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Service and Maintenance Manual

1. CHARGER RELAY z BEACON 1 BEACON 42 CORD BASE MTD MAST MTD REEL ELEVATION SPEED EI R LIFT CUTBACK SWITCHES VENDER e e Sunes E M CHARGER INPUT Q LIGHTS O O 90000 GROUND CONTROL BOX 5 TILT PHP AUX AUX AUX BRUSH S D OUTPUT OUTPUT INPUT INDICATOR 1 2 P1 P2 OIOI OO m mf PLAT HORN AUX gt m PLATFORM PLATFORM PLATFORM CONSOLE P5 ATE ATE f SWITCH SWITCH PLAT e FOOT e AUX i SWITCH PUMP MOTOR E 0 MAST m JUNCTION ERO I H SECURITY LOCK TRACTION i Y MODULE BATTERIES LEFT 1 RIGHT 59 DRIVE DRIVE 0 DIDIDIDIDID MOTOR 5 3 MOTOR 219191919 191919192 3121228 Figure 6 6 10MSP Overview of Electrical System Components JLG Lift 6 45 SECTION 6 TROUBLESHOOTING Keyed Switch Removed for Australia Spec FUNCTION SELECT 6 46 ES OUT YELLOW BLACK JUNCTION YELLOW Le ORANGE i 15 80 20980 90 20 10 710 Xp BLUE xp i RIGHT GATE
2. Figure 4 2 Component Electrical Connections 1 Ground Control Module a 4 Right Side Battery b 7 Power Cable To Right Drive Motor Brake a 2 Left Side Battery b c 5 Traction Control Module a 8 Hydraulic Pump Motor Tank Assembly b 3 175 Amp Fuse 6 Power Cable To Left Drive Motor Brake a Ground Control P1 Horn Alarm Beacons Lift Down Valve Harness a P4 Platform Joystick Harness a Module Plugs P2 Elevation Speed Charger Limit Switch Harness a P5 Joystick Protocol Harness to P3 Programmable Security Lock Harness Option a Traction Control Module a Notes Apply di electric grease JLG Part Number 3020038 to wiring harness terminals to prevent moisture from entering module b Seal and POS posts with battery grease to prevent corrosion c An quick disconnect is installed on the left battery POSITIVE cable for easier power disconnect when servicing machine See Section 6 Figure 6 7 Troubleshooting for complete machine wiring schematic 4 6 JLG Lift 3121228 SECTION 4 CONTROL COMPONENTS 4 3 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
3. Ac L shel Nm E vertens ne ERES e Figure 5 1 Mast Components 1 Material Handling Tray 3 Mast Assembly 2 Platform Assembly 4 Platform Mast Cover 3121228 JLG Lift 5 1 SECTION 5 MAST COMPONENTS 5 2 MAST COVER INSTALL REMOVE Mast Cover Installation 1 Mast Cover 2 Screws and Washers a 3 Platform Console Mount ing Screws Platform shown without right side rails for illustra tive purposes only Note Apply Loctite 242 to threads before final tightening 5 2 JLG Lift 5 3 PLATFORM ASSEMBLY INSTALL REMOVE Platform Installation 1 Platform Material Tray 3 Countersunk Flat Head Assembly Socket Screws Washers 2 Tie Straps for Platform and Locknuts Console Harness 4
4. Hydraulic Pump Assembly Components 1 Hydraulic 4 Hydraulic Extend Pres Reservoir Assembly sure Line to Lift Cylinder 2 Power Cable from b Ground Control Station a 3 Power Cable from Grou nd Control Station a 5 Hydraulic Return Line from Lift Cylinder b NOTE a Shown with protective cover removed b Completely lower platform before loosening any hydraulic lines to remove any pressure remaining in the lines Take proper caution and wear protective gear anytime you are opening a hydraulic line Once power cables and hydraulic lines are removed from this side of pump assembly remove the mounting screws from the other side of the pump see the follow ing illustration 3 22 JLG Lift Pump Motor Assembly Remove Install Hydraulic Pump Mount and Mounting Screws 1 Hydraulic Pump Motor Reservoir Assembly 2 Pump Ground Control Sta tion Mounting Bracket NOTE Apply Loctite 242 10 screw threads before final assembly 3 Pump Screws a Mounting Motor Assembly Remove Install Reference Marks Pump Motor Removal Installation Reference Marks For reference when reassembling mark motor cover housing and valve body position before disassembling 1 Motor Top Cover 2 Cover Housing Reference Mark 3 Motor Housing 4 Housing Motor Valve Body Reference Ma
5. 6 21 Code 13 Traction Module In Fold 6 21 Code 14 Pump Motor 6 22 Code 15 Lift Down Valve 6 22 Code 16 Lift Down Valve Short 6 23 Code 17 Ground Control Module In Fold 6 23 Gode 18 Alarm Short Gire it 452 5 or ELS c e ach NEU EI MEN ADS Mew kus 6 24 Code 19 Alarm Disconnected Loro err x ape et e a Ea 6 24 Code 20 Beacon Shore Circuit acd RENTA esee e d ARM 6 24 Code 21 Beacon 0 6 25 Code 22 s Horn Short ru Ier IIIA RTL ere d 6 25 Code 23 Horn Disconnected ys 25 254 Ok sree a ea kd Raa 6 26 Code 24 P1 Auxiliary 1 Circuit Short 6 26 Code 25 P1 Auxiliary 1 Circuit 6 27 Code 26 P1 Auxiliary 2 Short
6. 6 27 Code 27 P1 Auxiliary 2 6 28 Gode 28 RESERVED X CAR o C ER RP 6 28 Code 29 RESERVED do ster eR s week dtd end ee pe EU o doi eos PE dept n 6 28 Code 30 Traction Module No Communication with Ground Control 6 29 Code 31 Platform Control Console No Communication with Ground Control Module 6 30 Code 32 Pump Motor Over 1 4 4 6 30 Code 33 RESERVED o aeos s ag elk Ya vos er ente se tnos tle 6 31 Code 34 P2 Auxiliary 1 1 6 31 Code 35 P2 Auxiliary 1 TieDown m mrs 6 31 6 14 JLG Lift 3121228 SECTION 6 TROUBLESHOOTING Code 36 RESERVED Nee RR dU VM DD cde er Eig e e da 6 31 Code 37 RESERVED A t D DER ATIS Kid npe er Rx 6 31 Code 38 Battery Voltage Low Warning Level 2 Two 2 LED LCDs lit 6 32 Code 39 Battery Voltage Low Warning Level 3 One 1 6 32 Codes 100 199 Ground Control Module Fault
7. 3 32 JLG Lift 3121228 SECTION 4 CONTROL COMPONENTS gt A VAST qu 3 SECTION 4 CONTROL COMPONENTS 2 4 1 CONTROL COMPONENTS OVERVIEW 4 1 7 Platform Junction Box to Ground Control Harness Mounted inside lower gate hinge left and right side S JLG Lift Figure 4 1 Control Components Location 4 Platform Footswitch Interlock 5 Traction Control Module 6 Platform Junction Box 3 Platform Gate Interlock Switches 1 Ground Control Station 2 Platform Control Console 3121228 SECTION 4 CONTROL COMPONENTS 4 2 CONTROL COMPONENTS INSTALLATION NOTICE BEFORE REMOVING ANY COMPONENT FROM THE ELECTRICAL SYSTEM DISCONNECT THE POSITIVE TERMINAL FROM THE LEFT SIDE BATTERY Ground Control Module The face of the Ground Control Module is visible from the front of the machine and is located under the front cover It is mounted to a bracket on the base frame in front of the hydraulic pump 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 ma
8. Table 6 1 LCD Display Service Fault Code Conditions NEUE FAULT DESCRIPTION FOR TROUBLESHOOTING FAULT CONSOLE CODE LEDs LCD SYMBOL SCREEN LCD TEXT SCREEN MACHINE CONDITION REFER TO FLASHING 37 RESERVED RESERVED 2 LEDs BARS Flashing with T E manm CHARGE BATTERY fT an audible beep See Page 6 32 X 00000 0 38 Platform Lift UP Function is Locked Out 1 LED BAR Flashing with 80000000 p CHARGE audible beep 9 unum Drive and Platform Lift UP Functions Locked Out 40 RESERVED RESERVED 41 RESERVED RESERVED 42 RESERVED RESERVED 43 RESERVED RESERVED 44 RESERVED RESERVED 45 RESERVED RESERVED 46 RESERVED RESERVED nnm GROUND MODULE Ground Control Module See Table 6 34 my c mm cow Fault Condition Page 6 32 200 10 WN ee Platform Control Console See Table 6 35 X 000000 4200 4200 Fault Condition Page 6 33 EA numm TRACTION MODULE Traction Control Module See Table 6 36 X XN owm pu Fault Condition Page 6 34 400 RESERVED RESERVED 401 RESERVED RESERVED 3121228 JLG Lift 6 13 SECTION 6 TROUBLESHOOTING 6 8 TROUBLESHOOTING TABLES INDEX SPECIFICATIONS FOR VARIOUS COMPONENTS PAGE Ohm Ratings for Various Components 6 16 Amperage Draw for Various
9. 6 32 Codes 200 299 Platform Control Console Fault Condition 6 33 Codes 300 399 Traction Control Module Fault Condition 1 6 34 MAIN POWER CIRCUIT TROUBLESHOOTING Machine Will Not Power Up 2 2 2 4 ee rr er ud 6 35 MAST TROUBLESHOOTING Platform Will Not Lower Manually 6 36 Platform Lift Up And Down 4 6 36 Mast Noisy When Lifting And 0 1 14 4 6 37 Platform Mast Won t Stay 6 38 Platform Mast Descends Too 6 38 HYDRAULIC LEAK TROUBLESHOOTING Miscellaneous Hydraulic Leak Troubleshooting 2 Rh 6 39 BASE FRAME COMPONENTS TROUBLESHOOTING Caster Wheels Not Operating 6 40 DRIVE SYSTEM TROUBLESHOOTING Won t Climb Grade quee Qua Pe LOS Verde e aei 6 41 Machine Drives in Opposite 6 42 Machine Won t Drive Straight
10. 1 3 Machine Turning Radius 0 1 3 1 4 TORQUE REQUIREMENTS 1 8 1 5 CYLINDER SPECIFICATIONS 1 1 1 8 1 6 SERIAL NUMBER LOCATIONS 2 1 8 135 JEUBRIGATION tenis rt Gea dee eh Ime RM OM UIS 1 8 Hydraulic Oil 24 3 rst hehe Phare ade pA Cer ue dc PER ULL 1 3 Lubrication Specifications 1 1 3 18 TORQUE SPSGIFIGATIONS cx vice Hanes Ane Red AeA eae he T 1 5 SECTION 2 GENERAL SERVICE INFORMATION 2 1 MACHINE PREPARATION INSPECTION AND 2 1 General A eae a eat Gea VERI Ra A ee EET dU 2 1 Preparation Inspection and Maintenance 2 1 Pre Start Inspection ee Ie ae IR or ri V ee d 2 1 Pre Delivery Inspection and Frequent 2 1 Annual Machine 2 1 2 1 Preventative 1 1 2 0 2 1 2 2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE 2 2 Maintenance and Inspection Table Co
11. 6 25 Code 23 Horn Disconnected 6 26 Code 24 P1 Auxiliary 1 Circuit Short 6 26 Code 25 P1 Auxiliary 1 Circuit Disconnected 6 27 Code 26 P1 Auxiliary 2 Short 6 27 Code 27 P1 Auxiliary 2 Disconnected 6 28 Code 28 RESERVED bese tah ae d drea eoa AE dee dicet 6 28 Code29 RESERVED ia o RUE 6 28 Code 30 Traction Module No Communication with Ground Control Module 6 29 Code 31 Platform Control Console No Communication with Ground Control Module 6 30 Code 32 Pump Motor Over 6 30 Code 33 RESERVED py ee ee E ed 6 31 Code 34 P2 Auxiliary 1 6 31 Code 35 P2 Auxiliary 1 Tie 6 31 Code 36 RESERVED ERR LR eg el Dod RN A MS 6 31 Code 37 BESERVED uer ye ree CUSCO M EAUX M ROI en 6 31 Code 38 Battery Voltage Low Warning Level 2 Two 2 LED LCDs lit 6 32 Code 39 Battery Voltage Low Warning Level One 1 LED LCDs lit 6 32 40 RESERVED
12. 4 Remove countersunk flathead screws securing chain anchor block sheave wheel assembly attach bars on both side rails at TOP of mast section 2 and remove the anchor block sheave wheel assembly NOTE When sliding mast sections apart be careful not to Figure 5 2 Mast Cut a Way View scratch or score the anodized finish in the slide pad channels 1 Lift Cylinder 4 Narrow Chain Set 2 Cylinder Lift Point 5 Section 3 Lift Chain Anchor Bracket 5 Carefully slide mast section 2 out the TOP of sec 3 Wide Chain Set 6 Section 4 Lift Chain Anchor Bracket tion 1 Remove slide pads and shims if necessary 5 8 JLG Lift 3121228 SECTION 5 MAST COMPONENTS Mast Section 1 Disassembly 1 Remove the four 4 large screws 2 each side attaching the lift cylinder mounting block to mast section 1 Slide the cylinder out of the mast section and move to a suitable work surface 2 At the top end of mast section 1 remove the pin attaching the chain anchor block to the mast and remove chain anchor block assemblies from the mast and lay aside 3 Remove slide pads and shims from mast section 1 if necessary Mast disassembly should now be complete 5 9 CY
13. Drive Motor Cover Installation 1 Cover 3 Platform Stop a b 2 Screws Washers a 4 U Style Tapped Nuts NOTE a Apply 242 to threads before tightening b Height of the platform stops is set by installing two 2 5 16 dia wide plain steel flatwashers under the head of each stop tighten securely 3121228 JLG Lift 3 3 SECTION 3 BASE COMPONENTS 3 3 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 placing 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 HUB BE SURE TO USE ONLY THE LUG NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL Tighten the lug nuts to the proper torque see Table 3 1 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 lu
14. 4 2 E e Os 8623 o V TE AJ l UE Brush Carrier Assembly Remove Install 1 Stator Brush Carrier Screws Pump Rear 3 Mark Brush Carrier Position on Motor Housing 2 Stator Brush Carrier Screws Pump Front a 4 Brush Carrier Assembly NOTE a Removed previously with motor cover disassembly shown for reference only Brush Assembly Remove Install Tank Remove Install pcm e e T 20 Brush Assembly Remove Install 1 Brush Assembly a 4 Brush Terminal Screw 2 Brush Carrier Socket 5 Brush Attach Terminal Tank Remove Install 3 Brush Tab Slot For reassembly reference place a mark on tank and valve body NOTE a Slide brush assembly into socket until tab is in slot at 1 Tank Assembly 3 O Ring Seal a rear of socket 2 Tank Screws Qty 4 4 Reference Mark Note a Lubricate o ring with clean hydraulic fluid before sliding tank over during installation 3 24 JLG Lift 3121228 SECTION 3 BASE COMPONENTS Filter Screen Remove Install Pressure Adjust Valve Remove Install Filter Screen Remove Install Requires removal of tank assembly 4 Tube Attach Screw 5 O Ring
15. e ro Seve eu d i a uw PE WEM 2 8 Changing Hydraulic 2 8 Lubrication Specifications 1 4 0 2 8 SECTION 3 BASE COMPONENTS 31 BASE ASSEMBLY COMPONENTS 1 3 1 3 2 BASEFRAME COVERS eee ed edge ue 3 2 Carry Deck Support Frame 3 2 Rear Bumper Cover Installation 3 3 Drive Motor Cover Installation 2 III 3 8 3 8 DRIVE AND CASTER WHEELS 4 3 4 Tire Wear and 2 2 3 4 Wheel and Tire Replacement 3 4 Wheel Installation mpm RR emer RE ERE 3 4 Front Caster Wheel 1 3 4 3 4 DRIVE ELEVATION CUT OUT SWITCH 3 5 3 5 WHEEL DRIVE ASSEMBLY 3 5 Rolland Leak Testing 2 ee eR 3 5 Oil Type and 3 5 Drive Motor Brush Wear Warning
16. 4 40 01120 0 00604 380 8 6 07 E E e 32 0 1380 0 00909 580 16 1 8 12 1 4 40 0130 0 01015 60 18 20 13 15 E eel et omi Red 36 0 1640 0 01474 940 31 3 5 23 2 6 10 24 0 1900 0 01750 1120 43 48 32 35 32 0 1900 0 02000 1288 49 55 36 4 4 14 20 02500 0 0318 2020 96 108 75 9 105 12 28 0 2500 2320 120 E In LB FT LB N m 5 16 18 0 3125 3340 17 22 24 0325 00580 3700 19 26 4 9 21 2 17 23 24 0 3750 0 0878 5600 35 47 25 34 40 54 32 43 61 68 va 13 05000 01439 900 75 102 5 75 85 16 6 92 88 100 136 80 108 108 120 163 98 133 18 05625 0 2030 1290 120 163 90 122 135 14 109 148 183 18 0 6250 02560 16300 170 230 130 176 190 258 155 207 34 10 0 7500 0 3340 21300 260 353 200 271 285 388 240 325 __ 16 07500 0 3730 23800 300 407 220 298 330 449 268 363 78a 9 0 8750 0 4620 29400 430 583 320 44 45 66 386 523 475 520 707 425 576 651 675 918 579 785 858 968 1 12 11250 0 8560 47500 880 193 66 895 925 1258 802 1087 12 1 2500 1 0730 59600 1240 1681 920 1247 1300 1768 1118 1516 13 8 6 13750 11550 64100 1460 199 1100 1491 1525 204 1322 1792 11 2
17. 6 16 JLG Lift 3121228 SECTION 6 TROUBLESHOOTING 6 11 FAULT CODE TROUBLESHOOTING TABLES Machine in Drive Speed Cut Back Turtle Mode 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 proximity 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 Table 6 5 Machine In Drive Speed Cut Back Turtle Mode The Time STEP ACTION SPEC YES NO 1 With the machine powered on and the platform fully lowered check for con Replace Ground Repair or Replace tinuity on the wires of the Cutback Proximity Switches At the Ground Con Control Module Speed Cutback trol Module P2 connector check continuity between pins 8 and 18 switch Proximity Switch 1 and pins 9 and 19 switch 2 3121228 JLG Lift 6 17 SECTION 6 TROUBLESHOOTING Code 01 Low Battery Voltage Check For These Obvi
18. 3 21 3 5 Typical Hydraulic Pressure Gauge Installation After Hydraulic 3 21 3 6 Battery Cable to Battery Terminal Connections 4 6 3 27 4 1 Control Components Location 4 1 4 2 Component Electrical 4 6 4 3 Ground Control Module 4 7 4 4 Platform Control Console 4 15 5 1 dois ae cde pvp ERU eer VASE 5 1 5 2 Mast Cut a Way View 5 8 5 8 Lift Cylinder Component Cross Section 4 2 5 9 5 4 Mast Section Assembly Reference 5 12 5 5 Bottom of Mast Section 2 Slide Pad Installation 5 18 5 6 Top of Mast Section 2 Slide Pad Installation 5 14 5 T Platform Junction Box to Ground Control Station Wiring 5 20 5 8 Mast Chain and Sequence Cable Adjustment 5 5 22 6 1 Voltage Measurement 6 3
19. 3 6 Wheel Drive Assembly Removal From 3 6 Wheel Drive Disassembly Main 3 8 Replacing Drive Motor 3 9 Gear Box Main 2 e n 3 11 Input Carrier 3 12 H b Disassembly 25 e 1 oc ete esp eS d ey e ede pi We 3 13 Spindle Disassembly iasi toe ute dp ERI nee d 3 14 Spindle Sub Assembly 3 15 H b Sub Assembly e ee CHEN Abe us hee e 3 16 Input Carrier Sub Assembly 4 3 17 Main Gear Box 3 18 Motor Brake and Gear Box Assembly 3 19 3 6 PUMP MOTOR ASSEMBLY SERVICE PROCEDURE 3 20 General USCIRE e RC IEEE ERE S S 3 20 Hydraulic Pressure Settings and 3 20 Hydraulic Pressure Gauge 3 21 After Filter Pressure 3 21 Pump Motor Assembly
20. 6 16 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS Special Pin Extractor Tools for Electrical Connectors 2 6 16 FAULT CODE TROUBLESHOOTING TABLES Machine in Drive Speed Cut Back Turtle Mode All The 6 17 Code 01 Low Battery 1 1 rre 6 18 Code 6 18 Code 03 RESERVED dae a ate dede rod rec do oer aoo es deep ta 6 18 Code 04 Tilt Coriditiori i eor RR A igXraue rus evertere 6 19 05 gt RESERVED PR a et ce Mea ted Varo e A RE E ue Rud 6 19 Code 06 Drive Motor Brush Wear Warning 6 19 Code 07 Left Drive Motor 6 19 Code 08 Right Drive Motor 1 6 20 Code 09 Left Brake 6 20 Code 10 Right Brake 1 6 20 Code 11 Left Drive Motor Short 1 6 21 Code 12 Right Drive Motor Short
21. 2 3 22 Pump Motor Assembly 3 22 Motor Assembly Remove Install Reference 3 22 Motor Brush Cover 3 23 Brush Carrier Assembly 3 24 Brush Assembly 4 3 24 ii JLG Lift 3121228 TABLE OF CONTENTS Tank Remove Install 1 3 24 Filter Screen 1 3 25 Pump 3 25 Pressure Adjust Valve 4 3 25 Pressure Check Valve 3 25 3 7 BATTERIES AND BATTERY CHARGER SERVICE PROCEDURES 3 26 Battery Condition Testing 4 3 26 Battery 2 46 4 44 4 3 26 Battery Installation 2 12V 3 26 Battery Installation 4 6V Batteries OPTION 3 27 Battery Charge LED Indicator on Platform Control
22. ES YELLOW SHIELD B BLACK 1 RS485B BLUE RS485A ORANGE i AUX 1 SIGNAL B BROWN BLACK AUX 1 RETURN BLACK RED SEC LOCK SUPPLY 24V DC RED SEC LOCK SIG BROWN PROX SWITCH FOOT SWITCH a e OF V 15 ATFORM X 1 1 PL LEFT GATE 9 1 AU PROX _ SIGNAL OUT SIGNAL IN 1 SECURITY Lock OPTIONAL SEC LOCK SIG OUT ORANGE BLACK SPARE RED BLACK SPARE BLUE BLACK GROUND STATION MODULE P fa Q r i 1 i i 1 8 3 amp d i m 1 al gt I 1 19 1 1 515155 5 2 1 Sj lt 1 2 ols s ac ac ac ira 1 T EE BEN EEEEE 8 28882448 i 2 2 2 3 2 2 Lam Ne Wes SOs
23. 6 27 6 27 Code 26 P1 Auxiliary Z2 Short 6 27 6 28 Code 27 P1 Auxiliary 2 6 28 6 29 Code 30 Traction Module No Communication with Ground Control Module 6 29 6 30 Code 31 Platform Control Console No Communication with Ground Control Module 6 30 6 31 Code 32 Pump Motor Over Current nn 6 30 6 32 Code 34 P2 Auxiliary 1 6 31 6 33 Code 35 P2 Auxiliary 1 6 31 6 34 Codes 100 199 Ground Control Module Fault Condition 6 32 6 35 Code 200 299 Platform Control Console Fault 6 33 6 36 Codes 300 399 Traction Control Module Fault 6 34 6 37 Machine Will Not Power UP 6 35 6 38 Platform Will Not Lower 1 2 6 36 6 39 Platform Lift Up and Down Jerky 6 36 6 40 Mast Noisy when Lifting and Lowering 1 54 6 37 6 41 Platform Mast Won t Stay 6 38 6 4
24. p gt gt lt gt SHORTED Short Circuit X 000000 12 12 DRIVE Disabled 9 Traction Module TRACTION NOD S 13 6 E mmm p ence bns In Fold Back i X 000000 3 13 DRIVE Disabled 9 4 PUMP MOTOR i 14 7 e lt gt DISCONNECTED 2 as 000000 14 14 9 LiftDown Valve DOWN VALVE See Table 6 16 15 7 a lt gt DISCONNECTED 4 Disconnected Page 6 22 X 00000 0 15 15 Lift UP DOWN Disabled DOUN VALVE Down Valve or Down Valve Gee Table 6 17 16 7 Eus 4 lt gt SHORT Circuit Short 6 23 X 000000 416 416 LiftUP DOWN Disabled 9 PORIE 4 Ground Control Module _ 17 7 lt gt FOLD BACK 7 In Fold Back eng X 000000 17 Machine Stopped 9 18 _ ALARM SHORT Alarm or See Table 6 19 X 000000 18 18 Alarm Circuit Short Page 6 24 ALARM DISCONNECTED a 19 E gt Alarm Disconnected A X 000000 19 419 age o BERCON SHORT Beacon or See Table 6 21 20 ES Beacon Circuit Short Page 6 24 X 00000 0 20 20 BEACON DISCONNECTED 21 E lt gt Beacon Disconnected gis 2 X 000000 21 21 o 22 lt Horn or Horn Circuit Short a n Ta X 00000 0 22 22 age 6 3121228 JLG Lift 6 11 SECTION 6 TROUBLESHOOTING Table 6 1 LCD Display Service Fault Code Conditions FAULT DESCRIPTION FOR TROUBLESHOOTING FAULT CONSOLE CODE NN LCD SYMBOL SCREEN LC
