas 4 percer a 03750 _ 20 04375 12 20 0 5000 18 05625 5 8 11 0 6250 Tensile Stress Area Sq In 0 00604 0 00661 0 00909 0 01015 0 01400 0 01474 0 01750 0 02000 0 0318 0 0364 Sq In 0 0524 0 0580 0 0775 0 0878 0 1063 0 1187 0 1419 0 1599 0 1820 0 2030 e N Q SOCKET HEAD SCREWS Zinc Yellow Chromate Fasteners Ref 4150707 Torque Loctite 242 or 271 Torque Clamp Load E Loctite amp 2627 See Note 4 OR Vibra TITE 111 or or Vibra TITE 131 140 OR Precoat 85 K 0 15 K 0 18 IN LB N m IN LB IN LB N aE ei s D o T 1 f Ad gt d M f e o E D o o T 1 D o T 1 f D o o T f ee eh ol 2860 143 16 3280 164 19 18 17 LB e Nm rris Nm rris Nm 790 s 70 45 9 35 5 950 95 5 9 5 70 80 70 95 60 8 _ 1775 105 145 95 13 8 0 14400 120 165 mo o 120 20350 210 285 190 260 160 220 18 0 6250 215 290 180 245 3 4 10 0 7500 340 460 280 380 16 0 7500 380 515 315 430
85. 1 Use Platform UP DOWN buttons 1 to move the selection box 2 up or down to select item to pro gram 2 Press the Brake Release button 3 to enter selected mode then move on to Selecting Programmable Item to Adjust 3121231 Adjusting Programmable Setting 1 Adjust the programmable setting using the Platform UP DOWN buttons 1 see Table 4 1 for range of set tings for the item selected 2 Once parameter is set for the programmable item press the Brake Release button 2 this will enter the parameter and return you to the Programmable Set tings Menu TO EXIT Programming Mode after entering program mable settings power machine off with either the Main Power Selector Switch or Emergency Stop Button JLG Lift 4 13 SECTION 4 CONTROL COMPONENTS Service Programming Mode Level 2 In the Service Programming Mode the following items are shown on the main menu Reset Timers EEPROM Defaults Program OSS Sensor Tilt Sensor NOTE There are two production modules available at this time one for North South American and European languages and one for Asian languages All pro grammable items between these modules are identi cal with the exception of language selection Reset Timers This setting displays five 5 timers as described following Trip Time This timer displays total accumulated hours since last trip timer reset This is the hour meter reading displayed on the Ground Control
86. 1 000 micro Displayed Number 1 000 000 Example 1 2 1200 Q Example 50 mA 0 05 A 6 2 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING Voltage Measurement Resistance Measurement Figure 6 1 Voltage Measurement DC Figure 6 2 Resistance Measurement f 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 resistance Disconnect component from circuit before testing f meter is not auto ranging set it to the correct range See multimeter s operation manual Use firm contact with meter leads 3121231 JLG Lift 6 3 SECTION 6 TROUBLESHOOTING Continuity Measurement Current Measurement Tr 2 7 we 1 DIL PUER Figure 6 3 Continuity Measurement Figure 6 4 Current Measurement DC Set up the meter for the expected current range Be sure to connect the meter leads to the correct jacks for the current range you have selected f meter is not auto ranging set it to the correct range tinuity Disconnect component from circuit before testing See multi meter s operation manual Some meters require a separate button press to enable audible continuity testing Circuit pow
87. 10 MAST BEACON INSTALLATION GATE INTERLOCK INSTALLATION a MSP Platform Mid Gate Interlock Switch Installation 1 Pop Rivets 4 Mounting Holes 2 Interlock Switch 5 Mid Gate 3 Spacer 6 Wire Harness Clamp Mast Mounted Beacon Installation MVL MSP 1 Beacon Mounting Bracket 4 Beacon 2 Bracket Screws Nuts Washers Assembly 3 Beacon Screws Nuts Washers 5 n Guard a Note a Guard on UL EE specification machines only MSP Platform Mid Gate Interlock Switch Wiring Harness Routing 1 Interlock Switch 3 Connection at Junction Box 2 Wire Routing 4 Platform Junction Box Note Decal billboard removed in above illustration 5 28 JLG Lift 3121231 SECTION 5 MAST COMPONENTS 9 11 GATE ALARM INSTALLATION OPTION FOR SIDE ENTRY W FOLDING MATERIAL TRAY PLATFORM ONLY NOTE Machine must have v6 11 or higher software in the Ground Control Module Ground Control Module Programming settings required Set Ancillary 1 POL to HIGH Up Arrow Set AUX 1 INHIBIT to 5 Switches and Wiring WIRES FROM SWITCHES ROUTE THROUGH PLATFORM MID RAILS
88. 33 P2 Auxiliary 1 Inhibit n n 3 E3npmmmp e4224 mne lt gt 4 LIFTUP DOWNand DRIVE X 000000 34 are Disabled 9 P2 Auxiliary 1 Tie Down 4 E3mmmpee44 7 7 7 e eTuP DOWNandDRIVE S6 E637 X 00000 0 35 35 are Disabled 9 2 LEDs BARS Flashing with 7 38 2 mun A CHARGE BATTERY 52 a u See Page 6 33 ZU LE Platform Lift UP Function is Locked Out 6 12 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING Table 6 1 LCD Display Service Fault Code Conditions feat FAULT DESCRIPTION FOR TROUBLESHOOTING FAULT CONSOLE CODE LCD SYMBOL SCREEN LCD TEXT SCREEN MACHINE CONDITION REFER TO 1 LED BAR Flashing with an A Emm he CHARGE BATTERY aya 9 audible beep 39 1 a pa Drive and Platform Lift UP Functions Locked Out Obstruction Sensor System 055 40 5 4 lt gt n0 conns E No Communication With s X 000000 40 40 Ground Control Station 9 41 z Ea 22 055 FRULT A Internal OSS Sensor 1 See Table 6 39 X 000000 p41 ea Fault Condition Page 6 35 055 FRULT A Internal OSS Sensor 2 See Table 6 39 T COT A nterna ensor ee lable 5 E 2 lt re Fault Condition Page 6 35 055 FAULT amp Internal OSS Sensor 3 See Table 6 39 CAm 4 n 43 o E Fault Condition Page 6 35 44 _ ES 2 gt 055 FRULT A Internal OSS Sensor 4 See Table 6 39
89. 4 continuous EE e Platform Lift UP Function hours or more or 8 LEDs CHARGE BATTERY 7 is Locked Out BARS lit before operating a 4 38 LEVEL 3 1 LED BAR Flashing with Charge batteries for a mini E 3 an audible beep mum of four 4 continuous Z 00000 0 Drive and Platform Lift UP hours or more or 8 LEDs CHARGE 1 Functions Locked Out BARS lit before operating a BATTERY 39 NOTE a To maximize battery life it is recommended that the factory supplied batteries be charged continuously for a min imum of 4 hours or until 8 bars are lit on the ground station LCD Display before operating the machine When drained to Warning Level 2 batteries must be charged until 8 bars are lit on the ground station LCD display to clear the fault code 3 20 JLG Lift 3121231 SECTION 3 BASE COMPONENTS Battery Charging Status Indicators The battery charging status indicators are located just above the Charger AC input receptacle on the center cover section at the rear of the machine This LED indica tor set is plugged directly into a connector on the back of the battery charger and indicates current charging status When first plugged in the charger will automatically turn on and go through a short LED indicator self test all LED s will flash in an up down sequence for two seconds 3121231 then charging will begin CHARGING NEZ S YELLOW MIDDLE LED ON O Ch
90. 4 6V Batteries OPTION 4 7 4 5 GROUND CONTROL MODULE SERVICE PROCEDURE 4 8 Cover Removal Installation 4 9 Power Selector EStop Switch Installation 4 10 4 6 GROUND CONTROL MODULE 4 11 Generals oom etam edades Eee ux aiu AVE vue Ete 4 11 Programming Levels 2 05 2 rcu d UR RA RD ki 4 11 Activating Programming 4 11 Entering Password goa rer Fe CA EUR EUR REQUE E ded ae EUR 4 12 Programming Mode 4 12 Selecting Programmable Item to 4 12 Adjusting Programmable Setting 4 12 Service Programming Mode Level 2 4 13 Operator Programming Mode 3 4 14 4 7 PLATFORM CONTROL CONSOLE SERVICE PROCEDURES 4 16 Gerleral etu tn Eos 4 16 Remove Platform Control Console 2 4 16 Display Controller Module Electrical lt 5 4 17 Mountin
91. 5 out the BOTTOM of mast section 4 rails Disassemble slide pads shims and chain anchor plate from mast section 5 if nec essary Mast Section 4 Removal 6 NOTE 10 Remove chain adjust nuts from threaded ends of chains attached to the chain anchor plate lower on BOTTOM end of mast section 4 Push threaded ends of chains through anchor plate At TOP of mast section 4 pull chains out and allow to hang loose Be certain floor surface is clean and free of any metal chips or debris which may stick to lubricated chains Slide mast section 4 out the TOP of mast section 3 far enough to allow access to the chain sheave wheel assembly Remove countersunk flathead screws securing chain sheave wheel assembly attach bars on both side rails at TOP of mast section 4 and remove sheave wheel assembly When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 4 out BOTTOM of sec tion 3 Remove slide pads shims and cable anchor plate if necessary Mast Section 3 Removal 11 12 13 14 15 3121231 Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate on BOT TOM end of mast section 3 Push threaded ends of chain through the anchor plate At TOP of mast section 3 pull chains out and allow to hang loose be certain floor surface is clean and free of any metal chips or
92. 6 TROUBLESHOOTING 6 7 GROUND CONTROL MODULE LCD DISPLAY At power up and during operation the LCD display on the Ground Control Module displays the current machine operating status The following illustration explains the symbol indications N E3 mmm p 5 7 X 00000 0 00 E lt gt 00 5 LCD Display Symbols 1 Battery Charge Indicator 2 Function Display or Function Disable Indicators 3 Hour Meter Display 4 Fault Code Indicator 5 Fault Code Text Message Display a Note a When an Fault code is indicated the LCD screen will alternate between the text and symbol display modes In the LCD Display Symbols illustration item 2 above the Function Display or Function Disable Indicators will vary as shown following Both LIFT UP and LIFT DOWN Disabled gt DRIVE Disabled LIFT DOWN Disabled Battery Charger Plugged In LIFT UP Disabled 1 E 6 8 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING LIC 5 P2 2 s 1 Ground Control Module a 5 Tractio
93. 870202_F 6 50 Figure 6 7 Electrical Diagram MVL MSP JLG Lift 3121231 SECTION 6 TROUBLESHOOTING ES OUT YELLOW BLACK ES N YELLOW SHIELD B BLACK RS485B BLUE RS485A ORANGE AUX 1 SIGNAL B RED BLACK AUX 1 RETURN BLUE BLACK 0 5 5 SUPPLY 24V DC RED O S S DIGITAL RETURN BROWN SPARE ORANGE BLACK SPARE BROWN BLACK SPARE BLACK RED 39NYUO VS8vSH MOTTZA NI S3 2 PIP Pale lal l o mr olm oO Jor JE m Hb o m x Em c m m jo IF ale f CES a mir I mi A6 Is 6 m EJ mi c e 2 o z z 2 e le le SE 255 2 545 x gt 8 s 2 225 E SER 5x m P o gt Ls PLATFORM 5 AUX 2 _ WHEN EQUIPPED W LSS a j PLATFORM KOC AUX 1 1949 Aux INPUT 1 B BLACK B BLACK ON OFF BLUE ON OFF BLUE COM WHITE COM WHITE PI PA P5 AQ AAA 9950 waana P2 P3 9 6 Q38 39NYHO NANLIY 2 MOVIE JAYA SLIGIHNI TVNOIS XV H TAN 4 1 BLACK 5 YELLOW RED 2 1 BLACK 6 ORANGE RED 49 1 YELLOW RED 2 2 BLACK 7
94. 99 Platform Control Console Fault Condition 6 37 Codes 300 399 Traction Control Module Fault 6 38 6 12 MAIN POWER CIRCUIT 6 39 Machine Will Not Power 6 39 6 13 MAST TROUBLESHOOTING 1 6 40 Platform Will Not Lower 6 40 Platform Lift Up And Down Jerky 6 40 Mast Noisy When Lifting And Lowering 6 41 Platform Mast Won t Stay 6 42 Platform Mast Descends Too Slowly 6 42 6 14 HYDRAULIC LEAK 6 43 Miscellaneous Hydraulic Leak 6 43 6 15 BASE FRAME COMPONENTS TROUBLESHOOTING 6 44 Caster Wheels Not Operating 6 44 Pot Hole Protection PHP Bars will not 6 44 6 16 DRIVE SYSTEM 4 6 45 Won t Climb Grade i 22 uen ae er Iu RR
95. ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the voltage across pins 0 2VDC Goto Step 2 Replace Ground 10and3tothe lift down valve coil 15 reading within specification Control Module 2 Removethe wire terminals atthe lift down valve coil Check resistance read 6 Ohms Go to Step 3 Replace Coil ing of the coil Is coil within specification 3 With the terminals still removed from the lift down valve coil check continu 00 Ohms Repair or Replace ity ofthe wires from pins 10 and 3 onthe P1 connectorto the lift down valve Wiring Code 17 Ground Control Module In Fold Back Check For These Obvious Conditions First Has machine been operating on a continuous grade or rough terrain for a long period of time Table 6 21 Code 17 Ground Control Module In Fold Back STEP ACTION SPEC YES NO 1 Allow Ground Control Module to cool for 30 minutes Does the machine Replace Ground operate OK after cooling Control Module Table 6 3 Amperage Draw for Various Components NOTE If this is a recurring problem compare current draw of your machine with Ground Control Module specifications in Code 18 Alarm Short Circuit Check For These Obvious Conditions First Damaged wiring in the alarm wiring harness or a damaged alarm Table 6 22 Code 18 Alarm Short Circuit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the voltag
96. ALS An Oshkosh Corporation Company Service amp Maintenance Manual Model s 15 20MVL amp 15 20MSP Series P N 3121231 December 20 2013 JL BS NOTES INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS MAINTENANCE SAFETY PRECAUTIONS A GENERAL C MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial A WARNING platform It is of utmost importance that maintenance per FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN sonnel pay strict attention to these warnings and precau THIS SECTION COULD RESULT IN MACHINE DAMAGE PERSON tions to avoid possible injury to themselves or others or NEL INJURY OR DEATH AND IS A SAFETY VIOLATION damage to the equipment A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe to operate A WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA TION The specific precautions to be observed during machine maintenance are inserted at the appropriate point in the manual These precautions are for the most part those that apply when servicing hydraulic
97. AMP ASSEMBLY KIT JLG P N 7023275 TO ASSEMBLE THE CLAMP TO THE WIRE ROPE THE KIT CONSISTS OF VISE JAWS TO HOLD THE WIRE ROPE IN A VISE PROPERLY WITHOUT DAMAGING ANY ROPE STRANDS AND A PLUG DRIVER TO DRIVE THE PLUG INTO THE CENTER OF THE WIRE ROPE AND IS ALSO USED TO FORM THE STRANDS THE ROPE DURING ASSEMBLY NOTE The tools in the clamp assembly kit may be fabri cated if necessary The vise clamp consists of vise jaws with a hole drilled 1 32 in smaller than the diameter of the wire rope you are working with i e 1 8 in rope 3 32 in hole The plug driver is a metal tube with a hole in the bot tom to allow the strands of the wire rope to be shaped after the plug has been tapped into the cen ter of the wire rope 1 Using the recommended vise jaws clamp the wire rope into a vise with the bottom edge of the black mark made on the wire rope resting just above the vise jaws 1 Cable 2 Mark on Cable 3 Recommended Vise Jaws 3121231 SECTION 5 MAST COMPONENTS 2 Twist the sleeve from the clamp kit onto the rope until it is flat against the vise jaws at the mark made made on the wire rope 1 Sleeve Installed on Cable 3 Use a suitable tool and cut the cable as shown in the illustration following For 1 8 in cable the recom mended length is 5 8 in past the end of the sleeve 1 Cut To This Length 2 Sleeve 4 Unlay the cable strands by gently forcing a screw
98. ATTEMPT TO DISASSEMBLE THE PLATFORM CONTROL BOX IF MACHINE IS STILL UNDER WARRANTY OPENING THE PLATFORM CONTROL BOX WHILE THE MACHINE IS UNDER WARRANTY WILL VOID THE WARRANTY IF UNDER WARRANTY REQUEST A REPLACEMENT BOX FROM THE FACTORY The platform control console allows for replacement of nine 9 components Emergency Stop Switch Key Switch Joystick Assembly Display Controller Module Drive Lift Mode Selector Switch Horn Button Switch Rear Cover Wiring Harness Connector Socket Mounting Bracket Remove Platform Control Console First remove the platform control console completely from the platform assembly See Section 4 3 Control Compo nents Installation Figure 4 5 Platform Control Console Components 1 E Stop Shut Down Switch 5 Drive Lift Mode Selector Switch 2 ON OFF Key Switch a 6 Horn Button Switch 3 Joystick Assembly 7 Rear Cover 4 Display Controller Module 8 Wiring Harness Connector NOTE a No key switch on Australian spec machines 3121231 JLG Lift 4 17 SECTION 4 CONTROL COMPONENTS Display Controller Module Electrical Connections The internal switches and joystick controller of the plat form console plug directly into the Display Controller Module This module then relays the signals from these switches to the Ground Control Box through the commu nications cable running to the platform junct
99. DRIVE Lift UP DOWN decia X 000000 09 09 Disabled 9 Right Brake Disconnected RIGHT BRAKE 0 c 59 DRIVE LinUP DOWN ji 000000 10 10 Disabled agea Left Drive Motor LEFT MOTOR s 11 6 nmm lt gt SHORTED mo Short Circuit X 000000 en 11 DRIVE Disabled 9 Right Drive Motor RIGHT MOTOR d 12 6 E3 que SHORTED gt Short Circuit 6 X 000000 2 12 DRIVE Disabled 9 Traction Module 3 e E3 o gt Y In Fold Back X 00000 0 13 13 DRIVE Disabled 9 4 PUMP MOTOR Pump Motor Disconnected See Table 6 18 14 7 gt DISCONNECTED Lift UP Disabled Page 6 24 X 000000 14 14 LiftDown Valve DOWN VALVE See Table 6 19 15 7 4 lt gt DISCONNECTED A Disconnected Page 6 24 X 000000 15 15 Lift UP DOWN Disabled ca DOUN VALVE Down Valve or Down Valve Gee Table 6 20 16 7 SHORT Circuit Short Page 6 25 X 000000 16 16 Lift UP DOWN Disabled 9 REIN GALE 4 Ground Control Module 17 7 2 lt gt FOLD BACK 7 In Fold Back X 000000 17 17 Machine Stopped 9 _ E 3 ALARM SHORT Alarm or See Table 6 22 E gt lt 18 gt 18 Alarm Circuit Short Page 6 25 ALARM DISCONNECTED 19 Alarm Disconnected 23 X 000000 19 19 age 6 26 Beacon or See Table 6 24 20 m ES BEACON SHORT z Figs 20 Beacon Circuit Short Page 6 26 BERCON DISCONNECTED E 21 Beacon Disc
100. G Lift 3121231 SECTION 3 BASE COMPONENTS Gear Box Main Disassemhly SPINDLE SUB ASSEMBLY 777 SUB ASSEMBLY p CARRIER SUB ASSEMBLY G4 G2 Gad 19 qo 3121231 Gear Box Main Disassembly Using a screwdriver pry the end of the Retaining Ring G19 out of the groove in the Hub Subas sembly then grasp the loose end of the Retaining Ring and pull the rest of the way out Remove Cover G11 Thrust Washer G21 should remain in the inner counter bore of the Cover when removed To remove the cover the motor must be removed Slide a rod through the motor shaft hole and gently tap with a rubber hammer to force the cover out Remove Input Sun Gear G4 Remove Input Carrier Sub assembly Remove Cover 11 and O ring G20 Remove Input Ring Gear G3 The Input Ring Gear G3 is held in with a press fit on its outside diameter Insert jacking screws 1 4 20UNC grade 8 with at least 1 5 inches of thread length into each of the three tapped holes to force the ring gear out Be sure and alternate between the JLG Lift jacking screws to keep the ring gear from becoming misaligned in the bore The screws will push against the outer race of the main bearing This bearing will have to be replaced afterwards Using a screwdriver remove Spiral Retaining Ring G27 Pull Hub Sub assembly off of the Spindle Sub assembly 3 9 SECTION 3 BASE COMPONENTS
101. GE Ground Control Module 20MVL 95 Amps 9 room temperature with rated load 15MSP 110 Amps room temperature with rated load Traction Control Module LEVEL SURFACE 15 GRADE 24 RATED LOAD 24V RATED LOAD 71011 Amps 55 to 60 Amps 3 5 to 4 8 Amps per motor per motor 78to 86 RPM 6 10 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS The following table contains pin extractor tools for MVLMVL Series and MSP machine electrical connector components Table 6 4 Special Pin Extractor Tools for Electrical Connectors COMPONENT DESCRIPTION JLG PART NUMBER ILLUSTRATION Ground Control Station For removal of electrical con nector pins from the Ground Control Station connectors 7016618 Drive Motor For removal of electrical con nector pins from the Drive Motor main power connectors 7002841 Drive Motor Brake For removal of electrical con nector pins from the Drive Motor Brake power connec tors 7002842 6 16 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING 6 11 FAULT CODE TROUBLESHOOTING TABLES Machine in Drive Speed Cut Back Turtle Mode All The Time Overview of Procedure Under normal machine operation once the platform is elevated the machine s maximum drive speed is reduced to 1 4 the normal drive speed of when the platform is fully lowered This is detected with a drive speed cut back proxim
102. HE COVER CAREFULLY ONCE THE COVER SCREWS ARE REMOVED FROM THE BACK OF THE MODULE Cover Installation 1 Remove the 6 Hex Socket Screws from the Heat Sink Base One screw is under the Warranty Tamper Label Release Ribbon Cable 1 Ribbon Cable Connector Tabs Push tabs away from connector to release cable then slide cable out of connector Note Connector works same at both ends of the ribbon cable Disconnect the Ribbon Cable 1 Ribbon Cable Connector 3 Support for Cover 2 Ribbon Cable Reconnecting Ribbon Cable 1 Ribbon Cable Connector Release Tabs Slide cable into connector then push tabs back into connector Note Connector same at both ends of the ribbon cable 4 10 JLG Lift 3121231 SECTION 4 CONTROL COMPONENTS Power Selector EStop Switch Installation Emergency Stop Switch Installation 1 Emergency Stop Button 4 Nut 2 Button Seal 5 Emergency Stop Switch 3 Square Lock Washer 6 Switch Lock Release Lever Note Tighten nut enough to keep button from turning Reattach wires to same terminals on new switch Power Selector EStop Switch Connectors Location 1 LCD and Button Circuit Board 2 Emergency Stop Switch Connector 3 Main Power Selector Switch Connect
