Service & Maintenance Manual
Model(s)
15/20MVL &
15/20MSP
Series
P/N - 3121231
December 20, 2013
NOTES:
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
MAINTENANCE SAFETY PRECAUTIONS
A. GENERAL
This section contains the general safety precautions
which must be observed during maintenance of the aerial
platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others or
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.
MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY
A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST
AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLATION.
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 parts.
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of component weight and never attempt to
move heavy parts without the aid of a mechanical device.
Do not allow heavy objects to rest in an unstable position.
When raising a portion of the equipment, ensure that adequate support is provided.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL 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 disconnecting or removing any portion of the system.
C. MAINTENANCE
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
• 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, CAUTION AND OTHER INSTRUCTIONS ON MACHINE
AND IN SERVICE MANUAL.
• KEEP STANDING SURFACES AND HAND HOLDS
FREE OF OIL, GREASE, WATER, ETC.
• NEVER WORK UNDER AN ELEVATED PLATFORM
UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED
FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT
OFF ALL POWER CONTROLS.
•BATTERY SHOULD ALWAYS BE DISCONNECTED
DURING REPLACEMENT OF ELECTRICAL COMPONENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
• ENSURE REPLACEMENT PARTS OR COMPONENTS
ARE IDENTICAL OR EQUIVALENT TO ORIGINAL
PARTS OR COMPONENTS.
2. Relieve system pressure by lowering the platform
completely to direct any line pressure back into the
return line to the reservoir. Pressure feed lines to
system components can then be disconnected with
minimal fluid loss.
3121231 – JLG Lift – a
INTRODUCTION - REVISION LOG
REVISION LOG
Original Issue of Manual . . . . . . . . . . . . . . . . . . . . . January 5, 2006
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . April 3, 2006
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . October 4, 2006
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . October 8, 2007
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . April 17, 2008
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . October 7, 2008
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . May 15, 2009
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .July 19, 2010
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . December 21, 2010
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . .February 23, 2012
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . April 25, 2013
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . December 5, 2013
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . December 20, 2013
b – JLG Lift – 3121231
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
MAINTENANCE SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
A GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
B HYDRAULIC SYSTEM SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
C MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
REVISION LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
SECTION 1 - MACHINE SPECIFICATIONS
1.1 CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Drive Motor GearBox (gear oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.2 COMPONENT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hydraulic Pump/Pump Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Rear Wheel Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Batteries/Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.3 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Platform Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Machine Height (platform stowed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Machine Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Base Footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.5 CYLINDER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6 SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.7 TORQUE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SECTION 2 - GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Pre-Delivery Inspection and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Inspection and Maintenance Codes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Footnotes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 SERVICING AND MAINTENANCE GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3121231 – JLG Lift – i
TABLE OF CONTENTS
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Mast Chain Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4 LUBRICATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
SECTION 3 - BASE COMPONENTS
3.1 BASE ASSEMBLY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 BASE FRAME COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Drive Motor Cover - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Battery Charger Cover - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.3 DRIVE/ELEVATION CUT-OUT SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 DRIVE AND CASTER WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Tire Wear and Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Wheel and Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Caster Wheels - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.5 WHEEL DRIVE ASSEMBLY - SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Roll And Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Oil Type & Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Drive Motor Brush Wear - Warning Indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Wheel Drive Assembly - Removal From Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Wheel Drive Disassembly - Main Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Replacing Drive Motor Brushes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Gear Box Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Hub - Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Hub Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Main Gear Box Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Motor, Brake and Gear Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.6 POT HOLE PROTECTION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.7 BATTERY CHARGER - SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Battery Charger General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Battery Charger Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Battery Charge LED Indicator on Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . .3-20
Battery Low Voltage Warning Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Battery Charging Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Battery Charger Check/Change Charging Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
Battery Charger Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
SECTION 4 - CONTROL COMPONENTS
4.1 CONTROL COMPONENTS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 CONTROLS COVER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Battery Cover Doors (Optional Hinged) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Center, Left and Right Lower Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.3 CONTROL COMPONENTS - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Ground Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
ii – JLG Lift – 3121231
TABLE OF CONTENTS
Traction Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Platform Control Console Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Horn Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Alarm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.4 BATTERIES - SERVICE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Battery Condition Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Battery Disconnect (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Battery - Installation - (2-12V Batteries) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Battery Installation - (4-6V Batteries) (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4.5 GROUND CONTROL MODULE - SERVICE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Cover Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Power Selector/EStop Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
4.6 GROUND CONTROL MODULE - PROGRAMMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Programming Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Activating Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Entering Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Programming Mode Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Selecting Programmable Item to Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Adjusting Programmable Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Service Programming Mode - (Level-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Operator Programming Mode - (Level-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.7 PLATFORM CONTROL CONSOLE - SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Remove Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Display/Controller Module Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Mounting Bracket - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Rear Cover - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Display/Controller Module - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
Drive/Lift Mode Switch - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
Horn Button Switch - Install/Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Key Switch - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
E-Stop/ShutDown Switch - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
Joystick Assembly - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.8 PUMP-MOTOR ASSEMBLY - SERVICE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
Hydraulic Pressure settings and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Hydraulic Pressure Gauge Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
After Filter Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Pump/Motor/Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
General Installation and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Inline Hydraulic Filter Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
FENNER BRAND PUMP - Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Motor Cap/Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Motor Brush Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
Brush Housing Final Assembly Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
MONARCH BRAND PUMP - Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
Motor Assembly - Remove/Install - Reference Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Motor/Brush Cover - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
Brush Carrier Assembly - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
Brush Assembly - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
Tank Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
Filter Screen Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Pressure Adjust Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Pressure Check Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
3121231 – JLG Lift – iii
TABLE OF CONTENTS
4.9 OBSTRUCTION SENSOR SYSTEM - SERVICE PROCEDURE (MSP - OPTION) . . . . . . . . . . . . .4-29
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Transducer Sensor Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
OSS Component Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
SECTION 5 - MAST COMPONENTS
5.1 MAST COMPONENTS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Mast Chain/Cable Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Sequencing Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 SEQUENCE CABLE REPLACEMENT KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Remove Old Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Replacement Cable Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Clamp Installation (Drum/Socket Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5.4 HYDRAULIC LINE - DISCONNECT - SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Tool Use - In-Line Style Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Tool Use - Angled Style Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5.5 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILD . . . . . . . . . . . . . . . . . . .5-9
Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
Lift Cylinder Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Cylinder Assembly (See Figure 5-4.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
5.6 MAST ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
Mast Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.7 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Mast Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Mast Assembly - MVL/MSP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.8 MSP - STOCKPICKER PLATFORM - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.9 MSP - STOCKPICKER PLATFORM - MID-GATE INTERLOCK INSTALLATION . . . . . . . . . . . . . . 5-28
5.10 MAST BEACON - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28
5.11 GATE ALARM - INSTALLATION - OPTION (FOR SIDE ENTRY W/FOLDING
MATERIAL TRAY PLATFORM ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-29
Switches and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-29
5.12 MAST - 14 FT. HEIGHT LIMITING SWITCH -15MSP OPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
SECTION 6 - TROUBLESHOOTING
6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 TROUBLESHOOTING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3 HYDRAULIC CIRCUIT CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.4 ELECTRICAL CIRCUIT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.5 MULTIMETER BASICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Continuity Measurement Over Long Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Requirements: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
iv – JLG Lift – 3121231
TABLE OF CONTENTS
6.6 ELECTRICAL SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Basic Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Automatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Switch Wiring - Low Side, High Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.7 GROUND CONTROL MODULE LCD DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
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 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Hydraulic Leak Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Base Frame Components Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Drive System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