25. Magni Coating Ref 4150701 CLASS 12 9 SOCKET HEAD CAP SCREWS M6 AND ABOVE H i TM Tensile Dry or Loctite 2427 or 271 Loctite 262 Size PITCH Stress OR Vibra TITE Aron OR Vibra TITE EN Bs or 140 ACA 15 678 78 8 78 36 60 115 12 5 18 0 22 8 36 1 52 5 e as mm sen em m es 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 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 3121228 JLG Lift 1 11 SECTION 1 MACHINE SPECIFICATIONS BS NOTES JLG Lift 3121228 SECTION 2 GENERAL SERVICE INFORMATION SECTION 2 GENERAL SERVICE INFORMATION 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 maxi
26. 6 20 6 12 Code 11 Left Drive Motor Short 6 21 6 13 Code 12 Right Drive Motor Short Circuit 6 21 6 14 Code 13 Traction Module In Fold 6 21 6 15 Code 14 Pump Motor Disconnected 6 22 6 16 Code 15 Lift Down Valve 6 22 6 17 Code 16 Lift Down Valve Short 6 23 6 18 Code 17 Ground Control Module In Fold 6 23 6 19 Code 18 Alarm Short 4 6 24 6 20 Code 19 Alarm 6 24 6 21 Code 20 Beacon Short Circuit 4 6 24 6 22 Code 21 Beacon Short Disconnected 6 25 6 23 Code 22 Horn Short 6 25 6 24 Code 23 Horn Disconnected 6 26 6 25 Code 24 P1 Auxiliary 1 Circuit Short Circuit 6 26 6 26 Code 25 P1 Auxiliary 1 Circuit Disconnected
27. bee PE peius Gate a eleg s tt e B SECTION 1 MACHINE SPECIFICATIONS 131 CAPACITIES 2 PRSE thawed de dis bs 1 2 System Voltaje c pe pp dees A EAE 1 2 Hydraulic System ii sepe dled x ser RENTRER de dea A EE 1 2 Drive Motor GearBox Gear Oil 1 2 1 2 COMPONENT DATA oe eee ae eae bee aca Ub eb ed 1 2 Hydraulic Pump Pump Motor 1 2 Rear Wheel Drive 7 1 2 Batteries Battery Charger 1 2 1 3 PERFORMANCE DATA ELEME d Wen eb Ad dee bd hel oe eee pa 1 2 Platform Capacily ace Rupe Pewee ae ce es 1 2 Platform 1 2 Material Tray 5 2 ERAS REIP op deans ES een oa 1 2 Platform Height Fully 1 2 Platform Maximum Working Height 1 2 Machine Height sce bed E 1 2 Machine Overall oe bn Wer det PR 1 3 Platform Entry Height Floor to Platform 1 3 Machine Ground Clearance
28. REA 6 19 Code 06 Drive Motor Brush Wear Warning 6 19 Code 07 Left Drive Motor 6 19 Code 08 Right Drive Motor Disconnected 6 20 Code 09 Left Brake 6 20 Code 10 Right Brake 6 20 Code 11 Left Drive Motor Short Circuit 6 21 Code 12 Right Drive Motor Short 6 21 Code 13 Traction Module In Fold 6 21 Code 14 Pump Motor Disconnected 6 22 Code 15 Lift Down Valve Disconnected 6 22 Code 16 Lift Down Valve Short 6 23 Code 17 Ground Control Module In Fold 6 23 Code 18 Alarm Short 6 24 Code 19 Alarm Disconnected 6 24 Code 20 Beacon Short 6 24 Code 21 Beacon 6 25 Code 22 Horn Short
29. 3121228 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 e caster wheel on the front of the machine is seized up creating resistance Table 6 47 Machine Won t Drive Straight STEP ACTION SPEC YES NO 1 Checkforthefollowing onthe drive assembly drive attachment weldments Repair Replace Go to Step 2 is bent has broken welds or loose hardware Tighten weldment 2 Check forthe following on the drive assembly drive motor mounting plates EN 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 Go to Step 5 ing properly per procedure in this Service Manual 5 Isthe electrical signal and amperage draw to the drive motors equal Check See T
30. Check forthe following onthe drive assembly drive attachment weldment 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 hardware is Repair Replace Goto Step 3 hardware loose Tighten Component 3 Checkthe left right drive motor brakes for loose hardware amp not releas Tighten or Adjust Goto Step 4 ing properly per procedure inthis Service Manual 4 lstheelectrical signal and amperage draw tothe drive motors equal Check See Table 6 3 Recheck Steps Goto Step 5 with machine on level surface 1thru5 5 Checkthe drive motor brushes do they need replaced Replace per Goto Step 6 procedure in this Service Manual 6 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 6 44 JLG Lift 3121228 SECTION 6 TROUBLESHOOTING E 1
31. JLG Lift 4 3 SECTION 4 CONTROL COMPONENTS Platform Junction Box Install Remove All the platform mounted switches and controls connect to the platform junction box before running to the Ground Control Module P2 P3 and P4 Connectors the Ground Control Module Harness is attached to the side of the mast assembly Junction Box to Ground Control Harness Remove Install Platform Junction Box Installation 5 Platform Aux 2 Connec tor Spare 6 Platform Aux 1 Foot switch Platform Gate Inter lock Connector 7 Programmable Security Lock PSL Connector 1 Platform Junction Box 2 Junction Box Attach Screws 3 Platform Console Harness Connector 4 Ground Control Module Har ness Connector 4 4 JLG Lift 22 T 5555 Aw 7A NS S Li Of aN Ke MS MT Hue 25 kaka gt a LC An I A e C UN Li s Ws 5 t am gt X Junction Boxto Ground Control Module Harness Installation 1 Harness from Platform Junc 4 Platform Junction Box tion Box to Gr
32. JLG Lift 5 9 SECTION 5 MAST COMPONENTS Lift Cylinder Component Inspection Cylinder Rod There should be no scratches or pits deep enough to catch the fingernail Pits 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 exceeds 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 normal 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
33. 1 1 7 4 6 43 Noise From Drive Assembly il lp rre t hr rap eee 6 44 3121228 JLG Lift 6 15 SECTION 6 TROUBLESHOOTING 6 9 SPECIFICATIONS FOR VARIOUS COMPONENTS The following table contains specifications for 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 120hm 0 490hm Table 6 3 Amperage Draw for Various Components COMPONENT AMPERAGE Ground Control Module 95 Amps room temperature with rated load LEVEL SURFACE 15 GRADE 24 RATED LOAD 24V RATED LOAD AOLO e0 Traction Control Module 7to11 Amps 5510 60 Amps 3 5 to 4 8 Amps per motor per motor 78 to 86 RPM 6 10 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS The following table contains pin extractor tools for 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 7016618 nector pins from the Ground Control Station connectors Drive Motor For removal of electrical con 7002841 nector pins from the Drive Motor main power connec tors Drive Motor Brake For removal of electrical con 7002842 nector pins from the Drive Motor Brake power connec tors
34. 1 Filter Screen 2 Pump Pick Up Tube 3 Tube Retainer Clip Note Tubes shown shortened for illustrative purposes only Pump Remove Install Pump Remove Install Requires removal of tank assembly and pump pick up tube 1 Pump Assembly 2 Pump Assembly Screws 3 Motor to Pump Coupler 4 Pump Shaft Bearing 3121228 Pressure Adjust Valve Remove Install 1 Adjust Valve Cap 4 Valve Ball 2 Adjustment Screw 5 Adjust Valve Port 3 Valve Spring Note Adjust pressure per specification shown in Section 1 of this Service Manual Pressure Check Valve Remove Install Pressure Check Valve Remove Install 2 Check Valve Port 1 Check Valve Assembly JLG Lift 3 25 SECTION 3 BASE COMPONENTS 3 7 BATTERIES AND BATTERY CHARGER SERVICE PROCEDURES 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 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 c
35. 200 207 213 Goto Step 3 Replace Platform Code 202 205 206 Goto Step 4 Control Module 3 Remove the 9 pin Platform Control Module connector from the side of the 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 of this Service Done Replace Manual Does this clear the fault code Platform Control Module 3121228 JLG Lift 6 33 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 36 Codes 300 399 Traction Control Module 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 Is acode number 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 12 Volt DC 12V DC Goto Step 4 Replace with proper Batteries 4 Check battery voltag
36. 3 decreases the numerical digit Change all five digits 4 to match password level then press the Brake Release button 1 again 3121228 SECTION 4 CONTROL COMPONENTS Programming Mode Selection Adjusting Programmable Setting RESET TIMERS Programming Mode Selection 1 Use Platform UP DOWN buttons 1 to move the selection box 2 up or down to select item to program 2 Press the Brake Release button 3 to enter selected mode then move on to Selecting Programmable Item to Adjust Selecting Programmable Item to Adjust SEDESPEEDETITE NY 9 Selecting Programmable to Adjust 1 Usethe 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 settings adjustment mode 3121228 Adjusting Programmable Setting 1 Adjust the programmable setting using the Platform UP DOWN buttons 1 see Table 4 1 on Page 4 13 for range of settings 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 Settings Menu TO EXIT Programming Mode after entering program mable settings power machine off with either the Main Power Selector Switch or Emergency
37. 6 2 Resistance 2 55 4 6 3 6 3 Continuity 2 6 4 6 4 Current Measurement 2 6 4 6 5 Component Electrical 4 6 9 6 6 10MSP Overview of Electrical System 6 45 6 7 Electrical Diagram iie m eR UR e eR GER OP RE E RR ERE REA 6 46 6 8 Hydraulic Diagram 2792684 6 48 vi JLG Lift 3121228 TABLE OF CONTENTS LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 10MSP Machine Operating 1 1 1 2 Platform Maximum 2 1 1 2 1 3 Cylinder Specifications 1 3 1 4 Hydraulic Oil Operating 1 3 1 5 Lubrication 1 3 1 6 Lubrication Intervals for Various 1 4 2 1 Maintenance and Inspection Requirements 2 2 2 2 10MSP P
38. 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 Code 40 RESERVED Codes 41 thru 46 RESERVED 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 34 Codes 100 199 Ground Control Module Fault Condition 6 32 STEP ACTION SPEC YES NO 1 Recycle machine power 5 times allowing a 10 second interval between z 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 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 Ground Control Battery Charger
39. Hex Head Screws Wash ers and Locknuts a Platform shown without right side rails and plat form floor cutaway for illustrative purposes only Note a Raise platform and remove the hex head screw wash ers and nuts item 4 While under the platform unplug the wiring harness to the foot enable switch and the entry gate interlock switches from the platform junction box Using suitable lifting equipment carefully lift the plat form material tray assembly off the mast assembly 3121228 SECTION 5 MAST COMPONENTS 5 4 MATERIAL TRAY INSTALL REMOVE 5 5 PLATFORM 7 FT HEIGHT LIMIT SWITCH OPTION Material Tray Installation 1 Material Tray Assembly 3 Tray Release Bar c 2 Tray Bottom Stops b 4 Raise Platform a Note a Raise the platform approximately 2 ft 60cm when sliding the tray off the bottom of the mounting rails Tray Will not clear beacon or hood without raising platform b Remove stops to slide tray off the bottom of the mount ing rails c Once bottom stops are removed carefully lower the tray to bottom and slide off of the mounting rails and move clear of machine If tray is allowed to drop with stops removed damage to the amber beacon and hood could occur e 2 Platform 7 Ft Height Limit Switch OPTION Installatio
40. 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 10MSP 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 under the front hood The Ground Con trol 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 Battery Charge LED strip on the console When operating normally the LED panel on 3121228 JLG Lift 6 1 SECTION 6 TROUBLESHOOTING the platform control console indicates the battery voltage status using ten 10 LEDs red yellow green If a malfunction to the machine s electrical components occurs the platform console LED s will flash a number of LEDs to help indicate the problem to the Operator in
41. 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 additives 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 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 5 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 every 2 years 2 8 JLG Lift 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 maint
42. and retraining ring to the cylinder head 3 Lubricate the piston and all components with hydraulic fluid Install the seal and wear ring to the piston NOTE that seals are not twisted or and are properly seated 4 Place the rod on a clean table Install the static pis 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 3121228 SECTION 5 MAST COMPONENTS Lift Down Valve and Manual Release Installation 1 Lift Down Valve a 4 O Ring with Backing Rings a 2 Valve Solenoid b 5 Valve O Ring a 3 Manual Release Assembly 6 Solenoid O Ring a Notes a Coat all o rings with clean hydraulic fluid before assembling b Mount with electrical terminals pointing to right side of machine 3121228 JLG Lift 5 11 SECTION 5 MAST COMPONENTS 5 10 MAST ASSEMBLY Assemb
43. check for continu z Repair or Replace Go to 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 on the opposite end of the module Does this fix problem Control Module 5 Unplugthe P5 connector at the Ground Control Module Check voltage 4 5y DC Done Replace Ground between pins 2 lead in and 5 lead in Is voltage within spec Control Module 3121228 JLG Lift 6 29 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 30 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 Removethe9 pin Platform Control Console connector from the side of the RepairorReplace RepairorReplace Platform Junction Box and the connector the Ground Control Module Platform Control Wiring Check continuity fromthe connector pin 5 to Junction Box pin 3 and P4 Console pin 9 to Junction Box pin 4 3 Removethe
44. f Place a sheave pin support plate on each end of the shaft g Slide the whole anchor block sheave wheel assembly into top of mast section 2 Slide the anchor block onto the top of the cylinder rod Check that the hole in the cylinder rod aligns the the hole in the anchor block h Align the threaded holes in the sheave pin sup port bars with the mounting holes on each side of the top of mast section 2 mast and attach using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 on final assembly 14 Locate and assemble the narrow chains set 444 and attach to the small triangular shape chain equalizer anchor plate using the pins washers and cotter keys 15 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 16 Assemble the chain anchor plate assembly and the chain anchor block to the cylinder rod end using the anchor plate block attach pin and snap ring of Mast Section 2 Narrow Chain Set Installation 1 Anchor Block Attach Pin 3 Hole Through Anchor Block 2 Narrow Chain Set 4 Snap Ring 17 Slide mast section 2 back into section 1 until top and bottom ends are even 3121228 JLG Lift 5 15 SECTION 5 MAST COMPONENTS Mast
45. or 8 LEDs CHARGE 1 UP Functions Locked Out BARS lit before operating a BATTERY 38 NOTE a 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 batteries must be charged until 8 bars are lit on the ground station LCD display to clear the fault code 3 28 JLG Lift 3121228 SECTION 3 BASE COMPONENTS Battery Charger General Information NOTICE DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGER IF MACHINE IS STILL UNDER WARRANTY OPENING THE BAT TERY CHARGER WHILE THE MACHINE IS UNDER WARRANTY WILL VOID THE CHARGER WARRANTY IF UNDER WARRANTY REQUEST A REPLACEMENT CHARGER FROM THE FACTORY Battery Charging Status Indicators The battery charging status LED indicators are located next to the charger AC input receptacle on the rear bum per of the machine This LED indicator set is plugged directly into a connector on the back of the battery char ger 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 then charging will begin 1 3121228 The YELLOW CHARGING LED will turn on and a trickle current will be applied until a minimum volt age is reach
46. 0 0524 4720 25 35 20 25 20 25 0 3125 0 0580 5220 25 35 25 35 20 25 3 8 16 0 3750 0 0775 7000 45 60 40 55 35 50 24 0 3750 0 0878 7900 50 70 4 60 35 50 70 20 04375 0 1187 1070 80 10 70 95 60 80 1 2 13 110 120 155 175 5 8 11 220 245 3 4 10 380 430 7 8 9 620 22114 0 8750 05090 4580 670 910 60 85 500 680 875 a E 95 31855 m8 S 1015 1310 1475 1855 2055 2430 2760 3225 3625 NO 5000059 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 Figure 1 2 Torque Chart SAE Fasteners Sheet 2 of 7 JLG Lift 3121228 SECTION 1 MACHINE SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating Ref 4150701 ed TM Torque Tensile Clamp Load Torque roel Sx Pu 211 Loctite 2627 DES Vus sess Area See Note 4 Dry K 17 OR Vibra TITE 111 or or Vibra TITE 131 140 OR Precoat 858 6 4 6 8 gt 32 0 1900 1 4 20 0 2500 28 0 2500 In 5 16 0 3 8 24 0 3750 0878 7900 35 50 7 16 14 0 1063 20 0 1187 1 2 13 20 2 5 0 9 16 5 8 3 4 78 9 08750 04620 41600 55 700 485 660 455 620 1 8 1000 06060 51500 730 995 685 930 645 875 1 1 8 11 4 138 6 1375 1 1550
47. 20UNC x 3 8 long hex head bolts place 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 4 Shim slide pads using the following steps 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 mast section a Start with a 036 thick shim and a 075 thick shim per side at each slide pad b 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 JLG Lift 5 13 SECTION 5 MAST COMPONENTS 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 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
48. 9 Platform Control Console connector from the side of the 24V DC Repair or Replace Go to Step 4 Platform Junction Box Checkthe voltage across pins 1 and 5 in the Junc Platform Control tion Box connector Console 4 Check voltage across pins 10 and 2 on connector P4 at the 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 31 Code 32 Pump Motor Over Current STEP ACTION SPEC YES NO 1 Check current 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 Didunitgivea32 Fault Code while performing Step 1 Replace Ground Control Module 3 the pump hydraulic pressure setting within specification as showin Sec See Section 1 6 Goto Step 4 Adjustto tion 1 6 ofthis Service Manual Specification 4 Check pump motor brushes and rotor commutator for abnormal wear Z Replace as Replace Required Pump Motor 6 30 JLG Lift 3121228 SECTION 6 TROUBLE
49. 9 4 4 GROUND CONTROL MODULE 4 10 General ince Piet ae epe am eee Poe Dania e AVE bue Ee 4 10 Programming Levels 2 rcu do 4 10 Activating Programming 4 10 Entering Password issue gore Pes UA TUR EE UB RE SER Rc 4 10 Programming Mode 1 4 11 Selecting Programmable Item to 4 11 Adjusting Programmable Setting 4 11 Service Programming Mode Level 2 4 12 Operator Programming Mode 3 4 12 4 5 PLATFORM CONTROL CONSOLE SERVICE PROCEDURES 4 15 Gerleral ftat Met iss 4 15 Remove Platform Control Console 4 4 15 Display Controller Module Electrical Connections 4 16 Mounting Bracket 2 4 16 Rear Cover 4 16 Display Controller Module 4 17 Drive L