103. I 000000 p44 Fault Condition Page 6 35 4 05S FRULT 4 _ E 3 TE Z 4 Internal OSS Sensor 5 See Table 6 39 45 M M Fault Condition Page 6 35 5 055 FRULT 4 Internal OSS Sensor 6 See Table 6 39 _ Ex gt nterna enso lable 46 gt 5 M p nf Fault Condition Page 6 35 GROUND MODULE Ground Control Module See Table 6 40 i 100 10 E Md ot poe Fault Condition Page 6 36 200 10 PEN RU MODULE Platform Control Console See Table 6 41 X 000000 200 200 Fault Condition Page 6 37 E mmm E TRACTION MODULE Traction Control Module See Table 6 42 300 10 505 Fault Condition Page 6 38 4 055 FRULT OSS Control Module See Table 6 38 40 E3 4 Myr gt Low Internal Supply Page 6 34 401 _ E3 2 PN 055 FRULT g OSS Control Module See Table 6 38 X 000000 401 401 Amplifier Fault Page 6 34 3121231 JLG Lift 6 13 SECTION 6 TROUBLESHOOTING 6 8 TROUBLESHOOTING TABLES INDEX SPECIFICATIONS FOR VARIOUS COMPONENTS PAGE Ohm Ratings for Various 6 16 Amperage Draw for Various Components 6 16 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS Special Pin Extractor Tools for Electrical 6 16 FAULT CODE TROUBLESHOOTING TABLES Machine in Driv
104. ICS eee E M dn 6 2 etre tree ou t etes tdt 6 2 Backprobihg dre o UR WE ACQUE UN Cer eat et eR ME 6 2 2 ca E DR Due RUE a Ve d 6 2 Polarity o I bU ebore beatae alte iaa iex 6 2 DCN 6 2 Continuity Measurement Over Long Distances 6 5 Requirements niae E 6 5 Procedure xxi eet n E Mone WE s eu OM Rt Pan 6 5 iv JLG Lift 3121231 TABLE OF CONTENTS 6 6 ELECTRICAL SWITCH 1 6 6 Basic Check CPV rm OR qu ea m RC IRR PS 6 6 Litriit Swilces E ee mdp re e eR dore 6 6 Automatic Switches 22225 lere RR RH RU RO add Rech we ete 6 7 Switch Wiring Low Side High 6 7 6 7 GROUND CONTROL MODULE LCD 6 8 6 8 TROUBLESHOOTING TABLES INDEX 6 14 Specifications For Various 6 14 Special Pin Extractor Tools For Electrical 6 14 Fault Code Troubleshooting Tables 6 14 Main
105. ISASSEMBLY MAIN COMPONENTS ON THE PREVIOUS PAGES 1 Wrap tape around the end of the motor shaft that interfaces with the gearbox to avoid damage to this area 2 Remove the motor thru bolts 3 Remove the motor flange brake mount from the motor frame 4 Remove the brush housing from the motor frame and armature by tapping the edge of the brush housing with a soft tipped mallet The brushes will spring towards the center of the brush housing once it has separated from the armature 5 Remove the wave spring washer from the bearing bore of the brush housing and set aside 6 Pick a brush and remove the screw that fastens its lead to the brush holder NOTE If this is a wear indicator brush then there will be a second lead that will need to be removed from a spade terminal in the brush housing 7 Remove the brush and brush spring 8 Inspect the brush holder for corrosion Remove any corrosion that is found 9 Install a new brush spring into the brush holder Make sure that it is oriented in its correct recoil direc tion NOTE The spring contains a flat area with a coil at each end The spring should be oriented such that the bend from the flat area to the coil is towards the brush 10 Install a new brush into the brush holder make sure that the orientation of the lead wire is the same as the other brushes 11 Push the new brush up into the brush holder Insert a pin straightened paper clip into the small
106. Indicator Yes No Object distance from sensor 2 Sensor numbers 4 Signal strength Note This screen can be viewed while another person performs the transducer sensor check see Section 4 9 3121231 SECTION 4 CONTROL COMPONENTS Operator Programming Mode Level 3 In the Operator Programming Mode the following items are shown on the main menu also see Table 4 1 Tilt Sensor Program NOTE There are two production modules available at this time one for North South American and European languages and one for Asian languages All pro grammable items between these modules are identi cal with the exception of language selection Tilt Sensor Allows viewing current tilt sensor individual X and Y direc tion degree reading Program Allows the Operator to program Level 3 items shown in Table 4 1 following Table 4 1 MVL MSP Ground Control Module Field Programmable Settings and Factory Preset Level 2 Service Level Settings OnLCD Display Level 3 Operator Level Settings NO X Low LEVEL PROGRAMMABLE ITEM FACTORY PRESET SETTING RANGE 2 Back to Main 15 20MVL MSP Return to Programming Menu Set Language 1 English 6 Italian 2 German 7 Swedish NOTE There are two production modules available 1 3 Dutch 8 Brazilian Portuguese 3 one for North South American and European 4 French 9 Fi
107. Install the seal and wear ring to the piston NOTE Re check that seals are not twisted or pinched and are properly seated 4 Place the rod on a clean table Install the static pis 5 i ton o ring seal into the groove on the piston end of the rod 5 Install the head followed by the piston onto the rod noting the proper orientation of each component Torque the piston nut to 100 120 ft Ibs 6 When the rod assembly is ready to be installed into the tube liberally apply an anti seize lubricant to the cylinder head surface which slides into the cylinder tube 7 Next dip the entire rod assembly into hydraulic fluid and stuff this assembly into the tube Watch the seals as they pass over the rod port if visible to be sure they are not nicked or cut 8 Install the head until the retaining ring seats in it s groove Cylinder Installation To install the lift cylinder reverse the Lift Cylinder Removal instructions at the start of this section however perform the following additional steps during re assembly 1 Apply Loctite 222 purple and torque to 85 ft Ibs the cylinder mount shoulder screws securing the lift cylinder mount halves together at the bottom of the mast 2 Check that the platform electrical control cables and the sequence cables are seated in their sheave Figure 5 4 Lift Cylinder Component Cross Section w
108. K UNDER AN ELEVATED PLATFORM UNTIL PLAT FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING 5 5 2 Start with the mast section which needs adjustment and loosen the bottom jam nut on each chain cable NOTE 10 Tighten to raise mast section or loosen to lower mast section the adjusting nut against the anchor plate on each chain cable Adjust the nut the amount required to raise or lower the top of the mast section to match the side profile shown in Figure 5 2 when the mast is retracted It is more important that the threaded ends studs protruding on the adjustments are equal side to side on a mast section than it is that the tension in the chains is equal The chain equalizers will always assure equal tension but if the adjustment isn t equal as described the chains may tend to pull to one side or the other The threaded end of the chain cable may need to be restrained while tightening the adjust nut to keep the chain cable from twisting Retract the mast all the way and check if the top of the mast sections appear as shown in Figure 5 2 Repeat steps 1 through 7 for remaining mast sec tions Once mast section adjustment is completed apply loctite 242 to the threads under the jam nuts that were loosened Then re tighten the loosened jam nuts until tight against the top adjust nut Chain cable should have slight tension but should not be taut MSP Only After
109. LACEMENT PLEASE CONTACT YOUR LOCAL JLG SUPPORT OFFICE BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COM PATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES THE USE OF NON APPROVED BATTER IES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFORMANCE ISSUES OR BATTERY CHARGER FAULT CODES JLG ASSUMES NO RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES ARISING FROM THE USE OF NON APPROVED BATTERIES Replacement battery s must be of equivalent voltage and amperage output as the OEM battery s in order for the machine to operate to as manufactured specifications Battery replacement part weight must also be equivalent to OEM per battery in order to maintain machine stability as manufactured See Section 1 of this manual for battery specifications A WARNING DO NOT REPLACE ITEMS CRITICAL TO STABILITY SUCH AS BATTERIES WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFI CATION DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABIL ITY 3121231 Battery Condition Testing NOTE Batteries in storage should be kept at 12 5V or higher Before testing for battery condition the open circuit volt age should be taken from each battery If the voltage of the batteries differs by 0 3 volts or more the lower voltage battery should be replaced Battery Testing Can Be Performed In Two Ways 1 The batteries can be tested using a battery tester capable of testing 12V 100Ah AGM VRLA Valve
110. Left Side Side PHP bar limit switch between pins 10 and 20 on the P2 connector at PHP Limit Switch the Ground Control Module 3121231 JLG Lift 6 17 SECTION 6 TROUBLESHOOTING Obstruction Sensor System Detection Check For These Obvious Conditions First Look for an obstruction under platform remove obstruction Check for any external damage to sensor s or wiring harness Are the O S S side shield tubes secure to platform frame and not loose or protruding into the sensor detection area Are the isolation bushings in place and undamaged on both the O S S Module and each of the detection sensors Are the detection sensor mounting screws properly tightened not over torqued so not to damage the isolation bushings Also check that none of the sensor mounting screws are bent thereby touching the inside of the sensor mounting holes Are any of the Do not pressure wash decals loose and protruding into the sensor detection area Table 6 6 Obstruction Sensor System Detection STEP ACTION SPEC YES NO 1 Perform Daily Pre Start Inspection to test each transducer sensor Goto Step 2 Replace Sensor Did all sensors pass test 2 Disconnectthe OSS Control Module connection to the Platform Junction Goto Step 3 Replace Ground Box mounted on the mast platform header section above the 055 Control Control Module Module Does the Ground Control Module now show a Fault Code 5 3 Reconnectthe
111. Module LCD Display during normal machine operation Traction Time Displays the amount of accumulated DRIVE hours on the machine s current drive compo nents Lift UP Time Displays the amount of accumulated time the machine has operated the Lift UP function Lift DOWN Time Displays the amount of accumulated time machine has operated the Lift DOWN function Total Time Displays the total amount of time accumu lated by the Traction Lift UP and Lift DOWN Timers Of these five 5 timers only the Trip Timer can be RESET back to zero 00000 0 Brush Wear Sensor Timer This timer must be reset after the drive motor brushes are replaced and the brush wear sensors are repositioned When reset the display will go from WORN to a blank display Also the 25 hr 10 second countdown will stop and normal machine operation will resume Program Allows service personnel to program the Level 2 and Level 3 items shown in Table 4 1 Tilt Sensor Allows service personnel to reset the Ground Control Module s internal digital Tilt Sensor to zero 0 0 degrees in both the X and Y axis A DANGER ZEROING THE TILT SENSOR REQUIRES THE MACHINE TO BE RESTING ON A SURFACE CHECKED WITH A DIGITAL LEVEL MEASURING WITHIN 0 0 DEGREES LEVEL IN BOTH THE X AND Y AXIS DIRECTIONS 4 14 JLG Lift NOTE When entering this mode the LCD will display in real time the current X and Y degree readings of the tilt sensor The reading being disp
112. Motor Power Leads atthe Traction Module 2 Remove the Right Drive Motor power lead at the Traction Control Module Goto Step 3 Rewire as M2 and check if the WHITE wire is connected to the positive terminal Necessary and the BLACK wire is connected to the negative terminal Reference Figure 6 7 Electrical Diagram MVL MSP 3 Remove the Left Drive Motor power lead at the Traction Control Module Consult Rewire as M1 and check if the BLACK wire is connected to the positive terminal Factory Necessary andthe WHITE wire is connected to the negative terminal The Left Motor Power lead is reversed from the Right Motor lead due to the reverser harness Reference Figure 6 7 Electrical Diagram MVL MSP 3121231 JLG Lift 6 45 SECTION 6 TROUBLESHOOTING Machine Won t Drive Straight Overview Of Procedure The following procedure examines the drive motor assembly weldments attaching the drive motors to the base frame Also internal components of the drive motors gear box and a check of the components between the gear box and the drive wheels Check For These Obvious Conditions First Battery voltage 24 volts Fully charge batteries Nothing is lodged between one of the wheels and the base frame A caster wheel on the front of the machine is seized up creating resistance Table 6 54 Machine Won t Drive Straight STEP ACTION SPEC YES
113. N RESO HEP 1 2 1 4 LUBRICATION xu CUm Plt E QUE a ROME RR OE EARN A 1 4 Hydraulic Qil siese a haia eee an ead tei eMe 1 4 Lubrication Specifications 2 4 1 1 4 1 5 CYLINDER SPECIFICATIONS 1 4 1 6 SERIAL NUMBER LOCATIONS 1 4 1 7 TORQUE REQUIREMENTS 2 1 4 SECTION 2 GENERAL 2 1 MACHINE PREPARATION INSPECTION AND 2 1 le ePRUimS pex APR I 2 1 Preparation Inspection and 2 1 P e Start Inspection dr hem VPE LIPS E UE eee DP Uus 2 1 Pre Delivery Inspection and Frequent 2 1 Annual Machine 1 2 1 Preventative 1 94 4 2 1 2 2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE 2 2 Inspection and Maintenance Codes 2 4 Footnotes de bes d elected Sd EA iu 2 4 2 3 SERVICING AND MAINTENANCE
114. NTACT YOUR LOCAL JLG SUPPORT OFFICE BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COM PATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES THE USE OF NON APPROVED BATTER IES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFORMANCE ISSUES OR BATTERY CHARGER FAULT CODES JLG ASSUMES NO RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES ARISING FROM THE USE OF NON APPROVED BATTERIES 1 2 JLG Lift AGM 12 Volt 100 Amp Hour 20 Hr rate Sealed Maintenance Free Weight 71 75 Ib 34 Kg Per Battery AGM 6 Volt 220 Amp Hour 20 Hr rate Sealed Maintenance Free Weight 66 Ib 30 Kg Per Battery Batteries 2 STD Batteries 4 OPTION Battery Charger Microprocessor Controlled SCR Circuit Monitor 120 240 Volt A C Selectable 50 60 Hz input 24 volt 20 amp output with 2 amp finish Reset Circuit Breaker Automatic Charge Circuit Plug Interlock Circuit NOTE The batteries on MVL MSP machines require approximately five 5 hours to fully charge when drained to LOW BATTERY VOLTAGE warning on the Ground Control Module LCD display 1 3 PERFORMANCE DATA Platform Capacities GullWing Front 15 500 Ib 230kg 20MVL 350 Ib 160kg 15MVL 500 Ib 230kg 20MVL 350 Ib 160kg 15MSP 500 Ib 230kg 20MSP 400 Ib 180kg GullWing Extendible 15MVL 500 Ib 230kg 20MVL 350 Ib 160kg
115. OPTION i 22 B BLACK ON OFF BLUE COM WHITE GROUND STATION MODULE PI Q 5 Q 9980 Xx zm S 88 a g amp MEE e xz ul F gms SIE 21 152 e o 8 zs 9110 s 25 5 GEB B ue z E a zou A 5 5 1 1 n trs als PUMP JOYSTICK 12 8 MOTOR n STANDARD 2 12V BATTERY CONNECTION _ log 12 bo aL 8 50 E a V H Sls WHITE 9 8 pu Emu i Bp S OPTIONAL 4 6V BATTERY CONNECTION ev ev ev HORN 55 2 m Ut 1 5 AMP g 3 Slo 1 EP RIGHT RIGHT ee d MOTOR BRAKE S 7 d BA B BI ALARM 2 5 MAX B ES EIE BLACK a BASE B 6 L3 24VDC 5 MAX BEACON e gt 5 53 WHT RED 51 1 dpt m 7X BRUSH WEAR 0 wast INDICATOR S aix BEACON rst PICS WAX WHT RED 57 2 SEE ZONE C 2 n 32 e gt VALVE SPARE p m d PWM 4 105 VDC 5 siti TAN 4 1 LIFT DOWN e VALVE BLACK 5 PN 5 AUX OUTPUT 24VDC 5 AMP MAX YELLOW RED 2 1 LEFT LEFT B BLACK 6 MOTOR BRAKE n 5S ON 25 OFF OVERLOAD d MIMIC S BEACON WHEN NOT EQUIPPED W LSS BLACK a 2 F AUX 2 OUTPUT 24VDC 5 AMP MAX YELLOW RED 2 2 z 5 SHARED WITH OSS B BLACK 7 WHEN EQUIPPED W LSS 1
116. OR BRAKE ASSEMBLY TO THE GEARBOX SPINDLE HUB BE CERTAIN THE BRAKE CAVITY INSIDE THE GEARBOX IS CLEAN AND FREE OF ANY OIL RESI DUE 11 NOTE 12 13 14 15 JLG Lift Slowly slide the Motor 2 into the Gearbox 1 Make sure that the end of the motor shaft does not damage the Gearbox 1 lip seal The motor may need to be rotated to line up the sun gear splines with the motor shaft splines Install the 2 Motor Bolts 6 Tighten to 8 9 ft Ibs Apply a bead of silicone sealant to the slot in the motor flange where the brake leads are exiting Fill the Gearbox 1 with oil per instructions See Page 3 4 The wheel drive is now ready to be installed onto the machine reverse removal instructions See Page 3 5 3 17 SECTION 3 BASE COMPONENTS 3 6 POT HOLE PROTECTION SYSTEM 3 18 1 PHP Actuator Platform 2 Right Left PHP Limit Switch 3 Right Side Counterbalance 4 Left Side Counterbalance Pot Hole Protection System Components 5 PHP Link see detail illustration following 6 Left PHP Bar 7 Right PHP Bar 8 PHP Bar Pivot Pin and Retaining Ring FLANGE BEARING MUST BE ORIENTED AS SHOWN TOWARDS LINK PLATE Tm 1 BA 4 1 PHP Counterweight Bar Link 2 Flange Bearing 3 PHP Counterweight Link 4 Retaining Ring PHP Link Installation Ite
117. OSS Control Module connection to the Platform Junction Replace Box Check for original fault condition OSS System Battery Voltage Low Warning Level 3 Three 3 LED LCDs lit 3 LEDs BARS Flashing with an audible beep Machine will Operate No Control Functions are Locked Out When batteries are drained to Warning Level 3 charge batteries until a level of four 4 LEDs Platform or BARS Ground Control Module or more before operating Failure to do so will eventually result in a fault Code 38 Battery Voltage Low Warning Level 2 NOTE If battery is not charging properly see Battery Battery Charger Servicing Section 3 of this Manual 6 18 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING Code 02 Left PHP Bar UP Check For These Obvious Conditions First Obstruction under LEFT pot hole bar Obstruction around the actuator assembly at the base of the mast Table 6 7 Code 02 Left PHP Bar UP STEP ACTION SPEC YES NO CHECK THE FOLLOWING WITH THE PLATFORM ELEVATED 3 TO 4 FEET 1 TO 1 5m 1 Gotothe 20 pin molex connector atthe Ground Control Module back probe Replace Ground Goto Step 2 to check for continuity of pin 10 BLK 8 wire with pin 20 ORG RED 49 Control Module 1 wire Is there continuity 2 Checkthe actuator cables for adjustment or damage Adjust or Replace Goto Step 3
118. Planck Str 21 D 27721 Ritterhude Ihlpohl Germany FFE 49 0 421 69 350 20 49 0 421 69 350 45 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755 Castellbisbal Barcelona Spain f 34 93 772 4700 34 93 771 1762 e JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden 46 0 850 659 500 446 0 850 659 534 A JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI taly 39 029 359 5210 39 029 359 5845 ju B www jlg com Oshkosh JLG Singapore Technology Equipment Pte Ltd 29 Tuas Ave 4 Jurong Industrial Estate 639379 Singapore 65 6591 9030 65 6591 9031
119. Press three Input Planet Shafts G6 into the three holes of the Input Carrier 7 The head of the Input Planet Shaft G6 needs to sit flush in the counter bore of the Input Carrier G7 holes Insert Output Sun Gear G8 into the splined bore of the Input Carrier G7 The gear tooth end of the Output Sun Gear G8 should protrude in the oppo site direction of the Input Planet Shafts G6 Using retaining ring pliers install the Retaining Ring G24 into the groove of the Output Sun Gear G8 Make sure that the Retaining Ring G24 is cor rectly seated in the groove and that the Output Sun Gear G8 cannot be pulled out of the Input Carrier G7 Place a Thrust Washer G25 on each side of the Input Planet Gear 5 Line up the bores as well as you can visually JLG Lift 6 Place the Input Planet Gear G5 and Thrust Washers G25 onto the Input Planet Shaft G6 sticking out from the Input Carrier G7 Repeat 5 amp 6 for the other 2 Planet Gears G5 Put the Thrust Plate G23 onto the three Input Planet Shafts G6 Use the three holes on the out ermost bolt circle The other three holes are for a dif ferent gear ratio Using the appropriate retaining ring pliers put a Retaining Ring G18 into the groove of each Input Planet Shaft G6 NOTE NOTE Do not overstress the Retaining Rings 418 3 15 SECTION 3 BASE COMPONENTS Main Gear Box Sub Assemhly CARRIER SUB ASSEMBLY
120. RFACES AND HAND HOLDS FREE OF OIL GREASE WATER ETC NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVER HEAD SLING BEFORE MAKING ADJUSTMENTS LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPO NENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACH MENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS ENSURE REPLACEMENT PARTS OR COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS INTRODUCTION REVISION LOG Manual Revised Manual Revised Manual Revised Manual Revised Manual Revised Manual Revised Manual Revised Manual Revised Manual Revised Manual Revised Manual Revised Manual Revised REVISION LOG Original Issue of January 5 2006 April 3 2006 dw EU October 4 2006 ves irt s reines i a October 8 2007 e April 17 2008 PEE October 7 2008 Ld trek acies ATUS Sod SURE de dfe May 15 2009 eT ET July 19 2010 December 21 2010 oth ea tA cbe February 23 2012 TORT Oi des bet April 25 2013 uarie UE tte Ne December 5 2013 Uu tt m o December 20 2013 JLG Li
121. RNING HYDRAULIC CYLINDERS ARE DESIGNED TO HOLD HYDRAULIC FLUID UNDER HIGH PRESSURE ENSURE ALL APPROPRIATE MEASURES ARE TAKEN TO RELIEVE RESIDUAL PRESSURE IN THE CYLINDER BEFORE DISCONNECTING LINES Lift Cylinder Removal Removal of the hydraulic lift cylinder without removing the mast from the machine requires laying the machine on it s back hood side with the platform end on top 1 Remove the following components from the machine before laying machine on it s back Rear Covers See Section 4 Batteries See Section 3 Drive Motor Cover See Section 3 2 Seal the vented cap on the hydraulic fluid reservoir by removing the cap covering the hole with a few layers of plastic wrap or equivalent Then install and tighten the cap over the plastic wrap to prevent leak age of hydraulic oil from the reservoir while machine is in a layed back position 3 Use a forklift truck or overhead crane and carefully lay the machine on it s back place a support under the mast end keeping mast close to level See Fig ure 5 3 cf I R 1 2 Figure 5 3 Machine Positioned for Cylinder Removal 1 Be Careful of Control Components in this Area 2 Support Mast Here Keep Mast Approximately Lev