6.9 SPECIFICATIONS FOR VARIOUS COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.10 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS . . . . . . . . . . . . . . . . . . .6-16
6.11 FAULT CODE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Machine in Drive Speed Cut-Back (Turtle) Mode All The Time . . . . . . . . . . . . . . . . . . . . . .6-17
Obstruction Sensor System - Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Battery Voltage Low - Warning Level 3 - Three (3) LED/LCDs lit . . . . . . . . . . . . . . . . . . . . . 6-18
Code 02 - Left PHP Bar - UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 03 - Right PHP Bar - UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 04 - Tilt Condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
Code 05 - Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
Code 06 - Drive Motor Brush Wear Warning Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 07 - Left Drive Motor - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 08 - Right Drive Motor - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
Code 09 - Left Brake - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
Code 10 - Right Brake - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
Code 11 - Left Drive Motor - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
Code 12 - Right Drive Motor - Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code 13 - Traction Module - In Fold Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
Code 14 - Pump Motor - Disconnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code 15 - Lift Down Valve - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
Code 16 - Lift Down Valve - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Code 17 - Ground Control Module - In Fold Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Code 18 - Alarm - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Code 19 - Alarm - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
Code 20 - Beacon - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code 21 - Beacon - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27
Code 22 - Horn - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code 23 - Horn - Disconnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28
Code 24 - Auxiliary #1 Circuit - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Code 25 - Auxiliary #1 Circuit - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29
Code 26 - Auxiliary #2 - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code 27 - Auxiliary #2 - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30
Code 28 - Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30
Code 29 - Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30
Code 30 - Traction Module - No Communication with Ground Control Module . . . . . . . . . 6-30
Code 31 - Platform Control Console - No Communication with Ground Control Module . .6-31
Code 32 - Pump Motor - Over Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Code 33 - Both PHP Bars - UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Code 34 - P2-Auxiliary #1 - Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Code 35 - P2-Auxiliary #1 - Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Code 38 - Battery Voltage Low - Warning Level 2 - Two (2) LED/LCDs lit . . . . . . . . . . . . . . 6-33
3121231 – JLG Lift – v
TABLE OF CONTENTS
Code 39 - Battery Voltage Low - Warning Level 3 - One (1) LED/LCDs lit . . . . . . . . . . . . . .6-33
Code 40 - Obstruction Sensor System - No Communication with Ground Control Module 6-34
Codes 41 thru 46 - OSS - Sensor 1 through 6 - Fault Condition . . . . . . . . . . . . . . . . . . . . . 6-35
Codes (100 - 199) Ground Control Module - Fault Condition . . . . . . . . . . . . . . . . . . . . . . . 6-36
Codes (200 - 299) Platform Control Console - Fault Condition . . . . . . . . . . . . . . . . . . . . . . 6-37
Codes (300 - 399) Traction Control Module - Fault Condition . . . . . . . . . . . . . . . . . . . . . . . 6-38
6.12 MAIN POWER CIRCUIT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Machine Will Not Power Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
6.13 MAST TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40
Platform Will Not Lower Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Platform Lift Up And Down - Jerky . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Mast Noisy When Lifting And Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Platform (Mast) Won’t Stay Elevated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42
Platform (Mast) Descends Too Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42
6.14 HYDRAULIC LEAK TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Miscellaneous Hydraulic Leak Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
6.15 BASE FRAME COMPONENTS TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Caster Wheels Not Operating Freely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Pot Hole Protection (PHP) Bars will not Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44
6.16 DRIVE SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Won’t Climb Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45
Machine Drives in Opposite Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Machine Won’t Drive Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Noise From Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
vi – JLG Lift – 3121231
TABLE OF CONTENTS
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. Torque Chart (SAE Fasteners - Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-2. Torque Chart (SAE Fasteners - Sheet 2 of 7)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1-3. Torque Chart (SAE Fasteners - Sheet 3 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1-4. Torque Chart (SAE Fasteners - Sheet 4 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1-5. Torque Chart (METRIC Fasteners - Sheet 5 of 7)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-6. Torque Chart (METRIC Fasteners - Sheet 6 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
1-7. Torque Chart (METRIC Fasteners - Sheet 7 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
3-1. Base Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-2. Wheel Lug Nut Tightening Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
4-1. Control Components Location - MVL/MSP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4-2. Component Electrical Connections. (2-12V Batteries shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4-3. Battery Cable to Battery Terminal Connections (4-6V). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4-4. Ground Control Module Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-5. Platform Control Console Components.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
4-6. Hydraulic Pressure Adjustment Screw. (Machine Rear Covers Removed) . . . . . . . . . . . . . . . . . .4-20
4-7. Typical Hydraulic Pressure Gauge Installation (Hydraulic Filter Removed). . . . . . . . . . . . . . . . . .4-20
4-8. Typical Hydraulic Pressure Gauge Installation (After Hydraulic Filter). . . . . . . . . . . . . . . . . . . . . .4-21
4-9. Obstruction Sensor System Components (Platform Cutaway) . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
5-1. Mast Components. (MVL/MSP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5-2. MVL/MSP - Mast Chain and Sequence Cable Adjustment Components. . . . . . . . . . . . . . . . . . . . 5-3
5-3. Machine Positioned for Cylinder Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5-4. Lift Cylinder Component Cross-Section (MVL/MSP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
5-5. Mast Section - Assembly Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
5-6. Mast Chain Routing Diagram. - MVL/MSP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
5-7. Mast Bottom End - Slide Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
5-8. MSP - StockPicker Platform Installation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27
6-1. Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
6-4. Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
6-5. Component Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
6-6. Overview of Electrical System Components. (MVL/MSP) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . .6-48
6-7. Electrical Diagram. (MVL/MSP) (Sheet 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50
6-8. Hydraulic Diagram. (MVL/MSP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-52
3121231 – JLG Lift – vii
TABLE OF CONTENTS
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 General Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-2. 15MVL/MSP - Machine Maximum Wheel Loads (Lb.) and (PSI) - Per Wheel. . . . . . . . . . . . . . . . . 1-3
1-3. 20MVL/MSP - Machine Maximum Wheel Loads (Lb.) and (PSI) - Per Wheel. . . . . . . . . . . . . . . . . 1-3
1-4 Hydraulic Oil Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-5 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-6 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-7 Lubrication Intervals for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-2 MVL/MSP - Preventive Maintenance & Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-3 Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-2 Battery Low Voltage Warning Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-3 Battery Charger Algorithm Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
4-1 MVL/MSP Ground Control Module - Field Programmable Settings and Factory Preset. . . . . . . .4-14
5-1 MVL/MSP Mast Component Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
6-1 LCD Display - Service Fault Code Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-2 Ohm Ratings for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
6-3 Amperage Draw for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
6-4 Special Pin Extractor Tools for Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-5 Machine In Drive Speed Cut-Back (Turtle) Mode All The Time . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
6-6 Obstruction Sensor System - Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
6-7 Code 02 - Left PHP Bar - UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6-8 Code 03 - Right PHP Bar - UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6-9 Code 04 - Tilt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
6-10 Code 06 - Drive Motor Brush Wear Warning Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
6-11 Code 07 - Left Drive Motor - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
6-12 Code 08 - Right Drive Motor Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
6-13 Code 09 - Left Brake - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
6-14 Code 10 - Right Brake - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
6-15 Code 11 - Left Drive Motor - Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
6-16 Code 12 - Right Drive Motor - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
6-17 Code 13 - Traction Module - In Fold Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
6-18 Code 14 - Pump Motor - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
6-19 Code 15 - Lift Down Valve - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
6-20 Code 16 - Lift Down Valve - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6-21 Code 17 - Ground Control Module - In Fold Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6-22 Code 18 - Alarm - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6-23 Code 19 - Alarm - Disconnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
6-24 Code 20 - Beacon - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6-25 Code 21 - Beacon - Short Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27
6-26 Code 22 - Horn - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27
6-27 Code 23 - Horn - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28
6-28 Code 24 - Auxiliary #1 Circuit - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6-29 Code 25 - Auxiliary #1 Circuit - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29
6-30 Code 26 - Auxiliary #2 - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-31 Code 27 - Auxiliary #2 - Disconnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30
6-32 Code 30 - Traction Module - No Communication with Ground Control Module . . . . . . . . . . . . . .6-30
6-33 Code 31 - Platform Control Console - No Communication with Ground Control Module . . . . . . .6-31
6-34 Code 32 - Pump Motor - Over Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
6-35 Code 33 - Both PHP Bars - UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6-36 Code 34 - P2-Auxiliary #1 - Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6-37 Code 35 - P2-Auxiliary #1 - Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6-38 Code 40 - OSS - No Communication with Ground Control Module . . . . . . . . . . . . . . . . . . . . . . .6-34
6-39 Codes 41 thru 46 - OSS - Sensor 1 through 6 - Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
viii – JLG Lift – 3121231
TABLE OF CONTENTS
6-40 Codes (100 - 199) Ground Control Module - Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36
6-41 Code (200 - 299) Platform Control Console - Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37
6-42 Codes (300 - 399) Traction Control Module - Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38
6-43 Machine Will Not Power UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39
6-44 Platform Will Not Lower Manually. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40
6-45 Platform Lift Up and Down Jerky . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40
6-46 Mast Noisy when Lifting and Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41
6-47 Platform (Mast) Won’t Stay Elevated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42
6-48 Platform (Mast) Descends Too Slowly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42
6-49 Hydraulic Leak Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43
6-50 Caster Wheels Not Operating Freely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44
6-51 Pot Hole Protection (PHP) Bars will not Lower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44
6-52 Won’t Climb Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45
6-53 Machine Drive in Opposite Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45
6-54 Machine Won’t Drive Straight.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46
6-55 Noise from Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47
3121231 – JLG Lift – ix
TABLE OF CONTENTS
NOTES:
x – JLG Lift – 3121231
SECTION 1 - MACHINE SPECIFICATIONS
SECTION 1. MACHINE SPECIFICATIONS
Table 1-1. General Machine Specifications
15MVL 20MVL 15MSP 20MSP
Maximum Occupants: 1
Maximum Work Load (Capacity):
(MVL-Std. Platform / MSP - Stockpicker Platform)
Maximum Travel Grade (Gradeability):
(Platform STOWED ONLY)
Maximum Travel Grade (Side Slope):
(Platform STOWED ONLY)
Maximum Vertical Platform Height:
500 lb.