50. Console 3 28 Battery Low Voltage Warning 3 28 Battery Charger General Information 2 3 29 Battery Charging Status 0 3 29 Battery Charger Maintenance Information 3 30 Battery Charger Check Change Charging 3 30 Battery Charger Removal Installation 4 3 31 SECTION 4 CONTROL COMPONENTS 4 1 CONTROL COMPONENTS OVERVIEW 1 1 4 1 4 2 CONTROL COMPONENTS 4 2 Ground Control Module 2 mn 4 2 Traction Control Module 4 3 Platform Control Console Installation 4 3 Platform Junction Box Install Remove 4 4 Junction Box to Ground Control Harness Remove lnstall 4 4 Platform Interlock Switch 1 4 5 4 3 GROUND CONTROL MODULE SERVICE PROCEDURE 4 7 Cover Removal Installation lisse n 4 8 Power Selector EStop Switch 4
51. Control Mod Control Module ule 3 Remove the 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 connector on Ground Replace Platform Repair or Replace Control Module to the Platform Junction Box Control Console Wiring P4 connector Pin 1 to Junction Box Pin 2 and P4 connector Pin 10 to Junction Box Pin 1 3121228 JLG Lift 6 35 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 38 Platform Will Not Lower Manually STEP ACTION SPEC YES NO 1 Checkto see ifthe 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 T Clean or Replace Consult Factory Flow Valve Platform Lift Up And Down Jerky Overview Of Pr
52. Douglas AGM Flooded Default 43 US AGM 6V27 210AH 3121228 SECTION 3 BASE COMPONENTS Battery Charger Removal Installation 1 Remove the front cover carry deck from the machine Remove the carry deck support bracket from the base frame Disconnect the positive battery cable at the left side battery Remove the two 2 screws and washers from the top bracket securing the charger to the base frame mast mount Only loosen the two 2 screws on the bottom bracket of the charger enough to slide the charger out Lift charger up and lay on it s side to disconnect the wiring connectors from the bottom of the charger assembly Move the charger to a suitable work sur face 3121228 Battery Charger Remove Install 1 Battery Charger Assembly 2 Charger Attach Screws 4 remove the two on top loosen the two on bottom of bracket i JLG Lift Battery Charger Connections To AC 120 220Volt Input Socket On Rear Bumper Drive Cut Out Interlock Harness to P2 Connector on Ground Control Module DC Voltage Output to Battery Posts To Charging Status LED Indicators On Rear Bumper 3 31 SECTION 3 BASE COMPONENTS 27 NOTES
53. Elevate the platform and remove the wheel drive assembly cover and set aside see Section 3 2 on page 3 2 2 Disconnect the positive battery terminals from the left side battery 3 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 4 Remove the drive wheel mounting lugs and remove the wheel s 5 Disconnect the power harness terminals and brake harness connector s from the drive motor 6 Remove the six 6 hex head cap screws and wash ers attaching the drive assembly to the frame 7 Carefully slide the drive motor assembly out of the base frame assembly for disassembly 3121228 SECTION 3 BASE COMPONENTS Wheel Drive Assembly Installation Right Side Shown 1 Wheel Drive Assembly 4 Drive Wheel 2 Frame Mounting Surface 5 Wheel Mounting Lugs b 3 Mounting Bolts Washers a NOTE Installation same for left and right drive motor a Apply Loctite 242 to threads before tightening b Tighten to 120 ft Ibs 534 N m 3121228 JLG Lift 3 7 SECTION 3 BASE COMPONENTS Wheel Drive Disassembly Main Components Drive Motor Disassembly Main Components NOTE If possible remove the wheel drive assembly from the 6 machine frame 1 Drain the oil from the Gearbox 1 by removing the cover plugs in the cover 2 Remove the 2 Drive Motor Bolt
54. Fe OUR foe Qul RO deos 6 32 Codes 41 thru 46 RESERVED 6 32 Codes 100 199 Ground Control Module Fault Condition 6 32 Codes 200 299 Platform Control Console Fault 6 33 Codes 300 399 Traction Control Module Fault 6 34 3121228 JLG Lift V TABLE OF CONTENTS 6 12 MAIN POWER CIRCUIT 6 35 Machine Will Not Power 2 6 35 6 13 MAST TROUBLESHOOTING eee hr 6 36 Platform Will Not Lower 6 36 Platform Lift Up And Down Jerky 6 36 Mast Noisy When Lifting And Lowering 6 37 Platform Mast Won t Stay 6 38 Platform Mast Descends Too Slowly 6 38 6 14 HYDRAULIC LEAK 6 39 Miscellaneous Hydraulic Leak 6 39 6 15 BASE FRAME COMPONENTS TROUBLESHOOTING 6 40 Caster Wheels Not Operating 6 40 6 16 DRIVE
55. 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 Battery Installation 2 12V Batteries To gain access to the batteries requires removal of the front cover and rear drive motor cover see Section 3 2 on page 3 2 Procedure for removal is same for both batteries On installation batteries set in machine with the posts to the outside Left side battery POS post at front shown below Right side battery NEG post towards machine front A WARNING NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL THE PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVE MENT BY BLOCKING OR OVERHEAD SLING HN Battery Installation 2 12Volt Left Side Battery Shown 1 Battery a 3 Battery Posts 2 Hold Down Bracket and 4 Drive Motor Cover Screw Screw Brackets NOTE a The carry deck support frame will need to be pivoted up at the rear to remove the batteries Once hold down bracket item 2 is removed remove the cables from the battery posts slide battery forward to clear brackets item 4 Then lift battery out of base frame 3121228 SECTION 3 BASE COMPONENTS Battery Installation 4 6V Batteries OPTION Battery Installation 4 6V Left Side Batteries Shown with Machin
56. MAST DISASSEMBLY 4 5 7 Mast Disassembly 5 7 Mast Section 4 Removal Platform 5 7 Mast Section 3 5 8 Mast Section 2 5 8 Mast Section 1 5 9 5 9 CYLINDER DISASSEMBEY ie Et eb ER edd 5 9 Lift Cylinder Component 5 10 Cylinder Assembly i2 dx ERTEILEN ess 5 10 5 310 MAST ASSEMBLY b ue bd E MUR 5 12 Mast Section 1 Assembly 5 13 Mast Section 2 Assembly 5 13 Mast Section 3 5 16 Mast Section 4 Assembly 2 eee nes 5 18 5 11 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT 5 21 Mast Chain Cable 4 5 21 Sequencing Cable 5 21 SECTION 6 TROUBLESHOOTING GENERAL Pedum ue c duci den e doe RE TUS
57. P1 Auxiliary 1 Circuit Short Circuit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check voltage across 0 2VDC Goto Step 2 Replace Ground pins 9 and 2 to the Aux 1 component Is reading within specification Control Module 2 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 2 Component Replace Wiring component end 6 26 Lift 3121228 SECTION 6 TROUBLESHOOTING Code 25 P1 Auxiliary 1 Circuit Disconnected Check For These Obvious Conditions First Is machine equipped with a component on the Auxiliary 1 circuit Table 6 26 Code 25 P1 Auxiliary 1 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 enter the programming mode check if the Default NO Disable It Replace Ground Auxiliary 1 open circuit detection is enabled Control Module 3 Check voltage atthe P1 connector on the Ground Control Module between 2 4 Replace Ground Goto Step 4 pin 9 and pin 2 Is reading within specification Control Module 4 Remove the wire terminals atthe Aux 1 component check continuity of Replace the Repair or each of the wires from pins 9 and 2 onthe P1 connector to the Aux
58. Stop Button JLG Lift 4 11 SECTION 4 CONTROL COMPONENTS Service Programming Mode Level 2 In the Service Programming Mode the following items are shown on the main menu Also See Table 4 1 on Page 4 13 Reset Timers Program Tilt Sensor OSS 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 shows total accumulated hours since last trip timer reset This is the hour meter reading displayed on the Ground Control 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 the Trip Timer is the only timer which can be RESET back to 00000 0 Brush Wear Sensor Timer This timer must be reset after the drive motor brushes are replaced and the brush wear senso
59. as AR 1 z JOYSTICK S al PTEE E PEP E ERST i 5 S z 8 55 i 5 Sx 8 zavoc 5 WHITE gt 5 e a jg zz 7 4 ALARM Bt w 5 MAX B 5 F 2AVDC 5 AMP E B ED 5 WHT RED 57 1 UP BRUSH WEAR t RED VALVE SPARE B INDICATOR S WHT RED 57 2 SEE ZONE C 2 CE BLACK V PH LIFT DOWN 4 105 VDC 5 AMP MAX NEN VALVE 4 WITE AUX OUTPUT 24VDC 5 AMP MAX 8 MIMICKS BEACON B 57 x TR 3 im S AUX 2 OUTPUT 24VDC 5 B SHARED WITH 055 B lo BLACK E E lt 1870201 G Figure 6 7 Electrical Diagram JLG Lift 3121228 SECTION 6 TROUBLESHOOTING JONVYO 58758 53 NI 3018 asersy jma 1 22 jom gt Ao lo e 27 gt x B BLACK PLATFORM AUX 2 ON OFF BLUE COM WHITE 42v18 03H 38 45 32v18 3n18 3uvdS 915 4201 ALIYNDAS Jato NMOUS NI 4384 1144058 4201 ALIYNDIS 32v18 39NYHO LNO 915 201 ALYNDAS ORANGE RED 49 1 3121228 ORANGE RED 49 2 ORANGE RED 49 4 ORANGE RED 49 5 ORANGE RED 49 8 YELLOW RED 2 3 BLACK 14 ANALOGUE INPUT TILT S
60. 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 Low Voltage Warning Indicators On normal power up and operation this series of ten 10 The Platform Control Console and Ground Control Station LEDs visually indicates the amount of charge remaining in indicate battery low voltage at three 3 Warning Levels the batteries See the Table below The number of LEDs lit will change depending on the level of charge in the batteries WARNING INDICATOR LOCATION ACTION REQUIRED TO RESULT LEVEL pLATFORM CONTROLLED GROUND CONTROL LCD CLEAR FAULT LEVEL 1 3 LEDs BARS Flashing Charge batteries to a level of with an audible beep four 4 LEDs BARS or more SOHO e Machine will Operate No before operating LOU BRTTERS Control Functions Locked Out LEVEL 2 2 LEDs BARS Flashing Charge batteries for a mini ES coco with an audible beep mum of four 4 continuous 22000000 e Platform Lift UP Function hours or more or 8 LEDs CHARGE BATTERY f is Locked Out BARS lit before operating a 38 LEVEL 3 1 LED BAR Flashing with Charge batteries for a mini E an audible beep mum of four 4 continuous 3000800 Drive and Platform Lift hours or more
61. ground No Ground Components as Replace Required Traction Control Module Wiring harness from M2 connector on Traction Control Module to Left Drive Motor for damage Table 6 13 Code 12 Right Drive Motor Short Circuit STEP ACTION SPEC YES NO 1 Removethe M2connectorfromthe Traction Control Module and check both No Voltage This circuit should Goto Step 2 the pins to the drive motor for any voltage beisolated Ground the meter to the Ground Control Module Negative lug Repair or Replace 2 Check for continuity of both the pins to the drive motor to ground No Ground Components 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 14 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 3121228 JLG Lift 6 21 SECTION 6 TROUBLESHOOTING Code 14 Pump Motor Disconnected Check For These Obvious Conditions First Check the Positive Negative cables from the Ground Control Mod
62. high at start up 3121228 JLG Lift 4 13 SECTION 4 CONTROL COMPONENTS Table 4 1 Ground Control Module Field Programmable Settings and Factory Preset 10MSP Level 2 Service Level Settings OnLCD Display YES HIGH Level 3 Operator Level Settings NO X Low FACTORY LEVEL PROGRAMMABLE ITEM PRESET SETTING RANGE 2 Mode Select Delay Active before timeout 5 SEC 1 60 SECONDS 2 Acceleration Platform Lowered 80 1 100 2 Deceleration Platform Lowered 90 1 100 2 Turn Acceleration Platform Lowered 80 1 100 2 Turn Deceleration Platform Lowered 100 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 30 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 9 1 100 2 Minimum Turn Speed Platform Elevated 5 1 100 2 Motor Compensation 50 mOhms 0 500 mOhms 4 14 JLG Lift 3121228 SECTION 4 CONTROL COMPONENTS 4 5 PLATFORM CONTROL CONSOLE SERVICE PROCEDURES General DO NOT 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
63. 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 seals 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 5 10 JLG Lift Cylinder Assembly See Figure 5 3 1 Rinse the inside of the tube with hydraulic fluid and 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 prior to installation Install the seal wiper o ring back up ring
64. of chain anchors and sheaves Check chain anchors for wear breakage and misalignment Anchors with worn or broken fingers 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 SERVICE INFORMATION 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
65. of the Retaining Ring and pull the rest of the way out Remove Cover G11 Thrust Washer G21 should remain in the inner counterbore 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 NOTE JLG Lift The Input Ring Gear G3 is held in with a press fit on its out side 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 alter nate between the 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 11 SECTION 3 BASE COMPONENTS Input Carrier Disassembly 1 Input Carrier Disassembly Remove Retaining Rings G18 from each of the three Planet Shafts G6 NOTE Do not overstress these Retaining Rings when removing them 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 Sh
66. 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 33 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 Go to Step 2 Replace Ground pins 16 orange red 49 5 and 6 black 12 is reading within specification Control Module 2 Remove the P2 connector from the Ground Station Module check continu Goto Step3 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 36 RESERVED 37 RESERVED 3121228 JLG Lift 6 31 SECTION 6 TROUBLESHOOTING 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 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
67. 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 3121228 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 mechanic 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 Main
68. the lift cylinder If equipped with the OPTIONAL 7 ft height limiting proximity switch if necessary remove the fasteners attaching the bracket and switch to the left side of the mast assembly See Section 5 5 Platform 7 FT HEIGHT Limit Switch OPTION Mast Section 4 Removal Platform Mount 1 NOTE 3121228 JLG Lift Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate lower on BOTTOM end of mast section 4 platform mounting section Push threaded ends of chain through anchor plate At the 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 debris which may stick to lubricated chains When sliding mast sections apart be careful not to scratch or score the anodized surface in the slide pad channels Carefully slide mast section 4 out the BOTTOM of mast section 3 rails Disassemble slide pads shims and chain anchor plate from mast section 4 if nec essary 5 7 SECTION 5 MAST COMPONENTS Mast Section 3 Removal 1 Remove chain adjust nuts from threaded ends of chains attached to the chain anchor plate lower on BOTTOM end of mast section 3 Push threaded ends of chains through anchor plate 2 At TOP of mast section 2 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 lu
69. 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 Electrical Sys tem 6 5 MULTIMETER BASICS A wide variety of multimeters or Volt Ohm Meters VOM can be used for troubleshooting your equipment A digital meter with reasonable accuracy within 7 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 Backprobing To backprobe 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 If 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 in
70. 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 After Filter Pressure Check Reinstall the hydraulic oil filter and install a t fitting between the hydraulic filter and the extend line to the cyl inder Recheck the hydraulic pressure and compare with the previous readings when filter was removed If a signifi cant drop in pressure reading has occurred replace the hydraulic filter and recheck the after filter pressure read ing Figure 3 5 Typical Hydraulic Pressure Gauge Installation After Hydraulic Filter 1 Hydraulic Oil Filter 3 Pressure Gauge Assembly 2 T Fitting 4 Cylinder Extend Line Figure 3 4 Typical Hydraulic Pressure Gauge Installation Hydraulic Filter Removed 1 Pressure Gauge Assembly 3 T Fitting 2 Oylinder Extend Line 4 Cylinder Return Line 3121228 JLG Lift 3 21 SECTION 3 BASE COMPONENTS Pump Motor Assembly Remove Install A WARNING BE CERTAIN THE MAST IS FULLY LOWERED BEFORE REMOV ING ANY HYDRAULIC LINES FROM THE PUMP UNIT WEAR PRO TECTIVE GEAR WHEN WORKING AROUND PRESSURIZED HYDRAULIC LINES REMOVE CONNECTIONS CAREFULLY AND CAP ALL LINES AND PORTS WHEN DISCONNECTED
71. wires between the frame and the brush housing 19 Line up the timing marks between the brush housing and the motor frame 20 Install the motor bolts 21 Install the motor flange so that the tapped holes line up with the motor bolts 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 10 JLG Lift 22 Tighten the motor bolts to 65 in Ibs 23 Look at timing marks to make sure that they are still aligned If not loosen bolts line up the marks and then retighten the bolts 24 Remove the protective tape from the motor shaft BEFORE MOUNTING THE DRIVE MOTOR BRAKE ASSEMBLY TO THE GEAR BOX SPINDLE HUB BE CERTAIN THE BRAKE CAVITY INSIDE THE SPINDLE HUB IS CLEAN DRY AND FREE OF ANY OIL RESIDUE 3121228 SECTION 3 BASE COMPONENTS Gear Box Main Disassemhly SPINDLE SUB ASSEMBLY HUB SUB ASSEMBLY CARRIER SUB ASSEMBLY G4 521 52 6 69 NOTE 3 4 5 6 3121228 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
72. 1 Component Replace Wiring component Code 26 P1 Auxiliary 2 Short Circuit Check For These Obvious Conditions First Damaged wiring in the Auxiliary 2 Component wiring harness or a damaged Component Table 6 27 Code 26 P1 Auxiliary 2 Short Circuit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check voltage across 0 2VDC Go to Step 2 Replace Ground pins 8 and 1 to the Aux 2 component Is reading within specification Control Module 2 Remove the wire terminals atthe Aux 2 component check continuity of Replace the Repair or each of the wires from pins 8 and 1 onthe P1 connector to the Aux 2 Component Replace Wiring component end 3121228 JLG Lift 6 27 SECTION 6 TROUBLESHOOTING Code 27 P1 Auxiliary 2 Disconnected Check For These Obvious Conditions First Is machine equipped with a component on the Auxiliary 2 circuit Table 6 28 Code 27 P1 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 enterthe programming mode check if the Default NO Disable It Replace Ground Auxiliary 2 open circuit detection is enabled Control Module 3 Check voltage atthe P1 connector on the Ground Control Module between 2 AVDC Replace Ground Go to Step 4 pin 8 and pin 1 Is reading within specification Control Module
73. 104000 2025 2755 1905 2590 1785 2430 11 2 6 1 5000 1 4050 126500 2690 3660 2530 3440 2370 3225 12 1 5000 1 5800 142200 3020 4105 2845 3870 2665 3625 NOTES 1 THESE TORQUE VALUES DO NOT APPLY 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 3121228 NO 5000059 REV J CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 3 Torque Chart SAE Fasteners Sheet 3 of 7 JLG Lift SECTION 1 MACHINE SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners Ref 4150707 Torque Loctite amp 242 or 271 Torque o Semp ke Ed Loctite 26277 Stress Area See Note 4 OR Vibra TITE 111 or or Vibra TITE 131 140 OR 859 K 0 15 12 1 5000 1 5800 142200 3555 4835 3200 4350 2665 3625 PI K 0 18 o ose T e oe oe os 4 40 0120 0 00604 AJ 4 J pj pp 01 1 6 32 01380 00090 OT T T 140 o180 PT 32 060 00400 J 16 01640 00474 __ 141 10 24 01900 0070 A 411