122. SSEMBLY COMPONENTS 1 3 1 3 2 BASE FRAME COVERS Gowen eee ida 3 2 Drive Motor Cover 3 2 Battery Charger Cover Installation 3 2 3 8 DRIVE ELEVATION CUT OUT SWITCH 3 2 3 4 DRIVE AND CASTER WHEELS 2 2 3 3 Tire Wear and Damage cR ml Eee RM Rer LE E em Ee 3 3 Wheel and Tire Replacement 3 3 Wheel Installation n eR Re Re a beeps Ra 3 3 Caster Wheels 3 8 3 5 WHEEL DRIVE ASSEMBLY 3 4 Roll And Leak Testing oipe errai pepe e edd dea ae DE 3 4 Oil Type amp Capacity RI 3 4 Drive Motor Brush Wear Warning 3 4 Wheel Drive Assembly Removal From 3 5 Wheel Drive Disassembly Main 3 6 Replacing Drive Motor 3 7 Gear
123. Security Lock Harness Option a Notes Apply di electric grease JLG Part Number 3020038 to wiring harness terminals to prevent moisture from entering module b Seal NEG and POS posts with battery grease to prevent corrosion Figure 4 2 Component Electrical Connections 2 12V Batteries shown 3121231 JLG Lift 4 7 SECTION 4 CONTROL COMPONENTS Battery Installation 4 6V Batteries OPTION Battery Installation 4 6V Left Side Batteries Shown with Machine Covers Removed 1 Battery Cables a b 4 Upper Left Side Battery 2 Upper Battery Tray c 3 Upper Battery Hold down 5 Lower Battery Strap NOTE a See battery cable to battery terminal connec tion illustration Figure 4 3 b Apply battery terminal grease to prevent cor rosion c Three bolts hold the battery tray to the mast support two shown and one on the back of the support There is a left side and a right side tray H H 3 4 1 Ground Control Module 4 Lower Right Side Battery 2 Upper Left Side Battery 5 Upper Right Side Battery 3 Lower Left Side Battery 6 175 Amp Inline Fuse NOTE a Label battery cables before removing to ensure proper installation The battery cables connecting the batteries are identical on
124. UNDER PASS WORD LEVEL 2 OR LEVEL 3 LEVEL 1 SETTINGS MUST NOT BE MODIFIED UNLESS DIRECTED BY JLG ENGINEERING DEPART MENT PERSONNEL Level 1 JLG Engineering Settings include voltage amperage and ohm output settings that are within the operating parameters of various machine components This Level can adjust all programmable settings Level 2 Service and Maintenance Settings allow modi fication to machine personality settings such as lift speeds drive speeds as well as various switch polarity settings also enable various optional equipment if installed This level can also adjust Level 3 settings Level 3 Operator Settings allow the direct user to mod ify a few settings such as the language setting of text out put to the Ground Control Module LCD screen setting machine sleep time and enabling the detection of the horn and beacon components 4 12 JLG Lift Activating Programming Mode 2 Activating Programming Mode 1 With machine power off press and hold the Brake Release Button 1 on the Ground Control Module 2 While holding the Brake Release Button in power machine up by turning the Main Power Selector Switch 2 to either the Ground Control or Platform Control Mode 3 Release the Brake Release Button 1 after machine is powered up The LCD display should now display five zeros one with a box around Continue to next step Entering Password NOTE machine did not
125. Warning Timer see Section 4 6 Ground Control Module Programming of this manual 3121231 SECTION 3 BASE COMPONENTS Wheel Drive Assembly Removal From Machine The electric wheel drive assemblies are mounted indepen dent of each other in the base frame at the rear of the machine The wheel drive assembly consists of an 24V DC electric motor driving a 30 68 1 ratio gear box the assembly also included a friction disk parking brake assembly This brake assembly is mounted internally on the drive assem bly between the drive motor and the gear box assembly 1 3121231 Disconnect the positive battery terminal from the left side battery Raise the rear drive wheels of the machine off the ground use a fork truck or floor jack Place a block or safety stand under machine Remove the wheel drive cover assembly Remove the drive wheel mounting lugs and remove the drive wheel s Disconnect the power harness terminals and brake harness connector s from the drive motor Remove the six 6 hex head cap screws and wash ers attaching the drive assembly to the frame Carefully slide the drive motor assembly out of the base frame for disassembly Wheel Drive Assembly Installation Right Side Shown 1 Mounting Bolts Washers a 2 Frame Mounting Surface 3 Wheel Drive Assembly 4 Drive Wheel 5 Wheel Mounting Lugs b NOTE Installation same for left and right drive motor a Apply
126. Y RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING Cleanliness The most important single item in preserving the long ser vice 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 fil ters are provided to keep the wheel bearings mast sec tions and oil supply clean however these items must be maintained on a scheduled basis in order to function properly At any time when oil lines are disconnected clear adja cent areas as well as the openings and fittings them selves As soon as a line or component is disconnected cap or cover all openings to prevent entry of foreign mat ter Clean and inspect all parts during servicing or mainte nance 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 containers until they are ready to be used Components Removal and Installation 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 Should it be necessary to remove a component on an angle keep in mind that the capacity of an eyebolt or sim ilar bracket lessens as the angle between the supporting structure and the
127. ak checking fitting starts to fall after the unit has been pressurized and allowed to equal ize Leaks will most likely occur at the pipe plugs the main seal or wherever o rings are located The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where the o rings or gaskets meet on the exterior of the unit then checking for air bubbles If a leak is detected in a seal o ring or gas ket the part must be replaced and the unit rechecked Leak test at 10 psi for 20 minutes NOTE Due the small air volume inside this Torque Hub it will pressurize to 10 psi very quickly If the pressure becomes excessive in the unit the seals will be destroyed 3 4 JLG Lift Oil Type amp Capacity This torque hub unit is shipped with ISO 68 viscosity oil hydraulic fluid It is designed to utilize the same oil throughout its service life However should it need to be serviced the oil will need to be drained and replaced In the event of servicing fill the unit with ISO grade 68 oil or oil of a similar viscosity 80W gear oil or 20W engine oil The gearbox will need to be filled with 10 oz of oil Cil Filling Instructions 10 oz of gearbox oil will fill the gearbox cavity approxi mately half full To check the oil level rotate the wheel so that the cover plugs are at 12 o clock and 3 o clock Allow the oil to settle Slowly loosen the 3 o clock plug If oil begins to come ou
128. all mast adjustments are com plete if necessary adjust the bumpers on the under side of the stock picker platform so the platform rests slightly above the base frame when it is low ered and empty Sequencing Cable Adjustment 1 JLG Lift Retract mast completely and check each sequenc ing cable on outside of masts for excessive slack Adjust only to remove slack from cable Tighten nylock nut just enough to remove excessive slack from sequencing cable The springs should not be compressed more than 25 after adjusting Run mast through several cycles to verify cable chain adjustments and ensure no interference exists between chain anchor brackets and mast 3121231 SECTION 5 MAST COMPONENTS o Ew Y 9 10 Q n Figure 5 2 MVL MSP Mast Chain and Sequence Cable Adjustment Components
129. arge Incomplete fain The YELLOW CHARGING LED will turn on and a trickle current will be applied until a minimum volt age is reached Once a minimum battery voltage of 2 volts per cell is detected the charger will enter the bulk charging constant current stage and the YELLOW CHARG ING LED will remain on The length of charge time will vary by how large and how depleted the battery pack is the input voltage the higher the better and ambient temperatures the lower the better If the input AC voltage is low below 104VAC then the charging power will be reduced to avoid high input currents If the ambient temperature is too high then the charging power will also be reduced to maintain a maximum internal temperature When the GREEN CHARGED LED turns on the batteries are completely charged 4 CHARGE COMPLETE Za GREEN TOP LED ON 54 100 Complete The charger may now be unplugged from AC power always pull on plug and not cord to reduce risk of damage to the cord If left plugged in the charger will automatically restart a complete charge cycle if the battery pack voltage drops below a minimum voltage or 30 days has elapsed If a fault occurred anytime during charging a fault indication is given by flashing the RED FAULT LED with a code corresponding to the error There are several possible conditions that generate errors Some errors are se
130. chanic on an annual basis no later than thirteen 13 months from the date of the prior Annual Machine Inspection JLG Industries Inc recog nizes a qualified JLG equipment mechanic as a person who has successfully completed the JLG Service Training School for the subject JLG product model Reference the machine Service and Maintenance Manual and appropri ate JLG inspection form for performance of this inspec tion Reference the JLG Annual Machine Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the performance of this inspection Reference the appropriate areas of this man ual for servicing and maintenance procedures For the purpose of receiving safety related bulletins it is important that JLG Industries Inc has updated ownership information for each machine When performing each Annual Machine Inspection notify JLG Industries Inc of the current machine ownership Preventative Maintenance In conjunction with the specified inspections mainte nance shall be performed by a qualified JLG equipment mechanic JLG Industries Inc recognizes a qualified JLG equipment mechanic as a person who by possession of a recognized degree certificate extensive knowledge train ing or experience has successfully demonstrated the ability and proficiency to service repair and maintain the subject JLG product model Reference Table 2 2 MVL MSP Preventive Maintenance amp
131. cket Bottom of Mast 1 Chain Anchor Bracket 3 Anchor Bolts Washers a 2 Mast Section 3 a Apply Loctite 242 to threads J olo o o e Mast Section 3 Chain Anchor Plate Installation Mast Section 3 Shown Cut away 1 Chain Anchor Plate Assy 2 Anchor Pin 3 Spacer 4 Pin Keeper 5 Keeper Screw Note a Apply Loctite 242 to threads 3121231 SECTION 5 MAST COMPONENTS 36 37 pin keeper Allow to hang out the top of mast sec tion 3 for later assembly Insert the threaded the ends of chain assembly attached to top of mast section 1 into the opening between mast section 2 and mast section 3 Slide the threaded ends through the holes in chain anchor bracket attached at the bottom of mast section 3 Loosely thread two 2 3 8 16UNC nuts onto stud threads on each chain and remove any slack in the chains Chains will be adjusted later in assembly Assemble chain sheaves for narrow chain assem bly to top of mast section 3 as follows a Place four 4 of the 1 flat washers onto one of the remaining sheave pins Locate two 2 nar row chain sheave wheels and slide onto sheave pin on each side of the flat washers b Slide two 2 short spacer tubes onto sheave pin one each end of sheave pin to outside of sheave wheels c Place two 2 sheave pin support bars one each end of sheave pin onto outside of space
132. ction 6 8 TROUBLESHOOT ING TABLES Index in this section of the manual Each malfunction within an individual group or system is followed by a listing of probable causes which will enable determi nation of the applicable remedial action The probable causes and the remedial action should where possible be checked in the order listed in the troubleshooting tables It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electri cal systems For this reason every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment In the remaining machine groups only those problems which are symptomatic of greater problems which have more than one probable cause and remedy are included This means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if the cir cuit is lacking hydraulic oil and electrical control power This can be ascertained by overriding the bypass valve mechani cally or electrically so that oil is available to the function valve then overriding the function valve mechanically If the function performs satisfactorily the problem exist
133. d to prevent sensor detection of objects outside the plat form parameter The area under the platform floor must be free of any objects or debris dangling from beneath the platform to avoid false detection by the sensors DO NOT allow high pressure spray to directly contact the transducer sensor circular membrane this will damage the sensor 055 Control Module Installation 1 055 Control Module 4 Insulating Bushing 2 Mounting Screw a 9 Decal Billboard b 3 Nylon Washer Notes Apply Loctite 222 to threads b Drill out pop rivets to remove 1 RED 2 Sens TN 055 Control Module Connections LED Detection Indicator 3 Junction Box Harness or Harness oo oo B m3 90 un CH1 CH2 CH3 CH4 5 CH6 2 Internal View of OSS Control Module Back Removed 1 Sensor Comm Channels a 3 Wire Harness to Junction Box 2 Sensor Cables 4 LED Indicator Light Notes 4 32 JLG Lift a Channel 1 Sensor 1 Channel 2 Sensor 2 etc 3121231 SECTION 4 CONTROL COMPONENTS Transducer Sensor Installation Typical 1 Mounting Screws a 4 DO NOT Pressure Wash Decal 2 Bushings 5 Sensor Side Deflector 3 Transducer Sensor b Notes a Apply Loctit
134. ditives or be of comparable viscosities Good grade mineral oils with viscosities suited to the ambient temperatures in which the machine is operating are recommended for use NOTE Metal particles may appear in the oil of new machines due to the wear in of meshing compo nents 2 8 JLG Lift Hydraulic Oil For best performance JLG recommends the use of ISO Vg grade 32 46 oil with a viscosity range between 15 250 SUS at 100 degrees F 32 54 cST at 40 degrees C Refer to Section 1 of this Service Manual for recommended hydraulic oils Changing Hydraulic Oil Use of any of the recommended hydraulic oils eliminates the need for changing the oil on a regular basis If it is nec essary to change the oil use only those oils meeting or exceeding the specifications appearing in this manual If unable to obtain the same type of oil supplied with the machine consult local supplier for assistance in selecting the proper equivalent Avoid mixing petroleum and syn thetic base oils JLG Industries recommends changing the hydraulic oil annually 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 While the unit is shut down a good preventive mainte nance measure is to make a thorough inspection of all hydraulic components lines fittings etc as well asa functional check of each system
135. driver between the outer strands to unlay the cable When done properly the outer strands will form a symmetrical basket Do not straighten out the spiral lay of the strands unlay any wires that make up the strand or allow the strands to cross each other inside the sleeve 3121231 5 1 Cable Strands Unlayed Install the plug supplied with the kit by placing the plug in the center of the strands starting with the small tapered end of the plug Use a metal tube plug driver and hammer to drive the plug into the sleeve while assuring that the strands are spaced somewhat equally around the plug Drive the plug until it is firmly seated and no more than 1 3 of the plug is visible from above the sleeve JLG Lift 1 Plug Driver 2 Plug 3 Insert Plug in this Position 5 5 SECTION 5 MAST COMPONENTS 6 Reclamp the assembly in the vise on the flats of the sleeve Using the plug driver a metal tube or pliers bend the outer strands toward the center strands enough that the socket can be slipped over all the strands 1 Inspection Hole 3 Four Threads or Less Showing 2 Install Socket and Tighten 8 Inspect for proper assembly prior to loading the cable Strands visible through the inspection hole 1 Use Plug Driver Metal Tube or Pliers are your assurance of a proper assembly 2 Shape Strands Around Plug NOTE The end of the rope may not be vi
136. during machine power up NOTE the procedures below if you check continuity between pin 6 and 16 it should show open circuit when the platform gates are closed and nothing is on the foot switch When you step on the foot switch with the gates closed you should see a closed circuit Table 6 37 Code 35 P2 Auxiliary 1 Tie Down STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P2 connector check the voltage across 0 2VDC Goto Step 2 Replace Ground pins 16 orange red 49 5 and 6 black 12 is reading within specification Control Module 2 Removethe P2 connector from the Ground Station Module check continu Goto Step 3 Repair or ity ofthe individual wires inthe platform harness P2 to platform junction Replace Platform box Harness 6 32 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING Table 6 37 Code 35 P2 Auxiliary 1 Tie Down 3 Check continuity of gate switches and foot switch circuit Switches are wired in series doors shut and foot switch depressed circuit will be closed Consult Factory Replace Compo nent or Repair Wires Code 38 Battery Voltage Low Warning Level 2 Two 2 LED LCDs lit To maximize battery life it is recommended that the factory supplied batteries be charged continuously for a minimum of 4 hours or until 8 bars are lit on the ground station LCD Display before operating the machine When drained to Warning Level 2
137. e niu ern rad BE bans Rae tee 6 45 Machine Drive in Opposite Direction 6 45 Machine Won t Drive 6 46 Noise from Drive Assembly 1 2 6 47 JLG Lift TABLE OF CONTENTS B NOTES X JLG Lift 3121231 SECTION 1 MACHINE SPECIFICATIONS SECTION 1 MACHINE SPECIFICATIONS Table 1 1 General Machine Specifications 15MVL 20MVL 15MSP 20MSP Maximum Occupants 1 Maximum Work Load Capacity 500b 35016 50016 400b MVL Std Platform MSP Stockpicker Platform 230 kg 160 kg 230 kg 180 kg Maximum Travel Grade Gradeability Platform STOWED ONLY Maximum Travel Grade Side Slope po Platform STOWED ONLY nmm 15ft 2 in 19ft 1 in 15ft 1in 0 19ft Maximum Vertical Platform Height 4 69 m 5 80m 4 66 m 5 96 m Maximum Drive Speeds Operator Variable 0 5 3 4 mph 0 8 5 5 kph Max Platform Speeds w Max Load Platform Up 20 sec 22 5 sec
138. e 222 to screw threads and torque to 15 in Ib b Mount sensor with circular membrane facing down Sensor Side Deflectors 1 Sensor Side Deflector a 3 Platform Side Frame 2 Pop Rivet Note a One deflector required on each side of platform Secure Transducer Sensor Wiring 1 Nylon Tie Wraps a 2 Platform Floor Supports Note a Secure ALL sensor wire cables to platform side frame 3121231 JLG Lift Deflector must be even with and not extend inside of the platform side frame 4 33 SECTION 4 CONTROL COMPONENTS This page intentionally left blank 4 34 JLG Lift 3121231 SECTION 5 MAST COMPONENTS SECTION 5 MAST COMPONENTS 5 1 MAST COMPONENTS OVERVIEW Figure 5 1 Mast Components MVL MSP 4 Mast Section 4 5 Mast Section 5 6 Lift Cylinder 1 Mast Section 1 2 Mast Section 2 3 Mast Section 3 3121231 7 Lift Cylinder Mount 8 Slide Pads 9 Chain Anchor Plates 10 Lanyard Attach 11 Chain Guard 12 Sh
139. e Speed Cut Back Turtle Mode All The 6 17 Obstruction Sensor System Detection 6 18 Battery Voltage Low Warning Level 3 Three 3 LED LCDs 6 18 Code 02 Left PHP Bar s UP rur b ID REUS EAT TET SR e RI net e d LA 6 19 Code 03 Right PHP Bar UP Red per ub cem E RR RUE Ren 6 19 Code 04 Tilt Condition ned e rx deed e Fa e e Ye y Ca ee 6 20 Gode 05 Reserved rae ate bue ede race Po pouce beds eG 6 20 Code 06 Drive Motor Brush Wear Warning Indicator 6 21 Code 07 Left Drive Motor 6 21 Code 08 Right Drive Motor Disconnected 6 22 Code 09 Left Brake Disconnected 6 22 Code 10 Right Brake Disconnected 6 22 Code 11 Left Drive Motor Short 6 23 Code 12 Right Drive Motor Short 6 23 Code 13 Traction Module In Fold 6 23 Code 14 Pump Motor 6 24 Code 15 L
140. e across 0 2VDC Goto Step 2 Replace Ground pins 13 and 6 to the alarm Is reading within specification Control Module 2 Remove the wire terminals at the alarm check continuity of each of the Replace the Alarm Repair or wires from pins 13 and 6 onthe P1 connector to the alarm end Replace Wiring 3121231 JLG Lift 6 25 SECTION 6 TROUBLESHOOTING Code 19 Alarm Disconnected Check For These Obvious Conditions First Damaged wiring in the alarm wiring harness or a damaged alarm Activate a function to check if alarm beeps Table 6 23 Code 19 Alarm Disconnected STEP ACTION SPEC YES NO 1 Checkvoltage atthe P1 connector on the Ground Control Module between 2 4VDC Replace Ground Go to Step 2 pin 13 and pin 6 Is reading within specification Control Module 2 Remove the wire terminals at the alarm check continuity of each of the Replace the Alarm Repair or wires from pins 13 and 6 onthe P1 connector to the alarm end Replace Wiring Code 20 Beacon Short Circuit Check For These Obvious Conditions First Damaged wiring in the beacon wiring harness or a damaged beacon unit Table 6 24 Code 20 Beacon Short Circuit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the voltage across 0 2VDC Goto Step 2 Replace Ground pins 12 and 5 to the beacon Is reading within specification Control Module 2 Remov