(230 kg)
15 ft. 2 in.
(4.69 m)
350 lb.
(160 kg)
19 ft. 1 in .
(5.80 m)
20% (11.5°)
5°
15 f t . 1 i n.
500 lb.
(230 kg)
(4.66 m)
(1)
400 lb.
(180 kg)
19 ft. 6 in.
(5.96 m)
Maximum Drive Speeds (Operator Variable): 0.5 - 3.4 mph (0.8 - 5.5 kph)
Max. Platform Speeds (w/Max. Load): P la t fo r m Up : 2 0 s e c. 2 2. 5 se c . 2 0 s e c. 2 2. 5 se c .
P l a tf o rm D o wn : 15 - 21 s ec . 2 1 - 2 6 se c . 1 5 - 2 1 se c . 2 1 - 2 6 se c .
Gross Machine Weight (Platform Empty):
2,235 lb.
(955 kg)
2,235 lb.
(955 kg)
2,280 lb.
(975 kg)
2,280 lb.
(975kg)
NOTE: (1) Standard unless equipped with 14 ft. limiter circuit.
3121231 – JLG Lift – 1-1
SECTION 1 - MACHINE SPECIFICATIONS
1.1 CAPACITIES
System Voltage
All Models – 24 Volt DC
Hydraulic System
All Models – 5 qts. U.S. (4.7 L)
Drive Motor GearBox (gear oil)
All Models – 10 oz. (296cc)
1.2 COMPONENT DATA
Hydraulic Pump/Pump Motor Assembly
Pump Motor - 24 Volt DC motor, Standard Duty
Pump Displacement –
MVL/MSP – .098 cu. in./rev. (1.6cc/rev.)
Pump Output (Max.) –
MVL/MSP - 1.20 gpm @ 2200 psi @ 23.5 volts and
105 amps @ 45 centistrokes (200 SSU)
Reservoir Capacity –
MVL/MSP - 1 Gallon (3.78 L)
Rear Wheel Drive Motors
Drive Motors - 24 Volt DC, Variable
Gear Box - 3500 in. lb. (395.5 Nm) - Continuous Output
7000 in. lb. (791 Nm) - Intermittent Output
30.68:1 Gear Ratio
Brakes - Friction Disk - Spring Applied - Electrically
Released
Batteries/Battery Charger
Batteries (2) - AGM - 12 Volt/100 Amp Hour -
(STD) (@ 20 Hr. rate)
- Sealed/Maintenance Free
- Weight – 71-75 lb. (34 Kg) - Per Battery
Batteries (4) - AGM - 6 Volt/220 Amp Hour -
(OPTION) (@ 20 Hr. rate)
- Sealed/Maintenance Free
- Weight – 66 lb. (30 Kg) - Per Battery
Battery Charger –
Microprocessor Controlled/SCR Circuit Monitor
120/240 Volt A.C. Selectable 50/60 Hz input
24 volt, 20 amp output - with 2 amp finish
Reset Circuit Breaker
Automatic Charge Circuit
Plug Interlock Circuit
NOTE: The batteries on MVL/MSP machines require
approximately five (5) hours to fully charge when
drained to LOW BATTERY VOLTAGE warning on the
Ground Control Module LCD display.
1.3 PERFORMANCE DATA
Platform Capacities
GullWing-Front - 15MVL - 500 lb. (230kg)
20MVL - 350 lb. (160kg)
SlideBar-Front - 15MVL - 500 lb. (230kg)
20MVL - 350 lb. (160kg)
StockPicker - 15MSP - 500 lb. (230kg)
20MSP - 400 lb. (180kg)
GullWing-Extendible - 15MVL - 500 lb. (230kg)
20MVL - 350 lb. (160kg)
SideEntry/w Folding Material Tray -
JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS
ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES.
APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE
THROUGH JLG’S AFTERMARKET PARTS DISTRIBUTION CENTERS 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 COMPATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE
DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND
MACHINE CYCLE TIMES. THE USE OF NON APPROVED BATTERIES 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.
Platform
SPEC
ANSI/
CSA
CE
AUS
(1) This platform is only available on models shown.
NOTE: Distribute weight evenly in platform when loading.
Reference the capacity decal on the machines’ decal
billboard mounted on mast.
(1)
Model
15MSP 300 lb.
20MSP 300 lb.
20MVL 250 lb.
15MVL 350 lb.
20MVL 250 lb.
Capacity
(136 kg)
(136 kg)
(115kg)
(160 kg)
(115kg)
Tray
Capacity
150 lb.
(70 kg)
150 lb
(70 kg)
100 lb.
(45 kg)
150 lb.
(70 kg)
100 lb.
(45 kg)
Combined
Capacity
450 lb.
(206 kg)
450 lb.
(206 kg)
350 lb.
(160 kg)
500 lb.
(230 kg)
350 lb.
(160 kg)
1-2 – JLG Lift – 3121231
SECTION 1 - MACHINE SPECIFICATIONS
Platform Size
Oversized Standard - 26 in.- W x 28 in.- L (66cm x 71cm)
Stockpicker - 28 in.- W x 48 in.- L (71cm x 122cm)
Extendible - 26 in.- W x 49 in.- L (66cm x 124cm)
Plat. w/Mat’l Tray - 27 in.- W x 23 in.- L (68cm x 58cm)
Plat. w/Folding Tray - 26 in.- W x 30 in.- L (66cm x 76cm)
Machine Ground Clearance
PHP Retracted - 2 in. (5.1cm)
PHP Extended - 0.75 in. (1.9cm)
Base Footprint
MVL/MSP - 29.25 in.- W x 52 in.- L (74cm) x (132cm)
Machine Height (platform stowed)
MVL/MSP - 78 in. (198cm) height
Table 1-2. 15MVL/MSP - Machine Maximum Wheel Loads (Lb.) and (PSI) - Per Wheel.
15MVL 15MSP
Platform Type
(Loaded to Max.
Capacity)
22 x 25 SB 865 490 138 252
28 x 26 GW 845 550 128 265
26 x 50 GW 860 515 115 321 860 515 115 321
28 x 48 SP
w/Folding Tray 810 565 125 313
NOTE: Platform Types: SB - with Sliding Bar Gate GW - with Gull Wing Gate SP - Stock Picker Platform
Wheel Load Per Wheel (Lb.) (PSI) Per Whe el Wheel Load Per Wheel (Lb.) (PSI) Per Whee l
Rear Front Rear Front Rear Front Rear Front
Average Maximum Average Maximum
755 615 117 306
Table 1-3. 20MVL/MSP - Machine Maximum Wheel Loads (Lb.) and (PSI) - Per Wheel.
20MVL 20MSP
Platform Type
(Loaded to Max.