74. 2 Platform Mast Descends 2 ene 6 38 6 43 Hydraulic Leak IIIA 6 39 3121228 JLG Lift vii TABLE OF CONTENTS 6 44 Caster Wheels Not Operating 6 40 6 45 Wont Climb Grader i genie See ced neces Deanna Re 6 41 6 46 Machine Drive in Opposite Direction 6 42 6 47 Machine Won t Drive 6 43 6 48 Noise from Drive Assembly 1 6 44 viii JLG Lift 3121228 SECTION 1 MACHINE SPECIFICATIONS 3121228 SECTION 1 MACHINE SPECIFICATIONS Table 1 1 10MSP Machine Operating Specifications 10MSP Maximum Occupants 1 Maximum Work Load Capacity See Table 1 2 on Page 1 2 Maximum Travel Grade Gradeability Plattorm STOWED ONLY 2096 8 5 Maximum Travel Grade Side Slope Platform STOWED ONLY 5 TiitAlarm Cut Out Limit Direction Platform ELEVATED 1 5 Machine Height Platform Stowed 57 in 1 45m Maximum Vertical Platform H
75. 3 4 long bolts Apply Loctite 242 to threads on final assembly 1 Lower Chain Anchor Bracket Bottom of Mast Section 4 Chain Anchor Installation 4 Chain Adjust and Jam 2 Anchor Bracket Screws a Nuts 3 Narrow Chain Set Studs Note a Apply Loctite 242 to threads on final assembly 10 5 18 JLG Lift Slide the top of mast section 4 back in even with the top of mast section 3 Insert slide pads into the top end mast rails between section 3 and 4 on each side of the mast with beveled surface facing inward towards section 3 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts 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 3121228 SECTION 5 MAST COMPONENTS 11 Shim per instructions in step 7 Mast Section 2 Assembly Apply Loctite 242 to attach screw threads on final assembly Top of Mast Section 4 Slide Pad Installation 1 Slide Pads 2 Shim Stock Note Apply Loctite 242 to attach screws on final assembly 3 Slide Pad Attach Screws a 12 Attach the sequencing cables and hardware to the side of the mast assembly Side of Mast Section 2 Lower Sequence Cable Bracket 1 Mast Section 2 5 Sheave Wheel Thrust 2 Lower Bracket At
76. 4 Remove the wire terminals at the Aux 2 component check continuity of Replace the Repair or each of the wires from pins 8 and 1 onthe P1 connector to the Aux 2 Component Replace Wiring component Code 28 RESERVED 29 RESERVED 6 28 JLG Lift 3121228 SECTION 6 TROUBLESHOOTING 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 29 Code 30 Traction Module No Communication with Ground Control Module STEP ACTION SPEC YES NO 1 Check the voltage reading atthe main power Positive Negative 24v DC Go to Step 2 Repair or Replace cable connection on the Traction Control Module Positive or Negative Cable 2 Removethe communications cable P5 connector atthe Ground Control Goto Step 3 Repair or Replace Module and round connector atthe Traction Control Module Check conti Wire s of all three 3 wires the communications cable from end to end P5 Pins 2 3 and 4 3 With communications cable disconnected at both ends
77. 4141 132 01900 J A 1 1441 14 20 0250 0 0318 _ 2860 143 16 129 15 28 0250 0 0364 _ 3280 164 19 148 17 sm LT 24 0 3125 0 0580 520 25 35 25 35 20 25 LT 24 0 3750 0 0878 700 50 70 45 35 50 716 14 0435 0 1063 950 70 95 65 9 50 70 1 20 0437 0 1187 1070 80 no 70 95 6 1 20 05000 01599 _ 14400 120 165 10 9 120 118 0 5625 02030 _ 18250 170 230 155 210 130 175 5 8 1 0 6250 0 2260 20350 210 285 190 260 160 220 18 0 6250 0 2560 215 290 180 245 3 4 10 0 7500 0 3340 340 460 380 16 0 7500 0 3730 380 515 430 14 0 8750 0 5090 45800 670 910 600 815 500 680 112 1 0000 0 6630 5900 95 1355 895 1215 745 1015 112 11250 0 8560 7700 1445 1965 1300 170 1085 1475 112 12500 1 0730 59600 2015 2740 1810 240 1510 2055 LT 12 1370 13150 118100 2705 3680 2435 3310 2030 2760 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 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGH
78. 6 1 5000 1 4050 78000 1940 2630 1460 1979 2025 2754 1755 2379 12 15000 1 5800 8770 2200 2983 1640 224 2300 3128 194 2676 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 REFERENCE ANEROBIC THREAD LOCKING COMPOUND JLG P N Loctite amp P N Vibra TITE 140 High Strength Red 01000311 242 Vvibra TITE 121 Medium Strength Blue __ 242 0100019 0100071 Figure 1 1 Torque Chart SAE Fasteners Sheet 1 of 7 3121228 JLG Lift Vibra TITE 131 Medium High Strength Red 1 5 SECTION 1 MACHINE SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS TORIS Torque Torque Tensile Loctite 242 or 271 Loctite 262 or Vibra Size TPI Bolt Dia STO OS Clamp Load Dry or Loctite amp 263 OR Vibra TITE 411 or TITE 131 140 K 18 K 0 15 In Sq In LB IN LB N m IN LB N m 4 401 01120 00064 ooo e e e a 0 1380 0 01015 LL 2 36 a os ae octet 00200 6s 2 0 1900 0 02000 1800 68 8 128 02500 0 0364 3280 164 19 148 17 In LB FT LB N m FT LB N m FT LB 5 16 18 0 3125
79. 7 Mast Section 2 Assembly Apply Loctite 242 to attach screw threads on final assembly 9 10 NOTE 11 Top of Mast Section 3 Narrow Chain Sheave Wheel Installation 12 1 Narrow Spacer Tube 5 Key 2 Sheave Pin 6 Sheave Pin Support Plates 3 Sheave Wheels Narrow a a 7 Support Plate Screws b 4 Wide Spacer Tube a Note Install one on both sides of anchor block b Apply Loctite 242 to threads on final assembly d Insert key into the keyway on the end of the sheave pin e Place two 2 sheave pin support bars one each end of sheave pin onto outside of spacer tubes f 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 g Attach to top of mast section 3 using two 2 3 8 16UNC x 1 2 long socket head countersunk Top of Mast Section 3 Top Slide Pad Installation flathead cap screws each side Coat threads 1 Slide Pads 3 Slide Pad Attach Screws a with Loctite 171 and tighten 2 Shim Stock 4 Upper Sequence Cable Bracket Note a Apply Loctite 242 to attach screws on final assembly 3121228 JLG Lift 5 17 SECTION 5 MAST COMPONENTS Mast Section 4 Assemhly 1 Lay the narrow chain set attached to the cylinder attach anchor block at the top of mast section 2 into the open rail on mast section 3 of Ma
80. AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS IN THE EVENT PRES SURE WASHING THE MACHINE IS NEEDED ENSURE THE MACHINE IS SHUT DOWN BEFORE PRESSURE WASHING 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 ELEC TRONIC COMPONENTS ARE SPRAYED SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION 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 3121228 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 brac
81. Apply a coating of grease to the Cover O ring G20 and install it into the o ring groove of the Hub Subassembly It 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 3121228 SECTION 3 BASE COMPONENTS Motor Brake and Gear Box Assembly BRAKE CONTAINMENT HOLES Motor Brake and Gear Box Assembly 1 Place the Motor 2 shaft up on the bench 2 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 NOTICE WHEN MOUNTING THE BRAKE FRICTION PLATE 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 Place the Brake Disc B2 on the motor shaft Make sure the splines ar
82. C YES NO 1 Atthe Ground Control Module P1 connector check voltage across 0 2VDC Goto Step 2 Replace Ground pins 14 and 7 to the horn Is reading within specification Control Module 2 Removethe wire terminals atthe horn check continuity of each of the wires Replace the Repair from pins 14 and 7 onthe P1 connector to the horn end Horn Replace Wiring 3121228 JLG Lift 6 25 SECTION 6 TROUBLESHOOTING Code 23 Horn Disconnected Check For These Obvious Conditions First s machine equipped with a horn unit Table 6 24 Code 23 Horn Disconnected STEP ACTION SPEC YES NO 1 Is machine equipped with a horn unit Goto Step 3 Gotto Step 2 2 Atthe Ground Control Module enter the programming mode check if the Disable It Replace Ground horn open circuit detection is enabled Control Module 3 Check voltage at the P1 connector on the Ground Control Module between 2 4VDC Replace Ground Goto 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 Replace the Repair or from pins 14 and 7 onthe P1 connector to the horn end Horn Replace Wiring Code 24 P1 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 25 Code 24
83. Carry Deck has a maximum capacity of 250 Ib 115k b Unscrew the attach screw to release hood from the frame mount under the cover Lift the hood slightly out of the frame gasket and slide deck forward till the rear hold down bracket clears the support frame under the hood Then lift to remove deck from machine Carry Deck Support Frame Installation 1 Carry Deck Support 2 Support Screws 4 places Apply Loctite 242 Above or later design below Carry Deck Support Frame Installation 1 Carry Deck Support 3 2 JLG Lift 2 Support Screws Nuts Washers 2 places 3121228 SECTION 3 BASE COMPONENTS Rear Bumper Cover Installation Five 5 of the Drive Motor cover screws must be removed to remove the rear bumper cover see the Drive Motor Cover Installation illustration To gain access to those screws elevate the platform Rear Bumper Cover Installation 1 Bumper Cover 3 AC Input Receptacle 2 Screws Washers Assembly Cover Drive Motor Cover Installation WARNING NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL THE PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVE MENT BY BLOCKING OR OVERHEAD SLING To gain access to the drive motor cover and screws ele vate the platform
84. D TEXT SCREEN MACHINE CONDITION REFER TO 23 lt gt AO du Horn Disconnected See Table 6 24 X 000000 23 23 6 26 RUX 1 SHORT P1 Auxiliary 1 Circuit See Table 6 25 000000 24 24 Short Page 6 26 AUX 1 ili i 25 lt gt DISCONNECTED P n ood peces X 000000 25 25 26 umm RUX SHORT P1 Auxiliary 2 Circuit See Table 6 27 X 000000 26 26 Short Page 6 27 AUX 2 ili j j 27 u mnm WAS 1 P1 Auxiliary 3 2 Circuit See Table 6 28 X 000000 27 Disconnected Page 6 28 28 RESERVED RESERVED 29 RESERVED RESERVED Traction Module TRACTION 30 6 lt lt NODULE No Communication mt X 000000 30 0 conns 30 with Ground Control Module 9 Platform Control Console JOYSTICK 31 lt gt NODULE No Communication with m X 000000 31 MD EM 431 Ground Control Module 9 PURP MOTOR 5 32 7 Pump Motor Over Current See Table 6 31 22 LIFT UP Disabled Page 6 30 33 RESERVED RESERVED P2 Auxiliary 1 Inhibit 4 Z EAM 44 2 we LIFTUPDOWNandDRivE See Table 6 32 X 00000 0 4 34 are Disabled 9 P2 Auxiliary 1 Tie Down 4 5 COUN 2 92 LIFT UP DOWN and DRIVE X 00000 0 35 35 are Disabled 9 36 RESERVED RESERVED 6 12 JLG Lift 3121228 SECTION 6 TROUBLESHOOTING
85. ER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 4 Torque Chart SAE Fasteners Sheet 4 of 7 JLG Lift 3121228 SECTION 1 MACHINE SPECIFICATIONS Tensile Stress Area Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 8 8 METRIC BOLTS CLASS 8 METRIC NUTS Torque Loctite amp Loctite 262 242 or 271 OR Vibra OR Vibra TITE 131 TITE 111 or 140 561 3 694 302 0 1990 1490 2090 14 23 0 7 8 78 3 82 34 68 6 1 2010 874 n 79 12 19 125 3660 15 9 28 55 12 175 8430 367 66 97 154 241 331 469 22 303 639 24 353 811 27 459 1130 30 1530 33 36 42 5 4 817 355 5 2560 1920 2690 5 42 4 1120 487 0 4090 3070 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 3121228 Figure 1 5 Torque Chart METRIC Fasteners Sheet 5 of 7 JLG Lift SECTION 1 MACHINE SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 10 9 METRIC BOLTS CLA
86. ERA 6 1 6 2 TROUBLESHOOTING INFORMATION 1 5 6 1 6 3 HYDRAULIC CIRCUIT CHECKS SEE FIGURE 6 8 6 1 6 4 ELECTRICAL CIRCUIT 6 1 General 1 TIE ee ee Lei Ped 6 1 6 5 Wao eee edad dude heen edes 6 2 Grounding C EE Rss Se Edad Rd Lo ERU e 6 2 iere We Mee gen RA ra Rp AEN 6 2 Min Max x ieee tat eo Ted tico Mog e eh eit te Pes 6 2 Polarity e En ae eb haa os ques oaks aba RE Fer eta peas 6 2 Scale cucciolo Ober PET 6 2 Continuity Measurement Over Long Distances 6 5 Requirements lie e vt epe dem here be Y RS E ERE 6 5 Proced re x cae sod o ean race Rano dert Rae ov vate Mad 6 5 6 6 ELECTRICAL SWITCH 6 6 Basic Check s db ad o DUE LE Dee EE 6 6 Limit SWitches etre eoe ubi Ideen cues 6 6 Automatic be we UE EORR IER RD uos 6 7 Switch Wiring Low Side High 1 6 7 6 7 GROUND CONTROL MODULE LCD 1 6 8 iv JLG Li
87. 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 2 Control Compo nents Installation Plattorm Control Console Installation Figure 4 4 Platform Control Console Components Display Controller Module 9 Adjustable Mounting Bracket Drive Lift Mode Selector Switch 1 E Stop Shut Down Switch 6 Horn Button Switch 2 ON OFF Key Switch 7 Rear Cover 3 Joystick Assembly 8 Wiring Harness Connector 4 9 3121228 JLG Lift 4 15 SECTION 4 CONTROL COMPONENTS Display Controller Module Electrical Mounting Bracket Install Remove 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 junction box mounted to the mast under the platform TA Y Platform Console Mounti
88. IL 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 INTRODUCTION REVISION LOG REVISION LOG Original Issue of Manual December 23 2005 Manual 2 2005 Manual Revised January 6 2005 Manual Revised 23 2006 Manual Revised October 4 2006 Manual December 5 2007 Manual September 18 2008 Manual February 4 2011 Manual April 29 2013 b JLG Lift 3121228 TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO MAINTENANCE SAFETY PRECAUTIONS 1 1 A GENERAL uo eb E E dae den ient A B HYDRAULIC SYSTEM SAFETY 1 4 A G MAINTENANCE RUE Punt eet ane UEM REVISION LOG gt
89. 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 5 NOTE JLG Lift Place a Thrust Washer G25 on each side of the Input Planet Gear 5 Line up the bores as well as you can visually Place the Input Planet Gear G5 and Thrust Washers 225 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 different gear ratio Using the appropriate retaining ring pliers put a Retaining Ring G18 into the groove of each Input Planet Shaft G6 NOTE Do not overstress the Retaining Rings G18 3 17 SECTION 3 BASE COMPONENTS Main Gear Box Sub Assembly SPINDLE SUB ASSEMBLY SUB ASSEMBLY G2 pel CARRIER SUB ASSEMBLY 3 18 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 th
90. LG Lift 6 4 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 terminals also as a precaution 2 Measure continuity between all three wires the wire under test wire 1 and wire 2 These should be open If not repair the shorted wires or replace the harness 3 Onone side jumper from contact of wire 1 a
91. LINDER DISASSEMBLY See Figure 5 3 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 may 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 Figure 5 3 Lift Cylinder Component Cross Section 1 Cylinder Rod 6 Apply Anti Seize 10 Piston 2 Cylinder Head 7 Cylinder Tube 11 Wear Ring 3 Rod Wiper 8 Spacer 12 Piston O Ring 4 Rod Seal 9 Piston Seal 13 Piston Lock Nut a 5 O Ring Note Torque 100 120 ft Ibs 3121228
92. Load TrayLoad Deck 28 mph ANSI CSA 12 m s CE 350 Ib 25016 25016 IndoorUseOnly 160kg 115kg 115kg Australia Indoor Use Only Onvs NOTE Distribute weight evenly in platform and material tray when loading Reference the capacity decal located on the machines mast cover in the operators plat form Maximum Horizontal Manual Side Force Platform fully extended with Maximum load ANSI CSA 100 Lb 445 N CE AUST JPN 45 Lb 200 N Platform Size 23 in W x 19 5 in L 68cm x 49cm Material Tray Size 28 75 in W x 25 68 in L 73cm x 65cm Platform Height Fully Elevated 10 ft 3 05m Standard To floor of platform 7 ft 2 13m with Height Limiter To floor of platform Platform Maximum Working Height Platform fully elevated Operator height 16 ft 4 92m approximately 3121228 3121228 SECTION 1 MACHINE SPECIFICATIONS Machine Height Platform Elevated 13 74 ft 4 19m Top of platform rails Platform Stowed 57 in 1 44m Machine Overall Length 61 in 1 55m Width 29 5 in 75cm standard 32 5 in 82 5cm with bumpers 35 0 in 89cm with roller guides Platform Entry Height Floor to Platform Floor 13 75 in 34 9cm Machine Ground Clearance Front 0 872 in 22mm Center 1 872 in 47 5mm Rear 0 622 in 16mm Machine Turning Radius Outside 106 in 269cm 1 4 TORQUE REQUIREMENTS When maintenance become
93. ML E An Oshkosh Corporation Company Service and Maintenance Manual Model 10MSP Vertical Lift P N 3121228 April 29 2013 An Oshkosh Corporation Company LB 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 and larger machine component p
94. Module JLG Lift 3121228 SECTION 6 TROUBLESHOOTING Table 6 34 Codes 100 199 Ground Control Module Fault Condition 5 Remove the communications cable P5 connector at 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 in the 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 Go to Step 7 tinuity between Pins 2 3 and 4 atthe P5 connector end Wires 7 Plugthecommunications cable on the Traction Control Module to the round Done Replace socket on the opposite end of the module Does this fix problem Ground Control Module Codes 200 299 Platform Control Console Fault Condition Check For These Obvious Conditions First Damage to Platform Control Console wiring harness Secure harness connections 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 35 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 number is displaying Code
95. NING NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING 6 3121228 Start with the mast section which needs adjustment and loosen the bottom jam nut on each chain Tighten to raise mast section or loosen to lower mast section the adjusting nut against the anchor plate on each chain 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 8 when the mast is retracted NOTE 10 11 It is more important that the threaded ends studs 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 may need to be restrained while tightening the adjust nut to keep the chain from twisting Retract the mast all the way and check if the top of the mast sections appear as shown in Figure 5 8 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 should have slight tension but should not be taut After all mast adjustments are complete if neces s
96. OW 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 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 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 J305 DV DT CP 8 Concorde 10xAH AGM 23
97. 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 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 lis
98. 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 5 Emergency Stop Switches Ground amp Platform 5 Function Limit or Cutout Switch Systems 5 Brake Release 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 9 25 Hydraulic Fluid 11 11 11 Electrical Connections 20 20 Instruments Gauges Switches Lights Horn 5 3121228 JLG Lift 2 3 SECTION 2 GENERAL SERVICE INFORMATION Table 2 2 10MSP 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 OR FREQUENT YEARLY MAINTENANCE MAINTENANCE INSPECTION INSPECTION GENERAL Operation amp Safety Manual in Storage Box 21 21 21 ANSI amp EMI Handbooks in Storage Box 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 Safet
99. Pot Hole Input 1 0 0 DISABLED 1 LOW 2 HIGH 2 Set Polarity Of Right Pot Hole Input 2 0 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 HIGH HIGH LOW 2 Set Polarity Of Ancillary Input 2 LOW HIGH LOW 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 OSS NO YES NO 2 Enable Detection Of Ancl 1 Open Circuit NO YES NO 2 Enable Detection Of Ancl 2 Open Circuit NO YES NO 3 Forward Alarm Disable NO YES NO 2 Brush Wear Sensor Timer Reset BLANK WORN 3 055 Diagnostic NO YES NO 2 Load Sensing LSS OFF OFF CUTOUT PLAT CUTOUT ALL 2 Aux 1 Inhibit Active when Ancilliary 1 is HIGH 4 O Inhibit Lift 1 Inhibit Drive when Platform is elevated 2 Inhibit Drive regardless of Plat position 3 Inhibit Lift and Drive when Plat elevated 4 Inhibit Lift and Drive regardless of Plat position 2 Aux 2 Inhibit Active when Ancilliary 2 is setto HIGH 0 0 Inhibit Lift 1 Inhibit Drive when Platform is elevated 2 Inhibit Drive regardless of Plat position 3 Inhibit Lift and Drive when Plat elevated 4 Inhibit Lift and Drive regardless of Plat position 2 Aux 1 Tie Down 1 0 Disabled 1 trip if low at start up 2 trip high at start up 2 Aux 2 Tie Down 0 0 Disabled 1 trip if low at start up 2 trip