141. e cylinder rod end using the anchor plate block attach pin and snap ring XEM I LE 20 3121231 Install Chain Anchor Block to Top of Lift Cylinder 1 Attach Pin 4 Attach Pin Snap Ring 2 Chain Equalizer Assembly 5 Cylinder Rod Extended 3 Chain Anchor Block Assemble chain sheaves on chain assembly anchor block attached to cylinder rod end and attach to mast section 2 using following steps a Insert sheave pin through anchor block and inder rod on cylinder rod end b Load three 1 flat washers onto the sheave pin on each side of the anchor block c Place sheave wheels for wide 544 chain on sheave pin one each side of anchor block d On the outside of each sheave wheel place another 1 flatwasher a roll pin into the slot in each end of the pin and then place a sheave pin support bar rectangular plate with threaded holes on each side of pin bore hole e Slide the whole anchor block cylinder assembly with sheave pin wheels and pin support bars into top of mast section 2 f Align the threaded holes in the attach bars on each side of the mast and attach to top of mast section 2 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten
142. e out of for re installation 12 Slide the lift cylinder and mount assembly out of the bottom of mast section 1 and 2 and place on a suit able work surface JLG Lift 5 11 SECTION 5 MAST COMPONENTS Cylinder Disassembly See Figure 5 4 1 Before disassembling the cylinder clean away all dirt and foreign substances from openings particu larly the head area NOTE Always protect the chrome surface of the cylinder rod during assembly and disassembly Any damage to this surface will require replacement of the rod 2 Extend the rod until the piston bottoms out against the cylinder head 3 Compress the head retraining ring enough to allow the cylinder head to be removed 4 Carefully slide the head rod piston assembly out of the cylinder tube A gentle tap on the head assembly be required to remove the head from the cylin der tube 5 Place the head rod piston assembly on a surface that will not damage the chrome 6 Remove the piston locknut and separate the piston from the rod 7 Slide the head off the rod from the piston end NOTE When removing the old seals use only blunt tools be sure there are no sharp edges that may damage the seal grooves during removal Scratching the groove may cause by pass 8 Remove and discard all old seals 5 12 JLG Lift Lift Cylinder Component Inspection Cylinder Rod There should be no scratches or pits deep enough to catch the fingernail P
143. e the wire terminals at the beacon check continuity of each of the Replace the Repair or wires from pins 12 and 5 onthe P1 connectorto the beacon end Beacon Replace Wiring 6 26 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING Code 21 Beacon Disconnected Check For These Obvious Conditions First 5 machine equipped with flashing amber beacon light Table 6 25 Code 21 Beacon Short Disconnected STEP ACTION SPEC YES NO 1 Is machine equipped with a flashing amber beacon light Goto Step 3 Gotto Step 2 2 Atthe Ground Control Module enterthe programming mode check if the Disable It Replace Ground Beacon light open circuit detection is enabled Control Module 3 Checkvoltage atthe P1 connector on the Ground Control Module between 2 4VDC Replace Ground Goto Step 4 pin 12 and pin 5 Is reading within specification Control Module 4 Remove the wire terminals at the beacon check continuity of each of the Replace the Repair or wires from pins 12 and 5 onthe P1 connector to the beacon end Beacon Replace Wiring Code 22 Horn Short Circuit Check For These Obvious Conditions First Damaged wiring in the horn wiring harness or a damaged horn unit Table 6 26 Code 22 Horn Short Circuit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the voltage across 0 2VDC Goto Step 2 Replace Ground pins 14 and 7 to the horn Is reading wi
144. eals and bearings looking particularly for metallic particles embedded in the bearing and in the piston seal surface Remove the seals and bearings Damage to the seal grooves particularly on the sealing surfaces is unacceptable In the event that an unacceptable condition occurs the piston should be replaced Tube Assembly Visually inspect the inside bore for scratches and pits There should be no scratches or pits deep enough to catch the fingernail Scratches that catch the fingernail but are less than 0 5 inch long and primarily in the circumfer ential direction are acceptable provided they cannot cut the piston seal The roughness of the bore should be between 10 and 20 inches RMS Significant variation greater than 8 inches difference are unacceptable In the event that an unacceptable condition occurs the tube assembly should be repaired or replaced 3121231 SECTION 5 MAST COMPONENTS Cylinder Assembly see Figure 5 4 1 Rinse the inside of the tube with hydraulic fluid and f allow to drain A high pressure rinse followed by a wipe with a lint free rag is preferable Clean all inter nal components of any foreign material 2 Lubricate the head and all seals with hydraulic fluid G prior to installation Install the seal wiper o ring back up ring and retraining ring to the cylinder 1 3 Lubricate the piston and all components with hydraulic fluid
145. eave Assemblies 13 Chain Equalizer Plate Assemblies 14 Mast Mini Covers JLG Lift 5 1 SECTION 5 MAST COMPONENTS 9 2 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT Mast Chain Cable Adjustment The intention of this procedure is to assure equal load dis tribution between the individual chains of a mast section chain sets Also to step each front mast section up approximately 7 16 in 12mm from the section behind it to allow clearance for the individual mast section covers Adjust using the following procedure 1 NOTE With mast retracted step into the platform and bounce your weight up and down a few times to be certain platform is at the bottom of travel Be certain all chain cable sets are seated in their sheaves prop erly at the top of each mast section Then with no load in the platform check the side pro file of the top of the mast for the amount of adjust ment necessary to obtain the 7 16 in 12mm step for mast sections 3 and up See Illustration Mast section 1 is fixed to the base and mast section 2 is attached to the lift cylinder these sections require no adjustment Adjust one mast section at a time starting from the back section 8 section 4 etc of the mast and work forward i e if three is OK then jump to four etc To adjust elevate the platform until the chain cable anchor adjust nuts are accessible at the front and bottom of each mast section A WARNING NEVER WOR
146. ector on Traction Control Module to Left Drive Motor for damage Table 6 16 Code 12 Right Drive Motor Short Circuit STEP ACTION SPEC YES NO 1 Removethe M2 connector fromthe Traction Control Module and check both No Voltage PES Goto Step 2 the pins to the drive motor for any voltage This circuit should Ground the meter to the Ground Control Module Negative lug dris um 2 Check for continuity of both the pins to the drive motor to ground No Ground 1 as Replace Required Traction Control Module Code 13 Traction Module In Fold Back Check For These Obvious Conditions First Machine is operating on a continuous grade or rough terrain Table 6 17 Code 13 Traction Module In Fold Back STEP ACTION SPEC YES NO 1 Allow machine to cool the traction module for 30 minutes Does the Replace Traction machine operate OK after cooling Module Table 6 3 Amperage Draw for Various Components NOTE If this is a recurring problem compare current draw of your machine with Traction Control Module specifications in 3121231 JLG Lift 6 23 SECTION 6 TROUBLESHOOTING Code 14 Pump Motor Disconnected Check For These Obvious Conditions First Check the Positive Negative cables from the Ground Control Module to the Pump Motor studs for loose or cor roded connections Table 6 18 Code 14 Pump Motor Disconnected
147. eel that is consistently more than 015 off of flat surface Figure 3 2 Wheel Lug Nut Tightening Sequence 3121231 JLG Lift 3 3 SECTION 3 BASE COMPONENTS 3 5 WHEEL DRIVE ASSEMBLY SERVICING The component parts of the left and right drive motor assemblies are identical The left drive motor is run in the reverse direction of the right motor Roll And Leak Testing Torque Hub units should always be roll and leak tested before disassembly and after assembly to make sure that the unit s gears bearings and seals are working properly The following information briefly outlines what to look for when performing these tests NOTE The brake must be released before performing the roll test This can be accomplished by supplying 24 Volts D C to the gray 2 pin brake connector The Roll Test The purpose of the roll test is to determine if the unit s gears are rotating freely and properly You should be able to rotate the wheel or hub of the gearbox by hand If you feel more drag in the gears only at certain points then the gears are not rolling freely and should be examined for improper installation or defects Some gear packages roll with more difficulty than others Do not be concerned if the gears in your unit seem to roll hard as long as they roll with consistency The Leak Test The purpose of a leak test is to make sure the unit is air tight You can tell if your unit has a leak if the pressure gauge reading on your le
148. el Lift 5 9 SECTION 5 MAST COMPONENTS 4 At the base end remove and cap the extend and return hydraulic lines 7 Remove the adjust and lock nuts from the chain studs at the bottom of mast section 3 5 e iL 1 N mm Vi m ST P H 4 ea cA A B 1 2 3 Hydraulic Extend and Return Lines 1 Cylinder Return Line 3 Manual Descent Valve 2 Cylinder Extend Line 5 Remove the mini covers from the tops of the mast sections 6 Manually extend the mast assembly until the top of mast section 2 is extended approximately one 1 foot 31cm to allow access to the sheave wheel anchor block at the top of mast section 2 and the lift cylinder SC E 59 p Be Chain Assembly Bottom of Mast Section 3 1 Mast Section 4 4 Adjust Nut 2 Mast Section 3 5 Lock Nut b 3 Chain Assembly Stud a Note a Remove nuts and push studs through anchor plate 8 Push mast sections 3 4 and 5 back towards the base assembly al
149. ems 3 1 2 3 Covers or Shields 1 Sheave Systems 1 2 1 2 Bearings 1 2 Slide Pads 1 2 PLATFORM ASSEMBLY 7 Platform 1 1 Guard Rails 1 2 4 1 2 4 Gate 1 5 1 5 Floor 1 2 1 2 Extension Deck Assembly 1 5 1 5 Lanyard Anchorage Point 1 4 1 4 CHASSIS ASSEMBLY 7 PotHole Protection System 5 5 Battery and Valve Covers or Doors 1 7 1 7 Static Strap 1 Caster Wheels 1 2 14 1 2 1 2 Drive Wheels 2 2 Gear Box Assembly 1 7 9 11 Drive Motor Brushes Brake Release 5 5 FUNCTIONS CONTROLS 7 Platform Controls 5 6 7 5 6 7 Ground Controls 5 6 5 6 14 Function Control Locks Guards or Detents 5 5 Function Enable System Emergency Stop Switches Ground amp Platform 5 Function Limit or Cutout Switch Systems 5 Drive Brakes 5 Manual Descent or Auxiliary Power 5 5 POWER SYSTEM Batteries 19 9 18 Battery Charger 5 HYDRAULIC ELECTRIC SYSTEM 9 Hydraulic Pump 1 2 9 1 2 5 9 Hydraulic Cylinder 2 7 9 2 9 Cylinder Attachment Pins and Pin Retainers 1 2 1 2 Hydraulic Hoses Lines and Fittings 1 9 1 9 Hydraulic Reservoir Cap and Breather 5 7 5 7 Hydraulic Filter 3121231 JLG Lift 2 3 SECTION 2 GENERAL Table 2 2 MVL MSP Preventive Maintenance amp Inspection Schedule Continued INTERVAL AREA ON MACHINE PRE START a 3 MONTH 6 MONTH PRE DELIVERY b ANNUAL d INSPECTION PREVENTATIVE PREVENTATIVE ORFREQUENT c YEARLY MAINTENANCE MAINTENANCE INSPECTION INSPECTION
150. en If a malfunction to the 3121231 JLG Lift 6 1 SECTION 6 TROUBLESHOOTING machine s electrical components occurs the platform console LED s will flash a number of LEDs to help indicate the prob lem to the Operator in the platform The Fault Codes and LED Flash Codes are outlined in the following sub sections of this chapter NOTE For aid in troubleshooting electrical problem refer to Figure 6 7 for an ELECTRICAL DIAGRAM of the various circuits Also for a pictorial overview of the connected components See Figure 6 6 Pictorial Overview of the MVL MSP Electri cal System 6 5 MULTIMETER BASICS A wide variety of multi meters or Volt Ohm Meters VOM can be used for troubleshooting your equipment A digital meter with reasonable accuracy within 796 is recommended for the measurements in these procedures This section shows dia grams of a common digital VOM configured for several different circuit measurements Instructions for your VOM may vary Please consult the meter operator s manual for more information Grounding Grounding the meter means to take the black lead which is connected to the COM common or negative port and touch it to a good path to the negative side of the voltage source Back Probing To back probe means to take the measurement by accessing a connector s contact on the same side as the wires the back of the connector Readings can be done while maintaining circuit continuity this way I
151. eplace Ground pins 9 and 2 to the horn Is reading within specification Control Module 2 Removethe wireterminals atthe horn check continuity of each of the wires Replacethe Repair or from pins 9 and 2 onthe P1 connectorto the component end Component Replace Wiring 6 28 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING Code 25 Auxiliary 1 Circuit Disconnected Check For These Obvious Conditions First Is machine equipped with a component on the Auxiliary 1 circuit Table 6 29 Code 25 Auxiliary 71 Circuit Disconnected STEP ACTION SPEC YES NO 1 Is machine equipped with a component on the Auxiliary 1 circuit Goto Step 3 Gotto Step 2 2 Atthe Ground Control Module enterthe programming mode check if the Default NO Disable It Replace Ground Auxiliary 1 open circuit detection is enabled Control Module 3 Checkvoltage atthe P1 connector on the Ground Control Module between 2 4VDC Replace Ground Go to Step 4 pin 9 and pin 2 Is reading within specification Control Module 4 Remove the wire terminals at the Aux 1 component check continuity of Replace the Repair or each of the wires from pins 9 and 2 on the P1 connector to the Aux 1 Component Replace Wiring component Code 26 Auxiliary 2 Short Circuit Check For These Obvious Conditions First Damaged wiring in the Auxiliary 2 Component wirin
152. er must be turned OFF before testing con 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 6 4 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING 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 particular wire in the harness Requirements Harness with at least three separate wires including the wire under test These wires must be able to be isolated from other wires etc Jumper or method to connect contacts on one side of harness Meter that can measure resistance or continuity Procedure Test multimeter leads resistance Subtract this value from the measured resistance of the wires to get a more accurate mea surement Consult the circuit schematic to determine which wires to use in addition to wire under test here called wire 1 and wire 2 and how to isolate these wires These wires should appear in the same connectors as the wire under test or are within reach of the jumper 1 Disconnect all connections associated with the wire under test and the two additional wires If harness is not com pletely isolated disconnect battery termina
153. ers should be replaced They should also be adjusted to eliminate twisting the chain for an even load distribution Inspect the sheaves sheave bearings sheave grooves and pins for extreme wear replace as necessary A worn sheave can mean several problems as follows a Chains too tight b Sheave bearings pin bad c Bent misaligned chains JLG Lift 2 7 SECTION 2 GENERAL 2 4 LUBRICATION INFORMATION Hydraulic System The primary enemy of a hydraulic system is contamina tion 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 maintenance or by permitting the pump to cavitate due to insufficient system warm up or leaks in the pump supply The design and manufacturing tolerances of the compo nent 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 gener ally results in faulty operation Every precaution must be taken to keep hydraulic oil clean including reserve oil in storage Cloudy oils indicate a high moisture content which per mits organic growth resulting in oxidation or corrosion If this condition occurs the system must be drained flushed and refilled with clean oil It is not advisable to mix oils of different brands or types as they may not contain the same required ad
154. ew Machine Rear Covers Removed Perform pressure adjustment with oil at normal operating temperature If pressure is set when oil is cold platform may not raise rated load after soil has warmed 1 Pressure Gauge Assembly 3 T Fitting 2 Extend Line 4 Return Line Figure 4 7 Typical Hydraulic Pressure Gauge Installation Hydraulic Filter Removed 1 RemoveAdjustScrew 2 Pressure Adjustment Screw Note Machine rear covers must be removed to access pump motor Figure 4 6 Hydraulic Pressure Adjustment Screw Machine Rear Covers Removed 3121231 JLG Lift 4 21 SECTION 4 CONTROL COMPONENTS After Filter Pressure Check Pump Motor Tank Installation Reinstall the hydraulic oil filter and install the t fitting between the hydraulic filter and the extend line to the cyl NOTICE inder Recheck the hydraulic pressure and compare with BE CERTAIN THE MAST IS FULLY LOWERED BEFORE REMOV the previous readings when filter was removed If a signifi ING ANY HYDRAULIC LINES FROM THE PUMP UNIT WEAR PRO cant drop in pressure reading has occurred replace the TECTIVE GEAR WHEN WORKING AROUND PRESSURIZED hydraulic filter and recheck the after filter pressure read HYDRAULIC LINES REMOVE CONNECTIONS CAREFULLY AND ing CAP ALL LINES
155. f dry or rusting Mast Chains Spray v Key to Lubricants MPG Multipurpose Grease HO Hydraulic Oil ISO Vg grade 32 46 GEAR OIL Good Quality Worm Gear Oil SAE 90 AGMA 5 EP Compounded CL Chain Lube Use a good quality chain lubricant 3121231 Notes certain to lubricate like items on each side of the machine b Recommended lubricating intervals are based on normal use If machine is subjected to severe operating conditions such as a high number of cycles location corrosive dirty environment etc user must adjust lubricating requirements accordingly c Prior to checking hydraulic oil level operate machine through one complete cycle of lift function full up and down Failure to do so Will result in incorrect oil level reading on the hydraulic reservoir JLG Lift SECTION 1 MACHINE SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 5 BOLTS amp GRADE 2 NUTS Torque i Torque Loctite 242 or 271 SENEC 9 Loctite 262 or Vibra Stress Area Lubricated OR Vibra TITE 111 or TITE 131 0 1120 0 00661 0 1380 0 00909 580 0 1380 0 01015 610 Fox 0 640 0 01400 90 30 94 3 o 0 1640 0 01474 940 0 1900 0 01750 1120 0 1900 0 02000 1285 cum eu ae run Fus 0125 0 0524 3340 23 18 2 9 8 DS ESSE DOIN JP oO CO AJOA jJoIN AIDIN O NM
156. f supporting the weight of the entire mast assembly Slide mast out over end of work surface far enough to allow access to the chain anchor attach hole near the top of the mast Locate the two 2 single wide chain assemblies and attach to the large equalizer anchor plate if not already attached Lay out the chain anchor plate Mast Section 2 Assembly NOTE When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels 4 Locate mast section 2 carefully slide mast section 2 closed rail into section 1 open rail Slide sections together until ends are even 5 Insert slide pads into the slide pad channels at bot tom end of mast between section 1 and 2 one on each side of the mast with beveled surface facing out towards section 1 assembly with the anchor plate end towards top of the mast Be certain floor surface is clean and free of any metal chips or debris which may stick to lubri cated chains Insert the chain anchor plate assembly end into the top of mast section 1 and secure using the large anchor plate attach pin spacers and pin keeper Chain Anchor Plate Installation Mast Section 1 Shown Cut Away 1 Anchor Plate Pin 2 Short Spacer 3 Chain Anchor Plate Assy a Apply Loctite 242 to threads 4 Long Spacer 5 Pin Keeper 6 Keeper Screw Note 3121231
157. f the mast being shimmed to tight or dirt and debris in the slide pad channels causing the mastto be tight 5 Is the bore of the lift cylinder dry Replace Packing or Go to Step 6 Lift Cylinder 6 Arethe bearings in the lift pump motor and pump drive worn Repair or Replace Goto Step 7 Pump 7 Arethe hydraulic lines vibrating together Adjustthe Position Goto Step 8 ofthe Lines 8 Check ifthe pump motor is loose to it s mounting plate Tighten pump Goto Step 9 mounting fasteners 9 Hydraulic oil could be cavatating inside the pump Repair or Replace Pump 3121231 JLG Lift 6 41 SECTION 6 TROUBLESHOOTING Platform Mast Won t Stay Elevated Overview Of Procedure The following procedure requests that the lift down dump and pump internal valves be checked to see if any are stuck open it also examines the lift down and dump valve circuits Also suggests that the lift cylinder packing could be leaking internally Check For These Obvious Conditions First Manual descent valve is closed tight Table 6 47 Platform Mast Won t Stay Elevated STEP ACTION SPEC YES NO 1 Isthe lift down valve stuck open Repair or Clean Goto Step 2 Valve 2 Liftdownvalves could be open due to incorrect electrical signal Check Pump Valve Goto Step 3 Electrical Circuit 3 Oilcould be passing around the lift cylinder bo