Capacity)
22 x 25 SB 855 450 132 250
28 x 26 GW 835 460 121 261
26 x 50 GW 850 480 131 277 850 480 131 259
28 x 48 SP
w/Folding Tray 810 565 125 313
NOTE: Platform Types: SB - with Sliding Bar Gate GW - with Gull Wing Gate SP - Stock Picker Platform
Wheel Load Per Wheel (Lb.) (PSI) Per Wheel Wheel Load Per Wheel (Lb.) (PSI) Per Wheel
Rear Front Rear Front Rear Front Rear Front
Average Maximum Average Maximum
815 560 120 320
3121231 – JLG Lift – 1-3
SECTION 1 - MACHINE SPECIFICATIONS
1.4 LUBRICATION
NOTE: Also see Lubrication Interval Chart - Table 1-7, Lubri-
cation Intervals for Various Components in this section of the manual.
Hydraulic Oil
Hydraulic oils must have anti-wear qualities at least to API
Service Classification GL-3, and sufficient chemical stability 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 recommends 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 contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is
desired, contact JLG Industries for proper recommendations.
Table 1-4. Hydraulic Oil Operating Range
HYDRAULIC SYSTEM OPERATING
TEMPERATURE RANGE
+0° F to +180° F
(-18° C to +83° C)
SAE VISCOSITY
GRADE
10W
1.5 CYLINDER SPECIFICATIONS
NOTE: All dimensions are given in inches (in), with the met-
ric equivalent, centimeters (cm), given in parentheses.
Table 1-6. Cylinder Specifications
DESCRIPTION
15MVL/15MSP Lift Cylinder
20MVL/20MSP Lift Cylinder
BORE
in./(cm)
1.63
(4.10)
1.63
(4.10)
STROKE
in./(cm)
41.50
(105.4)
54.0
(137.1)
ROD DIA.
in./(cm)
1.375
(3.49)
1.375
(3.49)
1.6 SERIAL NUMBER LOCATIONS
For machine identification, a serial number plate is affixed
to the machine. The plate is located on the back of the
mast, just above the mast support column.
1.7 TORQUE REQUIREMENTS
When maintenance becomes necessary or a fastener has
loosened, refer to the applicable Torque Charts in this section of the manual, to determine proper torque values for
different size fasteners.
+0° F to +210° F
(-18° C to +99° C)
+50° F to +210° F
(+10° C to +99° C)
10W-20, 10W-30
20W-20
Lubrication Specifications
Table 1-5. Lubrication Specifications
KEY SPECIFICATIONS
MPG - Multipurpose Grease having a minimum dripping point
of 350° F. Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK
40 pounds minimum.)
EPGL - Extreme Pressure Gear Lube (oil) meeting API service
c la ss if i ca ti on GL- 5 or MI L-S pe c MI L-L- 21 0 5.
H O - H yd ra u li c Oi l . I SO -V g gr ad e 32 , 4 6.
CL - Chain Lube. Use a good quality chain lubricant.
1-4 – JLG Lift – 3121231
SECTION 1 - MACHINE SPECIFICATIONS
Table 1-7.Lubrication Intervals for Various Components
ITEM COMPONENT
1
Hydraulic Oil
2
Mast Chains
Key to Lubricants: MPG - Multipurpose Grease
Notes: (a) 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
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
will result in incorrect oil level reading on the hydraulic reservoir.
NO/TYPE
LUBE POINTS
Fill To Line on
Reservoir
5 Qt. Reservoir
2 - Per Section Chain Lube - Brush or
(a)
LUBE/METHOD
HO - Check Hyd. Oil
L e ve l
HO - Change Hyd. Oil
Spray
3
MONTHS6MONTHS1YEAR2YEARS
INTERVAL
✔
(b)
COMMENTS
Check fluid level every day.
✔
Change hydraulic oil every 2
years.
Inspect, lubricate if dry or rusting.
(c)
3121231 – JLG Lift – 1-5
SECTION 1 - MACHINE SPECIFICATIONS
REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND
JLG P/N Loctite® P/N ND Industries P/N
Description
0100011
242
TM
Vibra-TITE
TM
121
Medium Strength (Blue)
0100019
271
TM
Vibra-TITE
TM
140
High Strength (Red)
0100071
262
TM
Vibra-TITE
TM
131
Medium - High Strength (Red)
Size TPI Bolt Dia
Tensile
Stress Area
Clamp Load
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
NO. 5000059 REV. J
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
(Dry)
Torque
(Loctite® 262
TM
or Vibra-
TITE
TM
131)
Torque
Lubricated
Torque
(Loctite® 242
TM
or 271
TM
OR Vibra-TITE
TM
111 or
140)
3. * ASSEMBLY USES HARDENED WASHER
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%
Figure 1-1. Torque Chart (SAE Fasteners - Sheet 1 of 7)
1-6 – JLG Lift – 3121231
SECTION 1 - MACHINE SPECIFICATIONS
Size TPI Bolt Dia
Tensile
Stress Area
Clamp Load
In Sq In
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318
28 0.2500 0.0364
In Sq In
5/16 18 0.3125 0.0524
24 0.3125 0.0580
3/8 16 0.3750 0.0775
24 0.3750 0.0878
7/16 14 0.4375 0.1063
20 0.4375 0.1187
1/2 13 0.5000 0.1419
20 0.5000 0.1599
9/16 12 0.5625 0.1820
18 0.5625 0.2030
5/8 11 0.6250 0.2260
18 0.6250 0.2560
3/4 10 0.7500 0.3340
16 0.7500 0.3730
7/8 9 0.8750 0.4620
14 0.8750 0.5090
1 8 1.0000 0.6060
12 1.0000 0.6630
1 1/8 7 1.1250 0.7630
12 1.1250 0.8560
1 1/4 7 1.2500 0.9690
12 1.2500 1.0730
1 3/8 6 1.3750 1.1550
12 1.3750 1.3150
1 1/2 6 1.5000 1.4050
12 1.5000 1.5800
NO. 5000059 REV. J
3. * ASSEMBLY USES HARDENED WASHER
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%
LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
1320 43 5
1580 60 7
1800 68 8
2860 143 16 129 15
3280 164 19 148 17
LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m
4720 25 35 20 25 20 25
5220 25 35 25 35 20 25
70004560 40 553550
7900 50 70 45 60 35 50
9550 70 95 65 90 50 70
10700 80 110 70 95 60 80
12750 105 145 95 130 80 110
14400 120 165 110 150 90 120
16400 155 210 140 190 115 155
18250 170 230 155 210 130 175
20350 210 285 190 260 160 220
23000 240 325 215 290 180 245
30100 375 510 340 460 280 380
33600 420 570 380 515 315 430
41600 605 825 545 740 455 620
45800 670 910 600 815 500 680
51500 860 1170 770 1045 645 875
59700 995 1355 895 1215 745 1015
68700 1290 1755 1160 1580 965 1310
77000 1445 1965 1300 1770 1085 1475
87200 1815 2470 1635 2225 1365 1855
96600 2015 2740 1810 2460 1510 2055
104000 2385 3245 2145 2915 1785 2430
118100 2705 3680 2435 3310 2030 2760
126500 3165 4305 2845 3870 2370 3225
142200 3555 4835 3200 4350 2665 3625
Torque
(Loctite® 242
TM
or 271
TM
OR Vibra-TITE
TM
111 o r
140) K=.18
Torque
(Loctite® 262
TM
or Vibra-
TITE
TM
131)
K=0.15
SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque
(Dry or Loctite® 263)
K= 0.20
3121231 – JLG Lift – 1-7
Figure 1-2. Torque Chart (SAE Fasteners - Sheet 2 of 7))
SECTION 1 - MACHINE SPECIFICATIONS
Size TPI Bolt Dia
Tensile
Stress Area
Clamp Load
See Note 4
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
NO. 5000059 REV. J
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.
SOCKET HEAD CAP SCREWS
Magni Coating (Ref 4150701)*
Torque
(Dry) K = .17
Torque
(Loctite® 242
TM
or 271
TM
OR Vibra-TITE
TM
111 o r
140 OR Precoat 85®
K=0.16
Torque
(Loctite® 262
TM
or Vibra-
TITE
TM
131)
K=0.15
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
1-8 – JLG Lift – 3121231
Figure 1-3. Torque Chart (SAE Fasteners - Sheet 3 of 7)
SECTION 1 - MACHINE SPECIFICATIONS
Size TPI Bolt Dia
Tensile
Stress Area
Clamp Load
See Note 4
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 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 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
NO. 5000059 REV. J
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.