100. SERVED RESERVED Tilt Condition y nm platform Elevated ee X 00000 0 404 04 DRIVEandLift UP Disabled 9 05 RESERVED RESERVED Drive Motor Drive Motor Brushes Require 4 Brush Wear Warning Service Replacement 06 EA Countsdown25hrs of See Section 3 5 Wheel 00025 0 05 00010 0 05 DRIVE operation remaining Drive Assembly Servicing toa 10sec shut down mode for further Instructions Left Drive Motor 07 6 nm S Disconnected 2 X 000000 07 07 DRIVE Disabled 9 Right Drive Motor 6 gp 7 Disconnected X 000000 DRIVE Disabled Page 6 20 Left Brake Disconnected 09 6 EA us i 4 bicconnecteo DRIVE LiftUP DOWN 36e Table 6 10 X 00000 0 Page 6 20 Disabled 6 10 JLG Lift 3121228 SECTION 6 TROUBLESHOOTING Table 6 1 LCD Display Service Fault Code Conditions FAULT DESCRIPTION FOR TROUBLESHOOTING FAULT CONSOLE CODE LCD SYMBOL SCREEN LCD TEXT SCREEN MACHINE CONDITION REFER TO Right Brake Disconnected RIGHT BRAKE 10 6 7 4 DRIVE LIRUP DOWN pos Fi X 000000 10 10 Disabled tal Left Drive Motor LEFT MOTOR x 11 6 E nmm gt gt lt gt SHORTED lt Short Circuit 4 X 000000 11 11 DRIVE Disabled 9 Right Drive Motor RIGHT MOTOR E 12 6
101. SHOOTING Code 33 RESERVED Code 34 P2 Auxiliary 1 Inhibit Check For These Obvious Conditions First Platform Gates Closed Pressure on the Platform Footswitch 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 32 Code 34 P2 Auxiliary 1 Inhibit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P2 connector check the voltage across 0 2VDC Go to Step 2 Replace Ground pins 16 orange red 49 5 and 6 black 12 is reading within specification Control Module 2 Remove the 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 35 P2 Auxiliary 1 Tie Down Check For These Obvious Conditions First Pressure on the Platform Footswitch during machine power up NOTE In the procedures below if you check continuity between pin 6 and 16 it should show open circuit when the
102. SS 10 METRIC NUTS CLASS 12 9 SOCKET HEAD CAP SCREWS M5 Torque m Torque Lub OR Loctite amp Torque Dry or Loctite 24277 or 2711 OR Loctite 262 OR Size PITCH Stress TM TM Area 263 Vibra TITE 111 Vibra TITE 131 K 0 20 140 0 15 0 18 3 os sos s13 ECCE EE T PUES REN LER a oz ez 0 8 25 2 22 7 18 9 1 25 36 5 32 8 a NI NN ERE de ee ee ee c 2 wm ze 200 1 150 16 2 17 978 ss ET NETTO WARE EUN CNN DRE RN 20 25 245 1525 io sso 460 24 3 220 1065 960 800 561 2095 1885 1575 694 2855 2570 2140 3665 3300 2750 4s n ewo ses 5 4395 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 NJO Figure 1 6 Torque Chart METRIC Fasteners Sheet 6 of 7 1 10 JLG Lift 3121228 SECTION 1 MACHINE SPECIFICATIONS
103. SYSTEM 6 41 Wont Climb Grade esL LN LS 6 41 Machine Drives in Opposite 6 42 Machine Won t Drive 0 6 43 Noise From Drive Assembly 6 44 LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Torque Chart SAE Fasteners Sheet 1 7 1 5 1 2 Torque Chart SAE Fasteners Sheet 2 7 1 6 1 3 Torque Chart SAE Fasteners Sheet 3 7 1 7 1 4 Torque Chart SAE Fasteners Sheet 4 7 1 8 1 5 Torque Chart METRIC Fasteners Sheet 5 7 1 9 1 6 Torque Chart METRIC Fasteners Sheet 6 7 1 10 1 7 Torque Chart METRIC Fasteners Sheet 7 7 1 11 3 1 Components i em ER SG eaten eet 3 1 3 2 Wheel Lug Nut Tightening 3 4 3 3 Hydraulic Pressure Adjustment Screw Machine Front Cover Removed 3 20 3 4 Typical Hydraulic Pressure Gauge Installation Hydraulic Filter
104. Section 3 Assemhly 1 Lay the wide chain set attached to the top of mast section 1 into the open rail on mast section 2 Top of Mast Section 2 Slide Pad Installation 1 Wide Chain Set Attached to Mast Sec 2 Mast Section 2 tion 1 NOTE Before sliding mast sections together spray the slide pad channels with Krytox lubricant spray JLG P N 3020041 Be careful not to scratch or score the anodized finish in the slide pad channels 2 Carefully slide mast section 3 into section 2 until ends are even 3 At the bottom of mast section 3 install the slide pads between mast section 2 and 3 Shim per instructions in step 7 Mast Section 2 Assembly Bottom of Mast Section 3 Slide Pad Installation 1 Slide Pads 3 Shim Pad Screws 2 Shim Stock 4 Push mast section 3 out the top of mast section 2 approximately 1 ft 31cm 5 Locate the lower chain anchor bracket one with the threaded attach holes horizontally aligned to outside of bracket 6 Working at the bottom end of mast section 3 insert the threads stud ends of the wide chain set now laying between mast section 2 and 3 into the holes of the lower chain anchor bracket Loosely thread two 2 3 8 16UNC nuts onto the stud threads on each chain 7 Slide the anchor plate into the closed rail at the bot tom of mast section 3 and attach the anchor plate to the bottom of mast section 3 with f
105. UBLESHOOTING Caster Wheels Not Operating Freely Check For These Obvious Conditions First s machine operating on a smooth level surface Table 6 44 Caster Wheels Not Operating Freely STEP ACTION SPEC YES NO 1 Isthe caster rotating freely Goto Step 2 Lubricate or Replace Caster Housing 2 lsthe wheel spinning freely Goto Step 3 Lubricate or Replace Wheel 3 Is debris stuck in the rubber wheel Remove Debris or Replace Wheel 6 40 Lift 3121228 SECTION 6 TROUBLESHOOTING 6 16 DRIVE SYSTEM TROUBLESHOOTING Won t Climb Grade Overview Of Procedure The 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 1596 Grade Does the Travel Surface allow for Proper Drive Wheel Traction s Platform Load within the Maximum Rated Capacity Table 6 45 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 47 2 Dotheleftandright drive motor brakes release properly and allow the drive Goto Step 4 Dragging wheels to rotate freely Repair Replace or Adjust Brakes 3 Checkthe amperage output ofthe on the dr
106. WARRANTY WILL VOID THE WARRANTY IF UNDER WARRANTY REQUEST A REPLACEMENT MODULE FROM THE FACTORY The Ground Control Module allows for field replacement of two 2 components internal to the module Emergency Stop Switch Power Selector Switch Key NOTICE ELECTROSTATIC DISCHARGE CAN DAMAGE COMPONENTS ON THE INTEGRATED CIRCUIT BOARD PLACE THE GROUND CON TROL MODULE ON A NON CONDUCTIVE SURFACE WHEN OPEN ING Figure 4 3 Ground Control Module Components 1 Cover LCD Assembly 2 Power Selector Switch Assembly 3 Emergency Stop Switch Assembly 4 Main Board to LCD Ribbon Cable 5 Heat Sink Base Main Board Assembly 6 Cover Attach Screws 3121228 JLG Lift 4 7 SECTION 4 CONTROL COMPONENTS Cover Removal Installation THE MAIN CIRCUIT BOARD AND THE SMALLER LCD CIRCUIT BOARD MOUNTED TO THE COVER ASSEMBLY ARE CON NECTED BY A RIBBON CABLE REMOVE THE COVER CARE FULLY 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
107. WITCH RETURN CINHIBITS LIFT DRIVE BRUSH WEAR INDICATION p NT RED 57 1 87A MA SEE DRIVE MOTOR S ZONE B 8 HT RED 51 2 ORANGE RED 49 6 B AUX SIGNAL PROGRAMMAB B TILT SWITC B POWER LE CUT 0UT B AUX 2 SIGNAL SPARE DIGITAL INPUT 2 UX 2 RETURN PROGRAMMABLE CUT OUT 1 xnv 1 1 915 Q38 X2V18 Nuni3u 2v 18 NMO3U8 g 9 9 S 6y Q34 39NV4O NYNLIY Xnv 21 SLIGIHNI 1 915 8 AUX RETURN ORANGE RED 49 3 Lg nen ac m On PLUGGED IN B ET ELEVATION SPEED CUTBACK SWITCH ELEVATED OPEN ELEVATION SPEED CUTBACK SWITCH ELEVATED OPEN LEFT PHP NOT USED Figure 6 3 Electrical Diagram JLG Lift PLATFORM AUX 1 AUX INPUT 1 1870201 G 6 47 SECTION 6 TROUBLESHOOTING CYLINDER 1 2792684 A Figure 6 8 Hydraulic Diagram 2792684 A 1 Tank 5 Pressure Adjust Valve 9 Check Valve 2 Filter Screen 6 Extend Line 10 Pressure Compensator Flow Control Valve 3 Pump T Hydraulic Filter 11 Manual Decent Valve 4 Pump Motor 8 Retum Line 12 Lift Cylinder 6 48 JLG Lift 3121228 CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts terminals and related accessorie
108. a damaged lift down valve coil Table 6 17 Code 16 Lift Down Valve Short Circuit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the voltage across pins 0 2VDC Goto Step 2 Replace Ground 10and3to the lift down valve coil 15 reading within specification Control Module 2 Removethe wireterminals atthe lift down valve coil Check resistance read 6 Ohms Goto Step 3 Replace Coil ing ofthe 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 connectortothe 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 18 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 NOTE If this is a recurring problem compare current draw of your machine with Ground Control Module specifications Table 6 3 Amperage Draw for Various Components 3121228 JLG Lift 6 23 SECTION 6 TROUBLESHOOTING Code 18 Alarm Short Circuit Check For These Obvious Conditions First D
109. able 6 3 Recheck Steps Go to Step 6 with machine on level surface 1thru5 6 Checkthe drive motor brushes do they need replaced Replace per Go to Step 7 procedure in this Service Manual 7 Is joystick control defective Repair Replace Go to Step 8 If possible swap out with another platform control Platform control 8 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 Service Are any gears broken or gearteeth excessively worn Manual 3121228 JLG Lift 6 43 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 48 Noise from Drive Assembly STEP ACTION SPEC YES NO 1
110. ace 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 3121228 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 switch 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 sta
111. aft G6 5 Press out Bushing G26 from the bore of each 3 12 Planet Gear G5 when removed Bushings cannot be reused 6 7 8 9 NOTE JLG Lift Remove the other Thrust Washer G25 from each Planet Shaft G6 Remove Retaining Ring G24 from Output Sun Gear G8 Slide Output Sun Gear G8 out from the center of the Input Carrier G7 Remove the three Planet Shafts G6 from the Input Carrier The Planet Shafts G6 are held in with a press fit To avoid damage to the parts use an arbor or hydraulic press to remove the Planet Shafts G6 3121228 SECTION 3 BASE COMPONENTS Hub Disassembly Hub Disassembly 1 Remove Main Wheel Bearing G14 2 NOTE This part is held in the hub with a press fit To remove have NOTE the hub setting seal side up Use a plate or rod with a large enough diameter push in the inner race of the bearing Apply force to the push the bearing out This bearing will need to be replaced upon reassembly 3121228 JLG Lift Remove main Lip Seal G16 This Lip Seal G16 is also held in with a press fit Remove the Lip Seal only if the hub or seal needs to be replaced The Lip Seal will most likely become damaged during removal Try not to damage the hub bore 3 13 SECTION 3 BASE COMPONENTS Spindle Disassemhly NOTE NOTE NOTE 3 14 Spindle Disassembly Place Spindle Sub Assembly on bench
112. age across 0 2VDC Go to Step 2 Replace Ground pins 12 and 5 to the beacon Is reading within specification Control Module 2 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 6 24 Lift 3121228 SECTION 6 TROUBLESHOOTING Code 21 Beacon Disconnected Check For These Obvious Conditions First 5 machine equipped with flashing amber beacon light Table 6 22 Code 21 Beacon Short Disconnected STEP ACTION SPEC YES NO 1 15 machine equipped with a flashing amber beacon light Z Goto Step 3 Gotto Step 2 2 Atthe Ground Control Module enter the programming mode check if the Disable It Replace Ground Beacon light open circuit detection is enabled Control Module 3 Check voltage 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 atthe beacon check continuity of each of the Replace the Repair or wires from pins 12 and 5 on the 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 23 Code 22 Horn Short Circuit STEP ACTION SPE
113. amaged wiring in the alarm wiring harness or a damaged alarm Table 6 19 Code 18 Alarm Short Circuit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the voltage across 0 2VDC Go to 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 connectorto the alarm end Replace Wiring 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 20 Code 19 Alarm Disconnected STEP ACTION SPEC YES NO 1 Check voltage atthe P1 connector onthe Ground Control Module between 2 4VDC Replace Ground Goto Step 2 pin 13 and pin 6 Is reading within specification Control Module 2 Remove the wire terminals atthe 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 21 Code 20 Beacon Short Circuit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the volt
114. an all metal parts with non flammable cleaning solvent Lubricate components as required to aid assem bly Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart See Section 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 equivalent 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 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 for proper chain specifications and allowable stretch tolerances 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 replacement of the chain and correction of the cause Chain side wear noticeable when pin h
115. arger Limit Switch Harness a P5 Joystick Protocol Harness to Traction Control P3 Programmable Security Lock Harness Option a Module a Notes a 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 An quick disconnect is installed on the left battery POSITIVE cable for easier power disconnect when servicing machine See Figure 6 7 This section Troubleshooting for complete machine wiring schematic Figure 6 5 Component Electrical Connections 3121228 JLG Lift 6 9 SECTION 6 TROUBLESHOOTING Table 6 1 LCD Display Service Fault Code Conditions PLATFORM FAULT CONSOLE FAULT DESCRIPTION CODE LEDs LCD SYMBOL SCREEN LCD TEXT SCREEN MACHINE CONDITION TROUBLESHOOTING FLASHING Machine In Drive Speed Cut Back Turtle Mode pda X 000000 All The Time 9 Engage Brakes E XR PEE Press Bre Release Button X 000000 DRIVE Disabled on Ground Control Station Unplug Charger v Charger AC Pluggedin ac input power Cord X 000000 DRIVE Disabled from Machine Typein Code At PSL Key Pad _ _ E e Eus SECURITY s Security See Operators Manual for ock Password 00000 0 Proper Operation 01 1 PEN v Low Battery Voltage ig s i X 000000 age D 02 2 RESERVED RESERVED 03 2 RE
116. arts 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 3121228 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 SURFACES AND HAND HOLDS FREE OF O
117. ary readjust the bumpers mounted on the base frame under the platform so the platform rests slightly above the base frame when it is lowered and empty Sequencing Cable Adjustment 1 NOTE 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 at the sequence cable bracket located at the top of the mast just enough to remove excessive slack from sequencing cable The springs should not be compressed more than 25 after adjusting If slack cannot be adjusted out of the cable and adjust nut has completely compressed the spring then either the mast side profile is not adjusted prop erly even or the the cable will have to be replaced due to stretching After adjusting the mast chains and sequence cables cycle mast up and down several times to verify adjust ments are correct JLG Lift 5 21 SECTION 5 MAST COMPONENTS E Figure 5 8 Mast Chain and Sequence Cable Adjustment Components 1 Mast Side Profile 3 Mast Section 1 6 Mast Section 4 9 Chain Lock Jam Nut Sections Even at Top 4 Mast Section 2 7 Chain Ancho
118. at both ends of the ribbon cable Disconnect the Ribbon Cable 1 Ribbon Cable Connector 3 Support for Cover 2 Ribbon Cable 4 8 JLG Lift 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 3121228 SECTION 4 CONTROL COMPONENTS Power Selector EStop Switch Installation Emergency Stop Switch Installation EStop Power Selector Switch Connector Locations 1 Emergency Stop Button 4 Nut 1 LCD and Button Circuit Board 2 Button Seal 5 Emergency Stop Switch 2 Emergency Stop Switch Connector 3 Square Lock Washer 6 Switch Lock Release Lever 3 Main Power Selector Switch Connector Note Tighten nut enough to keep button from turning Note To release switch connectors push tab on top of connector Reattach wires to same terminals on new switch Power Selector Switch Installation 1 Selector Knob 3 Power Selector Switch 2 Nut 4 Align and insert tab into cover Note Reattach wires to the same terminals on new switch 3121228 JLG Lift 4 9 SECTION 4 CONTROL COMPONENTS 4 4 GROUND CONTROL MODULE Activating Programming Mode PROGRAMMING General The Ground Control Module allows on board program ming of various component and control function personal ity settings Programming may be required u
119. be rotated to line up the sun gear splines with the motor shaft splines 12 Install the 2 Motor Bolts 6 Tighten to 8 9 ft Ibs 13 Apply a bead of silicone sealant to the slot in the motor flange where the brake leads are exiting 14 Fill the Gearbox 1 with oil per instructions See Page 3 5 15 The wheel drive is now ready to be installed onto the machine reverse removal instructions See Page 3 6 NOTE 3 19 SECTION 3 BASE COMPONENTS 3 8 PUMP MOTOR ASSEMBLY SERVICE PROCEDURE General The following is a complete tear down re assembly of the 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 serviceable internal to the pump electric motor is the motor brush kit NOTE During reassembly of the pump motor assembly apply a liberal coat of JLG recommended hydraulic 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 DISCONNECT THE LEFT SIDE BATTERY POSITIVE BATTERY TERMINAL BEFORE REMOVING THE PUMP MOTOR FROM THE MACHINE 3 20 JLG Lift Hydraulic Pressure Settings and Adjustment Adjust system pressure so that platform will raise with maximum rated capacity in platform Perform pressure adjustment with o
120. bly b Apply Loctite 242 to threads 10 At the bottom of mast section 1 check for side to side clearance of the cylinder mount Use mounting shims of equal thickness on each side to center the mount in the closed rail portion as necessary 11 Install the mount reinforcement plates and mount bolt and washers Apply Loctite 242 to threads of mounting bolts before final assembly JLG Lift 3121228 SECTION 5 MAST COMPONENTS 12 Slide mast section 2 out of mast section 1 approxi mately one foot Top of Mast Section 2 Chain Anchor Sheave Wheel Installation Anchor Block 6 Sheave Pin Support Plates a Sheave Pin T Key Narrow Spacer Tube a 8 Support Plate Screws b Sheave Wheels Wide a 9 Align Pin Holes Thrush Washers a Note a Install one on both sides of anchor block b Apply Loctite 242 to threads on final assembly 13 Assemble the chain sheave wheel assembly to the chain assembly anchor block which will attach to the cylinder rod and to mast section 2 using following steps a Insert sheave pin through anchor block assem bly b Load one 1 narrow spacer tube 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 a large thrust washer e Insert the key bar into the keyway on the end of the sheave wheel pin
121. bricated chains NOTE When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels 3 Slide mast section 3 out the TOP of mast section 2 enough to allow removal of the sheave wheel assembly 4 Remove countersunk flathead screws securing chain sheave wheel assembly attach bars on both side rails at TOP of mast section 3 and remove sheave wheel assembly 5 Carefully slide mast section 3 out the BOTTOM of section 2 Remove slide pads shims and cable anchor plate if necessary Mast Section 2 Removal NOTE Since the lift cylinder rod is still attached to the anchor block at the top of the section 2 mast assem bly you will need to temporarily uncap the extend and return hydraulic lines to allow mast section 2 to be extended in the next step Capture any hydraulic fluid that may flow out of the lines and recap the lines once section is extended 1 Slide mast section 2 out TOP of mast section 1 far enough to allow access to the chain assembly anchor block sheave wheel assembly 2 Onthe underside of the mast assembly remove the snap ring securing the anchor pin running through the small chain equalizer plate the cylinder anchor block and the cylinder rod 3 Push or lightly tap the anchor pin up and remove Lay the small chain set aside