158. f the connector is the sealed type great care must be taken to avoid damaging the seal around the wire It is best to use probes or probe tips specifically designed for this technique especially on sealed connectors Whenever possible insert probes into the side of the connec tor such that the test also checks both terminals of the connection It is possible to inspect a connection within a closed con nector by back probing both sides of a connector 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 Min Max Use of the Min Max recording feature of some meters can help when taking measurements of intermittent conditions while alone For example you can read the voltage applied to a solenoid when it is only operational while a switch far from the solenoid and meter is held down Polarity Finding a negative voltage or current reading when expecting a positive reading frequently means the leads are reversed Check what reading is expected the location of the signal and that the leads are connected to the device under test cor rectly Also check that the lead on the port goes to the ground or negative side of the signal and the lead on the other port goes to the positive side of the signal Scale M Mega 1 000 000 Displayed Number k kilo 1 000 Displayed Number m milli Displayed Number
159. following procedure checks the drive motor and attached components for component failure misadjustment due to wear Check For These Obvious Conditions First Batteries are Fully Charged 24 Volts Speed Control is Set to Maximum s Grade within the Maximum Allowable Specification of 2096 Grade Does the Travel Surface allow for Proper Drive Wheel Traction s Platform Load within the Maximum Rated Capacity Table 6 52 Won t Climb Grade STEP ACTION SPEC YES NO 1 Does machine drive straight on a level surface Goto Step 2 Referto Machine Won t Drive Straight Table 6 54 2 Dotheleftandright drive motor brakes release properly and allow the drive Goto Step 3 Dragging wheels to rotate freely Repair Replace or Adjust Brakes 3 Checkthe amperage output ofthe on the drive motor leads They should not Controller will Shut Goto Step 5 exceed 100 amps while pulling a grade Drive Down and will flash a7 LED Code 4 Checkthe condition ofthe drive motor brushes goto Step 6 Worn down replace brushes or drive motor 5 Ifallaboveis OK Drive motors are working properly Consult Factory Machine Drives in Opposite Direction Table 6 53 Machine Drive in Opposite Direction STEP ACTION SPEC YES NO 1 Atthe Traction Control Module check ifthe left drive motor power lead is Goto Step 2 Switch the Left and plugged into the M1 socket Right Drive
160. ft 3121231 TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO MAINTENANCE SAFETY PRECAUTIONS WE DID EET B 555 sees G MAINTENANCE ces bete e o eo aset n REVISION B SECTION 1 MACHINE SPECIFICATIONS 131 CARACTE D e ice eter Ee bah bob Ba b ob 1 2 System Voltage ii eoi Ile HERD EV Sei WI REIS UPPER EPIO pae t 1 2 Hydraulic System nis 2c re ue Eu had weld ae area aes 1 2 Drive Motor GearBox gear 1 2 1 2 COMPONENT ebrium Rer ades Ets 1 2 Hydraulic Pump Pump Motor 1 2 Rear Wheel Drive 1 1 2 Batteries Battery Charger 1 2 1 3 PERFORMANCE DATA d dt Ve B e aad oe eL add a 1 2 Platform C pacilies cce eee WU ebrewuiw eee ien d 1 2 Platform Size 0c vere hr ue E LE Re Aber ipie munie 1 2 Machine Height platform stowed 1 2 Machine Ground Clearance 1 2 Base Footprint 2 Ree ed ER ee PU
161. g Bracket 4 17 Rear Cover Install Remove 4 17 Display Controller Module Install Remove 4 18 Drive Lift Mode Switch InstalllRemove 4 18 Horn Button Switch 4 18 Key Switch Install lRemove 4 18 E Stop ShutDown Switch 4 19 Joystick Assembly Install lRemove 4 19 4 8 PUMP MOTOR ASSEMBLY SERVICE PROCEDURE 4 20 Hydraulic Pressure settings and Adjustment 4 20 Hydraulic Pressure Gauge 4 20 After Filter Pressure 4 21 Pump Motor Tank 1 4 21 General Installation and 4 22 Inline Hydraulic Filter 5 4 22 FENNER BRAND PUMP Brush Replacement 4 22 Motor Cap Motor
162. g harness or a damaged Component Table 6 30 Code 26 Auxiliary 2 Short Circuit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the voltage across 0 2VDC Goto Step 2 Replace Ground pins 8 and 1 to the Aux 2 component Is reading within specification Control Module 2 Remove the wire terminals at the Aux 2 component check continuity of Replace the Repair or each ofthe wires from pins 8 and 1 onthe P1 connectorto the Aux 2 Component Replace Wiring component end 3121231 JLG Lift 6 29 SECTION 6 TROUBLESHOOTING Code 27 Auxiliary 2 Disconnected Check For These Obvious Conditions First Is machine equipped with a component on the Auxiliary 2 circuit Table 6 31 Code 27 Auxiliary 2 Disconnected STEP ACTION SPEC YES NO 1 Is machine equipped with a component on the Auxiliary 2 circuit Goto Step 3 Gotto Step 2 2 Atthe Ground Control Module enter the programming mode check if the Default NO Disable It Replace Ground Auxiliary 2 open circuit detection is enabled Control Module 3 Checkvoltage atthe P1 connector on the Ground Control Module between 2 4VDC Replace Ground Goto Step 4 pin 8 and pin 1 Is reading within specification Control Module 4 Remove the wire terminals at the Aux 2 component check continuity of Replace the Repair or each ofthe wires from pins 8 and 1 onthe P1 connectorto the Aux 2 Component Replace
163. gh BOTTOM of mast section 2 be careful not to nick or score cylin der rod surface while removing When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 2 out BOTTOM of sec tion 1 Remove slide pads and shims if necessary Mast Section 1 Disassembly 23 24 Slide the TOP of remaining mast section 1 out over edge of work surface and remove the pins attaching the chain anchor block to mast section 1 Remove chain anchor block assemblies from mast and lay aside Remove slide pads and shims from mast section 1 Mast disassembly should now be complete JLG Lift SECTION 5 MAST COMPONENTS MAST SECTION 5 MAST SECTION 4 MAST SECTION 3 MAST SECTION 2 MAST SECTION 1 1 T 2 1 LIFT CYL 9 LIFTS HERE 5 AT MAST O ANCHORED TO SECTION 2 l MAST SECTION 1 gt MAST SECTION 3 CHAIN ASSEMBLYS ATTACHED TO ATTACHED ATTACHED SECTION 3 L SECTION 5 MAST SECTION 1 BOLTED TO FRAME CHAIN ANCHOR BRACKETS 5 18 Figure 5 6 Mast Chain Routing Diagram MVL MSP JLG Lift 3121231 SECTION 5 MAST COMPONENTS Mast Assembly MVL MSP Mast Section 1 Assembly 1 Place mast section 1 rail open side up See Figure 5 5 on page 5 16 on a clean flat surface prefera bly a table or work bench capable o
164. h holes in outside rail on top of mast section 2 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Insert slide pads into the bottom end mast rails between section 2 and 3 one on each side of the mast with beveled surface facing out towards sec tion 2 Same as Figure 5 7 on page 5 19 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes on inside rail on bottom end of mast section 3 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Slide section 3 out the bottom of section 2 approxi mately one 1 foot Locate one 1 of the chain bottom anchor brackets one with threaded holes horizontally aligned to out side of bracket Attach using outer set of holes in bottom of mast section 3 with two 2 1 4 20UNC x 3 4 long bolts place a flatwasher under head of each bolt Slide section 3 out the top of section 2 approxi mately one 1 foot Locate the remaining narrow chain set 444 and attach them to the remaining triangular shaped anchor plate using the attach pins flat washers and cotter keys Install the chain anchor plate assembly into the top of mast section 3 using the remaining large pin and JLG Lift Mast Section 3 Chain Anchor Bra
165. h the platform and detect if an object has entered that zone when the platform is being lowered NOTE The OSS only operates normally when the Ground Control Module Power Selector Switch Key is set to PLATFORM CONTROL MODE When the Power Selector Switch Key is set to GROUND CONTROL MODE the OSS will detect an obstruction but will not stop platform downward movement or sound the horn However the OSS Control Module LED will flash if a sensor detects the presence of an object An OSS Sensor replacement kit is available from the JLG Parts Department for individual sensors The kit provides instructions and everything necessary to connect the new sensor to the existing soldered wire ends If the OSS Control Module has failed it is recommended to Th nsors are mounted in a manner to provi tec sensorsare mounted in ec SHOE IO provide detec replace the complete OSS system See Section 6 of this manual for further OSS Troubleshooting instructions 3 Obstruction Sensor Control Module 4 Transducer Sensor Arrangement 1 Mast Platform Header Section 2 Platform Electrical Junction Box Figure 4 9 Obstruction Sensor System Components Platform Cutaway 4 30 JLG Lift 3121231 SECTION 4 CONTROL COMPONENTS Transducer Sensor Check Perform the following daily Pre Start Inspection to check if each transducer sensor is work
166. hand Insert slide pads into the slide pad channels top of mast between section 1 and 2 one on each side of the mast with beveled surface facing in towards section 2 Before fastening and shimming the slide pad on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher 1 Slide Pads 2 Shim Stock Note 10 5 20 Mast Top End Slide Pad Installation Typical 3 Sequence Cable Bracket 4 Slide Pad Bolts Washers a a Apply Loctite 242 to threads Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in mast section 1 outside rail top of mast and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly 11 Lift cylinder installation into the bottom of Mast Sec tion 1 and 2 1 Cylinder Mount 2 Shim Stock Note NOTE 12 13 14 JLG Lift Lift Cylinder Mount Installation 3 Mast Reinforcement Plate 4 Mount Screws Washers a a Apply Loctite 242 to threads The cylinder rod needs to be extended out of the cyl inder approximately 12 in 30cm before installation for later attachment of the upper chain anchor block to mast section 2 Remove any protective caps on the extend and return ports temporarily to allow rod extension Catch any oil
167. heel Load Per Wheel Lb PSI Per Wheel Wheel Load Per Wheel Lb PSI Per Wheel Rear Front Rear Front Rear Front Rear Front 22x25 SB 865 490 138 252 28x26 GW 845 550 128 265 26x50 GW 860 515 115 321 860 515 115 321 28x48 SP 755 615 117 306 w Folding Tray 810 565 125 313 NOTE Platform Types SB with Sliding Bar Gate GW with Gull Wing Gate Stock Picker Platform Table 1 3 20MVL MSP Machine Maximum Wheel Loads Lb and PSI Per Wheel 20MVL 20MSP pere ne Average Maximum Average Maximum Capacity Wheel Load Per Wheel Lb PSI Per Wheel Wheel Load Per Wheel Lb PSI Per Wheel Rear Front Rear Front Rear Front Rear Front 22x25 SB 855 450 132 250 28x26 GW 835 460 121 261 26x50 GW 850 480 131 271 850 480 131 259 28x48 SP 815 560 120 320 w Folding Tray 810 565 125 313 NOTE Platform Types SB with Sliding Bar Gate GW with Gull Wing Gate SP Stock Picker Platform 3121231 JLG Lift SECTION 1 MACHINE SPECIFICATIONS 1 4 LUBRICATION NOTE Also see Lubrication Interval Chart Table 1 7 Lubri cation Intervals for Various Components in this sec tion of the manual Hydraulic Oil Hydraulic oils must have anti wear qualities at least to Service Classification GL 3 and sufficient chemical stabil ity for mobile hydraulic system service JLG Industries recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity of 1
168. heel assemblies when extending mast sections for MVL MSP reassembly 1 Cylinder Rod 6 Apply Anti Seize 10 Piston 3 After assembly readjust the chain at the bottom of 2 Cylinder Head 7 Cylinder Tube 11 Wear Ring mast section 3 and apply Loctite 242 to the lock ts before final tighteni 3 Rod Wiper 8 Spacer 12 Piston O Ring NUS senten Mna SGH IH Ge 4 Rod Seal 9 Piston Seal 13 Piston Lock Nut a 4 Remove the plastic from under the hydraulic reser 5 O Ring voir tank cap Note a Torque 100 120 ft Ibs 3121231 JLG Lift 5 13 SECTION 5 MAST COMPONENTS Lift Down Valve and Manual Release Installation 1 Lift Down Valve a 2 Valve Solenoid b 3 Manual Release Assembly Notes a Coat all o rings with clean hydraulic fluid before assembling b Mount with electrical terminals pointing to right side of machine 4 O Ring with Backing Rings a 5 Valve O Ring a 6 Solenoid O Ring a 5 14 JLG Lift 3121231 SECTION 5 MAST COMPONENTS 5 6 MAST ASSEMBLY INSTALLATION Mast Removal 1 The following components must be removed from the machine before removing the mast assembly Rear Covers Drive Motor Cover Disconnect the Platform Control Console from the Mast mounted junction box Platform Assembly 2 Disconnect the positive battery cable from the left side battery Unplug the platform control cable connector at the ground control
169. hole in the brush housing to keep the brush held up in the brush holder 12 Connect the brush lead wire to the brush holder tighten to 30 in Ibs If this is a wear indicator brush connect the brush wear indicator lead to the spade terminal in the brush housing 3121231 Brush Holder Brush Lead Wire Drive Motor Brush Holder Components 13 Repeat steps 6 thru 9 for the other 3 brushes 14 Remove the armature from the motor frame by grab bing onto the commutator and pulling it from the motor frame A CAUTION THE PERMANENT MAGNETS IN THE MOTOR FRAME ARE STRONG AND WILL TRY TO KEEP THE ARMATURE IN THE MOTOR FRAME MAKE SURE THAT YOU HAVE A FIRM GRIP ON BOTH THE ARMATURE AND THE MOTOR FRAME DURING THIS STEP 15 Using compressed air clean out all of the brush dust from the armature motor frame adapter plate and brush holder assembly 16 Carefully reinstall the armature back into the motor frame So that the commutator end of the armature is at the end of the frame with the timing marks A CAUTION THE PERMANENT MAGNETS IN THE MOTOR FRAME ARE STRONG AND WILL TRY TO PULL THE ARMATURE IN THE MOTOR FRAME MAKE SURE THAT YOU HAVE A FIRM GRIP ON BOTH THE ARMATURE AND THE MOTOR FRAME SO THAT YOU CAN CONTROL THE SPEED OF THIS INSTALLATION BE CARE FUL NOT TO PINCH YOUR FINGERS BETWEEN THE ARMATURE AND THE FRAME 17 Install the wave spring washer back into the bearing bore of the brush holder as
170. hydraulic lines Tighten or Replace Hydraulic Lines 4 Oilleaking around the lift down valve Tighten Cartridge in Pump Case 5 Oilleaking around the Red manual descent valve Replace Lift Down Valve Note Do not overtighten the nut on the solenoid in step 5 3121231 JLG Lift 6 43 SECTION 6 TROUBLESHOOTING 6 15 BASE FRAME COMPONENTS TROUBLESHOOTING Caster Wheels Not Operating Freely Check For These Obvious Conditions First s machine operating on a smooth level surface Table 6 50 Caster Wheels Not Operating Freely STEP ACTION SPEC YES NO 1 lsthecaster rotating freely Goto Step 2 Lubricate or Replace Caster Housing 2 Isthe wheel spinning freely Goto Step 3 Lubricate or Replace Wheel 3 15 debris stuck in the rubber wheel Remove Debris or Replace Wheel Pot Hole Protection PHP Bars will not Lower Check For These Obvious Conditions First e Obstruction under pot hole bar on either side of machine Obstruction around the actuator assembly at the base of the mast Table 6 51 Pot Hole Protection PHP Bars will not Lower STEP ACTION SPEC YES NO 1 Checkthe actuator assembly and cables for adjustment or damage AdjustorReplace ConsultFactory 6 44 Lift 3121231 SECTION 6 TROUBLESHOOTING 6 16 DRIVE SYSTEM TROUBLESHOOTING Won t Climb Grade Overview Of Procedure The
171. ide play If play exists use thicker shims dividing thickness equally between both sides of mast g When mast slide pads are shimmed properly there should be no side to side movement of slide pad in rail channel Mast sections should be very snug in channels but still be able to slide in channel by hand Slide mast section 5 out even with top of section 4 Insert threaded ends of chain assembly attached to top of mast section 3 into the opening between mast section 4 and mast section 5 Slide the threaded ends through the holes in bottom chain anchor plate located on bottom of mast section 5 Loosely thread two 2 3 8 16UNC nuts onto stud threads on each chain Chains will be adjusted later in assembly Mast Section 5 Bottom End Components Chain Anchor Bracket and Slide Pad Installation 1 Chain Anchor Bracket 3 Slide Pad 2 Anchor Bracket Bolts Washers a 4 Long Slide Pad Note Apply Loctite 242 to threads 3121231 JLG Lift 5 Slide Pad Bolts Washers a 5 25 SECTION 5 MAST COMPONENTS 6 Slide mast section 5 back into mast section 4 until bottom ends of masts are even Check to make sure chain set attached to top of section 3 is seating properly in cable sheave wheels attached to top of mast section 4 Mast section 3 may need to be restrained to keep it s slide pads from pushing out the bottom of mast sections 2 7 At bottom of mast assembly thread all chain adjust
172. ift Down Valve Disconnected 6 24 Code 16 Lift Down Valve Short 6 25 Code 17 Ground Control Module In Fold Back 6 25 Code 18 Alarm Short 6 25 Code 19 Alarm 6 26 Code 20 Beacon Short Circuit 4 6 26 Code 21 Beacon Disconnected 6 27 Code 22 Horn Short Circuit ce ree Ch CR he RR Rope DR tri ec 6 27 Code 23 Horn 6 28 Code 24 Auxiliary 1 Circuit Short 6 28 Code 25 Auxiliary 1 Circuit Disconnected 6 29 Code 26 Auxiliary 2 Short 0 6 29 Code 27 Auxiliary 2 6 30 Code 28 Reserved sect dane dre rect n a ee eg Ca e Ae 6 30 Code 29 Reserved s xu eL ce dd he e BARRERAS 6 30 Code 30 Traction Module No Communication with Ground Control Module 6 30 C
173. ifting And Lowering 6 41 Platform Mast Won t Stay Elevated 6 42 Platform Mast Descends Too Slowly 6 42 HYDRAULIC LEAK TROUBLESHOOTING Miscellaneous Hydraulic Leak 6 43 BASE FRAME COMPONENTS TROUBLESHOOTING Caster Wheels Not Operating Freely 6 44 Pot Hole Protection PHP Bars will not 6 44 DRIVE SYSTEM TROUBLESHOOTING Won t Climb Grade secede eee ile MISERE 6 45 Machine Drives in Opposite Direction 6 45 Machine Won t Drive 6 46 Noise From Drive 222 6 47 3121231 JLG Lift 6 15 SECTION 6 TROUBLESHOOTING 6 9 SPECIFICATIONS FOR VARIOUS COMPONENTS The following table contains specifications for MVL Series and MSP machine components Table 6 2 Ohm Ratings for Various Components COMPONENT NOMINAL RESISTANCE TEMPERATURE RESISTANCE RANGE POSSIBLE Pump Motor 0 20hm 0 4ohm 77deg F 0 12o0hm 0 490hm Table 6 3 Amperage Draw for Various Components COMPONENT AMPERA
174. imity Switch 4 Harness Connector a NOTE a Proximity switch wiring is routed through hole in the mast connect support to main harness Aux 2 Input connector orange red 49 6 black 13 located under center rear cover on the left side of the pump motor JLG Lift Target Plate Installation 1 Target Plate 2 Mounting Screws and Washers a NOTE a Secure to mast using existing holes 3121231 SECTION 6 TROUBLESHOOTING SECTION 6 TROUBLESHOOTING 6 1 GENERAL This section contains troubleshooting information to be used for locating and correcting most operating problems If a prob lem should develop which is not presented in this section or which is not corrected by listed corrective actions technically qualified guidance should be obtained before proceeding with any maintenance NOTICE IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELECTRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING 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 6 2 TROUBLESHOOTING INFORMATION Troubleshooting procedures applicable to this machine are listed and defined starting with Se
175. ing and valve body position before disassembling 1 Motor Top Cover 4 Housing Motor Valve Body 2 Cover Housing Reference Mark Reference Mark 5 Motor Valve Body 3 Motor Housing a LLLA 5 5 l 4 EO NI l Motor Brush Cover Removal Installation 1 Motor Brush Cover a 3 Washers 5 Power Lead Clip Attach Screws 2 Cover Screws b 4 Power Leads to Lead Clips Soldered NOTICE REMOVE THE MOTOR COVER CAREFULLY THE SHORT POWER LEADS INSIDE THE COVER FROM THE POSTS ARE SOL DERED TO ATTACH CLIPS WHICH ARE FASTENED TO THE BRUSH CARRIER ASSEMBLY WITH SCREWS ITEM 5 RAISE THE COVER STRAIGHT UP REMOVE THE SCREWS THEN HINGE THE COVER UP SEE CENTER ILLUSTRATION AND PRY THE CLIPS OFF OF THE BRUSH CARRIER ASSEMBLY TO COMPLETELY REMOVE THE MOTOR COVER NOTE a Once cover screws are removed you may need to tap lightly around the edge of the top cover to separate it from the motor housing Read the important note above before attempting to remove the cover b These steel screws are threaded into the aluminum valve body do not overtighten 4 26 JLG Lift 3121231 SECTION 4 CONTROL COMPONENTS Brush Carrier Assembly Remove Install
176. ing nuts on threaded ends until they are snug against the bottom anchor plates and all slack is removed from chains Check that chains are seated in their sheave wheels at top of mast assembly 8 Do not assemble the mini covers to the top of mast sections until the mast chains have been adjusted properly 9 Attach the lanyard attach assembly to the side of mast section 5 10 Attach the sequencing cables and hardware to the sides of the mast assembly 11 Install the mast chain guard to the top mast section 9 E D 9 9 62 5 The mast assembly is now ready to install on the machines base frame Lanyard Attach Installation 5 26 JLG Lift Sequence Cable Bracket Installation Bottom End 3121231 SECTION 5 MAST COMPONENTS 5 8 MSP STOCKPICKER PLATFORM INSTALLATION Figure 5 8 MSP StockPicker Platform Installation 1 Mast Platform Header Section 3 Washers 5 Hex Head Screws 2 1 2 inch 2 Nut 4 Hex Head Screws 2 inch 6 Platform Bumper Rest a Note a Once mounted adjust bumper rests on both sides evenly so the platform rests on the bumpers when in stowed position 3121231 JLG Lift 5 27 SECTION 5 MAST COMPONENTS 5 9 MSP STOCKPICKER PLATFORM MID 5