SOCKET HEAD CAP SCREWS
Torque
(Dry)
K = .20
Torque
(Loctite® 242TM or 271
TM
OR Vibra-TITE
TM
111 o r
140 OR Precoat 85®
K=0.18
Zinc Yellow Chromate Fasteners (Ref 4150707)*
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
Torque
(Loctite® 262
TM
or Vibra-
TITE
TM
131)
K=0.15
3121231 – JLG Lift – 1-9
Figure 1-4. Torque Chart (SAE Fasteners - Sheet 4 of 7)
SECTION 1 - MACHINE SPECIFICATIONS
Size PITCH
Tensile
Stress
Area
Clamp
Load
Torque
(Dry or Loctite®
263
TM
)
Torque
(Lub)
Torque
(Loctite® 262
TM
OR Vibra-
TITE
TM
131)
Torque
(Loctite®
242
TM
or 271
TM
OR Vibra-
TITE
TM
111 o r
140)
Sq mm KN [N.m] [N.m] [N.m] [N.m]
3 0.5 5.03 2.19 1.3 1.0 1.2 1.4
3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3
219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290
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.
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
CLASS 8.8 METRIC BOLTS
CLASS 8 METRIC NUTS
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%
NO. 5000059 REV. J
Figure 1-5. Torque Chart (METRIC Fasteners - Sheet 5 of 7))
1-10 – JLG Lift – 3121231
SECTION 1 - MACHINE SPECIFICATIONS
Size PITCH
Tensile
Stress
Area
Clamp
Load
Torque
(Dry or Loctite®
263
TM
)
K = 0.20
Torque
(Lub OR Loctite®
242
TM
or 271TM OR
Vibra-TITE
TM
111 o r
140)
K= 0.18
Torque
(Loctite® 262
TM
OR
Vibra-TITE
TM
131)
K=0.15
Sq mm KN [N.m] [N.m] [N.m]
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25.2 22.7 18.9
8 1.25 36.60 22.8 36.5 32.8 27.4
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8
315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395
CLASS 10.9 METRIC BOLTS
CLASS 10 METRIC NUTS
CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
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.
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
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%
NO. 5000059 REV. J
3121231 – JLG Lift – 1-11
Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 6 of 7)
SECTION 1 - MACHINE SPECIFICATIONS
Size PITCH
Tensile
Stress
Area
Clamp Load
See Note 4
Torque
(Dry or Loctite®
263
TM
)
K = .17
Torque
(Lub OR Loctite®
242
TM
or 271
TM
OR Vibra-TITE
TM
111 or 140)
K = .16
Torque
(Loctite® 262
TM
OR Vibra-TITE
TM
131)
K = .15
Sq mm kN [N.m] [N.m] [N.m]
30.55.03
3.5 0.6 6.78
40.78.78
50.814.20
6120.1012.5 13 12 11
7128.9018.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157
97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 220.0 900 845 790
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
CLASS 12.9 SOCKET HEAD CAP SCREWS
M6 AND ABOVE*
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.
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
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%
NO. 5000059 REV. J
Magni Coating (Ref 4150701)*
Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 7 of 7)
1-12 – JLG Lift – 3121231
SECTION 2. GENERAL
SECTION 2 - GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
General
This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness and maintain its safe
operating condition. For maximum service life and safe
operation, ensure that all the necessary inspections and
maintenance have been completed before placing the
machine into service.
Preparation, Inspection, and Maintenance
It is important to establish and conform to a comprehensive 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 further 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 perform a Pre-Start Inspection of the machine prior to use
daily or at each change of operator. Reference the Operator’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 performing 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 recognized degree, certificate, extensive knowledge, training, or
experience, has successfully demonstrated the ability and
proficiency to service, repair, and maintain the subject
JLG product model.
The Pre-Delivery Inspection and Frequent Inspection procedures are performed in the same manner, but at different 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 service 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.
Reference the JLG Pre-Delivery and Frequent Inspection
Form and the Inspection and Preventative Maintenance
Schedule for items requiring inspection during the performance of these inspections. Reference the appropriate
areas of this manual for servicing and maintenance procedures.
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. recognizes 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 appropriate JLG inspection form for performance of this inspection.
Reference the JLG Annual Machine Inspection Form and
the Inspection and Preventative Maintenance Schedule for
items requiring inspection during the performance of this
inspection. Reference the appropriate areas of this manual 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, maintenance 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, training, or experience, has successfully demonstrated the
ability and proficiency to service, repair, and maintain the
subject JLG product model.
Reference Table 2-2, MVL/MSP - Preventive Maintenance
& 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.
3121231 – JLG Lift – 2-1
SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance
Typ e Frequency
Pre-Start
Inspection
Pre-Delivery
Inspection
Frequent
Inspection
Annual
Machine
Inspection
Preventative
Maintenance
Prior to use each day; or
At each Operator change.
Prior to each sale, lease, or
rental delivery.
In service for 3 months; or Out of service
for a period of more than 3 months; or Purchased used.
Annually, no later than 13 months from the
date of the prior inspection.
At intervals as specified in the Ser vice and
Maintenance Manual.
Primary
Responsibility
User or Operator User or Operator Operator and Safety Manual
Owner, Dealer, or User Qualified JLG
Owner, Dealer, or User Qualified JLG
Owner, Dealer, or User Qualified JLG
Owner, Dealer, or User Qualified JLG
Service
Qualification
Mechanic
Mechanic
Mechanic
Mechanic
Reference
Service and Maintenance Manual and applicable JLG inspection form.
Service and Maintenance Manual and applicable JLG inspection form.
Service and Maintenance Manual and applicable JLG inspection form.
Service and Maintenance Manual
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 inspection time periods. The numbers listed within the interval
column represent the applicable inspection code for
which that component is to be checked.
The checks and services listed in this schedule are not
intended to replace any local or regional regulations that
may pertain to this type of equipment nor should the lists
be considered as all inclusive. Variances in interval times
may occur due to climate and/or conditions and depending on the location and use of the machine.
2-2 – JLG Lift – 3121231
SECTION 2 - GENERAL
Table 2-2. MVL/MSP - Preventive Maintenance & Inspection Schedule.
INTERVAL
AREA ON MACHINE
PRE-START (a)
INSPECTION
3 MONTH
PREVENTATIVE
MAINTENANCE
MAST ASSEMBLY 7
Mast Sections 2, 5 2, 5
Chain Systems 14 3, 14 14, 25
Sequence Cable Systems 31, 2, 3
Covers or Shields 1
Sheave Systems 1, 2 1, 2
Bearings 1, 2
Slide Pads 1, 2
PLATFORM ASSEMBLY 7
Platform 11
Guard Rails 1, 2, 4 1, 2, 4
Gate 1, 5 1, 5
Floor 1, 2 1, 2
Extension Deck Assembly 1, 5 1, 5
Lanyard Anchorage Point 1, 4 1, 4
CHASSIS ASSEMBLY 7
Pot Hole Protection System 55
Battery and Valve Covers or Doors 1, 7 1, 7
Static Strap 1
Caster Wheels 1, 2 14 1, 2 1, 2
Drive Wheels 22
Gear Box Assembly * 1, 7, 9, 11
Drive Motor Brushes ** —
Brake Release 55
FUNCTIONS/CONTROLS 7
Platform Controls 5, 6, 7 5, 6, 7
Ground Controls 5, 6 5, 6, 14
Function Control Locks, Guards, or Detents 5 5
Function Enable System
Emergency Stop Switches (Ground & Platform) 5
Function Limit or Cutout Switch Systems 5
Drive Brakes 5
Manual Descent or Auxiliary Power 5 5
POWER SYSTEM
Batteries 19 9 18
Battery Charger 5
HYDRAULIC/ELECTRIC SYSTEM 9
Hydraulic Pump 1, 2, 9 1, 2, 5, 9
Hydraulic Cylinder 2, 7, 9 2, 9
Cylinder Attachment Pi ns 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
6 MONTH
PREVENTATIVE
MAINTENANCE
PRE-DELIVERY (b)
OR FREQUENT (c)
INSPECTION
ANNUAL (d)
(YEARLY)
INSPECTION
3121231 – JLG Lift – 2-3
SECTION 2 - GENERAL
Table 2-2. MVL/MSP - Preventive Maintenance & Inspection Schedule. (Continued)
INTERVAL
AREA ON MACHINE
PRE-START (a)
INSPECTION
3 MONTH
PREVENTATIVE
MAINTENANCE
Hydraulic Fluid *** 11 11 11
Electrical Connections 20 20
Instruments, Gauges, Switches, Lights, Horn 5
GENERAL
Operator and Safety Manual in Storage Box 21 21 21
ANSI and EMI Manuals/Handbooks Installed 21 21 21
Capacity Decals Installed, Secure, Legible 21 21 21
All Decals/Placards Installed, Secure, Legible 21 21 21
"Walk-Around" Inspection Perfor med 22
Annual Machine Inspection Due 21
No Unauthorized Modifications or Additions 21 21
All Relevant Safety Publications Incorporated 21 21, 22
General Structural Condition and Welds 2, 4 2, 4
All Fasteners, Pins, Shields, and Covers 1, 2
Grease and Lubricate to Specifications 22 22
Function Test of All Systems 22 22
Paint and Appearance 77
Notify JLG of Change in Machine Ownership 22
* Change only when serviced, requires 10 oz. (296cc’s) to fill.