122. ce Free Weight 12V 65 7 Ib 29 8 Kg Per Battery 6V 64 Ib 29 Kg Per Battery 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 REPLACEMENT 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 Brakes 1 2 JLG Lift 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 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 10MSP batteries require approximately five 5 hours to fully charge when drained to 8096 discharge Only the RED LEDS on platform console lit 1 3 PERFORMANCE DATA Platform Capacity Table 1 2 Platform Maximum Capacity MAXIMUM CAPACITY MAX WIND SPECIFICATION Platform Material Carry SPEED
123. chines operating profile If replacing a Ground Control Module the new module may require some programming to enable any optional equipment For servicing and programming information for the Ground Control Modudle See Section 4 3 Ground Con trol Module Service Procedure and Section 4 4 Ground Control Module Programming 4 2 JLG Lift Ground Control Module Installation 1 Ground Control Station 8 From Inline Fuse Battery Module and To Traction Control Mounting Screws Washers a Module P1 Connector b 9 From Battery and To Trac P2 Connector b tion Control Module P3 Connector b 10 To Terminal on Hydraulic Connector b Pump P5 Connector b 11 To Terminal on Hydraulic Post C C Nole a Apply Loctite 242 to screw threads on final assembly b To help seal unit from dust and moisture apply electrical contact grease CG60 JLG Part 3020038 to all electrical connectors before assembly 3121228 SECTION 4 CONTROL COMPONENTS Traction Control Module Platform Control Console Installation The Traction Control Module is mounted to the base frame The platform control console is located in the platform and beneath the platform under the drive motor cover mounted on the right side of the mast assembly This module controls the voltage to the drive motors as regulated by the Ground Control Module from signals receive
124. ck the actual level ofthe machines resting surface in 1 5 Goto Step 2 Drive Machine to both the X and the Y directions Does surface check within machine X and Y Direction Level Surface cation 2 Atthe Ground Control Module enterthe programming mode See Ground 1 5 Replace Ground Go to Step 3 Control Programming Section 3 of Service Manual and checkthetiltsen x and Y Direction Control Module sor X and readings Are readings within machine specification 3 Zero Tilt Sensor on a surface checked to within 0 0 degrees with a digital a 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 Code 06 Drive Motor Brush Wear Warning Indicator Replace Drive Motor Brushes see Section 3 5 Wheel Drive Assembly Servicing for brush replacement instructions Program Ground Control Station module to reset the Brush Wear Warning Timer see Section 4 4 Ground Control Mod ule Programming 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 8 Code 07 Left Drive Motor Disconnected 3121228 JLG Lift STEP ACTION SPEC YES NO 1 Check re
125. crane or suitable lifting device each mast section These slide pads run up and down in capable of supporting the weight of the mast assem slide pad channels on each side of the mast bly attach a sling strap to the mast The mast assembly contains the number of mast sections 5 Remove the four 4 mast attach bolts with washers and nuts securing the mast to the mounting column NOTE When lifting the mast out of the base frame be care ful with the manual descent valve extend and return lines protruding from the bottom front of the mast assembly 6 Carefully lift the mast off the base frame and place on a suitable work surface Mast Installation 1 To install the mast assembly reverse the Mast Removal instructions however perform the following additional steps during re assembly 1 Once assembly is complete cycle the mast up and 2 down several times then check the oil level in the hydraulic reservoir NOTE as shown following Table 5 1 Mast Component Features No of Mast Extend Retract Model 2 Sections Device 10MSP 4 Chain Mast Disassembly Procedure 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 Remove the sequencing cables platform junction box and hardware from the sides of the mast assem bly Also remove the extend and return hydraulic lines from the bottom of
126. d from the Joystick Controller located on the Plat form Control Module For removal see below for servicing information see Sec tion 4 5 Platform Control Console Service Procedures There are no internal parts serviced on this module L 27 Traction Control Module Installation 1 Traction Control Module 2 Module Mounting Screws Washers a 3 Left Drive Motor Power Cable 4 Power From Ground Control Station 5 6 Right Drive Motor Power Cable 5 Communication Cable from Ground Control Station Planan Control 1 Console 3 Level Mounting Bracket 2 Mounting Bracket Screws and Washers 3 Platform Console to Junction Box Harness a 4 Harness Connector Removal Nut Nole a Apply Loctite 242 to mounting screw threads on final assembly Nole a The other end of this harness is plugged into the plat form junction box mounted to the mast under the platform From the platform console the harness is run under the mast cover is tie strapped to the top platform attach sup port and run inside the mast down and out the bottom rectangular hole Then runs down along the outside of the mast and through a large hole in the mast to the platform Junction box 3121228
127. d 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 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 13 Repeat steps 6 9 for the other 3 brushes 3121228 Brush Brush Lead Holder Wire Brush _ Spring Drive Motor Brush Holder Components 14 Remove the armature from the motor fram
128. des 2 4 OOO AS M PEDE MES 2 4 2 3 SERVICING AND MAINTENANCE 1 2 5 Eres V e UP IE Pu e ERN DS 2 5 Safety and Workmanship 2 5 Cleanliness e nee Ce T c POI aure 2 5 3121228 TABLE OF CONTENTS JLG Lift TABLE OF CONTENTS Components Removal and 2 5 Component Disassembly and Reassembly 2 5 Pressure FilParls iic ele ESTE Rex I pw ket eee tay ues wad 2 5 Bearings tC DR EE ee pa dn SYA ater aah DAGMAR RENE 2 5 GasKelS 24 2 5 Bolt Usage and Torque Application 1 2 6 Hydraulic Lines and Electrical Wiring 2 6 Hydraulic System e erc eer ex Pen Res me pere UR 2 6 Lubrication and Servicing 2 6 PUOI ESO qu aM DEM VIE Wb CM TUIS 2 6 Mast Chain Inspection 1 2 6 2 4 LUBRICATION INFORMATION 1 2 8 Hydraulic System hes nee deer gt ee ut Rae A 2 8 Hydraulic
129. dust boot and hose fitting shoulder Step 3 Insert the disconnect tool in the gap created between the dust boot and hose fitting shoulder 5 4 JLG Lift 3121228 SECTION 5 MAST COMPONENTS 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 3121228 to complete disconnection Tool Use Angled Style Fittings 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 JLG Lift 5 5 SECTION 5 MAST COMPONENTS 5 7 MAST ASSEMBLY INSTALL REMOVE Mast Removal The following components must be removed from the machine before removing the mast assembly With Platform Elevated approx 4 ft 1 2m Remove Front Hood See Section 3 2 Drive Motors Cover See Section 3 2 Platform Material Tray Assembly See Section 5 3 Remove the bottom bolts and unhook the enable foot switch and entry gate interlock wire harness from the platform junction box With Platform Completely Lowered If necessary use Step 4 Gen
130. e nance measure is to make a thorough inspection of all hydraulic components lines fittings etc as well asa functional check of each system before placing the machine back in service Lubrication Specifications Specified lubricants as recommended by the component manufacturers are always the best choice however multi purpose greases usually have the qualities which meet a variety of single purpose grease requirements Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion Refer to Section 1 of this Service Manual for an expla nation of the lubricant key designations appearing in the Lubrication Chart 3121228 SECTION 3 BASE COMPONENTS SECTION 3 BASE COMPONENTS 3 1 BASE ASSEMBLY COMPONENTS Figure 3 1 Base Components 1 Front Cover 4 Battery Charger 7 Front Caster Wheels 2 Drive Motor Cover 5 Batteries 8 Drive Motor Assemblies 3 Hydraulic Pump Motor Reservoir 6 Limit Switches Mast Activated 9 Rear Bumper Cover 3121228 JLG Lift 3 1 SECTION 3 BASE COMPONENTS 3 2 BASE FRAME COVERS Front Cover Installation Carry Deck Version S 5 Carry Deck Support Frame Installation Carry Deck Hood Removal 1 Hood Carry Deck 3 Rear Hold Down Bracket Located 2 Attach Screw Under Hood Slides Under Hood Support NOTE a The
131. e Covers Removed 1 Batteries Left Side 3 Drive Motor Cover Screw 2 Battery Hold Down Bra Bracket kets and Fasteners 4 Move Rear Battery For ward and Lift Out NOTE The carry deck support frame will need to be removed to remove the batteries Once hold down brackets item 2 are removed remove the cables from the batteries Slide the rear battery forward to clear the bracket item 3 Then lift battery out of base frame 3121228 FA Ve FS 5 Right Rear Battery 6 Left Rear Battery 7 Battery Quick Disconnect 1 Ground Control Module 2 Right Front Battery 3 Left Front Battery 4 175 Amp Inline Fuse NOTE Label battery cables before removing to ensure proper installation All other connections to Ground Control Module same as in Section 4 Figure 4 2 Figure 3 6 Battery Cable to Battery Termi nal Connections 4 6V JLG Lift 3 27 SECTION 3 BASE COMPONENTS Battery Charge LED Indicator on Platform All Three 3 GREEN LEDs lit up indicate maximum Control Console pattery charge Four 4 YELLOW LEDs indicate a two thirds to one third
132. e 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 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
133. e Lines 8 Checkifthe pump motoris 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 3121228 JLG Lift 6 37 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 41 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 2 Check Pump Valve Goto Step 3 Electrical Circuit 3 Oilcould be passing around the lift cylinder bore 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 42 Platform Mast Descends Too Slowly STEP ACTION SPEC YES NO 1 Check mast slide pads shimmed to tight ES Reshim Mast Goto Step 2 2 15 an obstruction inth
134. e by grab bing onto the commutator and quickly pulling it from the motor frame NOTICE 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 NOTICE 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 assembly Make sure that it is oriented such that the spring touches the outer raceway of the armature bearing 18 Install the brush housing onto the end of the motor frame and armature You may need to use a soft JLG Lift 3 9 SECTION 3 BASE COMPONENTS tipped mallet to tap the brush housing onto the bear ing of the armature Once the brush housing is par tially on the armature the brush retaining pins must be removed NOTE Do not pinch any
135. e mast Remove Goto Step 3 Obstruction 3 Theliftcylinder packing could be too tight in the bore of the cylinder barrel Rebuild or Replace Go to Step 4 Cylinder 4 Check ifthe lift down valve is opening completely Clean or Replace Go to Step 5 Valve 5 Isthere a restricted hydraulic line smashed Replace Hydraulic Goto Step6 Line 6 Check the flow valve in the cylinder valve block for a restriction i e dirt Clean or Replace Flow Valve 6 38 JLG Lift 3121228 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 43 Hydraulic Leak Troubleshooting STEP ACTION SPEC YES NO 1 Oilleaking around the 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 mE Fittings 3 Oilleaking around the 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 3121228 JLG Lift 6 39 SECTION 6 TROUBLESHOOTING 6 15 BASE FRAME COMPONENTS TRO
136. e properly lined up and the Brake Disc B2 is down against the Brake Friction Plate B3 4 Place the three Spacers B4 so that they line up with the three holes in the Brake Friction Plate B3 5 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 6 Install the three Brake Bolts 7 into the three holes in the Brake Housing B1 Tighten to 4 5 ft Ibs 7 Remove and discard the 2 bolts in the Brake Con tainment Holes 3121228 JLG Lift 8 Pull the Brake Lead through the slot in the motor flange Make sure the leads are all the way in the bottom of the slot 9 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 10 Ifthe 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 MOTOR 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 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
137. e while charger is operating Is voltage within specifi Maximum of Replace Repair or Replace cation 31 Volts DC Traction Control Battery Charger Module 5 Checkforshortin 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 34 JLG Lift 3121228 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 RESET position out Table 6 37 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 Replace the Ground Goto Step 3 trol Console pins 10 and 1 onthe P4 connector atthe Ground
138. eads and outside plates show a definite wear pattern is caused by misalignment 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 L 5 of H H for a 1 chain 0 950 Maximum wear 5 of 0 950 0 047 Minimum plate depth 0 950 0 047 0 903 Example 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 JLG Lift Fatigue Cracks Fatigue is a phenomenon that affects most metals and is the most common cause of chain plate fai
139. ed miis CHARGING A YELLOW MIDDLE LED ON Charge Incomplete 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 M dmi CHARGE COMPLETE GREEN TOP LED ON 10096 Complete The charger may now be unplugged from AC power always pull on plug and not cord to reduce risk of damage to the If left plugged in the charger will automatically restart a complete charge cycle if JLG Lift 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 NU e 100 CHARGING PROBLEM NEA RED BOTTOM LED ON AX See Flash Codes following There are several p
140. edial 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 exists 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
141. eight 7 ft 2 13m with Optional Height Limiter 10ft 3 05m Standard Maximum Wheel Load Per Wheel Rear 575 Ib Front 400 Ib Rear 86 6 PSI Front 151 2 PSI Maximum Drive Speeds Operator Variable 0 5 3 4 mph 0 8 5 5 kph Platform Elevated 0 5 mph 0 8 kph Max Platform Speeds w Max Load Platform Up 13sec Platform Down 9 13 sec Gross Machine Weight machine maximum capacity 195010 885kg JLG Lift 1 1 SECTION 1 MACHINE SPECIFICATIONS 1 1 CAPACITIES System Voltage 24 Volt DC Hydraulic System 5 gts U S 4 7 L Drive Motor GearBox Gear Oil 10 oz 296cc 1 2 COMPONENT DATA Hydraulic Pump Pump Motor Assembly Pump Motor 24 Volt DC motor Standard Duty Pump Displacement 098 cu in rev 1 6cc rev Pump Output Max 2 25 1400 psi 24 volts and 105 amps 9 43 centistrokes 200 SSU Reservoir Capacity 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 Friction Disk Spring Applied Electrically Released Batteries Battery Charger Batteries 12 Volt DC 2 in series 24 volt 6 Volt DC 4 in series 24 volt Nominal Capacity 12V 100 Amp Hour 20 Hr 6V 240 Amp Hour 9 20 Hr Type M2 Marine Combination AGM Valve Regulated Leak Proof NonCorrosive Maintenan
142. er unplug wire remove nut and lock washer then slide switch out of console Key Switch Install Remove 4 Platform Console Key Switch Installaiton 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 17 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 Turn Switch 909 6 Switch to Body Retainer 3 Pull Spring Loaded Hooks a Release Lever Out T Switch Retainer Slots 4 Remove Barrel Assembly Note Use small straight blade screwdriver to extend the spring loaded retainer hooks 6 out and release the switch from the body 4 18 JLG Lift Platform Console Joystick Installation 4 Rubber Boot Gasket 5 Install Remove through the Access Hole in Bottom of Housing a b Note a Remove the console mounting bracket b Remove the key switch and e stop switch to remove joystick assembly through access hole in bottom of con Sole 1 Joystick Assembly 2 Attach Screws 01 4 3 Nylon Washers Qty 4 3121228 SECTION 5 MAST COMPONENTS SECTION 5 MAST COMPONENTS 5 1 MAST COMPONENTS OVERVIEW
143. es 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 4 46 0 850 659 500 El 46 0 850 659 534 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy FF 39 029 359 5210 EL 39 029 359 5845 Oshkosh JLG Singapore Technology Equipment Pte Ltd 29 Tuas Ave 4 Jurong Industrial Estate 639379 Singapore 4 65 6591 9030 65 6591 9031 S www jlg com
144. ft 3121228 TABLE OF CONTENTS 6 8 TROUBLESHOOTING TABLES INDEX 6 14 SPECIFICATIONS FOR VARIOUS COMPONENTS 6 14 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS 6 14 FAULT CODE TROUBLESHOOTING TABLES 6 14 MAIN POWER CIRCUIT TROUBLESHOOTING 6 15 MAST 6 15 HYDRAULIC LEAK 6 15 BASE FRAME COMPONENTS TROUBLESHOOTING 6 15 DRIVE SYSTEM 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 Code 01 Low Battery 6 18 Code 02 RESERVED e P tree ege Ate 6 18 Code 03 RESERVED ves Vend RD UK A eee ERR Rd eae 6 18 Code 04 Tilt 6 19 Gode 05 RESERVED a TRU
145. g harness going to the left drive motor brake assembly Is reading Module within spec 2 Repair or replace left brake wiring or left brake assembly Z 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 11 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 3121228 6 20 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 12 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 RemovetheM1 connector fromthe Traction Control Module and check both No Voltage This circuit should Go to Step 2 the pins to the drive motor for any voltage be isolated Ground the meter to the Ground Control Module Negative lug Repair or Replace 2 Check for continuity of both the pins to
146. g 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 226 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 7 10 11 12 13 JLG Lift Insert Output Planet Shaft G10 into the Planet Shaft hole of the Spindle 1 and through the bores 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 G10 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 Mo
147. g 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 lubricant on threads or nuts 2 Tighten lug nuts in the following sequence Figure 3 2 Wheel Lug Nut Tightening Sequence 3 4 JLG Lift 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 30 105 65 80 ftIbs 105 120 1165 28 42 Nm 91 112 142 163 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 Front Caster Wheel Installation Front Caster Wheel Installation 1 Snap Ring 5 Spindle Axle Assy 2 Upper Bearing a 6 Caster Wheel b 3 Lower Bearing a 7 Snap Ring c 4 Spindle Shaft Seal NOTE Base is shown cutaway for illustrative purposes only a If replacing bearing pack bearing completely full of grease before assembling use JLG P N 3020029 Mobil SHC 460 Synthetic or equivalent tap in evenly until sea