177. ing properly 1 Power up machine by setting the Power Selector Key Switch to Ground Control Mode 2 Raise the platform approximately four 4 to five 5 feet 3 Hold an object about the size of 8 1 2 x 11 inches directly under one of the sensors The OSS Control Module RED LED will flash if the sensor is working properly 4 Remove object allow the LED to stop flashing and check the next sensor repeat this for all six 6 sen sors Transducer Sensor Check 1 Electronic Module LED Indicator a 2 Detection Zone 3 Place a pad of paper or similar size object 6 to 12 in 15 to 30cm individually beneath each transducer to check detection Note a The LED Indicator will flash when an object is delected at each sensor Remove object and allow the LED to stop flashing before testing next sensor 3121231 The Ground Control Module can also display the following sensor detection information when in Level 2 password Service and Maintenance Settings mode OSS Sensor Displays current Obstruction Sensor System status Detection YES NO Also if an object is detected the sensor s detecting the object and distance the object is from the sensor is displayed
178. ion Sensor System OBSTRUCTION BELOW 4 PLATFORN 4 Platform Elevated X 000000 LIFT DOWN Disabled 9 Type in Code At PSL Key Pad m cere ee a See Operators Manual for X 00000 0 Proper Operation 1 E Low Battery Voltage See Page 6 18 X 000000 Left PHP Bar UP LEFT PHP 4 o S iin s 2 gt 7 platform Elevated pod X 000000 02 pRIVEandLiftUP Disabled 9 Right PHP Bar UP 0 gt EA mmp nn n lt gt Platform Elevated X 00000 0 403 03 DRIVE and Lift UP Disabled 9 Tilt Condition EA mmm pee A gp lt gt Platform Elevated X 00000 0 404 04 DRIVE and Lift UP Disabled 9 05 RESERVED RESERVED Drive Motor 4 Brush Wear Warning _ 06 s E3 Countsdown25hrs of 00025 0 05 000100 06 DRIVE operation remaining toa 10sec shutdown mode Left Drive Motor v e E3mmmmyee 56 Disconnected RU X 000000 07 07 DRIVE Disabled 9 Right Drive Motor RIGHT MOTOR S 08 6 E x DISCONNECTED gt Disconnected 2 X 000000 08 08 DRIVE Disabled 9 6 10 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING Table 6 1 LCD Display Service Fault Code Conditions ere FAULT DESCRIPTION FOR TROUBLESHOOTING FAULT CONSOLE CODE LCD SYMBOL SCREEN LCD TEXT SCREEN MACHINE CONDITION REFER TO Left Brake Disconnected LEFT BRAKE 09 6 E mmm 5 lt gt DISCONNECTED v
179. ion box mounted to the mast under the platform P Y 5 oo Platform Console Circuit Board Connections 1 Horn Switch C5 4 E Stop Shut Down Switch 2 Communications Cable to C4 Platform Junction Box 5 Drive Lift Mode Select C6 Switch C7 3 ON OFF Key Switch C3 6 Joystick C8 Note The C numbers shown after the description above repre sent the corresponding identification of the plug on the module s circuit board 4 18 Lift Mounting Bracket Install Remove Platform Console Mounting Bracket 1 Mounting Bracket 2 Bracket Screws a Note Apply Loctite 242 to screw threads on final assembly Rear Cover Install Remove 5 Platform Console Rear Cover Installation 1 Rear Cover 2 Cover Mounting Screws 3121231 SECTION 4 CONTROL COMPONENTS Display Controller Module Install Remove Platform Console Display Module 1 Display Controller Module a 2 Mounting Screws Note a Unplug all connections on the back of the module before removing from console Drive Lift Mode Switch Install Remove Platform Console Drive Lift Mode Select Switch 2 Locking Tabs Nole a Remove rear cover unplug switch wire press tabs to remove 1 Switch Assembly a
180. ithin Module spec 2 Repair or replace left drive motor wiring brushes or motor For brush replacement see Section 3 of this Service Manual 3121231 JLG Lift 6 21 SECTION 6 TROUBLESHOOTING Code 08 Right Drive Motor Disconnected Check For These Obvious Conditions First Check right drive motor M2 connector at the Traction Control Module for secure and proper connection Table 6 12 Code 08 Right Drive Motor Disconnected STEP ACTION SPEC YES NO 1 Check resistance across positive and negative leads in M2 connec 1to 3ohms Replace Traction Go to Step 2 tor wiring harness going to the right drive motor Is reading within spec Module 2 Repair orreplace right drive motor wiring brushes or motor For brush replacement see Section 3 of this Service Manual Code 09 Left Brake Disconnected Check For These Obvious Conditions First Check left drive motor M1 connector at the Traction Control Module for secure and proper connection Table 6 13 Code 09 Left Brake Disconnected STEP ACTION SPEC YES NO 1 Check resistance across positive and negative leads in 1 connec See Table 6 2 Replace Traction Go to Step 2 tor wiring harness going to the left drive motor brake assembly Is reading Module within spec 2 Repair or replace left brake wiri
181. its that go to the base metal are unacceptable Scratches that catch the fingernail but are not to the base metal less than 0 5 inch long and primarily in the circumferential direction are acceptable provided they cannot cut the rod seal Chrome should be present over the entire surface of the rod and the lack thereof is unacceptable In the event that an unacceptable condition occurs the rod should be repaired or replaced Cylinder Head Visually inspect the inside bore for scratches or polishing Deep scratches are unacceptable Polishing indicates uneven loading and when this occurs the bore should be checked for out of roundness If out of roundness exceed 0 007 this is unacceptable Check the condition of the dynamic seals wiper rod seals looking particularly for metallic particles embedded in the seal surface It is nor mal to cut the static seal on the retaining ring groove upon disassembly Remove the rod seal static o ring and backup and rod wiper Damage to the seal grooves par ticularly on the sealing surfaces is unacceptable In the event that an unacceptable condition occurs the head should be replaced Piston Visually inspect the outside surface for scratches or pol ishing Deep scratches are unacceptable Polishing indi cates uneven loading and when this occurs the diameter should be checked for out of roundness If out of round ness exceeds 0 007 this is unacceptable Check the con dition of the dynamic s
182. ity switch mounted at the base of the mast assembly and a target mounted on the mast assembly When the mast is elevated and the target raised the proximity switch then cuts back the machine drive speed When machine is in the drive speed cut back mode a turtle is displayed on the Ground Control Module LCD display Check For These Obvious Conditions First Mast drive speed cut back proximity switch and target plate secure and undamaged Both Pot Hole Protection Bar Limit switches secure and undamaged Table 6 5 Machine In Drive Speed Cut Back Turtle Mode All The Time STEP ACTION SPEC YES NO 1 ThePot Hole Protection system bars should be raised when the platform is Checkthe Goto Step 2 fully lowered Check if the Pot Hole Protection bars are down when the plat mechanical formis fully lowered operation of the PHP System 2 With the platform fully lowered check for continuity on the Cutback Proxim Goto Step 3 Repair or Replace ity Switch wires between pins 8 and 18 onthe P2 connector at the Ground Speed Cutback Control Module Proximity Switch 3 With the platform fully lowered bars raised check for continuity on the Repair or Replace Right Side Right Side PHP bar limit switch between pins 9 and 19 onthe P2 connector PHP Limit Switch at the Ground Control Module Go to Step 4 4 Withthe platform fully lowered bars raised check for continuity on the Left Repair or Replace
183. layed is based on the previous zero setting and may not reflect level of the machines current resting surface 1 Position the machine on a level surface verified level in both the X and Y axis with a digital level 2 Select Zero Tilt Sensor from the menu and press the Brake Release button 3 The current tilt sensor readings are displayed To zero both the X and Y direction sensor setting to the machines present resting surface press the Brake Release button 4 Select Back to Main Menu and press the Brake Release Button 5 Power machine off and begin operation EEPROM Defaults Resets programmable settings to factory default settings for 10MSP and 15 20MVL MSP models NOTE New replacement Ground Control Modules are shipped with the EEPROM Defaults set up for 15 20 MSP MVL model machines If a the new replace ment module is installed on a 10MSP model the EEPROM Defaults must be reset to the 10MSP model EEPROM Defaults Select EEPROM Defaults from the menu and press the Brake Release button Select the CORRECT machine model then push Brake Release button to accept Power machine off and begin operation OSS Sensor Displays current Obstruction Sensor System status Detection YES NO Also if an object is detected the sensor s detecting the object and distance the object is from the sensor is displayed OBSTRUCTION BELOU E3 K a PLATEDRN 4 X 000000 055 Sensor LCD Display Mode 1 Detection
184. lf of the rear covers see Section 4 2 Controls Cover Installation Procedure for removal is same for both batteries On installation batteries set in machine with the posts to the inside Left side battery NEG post at front shown below Right side battery POS post towards machine front Battery Installation Left Side Battery Shown 1 Battery a 3 Battery Terminal Attach Nut Washer b 2 Hold Down Bar 4 Hold Down Bar Wing nut and Washer NOTE a Mount with terminal posts inboard b Apply battery terminal grease to prevent corro sion 4 6 JLG Lift 3121231 SECTION 4 CONTROL COMPONENTS 1 Ground Control Module 4 Right Side Battery b 7 Power Cable To Right Drive Motor Brake a 2 Left Side Battery b 5 Traction Control Module a 8 Pump Motor Tank Assembly b 3 175 Amp Inline Fuse 6 Power Cable To Left Drive Motor Brake a 9 Battery Disconnect Option Ground Control P1 Horn Alarm Beacons Lift Down Valve Harness a P4 Platform Junction Box Harness Module Plugs P2 PHP Elevation Speed Charger Limit Switch Harness a 5 Joystick Protocol Harness a P3 Programmable
185. lign with openings in the mating parts If it becomes necessary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usage and Torque Application 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 those having the same specifications of the origi nal or one which is equivalent 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 or Torque Chart in Section 1 3121231 JLG Lift 2 SECTION 2 GENERAL Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacles when disconnecting or removing them from the unit This will assure that they are correctly reinstalled Hydraulic System Keep the system clean If evidence of metal or rubber par ticles is found in the hydraulic system drain and flush the entire system Disassemble and reassemble parts on clean work sur face Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assem bly
186. lowing Step 2 Pull on hose assembly to create a gap between the dust boot and hose fitting shoulder Step 3 Insert the disconnect tool in the gap created between the dust boot and hose fitting shoulder 3121231 JLG Lift 5 7 SECTION 5 MAST COMPONENTS Tool Use In Line Style Fittings continued Step 4 Gently push hose assembly into coupling body see directional arrow Step 5 Maintaining slight pressure on the hose assembly actuate the tool see arrow Step 6 Release the tool and pull on hose assembly to complete disconnection Tool Use Angled Style Fittings JLG Lift Step 1 Prior to disconnection ensure that system is not under pressure Step 2 Pull on hose assembly to create a gap between the dust boot and hose fitting shoulder Step 3 Insert the disconnect tool in the gap created between the dust boot and hose fitting shoulder 3121231 SECTION 5 MAST COMPONENTS Tool Use Angled Style Fittings continued Step 4 Gently push hose assembly into coupling body see directional arrow Step 5 While maintaining slight pressure on the hose assembly actuate the tool see arrow Step 6 Pull on hose assembly to complete discon nection 3121231 5 5 HYDRAULIC LIFT CYLINDER REMOVAL INSPECTION AND REBUILD A WA
187. lowing the top of mast section 2 to be completely exposed Extending Mast Sections 1 Mast Section 2 2 1 ft 31cm Extended 5 10 JLG Lift 1 2 5 9 Exposing Top of Mast Section 2 1 Sections 3 4 and 5 Pushed Back 2 Top of Mast Section 2 Exposed 3121231 SECTION 5 MAST COMPONENTS 9 Remove the cylinder anchor block attach pin snap ring from the back of the top of mast section 2 Snap Ring Installation 1 Back of Mast Section 2 2 Cyl Chain Anchor Block 3 Pin and Snap Ring 4 Cylinder Rod 10 Remove the cylinder rod pin from the cylinder chain anchor block AX 3 AS T Cylinder Rod Pin Installation 1 Cylinder Rod Pin 3 Cyl Chain Anchor Block 2 Cylinder Rod 3121231 11 Atthe bottom of mast section 1 remove the cylinder mount bolts and mount reinforcement plates d Lift Cylinder Mount Installation 1 Cylinder Mount Assembly 3 Mast Reinforcement Plate 2 Mount Shims Mark Shims 4 Mounting Screws Washers a Notes a Apply Loctite 242 to threads at final assembly NOTE If mount shims are installed mark the mast and the shim to which side the shims cam
188. ls 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 Onone 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 measure ment If still no continuity repair wires or consult schematic for other wires to use for test 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 One can find the continuity of two wires here 1 and 2 at once by following steps 1 through 4 If there is a problem the third wire is used to troubleshoot the other wires To find the problem start at step 1 and use the entire procedure 3121231 JLG Lift 6 5 SECTION 6 TROUBLESHOOTING ELECTRICAL SWITCH TESTING Basic Check The following check determines if the switch is functioning properly not the circuit in which the switch is placed A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected 1 2 3 4 De energize the circuit Isolate the switch from the rest of the circuit
189. ly the cable connections to the GCM are different b All other connections to Ground Control Mod ule same as in Figure 4 2 Figure 4 3 Battery Cable to Battery Termi nal Connections 4 6V 4 8 JLG Lift 3121231 SECTION 4 CONTROL COMPONENTS 4 5 GROUND CONTROL MODULE SERVICE PROCEDURE NOTICE DO NOT ATTEMPT TO DISASSEMBLE THE GROUND CONTROL MODULE IF MACHINE IS STILL UNDER WARRANTY OPENING THE GROUND CONTROL MODULE WHILE THE MACHINE IS UNDER WARRANTY WILL VOID THE WARRANTY IF UNDER WARRANTY REQUEST A REPLACEMENT MODULE FROM THE FACTORY The MVL Series and MSP Ground Control Module allows for field replacement of two 2 components internal to the module Emergency Stop Switch Power Selector Switch Key ELECTROSTATIC DISCHARGE CAN DAMAGE COMPONENTS ON THE INTEGRATED CIRCUIT BOARD PLACE THE GROUND CON TROL MODULE ON A NON CONDUCTIVE SURFACE WHEN OPEN ING 1 Cover LCD Assembly 2 Power Selector Switch Nut 3 Emergency Stop Button 4 Emergency Stop Switch 5 Power Selector Switch 6 Main Board to LCD Ribbon Cable Connector T Heat Sink Base Main Board Assembly 8 Cover Attach Screws Figure 4 4 Ground Control Module Components 3121231 JLG Lift 4 9 SECTION 4 CONTROL COMPONENTS Cover Removal Installation NOTICE THE MAIN CIRCUIT BOARD AND THE SMALLER LCD CIRCUIT BOARD MOUNTED TO THE COVER ASSEMBLY COMMUNICATE THROUGH A RIBBON CABLE REMOVE T
190. m 5 in Component Illustration Above JLG Lift 3121231 SECTION 3 BASE COMPONENTS Actuator Limit Switch Counterweight Installation Machines Prior to S N 0130013258 Same both sides of machine PHP Actuator 6 Left Side Torsion Spring yellow Actuator Attach Screw Nut Limit Switch a Limit Switch Attach Screws b 7 Counterweight Attach Pin 8 Spacer 9 Pivot Pin and Retaining Ring gt an Shim Adhesive Backed max 2 per switch q DA Pun Pot Hole Switch and Mounting Bracket Machines S N 0130013258 to Present NOTE a When the pothole is in the deployed position bars down adjust plunger just past click tighten screws to frame b Apply Loctite 4222 to screw threads before tightening c Add as required if switch is adjusted to maximum and plunger has not clicked to engage switch 3121231 JLG Lift 3 19 SECTION 3 BASE COMPONENTS 3 7 BATTERY CHARGER SERVICE PROCEDURES Battery Charger General Information DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGER IF MACHINE IS STILL UNDER WARRANTY OPENING THE BAT TERY CHARGER WHILE THE MACHINE 15 UNDER WARRANTY WILL VOID THE CHARGER WARRANTY IF UNDER WARRANTY REQUEST A REPLACEMENT CHARGER FROM THE FACTORY Battery Charge LED Indicator on Platform Control Console On normal power up and operation this series of ten 10 LEDs visually indica
191. mbly 3 Pump Shaft Seal 2 Pump Assembly Screws 4 Pump End Head Pump O Ring Installation 1 Pump Assembly 2 O Ring Seal 3 O Ring Seal 3121231 SECTION 4 CONTROL COMPONENTS Pressure Adjust Valve Installation Pressure Check Valve Installation Pressure Adjust Valve Installation 1 Adjust Valve Cap 4 Valve Ball Pressure Check Valve Installation 1 Check Valve Assembly 5 Check Valve Port 3 Valve Spring 6 Extend Pressure Port 3 O Ring Seal 7 Return Port Shown Plugged 4 Backing Ring Note Adjust pressure per specification shown in Section 1 of this Note Extend Pressure and Return Ports Shown Plugged Service Manual 3121231 JLG Lift 4 29 SECTION 4 CONTROL COMPONENTS 4 9 OBSTRUCTION SENSOR SYSTEM SERVICE PROCEDURE MSP OPTION General The Obstruction Sensor System OSS Control Module is mounted between the rails of the mast platform header section under the platform decal billboard at the rear of the MSP model platform see illustration below The OSS Control Module communicates with the Ground Control Module through the platform electrical junction box also mounted on the mast behind the platform decal billboard The OSS Control Module circuit board monitors six 6 channels each channel is wired to an individual trans ducer sensor mounted under the MSP model platform tion zone beneat
192. module Remove the clamp attaching the platform control cable from inside the mast mounting column Disconnect the spring and clamp attaching the AC receptacle cable inside the mast mounting column Under the machine disconnect and cap the hydrau lic extend and return lines from the hydraulic cylin der Using an overhead crane or suitable lifting device capable of supporting the weight of the mast assem bly attach a sling strap to the mast If installed use the optional crane lifting lug on the back of the mast Remove the six 6 mast attach bolts with washers and nuts securing the mast to the mounting column Lift the mast off the base frame and place on a suit able work surface Mast Installation To install the mast assembly reverse the Mast Assembly Removal instructions however perform the following addi tional steps during re assembly 1 2 3121231 Install machine covers per instructions Section 3 Once assembly is complete cycle the mast up and down several times then check the oil level in the hydraulic reservoir
193. motor hous ing Brush Assembly Connections 1 Negative Post 3 Brush Assemblies 2 Positive Post 4 Spring Washer Note Length of wires to brush assemblies shown exaggerated for illustrative purposes 4 24 JLG Lift 3121231 SECTION 4 CONTROL COMPONENTS Brush Housing Final Assembly Tips It is easier to install the brush housing assembly by sliding the rotor assembly completely out of the other end of the motor housing then attach the brush housing first After the brush housing is installed look into the motor housing from the opposite end to check that the positive post wires and static winding wires are positioned not to block the holes for the motor mounting bolts inside the motor housing After final assembly of the brush housing check that all brush terminal screws are tight and the brush springs are positioned properly before mounting the motor to the pump motor end head Brush Final Positioning ONCE THE ROTOR ASSEMBLY IS IN PLACE REMEMBER TO PUSH EACH BRUSH DOWN UNTIL THE BRUSH FACE IS IN CONTACT WITH THE COMMUTATOR ON THE ROTOR SHAFT AND THE BRUSH SPRING IS PUSHING DOWN ON TOP OF THE BRUSH 3121231 JLG Lift 4 25 SECTION 4 CONTROL COMPONENTS MONARCH BRAND PUMP Brush Replacement Motor Assembly Remove Install Reference Marks Pump Motor Removal Installation Reference Marks For reference when reassembling mark motor cover hous
194. n Control Module a 9 Battery Disconnect Option 2 Left Side Battery b c 6 Power Cable To Left Drive Motor Brake a 3 175 Amp Fuse T Power Cable To Right Drive Motor Brake a 4 Right Side Battery b c 8 Pump Motor Tank Assembly b Ground Control P1 Horn Alarm Beacons Lift Down Valve Harness a P4 Platform Junction Box Harness a Module Plugs P2 PHP Elevation Speed Charger Limit Switch Harness a Pb Joystick Protocol Harness a P3 Programmable Security Lock Harness Option a Notes Apply di electric grease JLG Part Number 3020038 to wiring harness terminals to prevent moisture from entering module b Seal NEG and POS posts with battery grease to prevent corrosion c See Section 4 Figure 4 3 for the optional 4 6V battery cable connections Figure 6 5 Component Electrical Connections 3121231 JLG Lift 6 9 SECTION 6 TROUBLESHOOTING Table 6 1 LCD Display Service Fault Code Conditions PLATFORM FAULT CONSOLE FAULT DESCRIPTION CODE NN LCD SYMBOL SCREEN LCD TEXT SCREEN MACHINE CONDITION TROUBLESHOOTING Machine In Drive Speed _ Cut Back Turtle Mode X 000000 All The Time 9 Engage Brakes BRRHES RELERSED Z E3 lt 4 pes bii Press Brake Release Button X 000000 on Ground Control Station Unplug Charger 3 v ORE AC Input Power Cord X 000000 from Machine Obstruct