** Replace after system brush wear indicator warning is activated on Ground Control Station.
*** Drain and refill with fresh hydraulic fluid every two years.
6 MONTH
PREVENTATIVE
MAINTENANCE
PRE-DELIVERY (b)
OR FREQUENT (c)
INSPECTION
ANNUAL (d)
(YEARLY)
INSPECTION
Inspection and Maintenance Codes:
1. Check for proper and secure installation.
2. Visual inspection for damage, cracks, distortion, or
excessive wear.
3. Check for proper adjustment.
4. Check for cracked or broken welds.
5. Operates properly.
6. Returns to neutral or "off" position when released.
7. Clean and free of debris.
8. Interlocks function properly.
9. Check for signs of leakage.
10. Decals installed and legible.
11. Check for proper fluid level.
12. Check for chafing and proper routing.
13. Check for proper tolerances.
14. Properly lubricated.
15. Torqued to proper specification.
16. No gouges, excessive wear, or cords showing.
17. Properly inflated and seated around rim.
18. Proper and authorized components.
19. Fully charged.
20. No loose connections, corrosion, or abrasions.
21. Verify.
22. Perform.
23. Sealed properly.
24. Overrides Platform controls.
25. Inspected per Service and Maintenance Manual.
Footnotes:
(a) Prior to use each day; or at each Operator change
(b) Prior to each sale, lease, or delivery
(c) In service for 3 months; or Out of service for 3 months
or more; or Purchased used
(d) Annually, no later than 13 months from the date of the
prior annual inspection
2-4 – JLG Lift – 3121231
SECTION 2 - GENERAL
2.3 SERVICING AND MAINTENANCE GUIDELINES
General
The following information is provided to assist you in the
use and application of servicing and maintenance procedures 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 adequate support is provided.
NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT
BY BLOCKING OR OVERHEAD SLING.
Cleanliness
The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials
out of the vital components. Precautions have been taken
to safeguard against this. Shields, covers, seals, and filters are provided to keep the wheel bearings, mast sections and oil supply clean; however, these items must be
maintained on a scheduled basis in order to function
properly.
At any time when oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or component is disconnected,
cap or cover all openings to prevent entry of foreign matter.
Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are
unobstructed. Cover all parts to keep them clean. Be sure
all parts are clean before they are installed. New parts
should remain in their 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 similar bracket 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, complete the procedural steps in sequence. Do not partially
disassemble or assemble one part, then start on another.
Always recheck your work to assure that nothing has been
overlooked. Do not make any 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 solvent 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 pitted, 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 installation. When pressing a bearing into a retainer or bore,
apply pressure to the outer race. If the bearing is to be
installed on a shaft, apply pressure to the inner race.
Gaskets
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.
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 original, or one which is equivalent.
Unless specific torque requirements are given within the
text, standard torque values should be used on heattreated bolts, studs, and steel nuts, in accordance with
recommended shop practices or Torque Chart in Section
1.
3121231 – JLG Lift – 2-5
SECTION 2 - GENERAL
Hydraulic Lines and Electrical Wiring
Clearly mark or tag hydraulic lines and electrical wiring, as
well as their receptacles, when disconnecting or removing
them from the unit. This will assure that they are correctly
reinstalled.
Hydraulic System
Keep the system clean. If evidence of metal or rubber particles is found in the hydraulic system, drain and flush the
entire system.
Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning
solvent. Lubricate components, as required, to aid assembly.
Lubrication and Servicing
Components and assemblies requiring lubrication and
servicing are shown in the Lubrication Chart, (See Sec-
tion-1). Service applicable components with the amount,
type, and grade of lubricant recommended in this manual,
at the specified intervals. When recommended lubricants
are not available, consult your local supplier for an equivalent that meets or exceeds the specifications listed.
Mast Chain Inspection Procedure
Inspect mast chains for the following conditions:
Wear: Always inspect that segment of chain that operates
over a sheave. As the chain flexes over the sheaves, joints
and plate edges very gradually wear. Chain “stretch” can
be measured using a manufacturers wear scale or steel
tape. When chains have elongated 3% they must be
removed and replaced. Refer to Table 2-3 following for
proper chain specifications and allowable stretch 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 heads 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.
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.
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 cracking. 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 installation, factory lube must be supplemented by a maintenance 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
.50" pitch 12" or 24 pitches .24 in./12 in. span
.625 pitch 15" or 24 pitches .30 in./15 in. span
Fatigue Cracks: Fatigue is a phenomenon that affects
most metals, and is the most common cause of chain
plate failures. Fatigue cracks are found through the link
holes, perpendicular (90 degrees) from the pin in-line
position. Inspect chains carefully after long time use and
heavy loading for this type of crack. If any cracks are discovered, replace all chains, as seemingly sound plates
Pin to Pin
Measurement
Allowable Stretch
2-6 – JLG Lift – 3121231
SECTION 2 - GENERAL
TIGHT JOINTS
ABNORMAL PROTRUSION OR
TURNED PINS
ARC-LIKE CRACKED PLATES
(STRESS CORROSION)
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 lifting capacity of these chains.
Tight Joints: All joints in the leaf chain should flex freely.
On leaf chain, tight joints are usually caused by rust/corrosion, 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 lubrication. 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.
Protruding or Turned Pins: Chains operating with inadequate lube generate tremendous friction between the pin
and plates (pin and bushing on leaf chain). In extreme
cases, this frictional torque can actually turn the pins in
the outside press-fit 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.
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 atmosphere. Stress corrosion is an environmentally assisted
failure. Two conditions must be present; corrosive agent
and static stress.
In the chain, static stress is present at the aperture due to
the press fit pin. No cycle motion is required and the
plates can crack during idle periods. The reactions of
many chemical agents (such as battery acid fumes) with
hardened metals liberate hydrogen which attacks and
weakens the metal grain structure.
Chain Anchors and Sheaves: An inspection of the chain
must include a close examination of chain anchors and
sheaves. Check chain anchors for wear breakage and
misalignment. Anchors with worn or broken 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.
3121231 – JLG Lift – 2-7
SECTION 2 - GENERAL
2.4 LUBRICATION INFORMATION
Hydraulic System
The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means,
e.g., using inadequate hydraulic oil, allowing moisture,
grease, filings, sealing components, sand, etc., to enter
when performing 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 component working parts are very close, therefore, even the
smallest amount of dirt or foreign matter entering a system
can cause wear or damage to the components and generally results in faulty operation. Every precaution must be
taken to keep hydraulic oil clean, including reserve oil in
storage.
Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If
this condition occurs, the system must be drained,
flushed, and refilled with clean oil.
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.
Hydraulic Oil
For best performance, JLG recommends the use of ISOVg grade 32, 46 oil with a viscosity range between 15-250
SUS at 100 degrees F (32-54 cST at 40 degrees C). Refer
to Section 1 of this Service Manual for recommended
hydraulic oils.
Changing Hydraulic Oil
Use of any of the recommended hydraulic oils eliminates
the need for changing the oil on a regular basis. If it is necessary 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 synthetic base oils. JLG Industries recommends changing the
hydraulic oil annually.
Use every precaution to keep the hydraulic oil clean. If the
oil must be poured from the original container into
another, be sure to clean all possible contaminants from
the service container.