148. ge 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 3121228 JLG Lift 6 3 SECTION 6 TROUBLESHOOTING Continuity Measurement Current Measurement 4 7 DIL PUER Figure 6 3 Continuity Measurement Some meters require a separate button press to enable audible continuity testing Circuit power must be turned OFF before testing con tinuity Disconnect component from circuit before testing Use firm contact with meter leads First test meter and leads by touching leads together Meter should produce an audible alarm indicating continuity 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 See multi meter s operation manual Use firm contact with meter leads 3121228 J
149. harging them with the charger that is installed in 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 Ifa 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 current drops below 1 amp Battery Replacement 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 65 Ib 30Kg per battery in order to maintain machine stability as manufactured 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 NOTICE 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 REPLACEMENT 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 3 26 JLG Lift
150. ift Mode Switch InstalllRemove 4 17 Horn Button Switch 4 17 Key Switch Install Remove 2 4 17 E Stop ShutDown Switch 4 18 Joystick Assembly Install Remove 4 18 3121228 JLG Lift iii TABLE OF CONTENTS SECTION 5 MAST COMPONENTS 5 1 MAST COMPONENTS OVERVIEW 5 1 5 2 MAST COVER 1 5 2 5 3 PLATFORM ASSEMBLY 5 2 5 4 MATERIAL TRAY 5 3 5 5 PLATFORM 7 FT HEIGHT LIMIT SWITCH 5 3 5 6 HYDRAULIC LINE DISCONNECT SPECIAL 5 4 Tool Use In Line Style 0 1 5 4 Tool Use Angled Style Fittings 5 5 5 7 MAST ASSEMBLY 2 5 6 M st Removals 5 21 40 QUERER E AR UR A brat 5 6 Mast VERI WEM pesi eii 5 7 5 8
151. il at normal operating temperature If pressure is set when oil is cold platform may not raise rated load after oil has warmed The following pressure setting is the factory recom mended initial setting MODEL PRESSURE SETTING 10MSP 1800 PSI Turning adjustment screw clockwise increases system pressure turning screw counterclockwise decreases system pressure See Figure 3 3 Hydraulic Pressure Adjustment Screw Machine Front Cover Removed Figure 3 3 Hydraulic Pressure Adjustment Screw Machine Front Cover Removed 1 Pressure Adjustment 3 Pump Ground Station Screw Mounting Bracket 2 Remove Adjust Screw Cap 4 Ground Control Station NOTE Machine front cover must be removed to access pump motor 3121228 SECTION 3 BASE COMPONENTS Hydraulic Pressure Gauge Connection A CAUTION ONLY OPEN HYDRAULIC SYSTEM LINES WITH THE MAST FULLY LOWERED TO RELIEVE PRESSURE IN THE SYSTEM CAREFULLY LOOSEN REQUIRED FITTINGS WEAR SAFETY PROTECTION EQUIPMENT WHEN WORKING WITH HYDRAULIC SYSTEMS NOTE See Section 5 6 Hydraulic Line Disconnect Spe cial Tool for hydraulic line removal procedure 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 3 4 Typical Hydraulic Pressure Gauge Installation Hydraulic Filter Removed CHECK and if necessary ADJUST the hydraulic pressure
152. ivated the Ground Control Station LCD screen will indicate a fault code of 6 also the hourmeter 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 NOTE 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 seconds 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 Warning Timer see Ground Control Module Programming in Section 4 of this manual 3 6 JLG Lift Wheel Drive Assembly Removal From Machine The electric wheel drive assemblies are mounted indepen tent 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
153. ive motor leads They should not Controller will Shut Goto Step 5 exceed maximum amperage while pulling a grade Drive Down and will flash a7 LED Code 4 Checkthe condition of the drive motor brushes OK goto Step 6 Worn down replace brushes or drive motor 5 Ifall above is OK Drive motors are working properly Consult Factory zm an 3121228 JLG Lift 6 41 SECTION 6 TROUBLESHOOTING Machine Drives in Opposite Direction Table 6 46 Machine Drive in Opposite Direction STEP ACTION SPEC YES NO 1 Atthe Traction Control Module check left drive motor power lead is Go to Step 2 Switch the Left and plugged into the M1 socket Right Drive Motor Power Leads atthe Traction Module 2 Remove the Right Drive Motor power lead at the Traction Control Module L 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 3 Remove the Left Drive Motor power lead atthe Traction Control Module Consult Rewire as M1 and check if the BLACK wire is connected to the positive terminal Factory Necessary and the 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 6 42 JLG Lift
154. ket lessens as the angle between the supporting structure and the 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 a 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 p
155. l pres surize to 10 psi very quickly If the pressure becomes exces sive in the unit the seals will be destroyed Oil Type and 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 JLG Lift 3 5 SECTION 3 BASE COMPONENTS 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 out 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 o 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 replacment soon This warning protects the drive motors from damage due to extreme brush wear When the brush wear warning is act
156. lures Fatigue cracks are found through the link holes perpendicular 90 degrees from the pin in line 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 3121228 SECTION 2 GENERAL SERVICE INFORMATION 3121228 are 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 b
157. ly 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 in the wear pad channels 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 sections even Apply ing Krytox spray JLG P N 3020041 onto the slide pads and slide pad channels before assembly will help mast sections slide easier after slide pads have been properly shimmed CLOSED RAIL REFERS TO CLOSED RAIL BACK OF MAST SECTION REFERS TO BOTTOM END OF MAST SECTION WHICH SETS IN MACHINE S BASE FRAVE Figure 5 4 Mast Section Assembly Reference 5 12 JLG Lift 3121228 SECTION 5 MAST COMPONENTS Mast Section 1 Assemhly 1 Place mast section 1 rail open side up See Figure 5 4 on a clean flat surface preferably a table or work bench capable of 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 asse
158. mbly 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 1 4 Top of Mast Section 1 Upper Chain Anchor Plate Installation Mast Section 1 Shown Cut Away 1 Anchor Plate Pin 4 Long Spacer 2 Short Spacer 5 Pin Keeper 3 Chain Anchor Plate Assy 6 Keeper Screw a Note a Apply Loctite 242 to threads 3121228 Mast Section 2 Assembly NOTE Before sliding mast sections together spray the slide pad channels with Krytox lubricant spray JLG P N 3020041 Be careful not to scratch or score the anodized finish in the slide pad channels 1 Locate mast section 2 carefully slide mast section 2 closed rail into section 1 open rail Slide sections together until ends are even 2 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 Figure 5 5 Bottom of Mast Section 2 Slide Pad Installation 1 Slide Pads 2 Shim Stock 3 Slide Pad Bolts Washers a Note a Apply Loctite 242 to threads 3 Thread slide pad attaching bolts two 2 1 4
159. mum 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 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
160. n 1 Mast Front of Machine 3 Proximity Switch Bracket 2 Mast Platform Side and Fasteners 4 Switch Detection Plate While the standard maximum platform height for this machine is 10 ft this option limits platform height to 7 ft for certain applications NOTE Route the proximity switch wire with mast junction box wiring harness attach with tie straps Proximity switch wire connects to AUX 2 input on the main harness The ground control module AUX 2 setting must be programmed to HIGH and the AUX 2 INHIBIT setting must be set to 0 See Section 4 4 Ground Control Module Programming 3121228 JLG Lift 5 3 SECTION 5 MAST COMPONENTS 5 6 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 CAUTION FULLY LOWER THE MAST 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 Priorto 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 following Step 2 Pull on hose assembly to create a gap between the
161. n 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 require 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 f
162. nd 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 3121228 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 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 agai
163. nder 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 1 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 3 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 NOTICE Activating Programming Mode With machine power off press and hold the Brake Release But ton 1 on the Ground Control Module Power machine up by turning the Main Power Selector Switch 2 to either the Ground Control or Platform Control Mode 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 If machine did not power up check that both the Ground Control Module Emergency Stop Button and the Platform Control Console Emergency S
164. ndications 1 2 5 S ES GNI mmm e x 00000 0 4 00 00 LCD Display Symbols 1 Battery Charge Indicator BCI 4 Fault Code Indicator 2 Function Display or Function Disable Indicators 5 Fault Code Text Message Display a 3 Hour Meter Display 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 d DRIVE Disabled Drive Speed Cut Back Turtle 4 4 5 LIFT UP Disabled S S Mode Engaged 4 LIFT DOWN Disabled Battery Charger Plugged In 6 8 JLG Lift 3121228 SECTION 6 TROUBLESHOOTING E i 1 Ground Control Module a 4 Right Side Battery b 7 Power Cable To Right Drive Motor Brake a 2 Left Side Battery b c 5 Traction Control Module a 8 Hydraulic Pump Motor Tank Assembly b 3 175 Amp Fuse 6 Power Cable To Left Drive Motor Brake a Ground Control P1 Horn Alarm Beacons Lift Down Valve Harness a P4 Platform Joystick Harness a Module Plugs P2 Elevation Speed Ch
165. ng Bracket 1 Mounting Bracket 2 Bracket Screws a Note a Apply Loctite 242 to screw threads on final assembly Rear Cover Install Remove Platform Console Circuit Board Connections 1 Horn Switch C5 4 E Stop ShutDown Switch 2 Communications Cable to C4 Platform Junction Box 5 Drive Lift ModeSelect 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 the 1 Rear Cover 2 Cover Mounting Screws module s circuit board Platform Console Rear Cover Installation 4 16 JLG Lift 3121228 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 AN Platform Console Drive Lift Mode Select Switch 2 Locking Tabs Note a Remove rear cover unplug switch wire press tabs to remove 1 Switch Assembly a 3121228 Horn Button Switch Install Remove Platform Console Horn Switch Installation 1 Horn Button Switch a 3 Nut 2 Lock Washer Note a Remove rear cov
166. o 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 leak 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 loca tion 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 gasket 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 wil
167. ocedure 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 Hydraulic oil level in reservoir tank at full level Hydraulic oil is not milky presence of water or foamy full of air Table 6 39 Platform Lift Up and Down Jerky STEP ACTION SPEC YES NO CONTROLS ELECTRICAL 1 Is platform 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 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 6 36 JLG Lift 3121228 SECTION 6 TROUBLESHOOTING Table 6 39 Platform Lift Up and Down Jerky Continued STEP ACTION SPEC YES NO HYDRAULIC 5 Is the hydraulic valve working properly Goto Step 6 Replace Valve 6 Pump drive cavatating Replace Pump Go to Step 7 7 Liftcylinder Rebuild or Replace Cylinder 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 debri
168. on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher 1 2 Note 6 NOTE 5 14 Figure 5 6 Top of Mast Section 2 Slide Pad Installation Slide Pads 3 Sequence Cable Bracket Shim Stock 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 Before installing the lift cylinder to mast section 1 and into mast section 2 extend the lift cylinder rod out the top of the lift cylinder approximately 1 ft 31cm To extend the hydaulic cylinder the protective caps on the extend and return ports will need to be tempo rarily removed Be careful not to nick or scour rod surface when extending also catch any oil draining out of cylinder to avoid spillage onto work area 9 Install the lift cylinder mount into the bottom of Mast Section 1 and the cylinder into Section 2 Bottom of Mast Section 2 Cylinder Assembly Installation 1 Cylinder Assembly 3 Cyl Mount Reinforcement Plate 2 Shim Stock a 4 Cyl Mount Bolts and Washers b Note a Thickness as required both sides to center cylinder mount in mast assem
169. ossible conditions that generate errors Some errors are serious and require human 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 Timeout 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 Indi cates charger has shutdown due to high internal temperature which typicall
170. ound Control 5 Platform Junction Box to Module Platform Control Harness 2 Spring Tensioner Clamp 3 Power Trak Assembly Nole See Figure 5 7 Section 5 Mast Components for more detailed harness hardware installation 3121228 SECTION 4 CONTROL COMPONENTS Platform Interlock Switch Circuit The platform interlock circuit consists of the platform foot switch and the platform gate switches wired in series This circuit will inhibit the machines lift and drive functions and display a fault code on the Ground Control Station if the circuit is not closed during machine operation The circuit utilizes the Auxiliary 1 plug on the Platform Junction Box located under the platform From there the circuit is wired to the Ground Control Module P2 connector through the Platform Junction Box to Ground Control Module wiring harness For Ground Control Module P2 pin assignments see the machine wiring schematic in Section 6 Troubleshooting Platform Interlock Switch Circuit Platform Interlock Switch Components 1 Platform Junction Box 4 Right Gate Interlock Switch Location 2 Platform Aux 1 Connector 5 Left Gate Interlock Switch Location Footswitch Platform Gate Interlock Connector 3 Platform Footswitch 3121228 JLG Lift 4 5 SECTION 4 CONTROL COMPONENTS
171. our 4 1 4 20UNC x 3 4 long bolts Apply Loctite 242 to threads on final assembly Bottom of Mast Section 3 Chain Anchor Plate Installation 1 Lower Chain Anchor Bracket 3 Wide Chain Set Studs 2 Anchor Bracket Screws 4 Chain Adjust and Jam Nuts 8 At the top of mast section 3 assemble the chain sheaves for narrow chain assembly to top of mast section 3 as shown following a Slide the narrow spacer tube onto one of the remaining sheave pin b Place the narrow chain sheave wheel assem blies one on each side of the narrow spacer onto the sheave pin c Place one wide spacer tube on the outside of each sheave wheel on the sheave pin 5 16 JLG Lift 3121228 SECTION 5 MAST COMPONENTS Slide the top of mast section 3 back in even with the top of mast section 2 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 Same as Figure 5 6 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
172. ous Conditions First Battery cable ends loose or corroded at battery posts Charger DC output wires from charger to batteries damaged or disconnected Table 6 6 Code 01 Low Battery Voltage STEP ACTION SPEC YES NO 1 Does battery charger power up through diagnostic cycle when pluggedinto Go To Step 2 See Battery Battery Char an AC outlet ger Servicing Section 3 of this Manual 2 Is the Abnormal RED LED litwhen charger is in charge mode Goto Step 3 Charge Batteries Until 100 Green LED is lit Goto Step 4 3 Test Batteries See Battery Condition in Section 3 of this Service Manual See Battery Battery Char Replace Battery ger Servicing Section 3 of this Manual 4 Check Battery Condition See Battery Condition in Section 3 ofthis Service Replace Batteries Manual Dothe batteries pass condition tests as Necessary Code 02 RESERVED Code 03 RESERVED 6 18 JLG Lift 3121228 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 7 Code 04 Tilt Condition STEP ACTION SPEC YES NO 1 Usingadigitallevel che
173. r Plate Inside 10 Threaded Chain End Stud 2 Sequence Cable Adjust Nut 5 Mast Section 3 8 Chain Adjust Nut 5 22 JLG Lift 3121228 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 IT IS GOOD PRACTICE TO AVOID PRESSURE WASHING ELECTRICAL ELECTRONIC COMPONENTS IN THE EVENT PRESSURE WASH ING THE MACHINE IS NEEDED ENSURE THE MACHINE IS SHUT DOWN BEFORE PRESSURE WASHING SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC RECOMMENDS A MAXI MUM PRESSURE OF 750 PSI 52 BAR AT A MINIMUM DISTANCE OF 12 INCHES 30 5 CM AWAY FROM THESE COMPONENTS IF ELEC TRICAL 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 Section 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 rem
174. ressure to the inner race Gaskets Check that holes in gaskets align 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 JLG Lift 2 5 SECTION 2 GENERAL SERVICE INFORMATION 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 the Torque Chart Figures in Section 1 of this Service Manual 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 Cle
175. reventive Maintenance amp Inspection Schedule 2 8 2 3 Chain Stretch Tolerance 2 6 3 1 Wheel Torque Chart EU UL eoe 3 4 4 1 Ground Control Module Field Programmable Settings and Factory Preset 10MSP 4 13 5 1 Mast Component 4 5 7 6 1 LCD Display Service Fault Code 6 10 6 2 Ohm Ratings for Various 5 nn 6 16 6 3 Amperage Draw for Various Components 1 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 Time 6 17 6 6 Code 01 Low Battery 6 18 6 7 04 ette ante ue Bin rada ts 6 19 6 8 Code 07 Left Drive Motor 6 19 6 9 Code 08 Right Drive Motor Disconnected 6 20 6 10 Code 09 Left Brake Disconnected 6 20 6 11 Code 10 Right Brake Disconnected
176. rk 5 Motor Valve Body 3121228 SECTION 3 BASE COMPONENTS Motor Brush Cover Remove Install USS c 3 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 note above before attempting to remove the cover b These steel screws are threaded into the aluminum valve body do not overtighten 3121228 JLG Lift 3 23 SECTION 3 BASE COMPONENTS Brush Carrier Assembly Remove Install
177. rom the date of the 14 Properly lubricated prior inspection 15 Torqued to proper specification 16 No gouges excessive wear or cords showing 17 Properly inflated and seated around rim JLG Lift 3121228 SECTION 2 GENERAL SERVICE INFORMATION 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 SAFELY 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 vital components Precautions have been taken to safeguard against this Shields covers seals and filters are provided to keep the wheel bearings mast sections and oil supply clean however these items must be main tained on a scheduled basis in order to function properly NOTICE IT IS GOOD PRACTICE TO
178. rs 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 on Page 4 13 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 4 12 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 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 displayed 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 Operator Programming Mode Level 3 In the Operator Programming Mode the following items are sho