195. n the platform and lt mounted on the right side platform rail EE For removal see below for servicing information see Sec tion 4 7 Platform Control Console Service Procedures Horn Installation 1 Horn Assembly 2 Attach Screws Washers Note See Figure 4 2 for wiring connection instructions Alarm Installation 1 Console Mounting Bracket and Attach Pin 2 Platform Control Console 3 Platform Console to Junction Box Harness a Nole The other end of this harness is plugged into the plat form junction box mounted to the mast behind the platform decal board From the console the harness is tie strapped to the platform rail and run inside the mast through a large hole in the mast to the platform junction box Platform Control Console Installation Alarm Installation 1 Alarm Assembly 2 Attach Screws Washers Note See Figure 4 2 for wiring connection instructions 4 4 JLG Lift 3121231 SECTION 4 CONTROL COMPONENTS 4 4 BATTERIES SERVICE PROCEDURES Battery Replacement JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FAC TORY APPROVED BATTERIES APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG S AFTERMARKET PARTS DISTRIBUTION CEN TERS OR JLG S AFTERMARKET PROGRAMS FOR ASSISTANCE WITH PROPER BATTERY REP
196. ng or left brake assembly Code 10 Right Brake Disconnected Check For These Obvious Conditions First Check right drive motor M2 connector at the Traction Control Module for secure and proper connection Table 6 14 Code 10 Right Brake Disconnected STEP ACTION SPEC YES NO 1 Checkresistance across positive and negative leads in M2 connec See Table 6 2 Replace Traction Goto Step 2 tor wiring harness going to the right drive motor brake assembly Is reading Module within spec 2 Repair or replace right brake wiring or right brake assembly JLG Lift 3121231 6 22 SECTION 6 TROUBLESHOOTING Code 11 Left Drive Motor Short Circuit Check For These Obvious Conditions First Wiring harness from M1 connector on Traction Control Module to Left Drive Motor for damage Table 6 15 Code 11 Left Drive Motor Short Circuit Code 12 Right Drive Motor Short Circuit Check For These Obvious Conditions First STEP ACTION SPEC YES NO 1 Removethe 1 connector fromthe Traction Control Module and check both No Voltage Goto Step 2 the pins to the drive motor for any voltage This circuit should Ground the meter to the Ground Control Module Negative lug be isolated Repair or Replace 2 Check for continuity of both the pins to ground No Ground Components as Replace Required Traction Control Module Wiring harness from M2 conn
197. nnections from Platform Control Console to Platform Junction Box to Ground Control Module Confirm that the static ground strap attached under base frame is secure and undamaged Table 6 41 Code 200 299 Platform Control Console Fault Condition STEP ACTION SPEC YES NO 1 Recycle machine power 5 times allowing a 10 second interval between Done Goto Step 2 each power recycle Does fault clear 2 Which 200 code numberis displaying Code 200 207 213 Goto Step 3 Replace Platform Code 202 205 206 Goto Step 4 Control Module 3 Removethe 9 pin Platform Control Module connector from the side ofthe Replace Repair or Replace Platform Junction Box and the connector at the Ground Control Mod Platform Wiring ule Check continuity from the P4 connector pin 5 to Junction Box pin 3 Control Module and P4 pin 9 to Junction Box pin 4 Is there continuity on these wires 4 Performthe Joystick Calibration Procedure in Section 4 5 ofthis Service Done Replace Manual Does this clearthe fault code Platform Control Module 3121231 JLG Lift 6 37 SECTION 6 TROUBLESHOOTING Codes 300 399 Traction Control Module Fault Condition Check For These Obvious Conditions First Damage to Traction Control Module wiring harness Confirm that the static ground strap attached under base frame is secure and undamaged Table 6 42 Codes 300 399 Traction Control Mod
198. nnish Languages and one for Asian Languages 5 Spanish 2 1 English 3 Japanese 2 Chinese 2 Set Maximum Lift Up Speed 100 0 100 2 Set Maximum Lift Down Speed 100 0 100 2 3 Set Sleep Time 5MINS 0 60 MINS 2 Set Polarity Of Left Pot Hole Input 1 2 0 Disabled 1 LOW 2 HIGH 2 Set Polarity Of Right Pot Hole Input 2 2 0 Disabled 1 LOW 2 HIGH 2 Set Polarity Of Up Limit Elevation Input HIGH HIGH LOW 2 Set Polarity Of Charger Inhibit LOW HIGH LOW 2 3 Set Polarity Of The Keypad Code LOW HIGH LOW 2 Set Polarity Of Ancillary Input 1 LOW a HIGH LOW 2 Set Polarity Of Ancillary Input 2 LOW b HIGH LOW 2 Load Sensing LSS OFF ON OFF 2 3 Enable Detection Of Horn Open Circuit NO YES NO 2 3 Enable Detection Of Beacon Open Circuit NO YES NO 2 Enable Obstruction Sensor System 055 NO YES NO 2 Enable Detection Of Aux 1 Open Circuit NO YES NO 2 Enable Detection Of Aux 2 Open Circuit NO YES NO 3 Forward Alarm Disable NO YES NO 3 OSS Diagnostic NO YES NO 2 Zero the On Board Tilt Sensor NO YES NO 3 View Tilt Sensor Readings 2 Brush Wear Sensor Timer Reset BLANK WORN 2 Ancillary 1 Input Inhibit 0 0 4 2 Ancillary 2 Input Inhibit 0 0 4 3121231 JLG Lift 4 15 SECTION 4 CONTROL COMPONENTS Table 4 1 MVL MSP Ground Control Module Field Programmable Settings and Factory Preset Level 2 Service Level Settings OnLCD Display
199. ode 31 Platform Control Console No Communication with Ground Control Module 6 31 6 14 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING Code 33 Both PHP Bars 6 32 Code 34 P2 Auxiliary 1 1 6 32 Code 35 P2 Auxiliary 1 Tie DOWN 6 32 Code 38 Battery Voltage Low Warning Level 2 Two 2 LED LCDs 6 33 Code 39 Battery Voltage Low Warning Level One 1 LED LCDs 6 33 Code 40 Obstruction Sensor System No Communication with Ground Control Module 6 34 Codes 41 thru 46 OSS Sensor 1 through 6 Fault Condition 6 35 Codes 100 199 Ground Control Module Fault Condition 6 36 Codes 200 299 Platform Control Console Fault Condition 6 37 Codes 300 399 Traction Control Module Fault Condition 6 38 MAIN POWER CIRCUIT TROUBLESHOOTING Machine Will Not Power Up 6 39 MAST TROUBLESHOOTING Platform Will Not Lower 11 1 6 40 Platform Lift Up And Down 4 6 40 Mast Noisy When L
200. onnected pa 5 000000 21 21 age 0 3121231 Lift 6 11 SECTION 6 TROUBLESHOOTING Table 6 1 LCD Display Service Fault Code Conditions M FAULT DESCRIPTION FOR TROUBLESHOOTING FAULT CONSOLE CODE EN LCD SYMBOL SCREEN LCD TEXT SCREEN MACHINE CONDITION REFER TO 22 lt gt ur Horn or Horn Circuit Short e X 000000 22 22 ages HORN DISCONNECTED See Table 6 27 23 Horn Disconnected 6 28 X 000000 23 23 0683 RUX 1 SHORT A See Table 6 28 24 Auxiliary 1 Circuit Short Page 6 28 X 000000 24 24 RUX 1 Auxiliary 1 Circuit SeeTable 6 29 25 gt DISCONNECTED Disconnected Page 6 29 X 00000 0 25 25 RUX 2 SHORT Auxiliary 2 Circuit Short ath X 00000 0 26 age 6 29 RUX 2 Auxiliary 2 Circuit See Table 6 31 27 ee lt gt DISCONNECTED P Disconnected Page 6 30 Traction Module 30 6 lt gt PME i No Communication 4 X 00000 0 30 cons 30 with Ground Control Module 9 Platform Control Console JOYSTICK 31 BH lt gt NODULE No Communication with sien X 000000 431 0 conns 431 Ground Control Module 9 PURP MOTOR amp Pump Motor Over Current See Table 6 34 32 gt OVER CURRENT LIFT UP Disabled Page 6 31 X 000000 32 32 4 BOTH PHP BARS Both PHP Bars UP See Table 6 35 lt gt 33 2 0 DRIVE and Lift UP Disabled Page 6 32 X 000000 33
201. op switch to remove joystick assembly through access hole in bottom of con Sole 3121231 SECTION 4 CONTROL COMPONENTS 4 8 PUMP MOTOR ASSEMBLY SERVICE Hydraulic Pressure Gauge Connection PROCEDURE CAUTION Hydraulic Pressure settings and Adjustment ONLY OPEN HYDRAULIC SYSTEM LINES WITH THE MAST FULLY ME LOWERED TO RELIEVE PRESSURE IN THE SYSTEM CAREFULLY Adjust system pressure so that platform will raise with LOOSEN REQUIRED FITTINGS WEAR SAFETY PROTECTION maximum rated capacity in platform EQUIPMENT WHEN WORKING WITH HYDRAULIC SYSTEMS The following pressure setting are factory recommended initial settings Remove the hydraulic oil filter and install a t fitting between the pump and the extend line to connect a hydraulic pressure gauge as shown in Figure 4 7 Typical MODEL PRESSURE SETTING Hydraulic Pressure Gauge Installation Hydraulic Filter 15MVL 15MSP 2600 PSI Removed 20MVL 1800 PSI CHECK and if necessary ADJUST the hydraulic pressure 20MSP 2800 PSI to initial settings shown in table at the beginning of this section Cycle the hydraulic system several times with the maximum load capacity in the platform then recheck pressure setting When pressure has stabilized continue to After Filter Pressure Check following Turning adjustment screw clockwise increases system pressure turning screw counterclockwise decreases system pressure See Figure 4 6 Hydraulic Pressure Adjustment Scr
202. or Note To release switch connectors push tab on top of connector Power Selector Switch Installation 1 Nut 2 Power Selector Switch 3 Align and insert tab on switch into slot on cover Note Re attach wires to the same terminals on new switch 3121231 JLG Lift 4 11 SECTION 4 CONTROL COMPONENTS 4 6 GROUND CONTROL MODULE PROGRAMMING General The MVL MSP machine Ground Control Module allows on board programming of various component and control function personality settings Programming may be required under circumstances such as Replacement of the Ground Control or Traction Control Module some components or optional equipment may not be enabled under the standard default settings of the replacement unit Optional equipment has been added to the machine in the field and that function must be enabled before oper ation Customizing the machine to fit a specific application such as changing the LCD display language program ming operating speeds such as braking turning or lift ing speeds Programming Levels There are three 3 password protected programming levels from highest to lowest the levels are Level 1 JLG Engineering Settings Level 2 Service and Maintenance Settings Level 2 Password 91101 Level 3 Operator Settings Level 3 Password 33271 THE LEVEL 1 JLG ENGINEERING SETTINGS ARE NOT DIS PLAYED IN THE PROGRAMMABLE SETTINGS
203. oved Remove the shaft Ball Bearing G15 from the cen ter bore 3121231 SECTION 3 BASE COMPONENTS Spindle Sub Assemhly NOTE 3121231 Spindle Sub Assembly Place the spindle G1 on the bench with the carrier portion facing up Do not damage or scratch the seal surface of the spindle G1 during assembly Using the appropriate pressing tool T 182377 press on Main Bearing G14 until it is fully seated Use the Output Planet Pin G10 as a pressing tool to install the Planet Bushing G26 into the bore of each Planet Gear G9 The shaft will help guide the bushing into the bore as well as prevent damage from the press Place Tanged Thrust Washer G32 into each planet window of the Spindle G1 Make sure the tang sits in the cast groove on the inside of the win dow Place a Thrust Washer G25 onto the Output Planet Gear G9 Line up the bores as best as you can Use grease to hold the Thrust Washer in place Slide the Output Planet Gear G9 into the window with the Tanged Thrust Washer G32 until the bores line up Insert Output Planet Shaft G10 into the Planet Shaft hole of the Spindle 1 and through the bores 10 11 12 13 JLG Lift of the Thrust Washers G25 amp G32 and the Planet Gear G9 Before pressing the Output Planet Shaft G10 into the Spindle G1 make sure the Output Planet Gear G9 spins freely Press the Output Planet Shaft G1
204. pause To Check Change The Charging Algorithm 1 Disconnect the charger positive connector from bat tery pack Apply AC power and after the LED test the Algorithm will display for 11 seconds 2 To change algorithm touch connector during the 11 second display period to the battery pack s positive terminal for 3 seconds and then remove the Algo rithm will advance after 3 seconds Repeat until desired Algorithm is displayed A 30 second time out is extended for every increment Incrementing beyond last Algorithm moves back to first Algorithm After desired Algorithm is displayed touch the charger connector to the battery positive until the output relay is heard to click 10 seconds algo rithm is now in permanent memory 3 Remove AC power from the charger and reconnect the charger positive connector to the battery pack It is highly recommended to check a newly changed algorithm by repeating the above steps 1 and 3 Table 3 3 Battery Charger Algorithm Settings ALGORITHM SETTING BATTERY TYPE 1 Trojan T105 2 Trojan T105 Tapped 3 T105 DV DT CP 4 US Battery USB2200 5 Trojan 30 31XHS 6 DEKA 8631 Gel 7 4305 DV DT CP 8 Concorde 10xAH AGM Douglas DG12 100M US 12V100AH AGM Full River HGL100 12X Universal Battery UB121000 23 Douglas Flooded Default 25 JLG P N 0400242 43 Harris Batt Discover EVGGC6A A 3 22 Battery Charger Removal Installation 1
205. quire contact and must be energized to actuate These types of switches can be used to detect boom or platform position for example These switches have a sensing face where the switch can detect ferrous metal close to it To find the sensing face take note how the switch is mounted and how the mechanisms meet the switch Test this type of switch as follows 1 2 3 6 6 Remove prox switch from its mount Reconnect harness if it was disconnected for step 1 and turn on machine Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer See vehi cle or control system documentation on how to do this Place sensing face of switch on the object to be sensed by the switch If that is not available use a piece of ferrous metal physically similar to it The switch state in the control system diagnostics should change When reinstalling or replacing switch be sure to follow mounting instructions and properly set the gap between the switch and object sensed JLG Lift 3121231 SECTION 6 TROUBLESHOOTING Automatic Switches If the switch is actuated automatically by temperature or pressure for example find a way to manually actuate the switch to test it Do this either by applying heat or pressure for example to the switch These switches may need to be energized to actuate 1 Connect instrumentation to monitor and or control the parameter the switch is measuring 2 Observe s
206. r Brushes for brush replacement instructions Table 6 10 Code 06 Drive Motor Brush Wear Warning Indicator STEP ACTION SPEC YES NO 1 Ifthe WORN code immediately comes up again after resetting then check the voltage atthe brush wear indication relay where the wires wht red 57 1 us and 57 2 from the drive motors connect atterminal 85 0 Volts i dd Go To Step 2 If there is voltage on relay terminal 85 you have a problem with the renlacement p motor check for voltage atthe terminals atthe motor to determine which motor has the bad brushes 2 Ifthereis no voltage at terminal 85 on the wear indication relay and there Check rela is voltage on relay terminal 87 you have a problem with the relay or the erwin Goto Step 3 wiring 9 3 no voltage at relay terminal 85 and there is no voltage on relay Replace wirin terminal 87 you have a problem with the wiring or controller if the code ROM 9 immediately repeats Code 07 Left Drive Motor Disconnected Check For These Obvious Conditions First Check left drive motor M1 connector at the Traction Control Module for secure and proper connection Table 6 11 Code 07 Left Drive Motor Disconnected STEP ACTION SPEC YES NO 1 Checkresistance across positive and negative drive motor leads in 1to 3 ohms Replace Traction Goto Step 2 M1 connector wiring harness going to the left drive motor Is reading w
207. r bracket until it is completely clear of the machine Replacement Cable Installation 1 Be certain the mast is completely retracted and at the bottom of travel Check the mast Side Profile at the top of the mast as shown in Figure 5 2 adjust mast sections to proper height if necessary 2 To determine where the clamp will be installed at the bottom of the replacement cable temporarily assemble the new replacement cable to the top cable anchor bracket on the mast using the wash ers spring spring cap and lock nut previously dis assembled Thread the lock nut on until approximately 1 8 in mm of threads are exposed 3 At the bottom of the mast thread the loose end of the replacement cable through the proper sheave pulley and through the hole in the sheave pulley anchor bracket on the mast section ahead of the sheave pulley 4 Grasp the cable and pull on the cable until the spring at the top of the cable is slightly compressed Use a black marker to mark the cable on the top side of the sheave pulley anchor bracket This will determine where the clamp drum socket sleeve will be positioned on the cable DO NOT CUT THE CABLE AT THE MARKED POINT ON THE CABLE THIS IS ONLY USED AS A REFERENCE FOR POSITIONING THE CABLE SLEEVE WHICH WILL REST AGAINST THE ANCHOR BRACKET ONCE INSTALLED 5 4 JLG Lift Clamp Installation Drum Socket Type THE MANUFACTURER OF THE DRUM SOCKET CLAMP RECOM MENDS THE USE OF THEIR CABLE CL
208. r tubes Place a roll pin in the slots at each end of the sheave pins and align with the cutouts in the pin support bars d Holding complete sheave wheel assembly slide assembly into top of mast section 3 and align threaded holes in sheave pin support bars with holes in mast rails e Attach to top of mast section 3 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten TIME 7 Note 3121231 Mast Section 3 Sheave Wheel Assembly 5 Narrow Washer 6 Sheave Pin T Square Keys 1 Support Bar Screws a 2 Pin Support Bars 3 Wide Spacers 4 Sheave Wheel Assys a Apply Loctite 242 to threads 38 Slide mast section 3 back into section 2 until ends are even Check to make sure chain assembly wide chains are seating properly in chain anchor block chain sheave wheels attached to mast section 2 Mast Section 4 Assembly NOTE NOTE JLG Lift When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 4 into section 3 until ends are even Insert slide pads into the top end mast rails between section 2 and 3 one on each side of the mast with beveled surface facing inward towards section 3
209. re packing Replace or Rebuild the Lift Cylinder Platform Mast Descends Too Slowly Overview Of Procedure The following procedure examines the mast some hydraulic components for obstructions and defects Table 6 48 Platform Mast Descends Too Slowly STEP ACTION SPEC YES NO 1 Check mast slide pads shimmed to tight Reshim Mast Goto Step 2 2 lsthereanobstruction inthe mast Remove Goto Step 3 Obstruction 3 Theliftcylinder packing could be too tight in the bore of the cylinder barrel Rebuild or Replace Goto Step 4 Cylinder 4 Check if the lift down valve is opening completely Clean or Replace Goto Step 5 Valve 5 Isthere arestricted hydraulic line smashed Replace Hydraulic Goto Step6 Line 6 Checktheflow valve in the cylinder valve block for a restriction i e dirt Clean or Replace Flow Valve 6 42 Lift 3121231 SECTION 6 TROUBLESHOOTING 6 14 HYDRAULIC LEAK TROUBLESHOOTING Miscellaneous Hydraulic Leak Troubleshooting Overview Of Procedure This series of steps gives remedies for various areas of the machine where leaks could occur Table 6 49 Hydraulic Leak Troubleshooting STEP ACTION SPEC YES NO 1 Oilleaking aroundthe lift cylinder rod Replace the Seal at theendofthe Piston and Cylinder Barrel 2 Oilleaking around the cylinder extend or return line fittings Tighten or Replace Fittings 3 Oilleaking around the
210. ring Apply force to the push the damaged during removal Try not to damage the hub bearing out This bearing will need to be replaced bore upon reassembly 3121231 JLG Lift 3 11 SECTION 3 BASE COMPONENTS Spindle Disassemhly 1 Spindle Disassembly Place Spindle Sub Assembly on bench with Planet Gears G9 facing up NOTE Do not damage or scratch the seal surface of the 2 Spindle G1 during disassembly Remove three Output Planet Shafts G10 NOTE These Planet Shafts are held in with a press fit Use 3 the tapped hole in the end of the pin in conjunction with a slide hammer or similar tool to remove them Remove the Output Planet Gear G9 Thrust Washer G25 and Tanged Washer G32 out each of gear window of the Spindle G1 NOTE The Output Planet Gears G9 are very similar in size to the Input Planet Gears 5 tag or label the Planet Gears to avoid confusion 4 Press out Bushing G26 from the bore of each Planet Gear G9 Bushings cannot be reused when removed 5 Remove the Main Bearing G14 from the outside 3 12 diameter of the Spindle G1 JLG Lift NOTE This bearing is held in with a press fit You will need to pry against the Spindle 1 to remove it A new bearing should be used when the unit is reassem bled Flip over the Spindle G1 Press out the Motor Shaft Seal G17 from the cen ter bore The seal cannot be reused when rem