While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all
hydraulic components, lines, fittings, etc., as well as a
functional check of each system, before placing the
machine back in service.
NOTE: Metal particles may appear in the oil of new
machines due to the wear-in of meshing components.
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 evaluation. Refer to Section-1 in this Service Manual for an explanation of the lubricant key designations appearing in the
Lubrication Chart.
2-8 – JLG Lift – 3121231
SECTION 3. BASE COMPONENTS
3.1 BASE ASSEMBLY COMPONENTS
SECTION 3 - BASE COMPONENTS
Figure 3-1. Base Components.
1. Base Mounted Beacon
2. Battery Charger Cover
3. Front Tie Down Lug
4. Battery Charger Assembly
5. Base Frame
6. Front Caster Wheel Assembly
7. Left Drive Motor Assy.
8. Pot Hole Protection System
9. Drive Motor Cover
10. Rear Tie Down Lug
11. Right Drive Motor Assy.
3121231 – JLG Lift – 3-1
SECTION 3 - BASE COMPONENTS
3.2 BASE FRAME COVERS
Drive Motor Cover - Installation
Drive Motor Cover Installation
1. Cover
2. Attach Screws and Wash-
ers (a)
NOTE: (a) Apply Loctite #242 to screw threads before
tightening.
Battery Charger Cover - Installation
3. Set Cover Tab on Lower
portion of Cover, in Slot on
Base Frame
3.3 DRIVE/ELEVATION CUT-OUT SWITCH INSTALLATION
Drive/Elevation Switch Cut-Out Switch Installation
1. Mounting Screws (a)
2. Proximity Switch (b)
NOTE: Elevate and block platform to gain access to
switch.
(a) Apply Loctite #242 to mounting screw
threads on final assembly.
3. Switch Mounting Block
4. Frame Mounting Holes
Batttery Charger Cover Installation
1. Charger Cover
2. Front Attach Screws
and Washers
3. Rear Attach Screws
and Washers - Loosen
Only - Cover Slotted
3-2 – JLG Lift – 3121231
SECTION 3 - BASE COMPONENTS
321
3.4 DRIVE AND CASTER WHEELS
Tire Wear and Damage
Inspect tires periodically for wear or damage. Tires with
worn edges or distorted profiles require replacement.
Tires with significant damage in the tread area or side wall,
require immediate evaluation before replacing the
machine into service.
Wheel and Tire Replacement
Replacement wheels must have the same diameter and
profile as the original. Replacement tires must be the
same size and rating as the tire being replaced.
Wheel Installation
It is extremely important to apply and maintain proper
wheel mounting torque.
WHEEL LUG NUTS MUST BE INSTALLED AND MAINTAINED AT
THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN
LUG NUTS, AND POSSIBLE SEPARATION OF WHEEL FROM THE
AXLE. BE SURE TO USE ONLY THE LUG NUTS MATCHED TO THE
CONE ANGLE OF THE WHEEL.
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
1st Stage 2nd Stage 3rd Stage
20-30 ft lbs
(28 - 42 Nm)
4. Wheel lug nuts should be torqued after the first 50
hours of operation and after each wheel removal.
Check torque every 3 months or 150 hours of operation.
65-80 ft lbs
(91 - 112 Nm)
105 -120 ft lbs
(142 - 163 Nm)
Caster Wheels - Installation
Tighten the lug nuts to the proper torque to prevent
wheels from coming loose. Use a torque wrench to tighten
the fasteners. If you do not have a torque wrench, tighten
the fasteners with a lug wrench, then immediately have a
service garage or dealer tighten the lug nuts to the proper
torque. Over-tightening will result in breaking the lug nuts
or permanently deforming the mounting holes in the
wheels. The proper procedure for attaching wheels is as
follows:
1. Start all lug nuts by hand to prevent cross threading.
DO NOT use a lubricant on threads or nuts.
2. Tighten lug nuts in the following sequence.
Caster Wheel - Installation
1. Caster Wheel Assembly
2. Attach Screws and Wash-
ers (Qty. 4) (a)
NOTE: (a) On assembly, apply Loctite 242 to threads.
(b) As required; Place unit on a flat surface, shim a
caster wheel that is consistently more than .015" off of
flat surface.
3. Caster Shim (b)
Figure 3-2. Wheel Lug Nut Tightening Sequence
3121231 – JLG Lift – 3-3
SECTION 3 - BASE COMPONENTS
3.5 WHEEL DRIVE ASSEMBLY - SERVICING
The component parts of the left and right drive motor
assemblies are identical. The left drive motor is run in the
reverse direction of the right motor.
Roll And Leak Testing
Torque-Hub units should always be roll and leak tested
before disassembly and after assembly to make sure that
the unit's gears, bearings and seals are working properly.
The following information briefly outlines what to look for
when performing these tests.
NOTE: The brake must be released before performing the
roll test. This can be accomplished by supplying 24
Volts D.C. to the gray 2-pin brake connector.
The Roll Test
The purpose of the roll test is to determine if the unit's
gears are rotating freely and properly. You should be able
to rotate the wheel or hub of the gearbox by hand. If you
feel more drag in the gears only at certain points, then the
gears are not rolling freely and should be examined for
improper installation or defects. Some gear packages roll
with more difficulty than others. Do not be concerned if the
gears in your unit seem to roll hard as long as they roll
with consistency.
Oil Type & 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.
Oil Filling Instructions
10 oz. of gearbox oil will fill the gearbox cavity approximately 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-clock plug location. Reinstall and tighten plugs to 6-8 ft-lbs.
Drive Motor Brush Wear - Warning Indication
The machines drive motors include brush wear sensors
that activate a warning indicating the drive motor brushes
will require replacement soon. This warning protects the
drive motors from damage due to extreme brush wear.
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 equalize. Leaks will most likely occur at the pipe plugs, the main
seal or wherever o-rings are located. The exact location of
a leak can usually be detected by brushing a soap and
water solution around the main seal and where the o-rings
or gaskets meet on the exterior of the unit, then checking
for air bubbles. If a leak is detected in a seal, o-ring or 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
will pressurize to 10 psi very quickly. If the pressure
becomes excessive in the unit the seals will be
destroyed.
When the brush wear warning is activated the Ground
Control Station LCD screen will indicate a fault code of 6,
also the hour-meter is set to countdown 25 hours of
(DRIVE) operation remaining.
The Platform Control LEDs will indicate this warning with 8
flashing LEDs and an intermittent beep.
Only the drive function when used will affect the hour
meter count down once the warning has been activated.
The machine will operate normally until the last 10 seconds of the 25 hour countdown.
During the last 10 seconds of the 25 hour (DRIVE) countdown 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 programmed to reset the Brush Wear - Warning Timer - see
Section 4.6, Ground Control Module - Programming of
this manual.
3-4 – JLG Lift – 3121231
SECTION 3 - BASE COMPONENTS
Wheel Drive Assembly - Removal From Machine
The electric wheel drive assemblies are mounted independent 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 assembly between the drive motor and the gear box assembly.
1. Disconnect the positive battery terminal from the left
side battery.
2. 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.
3. Remove the wheel drive cover assembly.
4. Remove the drive wheel mounting lugs and remove
the drive 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 washers attaching the drive assembly to the frame.
7. Carefully slide the drive motor assembly out of the
base frame for disassembly.
Wheel Drive Assembly - Installation (Right Side Shown)
1. Mounting Bolts/Washers (a)
2. Frame Mounting Surface
3. Wheel Drive Assembly
NOTE: Installation same for left and right drive motor - (a) Apply Loctite #242 to threads before tightening.
(b) Tighten to 120 ft. lbs. (534 N-m)
4. Drive Wheel
5. Wheel Mounting Lugs (b)
3121231 – JLG Lift – 3-5
SECTION 3 - BASE COMPONENTS
Wheel Drive Disassembly - Main Components
Drive Motor Disassembly - Main Components
NOTE: If possible, remove the wheel drive assembly from
the machine frame.
1. Drain the oil from the Gearbox (1) by removing the
cover plugs in the cover.
2. Remove the 2 Drive Motor Bolts (6) and slowly pull
the Motor (2) out of the gearbox.
3. Obtain and install 2 bolts (M5 x 0.8 - 20mm long)
into the brake containment holes. This will keep the
brake housing in one piece.