179. s 6 and slowly pull the Motor 2 out of the gearbox 3 Obtain and install 2 bolts M5 x 0 8 20mm long 5 into the brake containment holes This will keep the brake housing in one piece 8 4 Cutthe black wire tie not shown from the frame of the motor 5 Remove the 3 Brake Bolts 7 3 8 JLG Lift NOTE 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 3121228 SECTION 3 BASE COMPONENTS Replacing Drive Motor Brushes NOTICE 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 DISASSEMBLY MAIN COMPONENTS ON THE PAGES FOLLOWING 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 separate
180. s 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 Oshkosh Truck Corporation Company Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 JLG Worldwide Locations USA 717 485 5161 717 485 6417 3121228 JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 61 265811111 61 2 65 813058 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil 2 55 19 3295 0407 55 19 3295 1025 Cay JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England FE 44 0 161 654 1000 El 44 0 161 654 1001 JLG France SAS 2 1 de Baulieu 47400 Fauillet France 33 0 5 53 88 31 70 33 0 5 53 88 31 79 Xm JLG Deutschland GmbH Max 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 P I Castellbisbal Sur 08755 Castellbisbal Barcelona Spain c 34 93 772 4700 34 93 771 1762 JLG Equipment Servic
181. s proper lubrica tion and operation Table 6 40 Mast Noisy when Lifting and Lowering STEP ACTION SPEC YES NO 1 Doslide pads and slide pad channels need to be cleaned of dust dirt or Clean Pads and Go to 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 Arethe chain 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 E Clean Slide Pads Goto Step 5 springs are compressed Channels or Re Note This noise is normal at the 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 of the mast being shimmed to tight or dirt and debris in the slide pad channels causing the mastto be tight 5 Isthe 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 m Repair or Replace Go to Step 7 Pump 7 Arethe hydraulic lines vibrating together Adjustthe Position Goto Step 8 ofth
182. s necessary or a fastener has loosened refer to the applicable Torque Chart in this sec tion of the manual to determine proper torque values for various size fasteners 1 5 CYLINDER SPECIFICATIONS NOTE All dimensions are given in inches in with the met ric equivalent centimeters cm given in parenthe 565 Table 1 3 Cylinder Specifications BORE STROKE ROD DIA sene in cm in cm in cm 10MSP 1 63 41 50 1 375 Lift Cylinder 4 10 105 4 3 49 1 6 SERIAL NUMBER LOCATIONS For machine identification a serial number plate is affixed to the machine The plate is mounted on the base frame between the front caster wheels under the front cover The serial number is also stamped on the front of the mast assembly near the amber beacon 1 7 LUBRICATION 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 10W 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 h
183. sert 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 backprobing 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 COM 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 1 000 u micro Displayed Number 1 000 000 Example 1 2 KQ 1200 Q Example 50 mA 0 05 A 6 2 JLG Lift 3121228 SECTION 6 TROUBLESHOOTING Voltage Measurement Resistance Measurement Figure 6 1 Volta
184. sistance across positive and negative drive motor leads in 1to 30hms Replace Traction Goto Step 2 M1 connector wiring harness going to the left drive motor Is reading within Module spec 2 Repair or replace left drive motor wiring brushes or motor For brush replacement see Section 3 of this Service Manual 6 19 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 9 Code 08 Right Drive Motor Disconnected STEP ACTION SPEC YES NO 1 Checkresistance across positive and negative leads in M2 1 to 3 ohms Replace Traction Goto Step 2 tor wiring harness going to the right drive motor Is reading within spec Module 2 Repairorreplace 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 10 Code 09 Left Brake Disconnected STEP ACTION SPEC YES NO 1 Check resistance across positive and negative leads in 1 See Table 6 2 Replace Traction Goto Step 2 tor wirin
185. st Section 3 Narrow Chain Set Layout 2 Chain Anchor Block 3 Mast Section 3 1 Narrow Chain Set Attached to Chain Anchor Block on Mast Section 2 NOTE Before sliding mast sections together spray the slide pad channels with Krytox lubricant spray JLG P N 3020041 Be careful not to scratch or score the anodized finish in the slide pad channels 2 Carefully slide mast section 4 into section 3 until ends are even 3 At the bottom of mast section 4 install the slide pads between mast section 3 and 4 Shim per instructions in step 7 Mast Section 2 Assembly Apply Loctite 242 to the threads of the pad screws on final assembly Bottom of Mast Section 4 Slide Pad Installation 1 Slide Pads 2 Shim Stock 3 Shim Pad Screws Apply Loctite 242 Slide mast section 4 out the top of mast section 3 approximately 1 ft 31cm Locate the lower chain anchor bracket one with the threaded attach holes in a triangular shape pattern Working at the bottom end of mast section 4 insert the threads stud ends of the narrow chain set now laying between mast section 3 and 4 into the holes of the lower chain anchor bracket Loosely thread two 2 3 8 16UNC nuts onto the stud threads on each chain Slide the anchor plate into the closed rail at the bot tom of mast section 4 and attach the anchor plate to the bottom of mast section 4 with three 3 1 4 20UNC x
186. tach Washer Screws 6 Sequence Cable Sheave 3 Lower Bracket Wheel 4 Sheave Wheel Attach Bolt 7 Spacers Qty 4 3121228 2 Side of Mast Section 3 Lower Sequence Cable Bracket 1 Mast Section 3 5 Sheave Wheel Thrust 2 Lower Bracket Attach Washer Screws 6 Sequence Cable Sheave 3 Lower Bracket Wheel 4 Sheave Wheel Attach Bolt 7 Spacers Qty 4 gt Side of Mast Section 4 Lower Sequence Cable Bracket 3 Lower Bracket Mast Section 4 Bracket Attach Screws 13 Install the platform junction box to ground control station wiring harness See Figure 5 7 including the platform junction box powertrack assembly har ness cable sheave assembly and harness spring tensioner to the side of the mast assembly Refer ence Section 4 Platform Junction Box Install Remove If equipped re install the OPTIONAL 7 ft height limit ing switch and bracket to the mast See Section 5 5 Platform 7 FT HEIGHT Limit Switch OPTION 14 The mast assembly is now complete and ready to install onto the base frame JLG Lift 5 19 SECTION 5 MAST COMPONENTS Figure 5 7 Platform Junction Box to Ground Control S
187. tation Wiring Harness 3 Upper Powertrak Bracket 5 Lower Powertrak Bracket 1 Harness Sheave Wheel 4 Mid Powertrak Bracket Powertrak 2 Harness Spring Tensioner Shown Cutaway 3121228 JLG Lift 5 20 SECTION 5 MAST COMPONENTS 9 11 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT NOTE This procedure is to be performed with the mast mounted on the machine Mast Chain Cable Adjustment See Figure 5 8 The intention of this procedure is to assure equal load dis tribution between the individual chains of a mast section chain sets Adjust using the following procedure 1 Remove the mast cover from the platform See Sec tion 5 2 Mast Cover Install Remove With mast completely lowered 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 cer tain the chain 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 the mast sections should all be even at the top and not stepped See Figure 5 8 If adjustment is required adjust one mast section at a time starting from the front of the mast section 3 and work towards the platform only mast section 3 and 4 are adjustable To adjust elevate the platform until the chain anchor adjust and jam nuts are accessible at the front and bottom of each mast section A WAR
188. te 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 3121228 JLG Lift 6 7 SECTION 6 TROUBLESHOOTING 6 7 GROUND CONTROL MODULE LCD DISPLAY Sad 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 i
189. ted b Coat the axle shaft with Loctite Moly Paste lubricant before assembling wheel Wheel axle bearings are maintenance free Original spoke wheel mounts same c After installing the wheel and just before installing the Snap Ring wipe the end of the axle clean and coat the end of the axle with Clear Varnish 3121228 SECTION 3 BASE COMPONENTS 3 4 DRIVE ELEVATION CUT OUT SWITCH INSTALLATION Drive Elevation Switch Cut Out Switch Installation 1 Mounting Screws a 2 Proximity Switch b 3 Switch Mounting Block NOTE a Apply Loctite 242 to mounting screw threads on final assembly b The 10MSP is designed with two 2 drive elevation cut out proximity switches in the event that if one fails the other will continue to operate Both are plugged into the wiring harness to the P2 connector on the Ground Control Station If either switch would fail the Ground Control Module will signal a fault condition 4 Mounting Holes 5 Proximity Switch b 3121228 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 t
190. ted 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 3121228 SECTION 2 GENERAL SERVICE INFORMATION Table 2 2 10MSP Preventive Maintenance amp Inspection Schedule 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 MAST ASSEMBLY 7 Mast Sections 2 5 2 9 Chain Systems 14 3 14 14 25 Sequence Cable Systems 3 1 2 3 Covers and Shields 1 Sheave Systems 1 2 1 2 Bearings 1 2 Slide Pads 1 2 PLATFORM ASSEMBLY 7 Platform and Material Tray 1 1 Guard Rails 1 2 4 1 2 4 Gate 1 5 1 5 Floor 1 2 1 2 Lanyard Anchorage Point 1 4 1 4 CHASSIS ASSEMBLY 7 Hood and Covers Installation 1 7 1 7 Static Strap 1 1 Caster Wheels 1 2 1 2 1 2 Drive Wheels Axle Assembly 2 2 Gear Box Assembly Drive Motor Brushes FUNCTIONS CONTROLS 7
191. tenance 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 10MSP Preventive Maintenance amp 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 SERVICE INFORMATION Table 2 1 Maintenance and Inspection Requirements Type Frequenc sanies Reference 4 Responsibility Qualification Pre Start Priorto use each day or User or Operator User or Operator
192. tick 5Qt Level v aaa Sie Reservoir HO Change Hyd Oil Upper Permanently Sealed 2 Swivel Raceways MPG v Lower Repack if Serviced 3 Mast Chains 2 Per Section CL Brush or Spray v Inspect lubricate if dry or rusting 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 Notes Be 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 1 4 JLG Lift 3121228 SECTION 1 MACHINE SPECIFICATIONS 1 8 TORQUE SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 5 BOLTS amp GRADE 2 NUTS Torque Tensil Loctite amp 242 or 271 Size TP BoltDia 996 Clamp Load your oe ny Loctite 2627 or Vibra Stress Area Dry Lubricated OR Vibra TITE 111 or y 140 TITE 131
193. tly push hose assembly into coupling Manual Descent Valve Remove body see directional arrow Platform Control Console See Section 4 2 Mast Cover See Section 5 2 Platform Material Tray Assembly See Section 5 3 Battery Charger Assembly See Section 3 7 Step 5 While maintaining slight pressure on the hose assembly actuate the tool see arrow Mast Assembly Mounting Bolt Location 1 Mast Mounting Column a 2 Mounting Bolt Washer Nut Locations b Notes Battery charger removed b Apply Loctite 271 to bolt threads on final assembly 1 Unplug the platform control cable P4 connector at Step 6 Pull on hose assembly to complete discon the ground control module nection 2 Unplug and remove the amber beacon mounted on the front of the mast assembly 5 6 JLG Lift 3121228 SECTION 5 MAST COMPONENTS 3 Disconnect and cap the hydraulic extend and return 5 8 MAST DISASSEMBLY PROCEDURE lines from the hydraulic cylinder either on the valve block at the bottom of the cylinder or at the pump The mast sections are constructed of extruded aluminum assembly See Section 5 6 for special tool instruc protected with an anodized surface finish The mast sec tions tions are interlocked into each other when assembled by internally mounted slide pads at the top and bottom of 4 Using an overhead
194. top Button are in the RESET position Also if machine is equipped with the PSL Program mable Security Lock option refer to the Operators Manual for additional machine power up steps Entering Password THE LEVEL 1 JLG ENGINEERING SETTINGS ARE NOT DIS PLAYED IN THE PROGRAMMABLE SETTINGS 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 4 c Oe 2 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 2 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 4 horn and beacon components 4 10 JLG Lift Entering Password The Brake Release button 1 moves the box around digit from left to right to select which digit to change Platform UP button 2 increases the numerical digit Platform DOWN button
195. tor Shaft Seal G17 into the center bore so that it is flush with the face of the Spindle G1 3 15 SECTION 3 BASE COMPONENTS Hub Sub Assembly Hub Sub Assembly 1 Put Hub G2 on a table with the tapped holes fac 3 ing down 2 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 NOTE The Seal has a thin outer shell that can be easily dam aged if not installed with care It is a good idea to start the Seal into the bore with a rubber mallet before pressing 3 16 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 3121228 SECTION 3 BASE COMPONENTS Input Carrier Sub Assembly 3121228 Input Carrier Sub Assembly Use the Input Planet Shaft G6 as a pressing tool to install the Planet Bushing 226 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 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
196. ule to the Pump Motor studs for loose or cor roded connections Table 6 15 Code 14 Pump Motor Disconnected STEP ACTION SPEC YES NO 1 Check resistance across the positive and negative studs on the 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 16 Code 15 Lift Down Valve Disconnected STEP ACTION SPEC YES NO 1 Check voltage atthe P1 connector on the Ground Control Module between 2 AVDC Replace Ground Go to Step 2 pin 10 and pin 3 Is reading within spec Control Module 2 Check resistance between the terminals on the lift down valve located at 6 Ohms Repair or Replace Replace the the base of the lift cylinder Is reading within spec Wiring Harness Lift Down Valve from Ground Con Solenoid trol Module 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 connectortothe lift down valve Wiring 6 22 JLG Lift 3121228 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
197. ushing on leaf chain In extreme cases this frictional torque can actually turn the pins in the outside press fit plates 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
198. with Planet Gears G9 facing up Do not damage or scratch the seal surface of the Spindle G1 during disassembly Remove three Output Planet Shafts G10 These Planet Shafts are held in with a press fit Use 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 The Output Planet Gears 69 are very similar in size to the Input Planet Gears 5 tag or label the Planet Gears to avoid confusion 4 NOTE JLG Lift Press out Bushing G26 from the bore of each Planet Gear G9 Bushings cannot be reused when removed Remove the Main Bearing G14 from the outside diameter of the Spindle G1 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 reassembled Flip over the Spindle G1 Press out the Motor Shaft Seal G17 from the cen ter bore The seal cannot be reused when removed Remove the shaft Ball Bearing G15 from the cen ter bore 3121228 SECTION 3 BASE COMPONENTS Spindle Sub Assemhly NOTE 3121228 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 61 during assembly Using the appropriate pressin
199. wn on the main menu Also See Table 4 1 on Page 4 13 Tilt Sensor Program NOTE There are two production modules available one for North South American and European languages and one for Asian languages All programmable items between these modules are identical 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 on Page 4 13 JLG Lift 3121228 SECTION 4 CONTROL COMPONENTS Table 4 1 Ground Control Module Field Programmable Settings and Factory Preset 10MSP Level 2 Service Level Settings OnLCD Display YES HIGH Level 3 Operator Level Settings NO X Low FACTORY LEVEL PROGRAMMABLE ITEM PRESET SETTING RANGE 2 Backto Main Return to Programming Menu 3 Set Language 1 1 English 6 Italian 2 German 7 Swedish 5 3 Dutch 8 Brazilian Portuguese NOTE There are two production modules available at this time 4 French 9 Finnish one for North South American and European Lan 5 Spanish guages and one for Asian Languages 2 1 Engiish 3 Japanese 2 Chinese 2 Set Maximum Lift Up Speed 10096 0 100 2 Set Maximum Lift Down Speed 10096 0 100 2 Zerothe On Board Tilt Sensor NO YES NO 2 3 SetSleep Time 10 MINS 0 60 MINS 2 Set Polarity Of Left
200. y 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 Fill half full Replace after system brush wear indicator warning is activated Drain and refill with fresh hydraulic fluid every two years Maintenance and Inspection Table Codes 1 Check for proper and secure installation 18 Proper and authorized components 2 Visual inspection for damage cracks distortion or 19 Fully charged excessive wear 3 20 Noloose connections corrosion or abrasions 3 Check for proper adjustment 21 Verify 4 Check for cracked or broken welds 22 Perform By Operates DIOE 23 Sealed properly 6 Returns to neutral or off position when released Blattofm a i 25 Inspected per Service and Maintenance Manual 8 Interlocks function properly F 9 Check signs of leakage ootnotes 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 or more or Purchased used 18 gt Check Io proper iolpiances d Annually no later than 13 months f
201. y 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 QuiQ 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 3 29 SECTION 3 BASE COMPONENTS 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 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 high pres sure water spraying when cleaning vehicle 3 30 JLG Lift Battery Charger Check Change Charging Algorithm The charger comes pre loaded with nine algorithms for various battery types as detailed in the table below If your specific battery 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 Repeat until desired Algorithm is displayed A 30 sec ond time out is extended for every increment During this time the current Algorithm 4 is indicated on the YELL
202. ydraulic 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 1809 18 to 83 C 0 F to 2109 18 to 99 C 50 to 2109 10 C to 4 99 C 10W 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 qualities and being of extreme pressure type Timken OK 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API ser vice classification GL 5 or MIL Spec MIL L 2105 HO Hydraulic Oil ISO Vg grade 32 46 CL Chain Lube Use a good quality chain lubricant JLG Lift 1 3 SECTION 1 MACHINE SPECIFICATIONS Lubrication Points See Table Below Table 1 6 Lubrication Intervals for Various Components INTERVAL 0 ITEM NO TYPE LUBE METHOD 3 6 1 2 COMMENTS LUBE POINTS MONTHS MONTHS YEAR YEARS Fill To Full Line on Check Hyd Oil c 1 be heck fluid 1 Hydraulic Oil Dips

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