211. rious and require human JLG Lift NUM O o CHARGING PROBLEM 9 ane RED BOTTOM LED ON Wr Ext See Flash Codes following intervention to first resolve the problem and then to reset the charger by interrupting AC power for at least 10 seconds Others may be simply transient and will automatically recover when the fault condi tion is eliminated To indicate which error occurred the RED FAULT LED will flash a number of times pause and then repeat 1 FLASH Battery Voltage High auto recover Indi cates a high battery pack voltage 2 FLASH Battery Voltage Low auto recover Indi cates either a battery pack failure battery pack is not connected to charger or battery volts per cell is less than 0 5 VDC Check the battery pack and battery pack connections 3 FLASH Charge Time out Indicates the battery did not charge within the allowed time This could occur if the battery is of a larger capacity than the algorithm is intended for It can also occur if the bat tery pack is damaged old or in poor condition In unusual cases it could mean charger output is reduced due to high ambient temperature 4 FLASH Check Battery Indicates the battery pack could not be trickle charged up to the mini mum 2 volts per cell level required for the charge to be started This may also indicate that one or more cells in the battery pack are shorted or damaged 5 FLASH Over Temperature auto recover
212. s 1 5 2 1 Inspection and 5 4 2 2 2 2 MVL MSP Preventive Maintenance amp Inspection Schedule 2 3 2 3 Chain Stretch 2 6 3 1 Wheel Torque Chart nce wie ioe oe ida uei eV P bug ds 3 3 3 2 Battery Low Voltage Warning 3 20 3 3 Battery Charger Algorithm 08 3 22 4 1 MVL MSP Ground Control Module Field Programmable Settings and Factory Preset 4 14 5 1 MVL MSP Mast Component 5 16 6 1 LCD Display Service Fault Code 6 10 6 2 Ohm Ratings for Various 1 6 16 6 3 Amperage Draw for Various Components 6 16 6 4 Special Pin Extractor Tools for Electrical Connectors 6 16 6 5 Machine In Drive Speed Cut Back Turtle Mode All The 6 17 6 6 Obstruction Sensor System 6 18 6 7 Code 02 Left PHP
213. s with the control circuit 6 3 HYDRAULIC CIRCUIT CHECKS SEE FIGURE 6 8 The first reference for improper function of a hydraulic system where the cause is not immediately apparent should be the Hydraulic Diagram Circuit The best place to begin the problem analysis is at the power source pump Once it is deter mined that the pump is serviceable then a systematic check of the circuit components would follow NOTE For aid in troubleshooting refer to Figure 6 8 for HYDRAULIC DIAGRAM circuit 6 4 ELECTRICAL CIRCUIT CHECKS General The drive system on the MVL and MSP machines requires a microprocessor controlled electrical circuit to operate smoothly and accurately All platform control console functions are relayed to various machine components i e platform up down drive functions etc through the Ground Control Module microprocessor box mounted at the rear of the machine The Ground Control Module is pre programmed with factory pre set personality settings for each machine function To help diagnose any problems with components plugged into the Ground Control Module the module is designed with an internal fault code and text messaging system displayed on an LCD screen at the module The platform control console also will display LED Flash Codes using the LED strip at the top of the console When operating normally the LED panel on the platform control console indicates the battery voltage status using ten 10 LEDs red yellow gre
214. sembly Make sure that it is oriented such that the spring touches the outer raceway of the armature bearing JLG Lift 3 7 SECTION 3 BASE COMPONENTS 18 Install the brush housing onto the end of the motor 22 Tighten the motor bolts to 65 in Ibs frame and armature You may need to use a soft UL tipped mallet to tap the brush housing onto the bear 2 2 s 52 they ing of the armature Once the brush housing is par S 22 ti As PCM A ic tially on the armature the brush retaining pins must SISTERS REN NUTS be removed 24 Remove the protective tape from the motor shaft NOTE Do not pinch any wires between the frame and the brush housing NOTICE BEFORE MOUNTING THE DRIVE MOTOR BRAKE ASSEMBLY TO 19 Line up the timing marks between the brush housing THE GEAR BOX SPINDLE HUB BE CERTAIN THE BRAKE CAVITY and the motor frame INSIDE THE SPINDLE HUB IS CLEAN DRY AND FREE OF ANY 20 Install the motor bolts S RESO 21 Install the motor flange so that the tapped holes line up with the motor bolts NOTICE WHEN TIGHTENING THE MOTOR HOUSING TO MOUNTING FLANGE CHECK THAT THE MOUNTING BOLTS ARE NOT PRO TRUDING TO FAR THROUGH THE MOTOR MOUNTING FLANGE AND COME INTO CONTACT WITH THE BRAKE FRICTION PLATE ON THE OTHER SIDE OF THE FLANGE THIS COULD CAUSE THE BRAKE FRICTION PLATE TO BECOME WARPED AND THE BRAKE TO NOT WORK PROPERLY IF NECESSARY ADD ANOTHER WASHER UNDER THE HEAD OF THE MOTOR HOUSING MOUNT ING BOLTS 3 8 JL
215. sible in the inspec tion hole after loading NOTE When assembling stainless steel parts all threads must be coated with a dry lubricant or an anti seize 9 Install cable on machine and adjust per instructions lubricant to prevent seizing shown previously in Section 5 2 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT 7 Coat the threads of the socket and sleeve with lubri cant and install the socket by twisting it over the strands of the cable and engage the threads of the sleeve with the socket Tighten until four threads or fewer are visible If more than four threads are visi ble proof load the cable and retighten the socket fit ting There is no specific requirement for torque 5 6 JLG Lift 3121231 SECTION 5 MAST COMPONENTS 5 4 HYDRAULIC LINE DISCONNECT Tool Use In Line Style Fittings SPECIAL TOOL The extend and return hydraulic line couplings and hose fittings on this machine require special tool JLG P N 7027247 to remove and install them A CAUTION FULLY LOWER THE MAST TO RELIEVE PRESSURE IN THE SYS TEM BEFORE REMOVING ANY HYDRAULIC LINES CAREFULLY LOOSEN REQUIRED FITTINGS WEAR SAFETY PROTECTION EQUIPMENT WHEN WORKING WITH HYDRAULIC SYSTEMS Step 1 Prior to disconnection ensure that system is not under pressure Push Type Hydraulic Line Removal SpecialTool JLG P N 7027247 Instructions for tool use on both in line and angled hose fittings are shown on the pages fol
216. t 2 6 3 6 2 Resistance 1 2 6 3 6 3 Continuity 6 4 6 4 Current Measurement 6 4 6 5 Component Electrical 4 6 9 6 6 Overview of Electrical System Components MVL MSP Sheet 1 2 6 48 6 7 Electrical Diagram MVL MSP 1 6 50 6 8 Hydraulic Diagram MVL MSP 6 52 3121231 JLG Lift vii TABLE OF CONTENTS LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 General Machine 1 1 1 2 15MVL MSP Machine Maximum Wheel Loads Lb PSI 1 3 1 3 20MVL MSP Machine Maximum Wheel Loads Lb and PSI Per Wheel 1 3 1 4 Hydraulic Oil Operating 1 1 4 1 5 Lubrication 1 4 1 6 Cylinder Specifications 1 1 4 1 7 Lubrication Intervals for Variou
217. t Section 4 Chain Anchor Bracket Bottom of Mast 3 Anchor Bolts Washers a 4 Pot Hole Actuator Bracket a Apply Loctite 242 to threads Slide section 4 out the top of section 3 approxi mately one 1 foot Insert threaded ends of chain assembly attached to top of mast section 2 into the opening between mast section 3 and mast section 4 Slide the threaded ends through the holes in bottom anchor plate attached to bottom of mast section 4 Loosely thread two 2 3 8 16UNC nuts onto stud threads on each chain until all slack is taken out of chain Chains will be adjusted later in assembly Assemble chain sheaves for narrow chain assem bly to top of mast section 4 as follows a Locate the remaining sheave pin and slide the wide tube spacer onto the pin shaft b Place two 2 of the narrow chain sheave wheels onto the sheave pin on each side of the wide spacer c Slide two 2 1 flat washers onto each end of sheave pin to outside of sheave wheels d Place two 2 sheave pin support bars one each end of sheave pin to outside of space tubes Place a roll pin in the slots at each end of the sheave pins and align with the cutouts in the pin support bars e Holding complete sheave wheel assembly slide assembly into top of mast section 4 and align threaded holes in sheave pin support bars with holes in mast rails f Attach to top of mast section 4 using two 2 3 8 16UNC x 1 2 long socket head counters
218. t then the oil level is sufficient If no oil is noticed at the 3 o clock plug location then remove both plugs Slowly add oil at the 12 o clock plug location until oil begins to seep out of the 3 clock plug location Rein stall and tighten plugs to 6 8 ft Ibs Drive Motor Brush Wear Warning Indication The machines drive motors include brush wear sensors that activate a warning indicating the drive motor brushes will require replacement soon This warning protects the drive motors from damage due to extreme brush wear When the brush wear warning is activated the Ground Control Station LCD screen will indicate a fault code of 6 also the hour meter is set to countdown 25 hours of DRIVE operation remaining The Platform Control LEDs will indicate this warning with 8 flashing LEDs and an intermittent beep Only the drive function when used will affect the hour meter count down once the warning has been activated The machine will operate normally until the last 10 sec onds of the 25 hour countdown During the last 10 seconds of the 25 hour DRIVE count down the machine will only drive in creep turtle drive mode and platform lift up will be disabled At this point cycling power on off will only repeat the final 10 second mode cycle The machine will not operate normally until the drive motor brushes are replaced repositioning the brush warn ing sensors and the Ground Control Station is pro grammed to reset the Brush Wear
219. tes Inspect for turned pins which can be easily spotted as the V flats on the pin heads are no longer in line Replace all chains showing evidence of turned or protruding pins Keep chains lubricated Stress Corrosion Cracking The outside link plates which are heavily press fitted to the pins are particularly susceptible to stress corrosion cracking Like fatigue cracks these initiate at the point of highest stress aper ture but tend to extend in an arc like path often parallel to the rolling grain of the material ABNORMAL PROTRUSION OR TURNED PINS e Also more then one crack can often appear on a link plate In addition to rusting this condition can be caused by exposure to an acidic or caustic medium or atmo sphere Stress corrosion is an environmentally assisted failure Two conditions must be present corrosive agent and static stress ARC LIKE CRACKED PLATES STRESS CORROSION In the chain static stress is present at the aperture due to the press fit pin No cycle motion is required and the plates can crack during idle periods The reactions of many chemical agents such as battery acid fumes with hardened metals liberate hydrogen which attacks and weakens the metal grain structure Chain Anchors and Sheaves An inspection of the chain must include a close examination of chain anchors and sheaves Check chain anchors for wear breakage and misalignment Anchors with worn or broken fing
220. tes the amount of charge remaining in the batteries The number of LEDs lit will change depending on the level of charge in the batteries All Three 3 GREEN LEDs lit up indicate maxi mum battery charge Four 4 YELLOW LEDs indicate a two thirds to one third battery charge remaining Three 3 RED LED s lit indicate minimum battery charge remaining The machine will continue to operate at this charge level but will begin to indicate battery low voltage warning indicators Battery Charger Maintenance Information 1 Make sure charger connections to battery terminals are tight and clean 2 Do not expose charger to oil or to direct heavy water spraying when cleaning vehicle Battery Low Voltage Warning Indicators The Platform Control Console and Ground Control Station indicate battery low voltage at three 3 Warning Levels See Table 3 2 following Table 3 2 Battery Low Voltage Warning Indicators WARNING INDICATOR LOCATION ACTION REQUIRED TO RESULT LEVEL PLATFORM CONTROLLED GROUND CONTROL LCD CLEAR FAULT LEVEL 1 3 LEDSs BARS Flashing Charge batteries to a level of ES mco p with an audible beep four 4 LEDs BARS or more Z 0000A e Machine will Operate No before operating LOU BATTERY Control Functions Locked Out LEVEL 2 e2 LEDs BARS Flashing Charge batteries for a mini with an audible mum of four
221. these steps correctthe problem 2 Perform steps in Table 6 5 Machine In Drive Speed Cut Back Turtle Done Consult Factory Mode All The Time of this section Code 34 P2 Auxiliary 1 Inhibit Check For These Obvious Conditions First Platform Gates Closed Pressure on the Platform Foot switch after power up NOTE the procedures below if you check continuity between 6 and 16 it should show open circuit when the platform gates are closed and nothing is on the foot switch When you step on the foot switch with the gates closed you should see a closed circuit Table 6 36 Code 34 P2 Auxiliary 1 Inhibit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P2 connector check the voltage across 0 2VDC Goto Step 2 Replace Ground pins 16 orange red 49 5 and 6 black 12 is reading within specification Control Module 2 Removethe P2 connector from the Ground Station Module check continu Goto Step 3 Repair or ity of the individual wires in the platform harness P2 to platform junction Replace Platform box Harness 3 Check continuity of gate switches and foot switch circuit Switches are ConsultFactory Replace Compo wired in series doors shut and foot switch depressed circuit will be nent or Repair closed Wires Code 35 P2 Auxiliary 1 Tie Down Check For These Obvious Conditions First Pressure on the Platform Foot switch
222. thin specification Control Module 2 Remove the wire terminals atthe horn check continuity of each of the wires Replace the Repair or from pins 14 and 7 onthe P1 connectorto the horn end Horn Replace Wiring 3121231 JLG Lift 6 27 SECTION 6 TROUBLESHOOTING Code 23 Horn Disconnected Check For These Obvious Conditions First s machine equipped with a horn unit Table 6 27 Code 23 Horn Disconnected horn open circuit detection is enabled STEP ACTION SPEC YES NO 1 Is machine equipped with a horn unit Goto Step 3 Gotto Step 2 2 Atthe Ground Control Module enterthe programming mode check if the Disable It Replace Ground Control Module 3 Checkvoltage atthe P1 connector on the Ground Control Module between 2 4VDC Replace Ground Go to Step 4 pin 14 and pin 7 Is reading within specification Control Module 4 Remove the wire terminals atthe horn check continuity of each of the wires Replacethe Repair or from pins 14 and 7 onthe P1 connector to the horn end Horn Replace Wiring Code 24 Auxiliary 1 Circuit Short Circuit Check For These Obvious Conditions First Damaged wiring in the Auxiliary 1 Component wiring harness or a damaged Component Table 6 28 Code 24 Auxiliary 1 Circuit Short Circuit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the voltage across 0 2VDC Goto Step 2 R
223. tructions following Motor Cap Installation Inline Hydraulic Filter Installation 1 Cap Assembly Screws 2 Assembly V Q Pump Motor Tank Assembly Installation 1 Valve Body Extend Line Fitting 3 Extend Line to Lift Cylinder 2 Inline Hydraulic Filter 1 Motor Assembly 3 Pump End Head 2 Motor Assembly Screws 4 Motor to Pump Coupler Motor Installation 3121231 JLG Lift 4 23 SECTION 4 CONTROL COMPONENTS Motor Brush Installation Once brush housing has been removed inspect the rotor commutator for excessive wear before installing a new brush set The rotor commutator surface when new is approximately 1 8 in 8mm in thickness 2 I 2 Ww f Brush Housing Installation OFT 1 Brush Housing 2 Brush Housing Screws 3 Mark Front of Motor and Brush Housing for reference when reassembling New Brush Installation 1 Brush Terminal Screw 4 Brush Spring 2 Brush 5 See Installation Note Below 3 Brush Holder Installation the same for all four 4 brush assemblies Note Using a clean towel push each brush 2 up into it s holder 3 slide the spring 4 over the side of the brush This will hold each brush in place and allow them to clear the rotor commutator during reassembly Clean the rotor commutator with a non conductive electrical cleaner before assembling the brush housing to the
224. ule Fault Condition STEP ACTION SPEC YES NO 1 Recycle machine power 5 times allowing a 10 second interval between Done Goto Step 2 each power recycle Does fault clear 2 lsacodenumber displaying on the Ground Control Station Code 316 Goto Step 3 Replace Traction Control Module Code 325 Goto Step 5 3 Confirm that both installed batteries are 12 Volt DC 12V DC Goto Step 4 Replace with proper Batteries 4 Check battery voltage while charger is operating Is voltage within specifi Maximum of Replace Repair or Replace cation 31 Volts DC Traction Control Battery Charger Module 5 Check for shortin harness wires from Ground Control Station connector P5 Repair or Replace to Traction Module round din plug Wiring Note This harness contains 6 wires only 3 are used See Figure 6 7 Elec trical Diagram 6 38 JLG Lift 3121231 SECTION 6 TROUBLESHOOTING 6 12 MAIN POWER CIRCUIT TROUBLESHOOTING Machine Will Not Power Up Check For These Obvious Conditions First Battery voltage is 24 volts Sufficient Charge in Batteries to Operate Machine Positive and negative battery cable connections clean and tight at both the Batteries and the Ground Control Mod ule lugs Main Power Selector Switch key positioned to either Platform or Ground Control Mode Emergency stop buttons on both the Ground Control Module and the Platform Control Console in the
225. ulic Filter 4 Pump Motor 8 Return Line 2792504 B 9 Check Valve 10 Pressure Compensator Flow Control Valve 11 Manual Decent Valve 12 Lift Cylinder 6 52 Figure 6 8 Hydraulic Diagram MVL MSP JLG Lift 3121231 CALIFORNIA PROPOSITION 65 BATTERY WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Batteries also contain other harmful chemicals known to the State of California WASH HANDS AFTER HANDLING An Oshkosh Corporation Company Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 61265811111 61 2 65 813058 es JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil 55 19 3295 0407 55 19 3295 1025 USA 717 485 5161 amp 717 485 6417 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 44 0 161 654 1000 44 0 161 654 1001 3121231 JLG France SAS 2 1 de Baulieu 47400 Fauillet France 4 33 0 5 53 88 31 70 33 0 5 53 88 31 79 A JLG Deutschland GmbH Max
226. unk flathead cap screws each side Coat threads with Loctite 171 and tighten 34 43 5 le 1 Li U U 1 Support Bar Screws a 2 Pin Support Bars 3 Narrow Washers Mast Section 4 Sheave Wheel Assembly 5 Wide Spacer 6 Sheave Pin 7 Square Keys 4 Sheave Wheel Assys Note 13 a Apply Loctite 242 to threads Carefully slide mast section 4 into section 3 until ends are even Check to make sure chain assembly narrow chains are seating properly in chain anchor block chain sheave wheels attached to mast sec tion 3 Mast Section 5 Assembly 1 NOTE JLG Lift Locate the remaining mast section 5 platform mounting mast section Lay mast section on a flat stable surface Attach the remaining chain bottom anchor plate one with threaded holes aligned at the outside of bracket Attach through set of holes in bottom of mast section 5 with four 4 1 4 20UNC x 3 4 long bolts place a flatwasher under head of each bolt The platform mounting section slide pads are assembled differently than the slide pads for the other mast sections Mast section 5 slide pads may need to be assembled disassembled several times in order to determine the correct shim stock required for proper fit 3121231 SECTION 5 MAST COMPONENTS
227. ve Motor Disconnected 6 22 Code 09 Left Brake Disconnected 6 22 Code 10 Right Brake lt 6 22 Code 11 Left Drive Motor Short 6 23 Code 12 Right Drive Motor Short 6 23 Code 13 Traction Module In Fold 6 23 Code 14 Pump Motor 6 24 Code 15 Lift Down Valve Disconnected 6 24 Code 16 Lift Down Valve Short 6 25 Code 17 Ground Control Module In Fold 6 25 Code 18 Alarm Short 6 25 Code 19 Alarm lt 6 26 Code 20 Beacon Short Circuit 6 26 Code 21 Beacon Disconnected 6 27 Code 22 Horn Short 6 27 Code 23 Horn 6 28 Code 24 Auxiliary 1 Circuit Short
228. witch state in control system with the Analyzer See vehicle or control system documentation on how to do this 3 Operate system such that the switch actuates This could be going over a certain pressure or temperature for exam ple The state indicated in the control system should change Switch Wiring Low Side High Side When controlling a load a switch can be wired between the positive side of the power source and the load This switch is called a high side switch The switch supplies the power to the load When a switch is wired between the negative side of the power source and the load it is a low side switch The switch provides the ground to the load A low side switch will allow voltage to be present on the load No power is applied because the switch is stopping current flow This voltage can be seen if the measurement is taken with one test lead on the load and the other on the battery nega tive side or grounded to the vehicle What is actually being measured is the voltage drop across the switch This could mis lead a technician into thinking the load is receiving power but not operating To produce an accurate picture of power or voltage applied to the load measure voltage across the load s power terminals Also the technician can measure the volt age at both power terminals with respect to battery ground The difference between those two measurements is the voltage applied to the load 3121231 JLG Lift 6 7 SECTION

Service & Maintenance Manual

Contents

Download Pdf Manuals

Related Search

Related Contents

Service &amp; Maintenance Manual

Contents

Download Pdf Manuals

Related Search

Related Contents

Service & Maintenance Manual