4. Cut the black wire tie (not shown) from the frame of
the motor.
5. Remove the 3 Brake Bolts (7).
6. Remove the Brake Housing (B1) and the Spacers
(B4).
NOTE: 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.
7. Remove the Brake Disc (B2) from the splined motor
shaft.
8. Remove the Brake Friction Plate (B3) from the
motor flange.
3-6 – JLG Lift – 3121231
SECTION 3 - BASE COMPONENTS
Replacing Drive Motor Brushes
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
PREVIOUS PAGES.
1. Wrap tape around the end of the motor shaft that
interfaces with the gearbox to avoid damage to this
area.
2. Remove the motor thru bolts.
3. Remove the motor flange/brake mount from the
motor frame.
4. Remove the brush housing from the motor frame
and armature by tapping the edge of the brush
housing with a soft-tipped mallet. The brushes will
spring towards the center of the brush housing once
it has separated from the armature.
5. Remove the wave spring washer from the bearing
bore of the brush housing and set aside.
6. Pick a brush and remove the screw that fastens its
lead to the brush holder.
Drive Motor - Brush Holder Components
13. Repeat steps 6 thru 9 for the other 3 brushes.
14. Remove the armature from the motor frame by grabbing onto the commutator and pulling it from the
motor frame.
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 direction.
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-lbs. If this is a wear indicator brush,
connect the brush wear indicator lead to the spade
terminal in the brush housing.
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.
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 CAREFUL 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.
3121231 – JLG Lift – 3-7
SECTION 3 - BASE COMPONENTS
18. Install the brush housing onto the end of the motor
frame and armature. You may need to use a softtipped mallet to tap the brush housing onto the bearing of the armature. Once the brush housing is partially on the armature, the brush retaining pins must
be removed.
NOTE: Do not pinch any 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 PROTRUDING 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 MOUNTING BOLTS.
22. Tighten the motor bolts to 65 in-lbs.
23. Look at the 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.
3-8 – JLG Lift – 3121231
Gear Box Main Disassembly
SECTION 3 - BASE COMPONENTS
Gear Box Main Disassembly
1. Using a screwdriver, pry the end of the Retaining
Ring (G19) out of the groove in the Hub Subassembly, then grasp the loose end of the Retaining
Ring and pull the rest of the way out.
2. Remove Cover (G11), Thrust Washer (G21) should
remain in the inner counter-bore of the Cover when
removed.
NOTE: 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.
3. Remove Input Sun Gear (G4).
4. Remove Input Carrier Sub-assembly.
5. Remove Cover (11) and O-ring (G20).
6. Remove Input Ring Gear (G3).
NOTE: The Input Ring Gear (G3) is held in with a press fit
on its outside diameter. Insert jacking screws (1/420UNC, grade 8) with at least 1.5 inches of thread
length into each of the three tapped holes to force
the ring gear out. Be sure and alternate between the
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.
7. Using a screwdriver, remove Spiral Retaining Ring
(G27).
8. Pull Hub Sub-assembly off of the Spindle Subassembly.
3121231 – JLG Lift – 3-9
SECTION 3 - BASE COMPONENTS
Input Carrier Disassembly
Input Carrier Disassembly
1. 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
Shaft (G6).
5. Press out Bushing (G26) from the bore of each
Planet Gear (G5). Bushings cannot be reused when
removed.
6. Remove the other Thrust Washer (G25) from each
Planet Shaft (G6).
7. Remove Retaining Ring (G24) from Output Sun
Gear (G8).
8. Slide Output Sun Gear (G8) out from the center of
the Input Carrier (G7).
9. Remove the three Planet Shafts (G6) from the Input
Carrier.
NOTE: 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).
3-10 – JLG Lift – 3121231
Hub - Disassembly
SECTION 3 - BASE COMPONENTS
Hub Disassembly
1. Remove Main Wheel Bearing (G14).
NOTE: This part is held in the hub with a press fit. To
remove have 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.
2. Remove main Lip Seal (G16).
NOTE: 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.
3121231 – JLG Lift – 3-11
SECTION 3 - BASE COMPONENTS
Spindle Disassembly
Spindle Disassembly
1. Place Spindle Sub-Assembly on bench with Planet
Gears (G9) facing up.
NOTE: Do not damage or scratch the seal surface of the
Spindle (G1) during disassembly.
2. Remove three Output Planet Shafts (G10).
NOTE: 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.
3. Remove the Output Planet Gear (G9), Thrust
Washer (G25), and Tanged Washer (G32) out each
of gear "window" of the Spindle (G1).
NOTE: The Output Planet Gears (G9) are very similar in
size to the Input Planet Gears (5), tag or label the
Planet Gears to avoid confusion.
4. Press out Bushing (G26) from the bore of each
Planet Gear (G9). Bushings cannot be reused when
removed
5. Remove the Main Bearing (G14) from the outside
diameter of the Spindle (G1).
NOTE: This bearing is held in with a press fit. You will need
to pry against the Spindle (1) to remove it. A new
bearing should be used when the unit is reassembled.
6. Flip over the Spindle (G1).
7. Press out the Motor Shaft Seal (G17) from the center bore. The seal cannot be reused when removed
8. Remove the shaft Ball Bearing (G15) from the center bore.
3-12 – JLG Lift – 3121231
Spindle Sub-Assembly
SECTION 3 - BASE COMPONENTS
Spindle Sub-Assembly
1. Place the spindle (G1) on the bench with the carrier
portion facing up.
NOTE: Do not damage or scratch the seal surface of the
spindle (G1) during assembly.
2. Using the appropriate pressing tool (T-182377),
press on Main Bearing (G14) until it is fully seated.
3. Use the Output Planet Pin (G10) as a pressing tool
to install the Planet Bushing (G26) into the bore of
each Planet Gear (G9). The shaft will help guide the
bushing into the bore as well as prevent damage
from the press.
4. 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 window.
5. 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.
6. Slide the Output Planet Gear (G9) into the window
with the Tanged Thrust Washer (G32) until the
bores line up.
7. Insert Output Planet Shaft (G10) into the Planet
Shaft hole of the Spindle (1) and through the bores
of the Thrust Washers (G25) & (G32) and the
Planet Gear (G9).
8. Before pressing the Output Planet Shaft (G10) into
the Spindle (G1), make sure the Output Planet
Gear (G9) spins freely.
9. 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.
10. Repeat Steps 5-11 for the other two Output Planet
Gears (G9).
11. Turn the Spindle (G1) over so that the carrier end is
down.
12. Install Input Ball Bearing (G15) into the Spindle
(G1) bore.
13. Using a flat plate or rod, press the Motor Shaft Seal
(G17) into the center bore so that it is flush with the
face of the Spindle (G1).
3121231 – JLG Lift – 3-13
SECTION 3 - BASE COMPONENTS
Hub Sub-Assembly
Hub Sub-Assembly
1. Put Hub (G2) on a table with the tapped holes facing 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 damaged if not installed with care. It is a good
idea to start the Seal into the bore with a rubber mallet before pressing.
3. Flip the Hub (G2) over
4. Using the appropriate pressing tool (T-174356),
press the Main Bearing (G14) into the bore until it
bottoms out.
3-14 – JLG Lift – 3121231
Input Carrier Sub-Assembly
SECTION 3 - BASE COMPONENTS
Input Carrier Sub-Assembly
1. Use the Input Planet Shaft (G6) as a pressing tool
to install the Planet Bushing (G26) into the bore of
each Planet Gear (G5). The shaft will help guide the
bushing into the bore as well as prevent damage
from the press.
2. 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
3. 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 opposite direction of the Input Planet Shafts (G6).
4. 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 correctly seated in the groove and that the Output Sun
Gear (G8) cannot be pulled out of the Input Carrier
(G7).
5. Place a Thrust Washer (G25) on each side of the
Input Planet Gear (5). Line up the bores as well as
you can visually.
6. Place the Input Planet Gear (G5) and Thrust
Washers (G25) onto the Input Planet Shaft (G6)
sticking out from the Input Carrier (G7).
7. Repeat 5 & 6 for the other 2 Planet Gears (G5).
8. Put the Thrust Plate (G23) onto the three Input
Planet Shafts (G6). Use the three holes on the outermost bolt circle. The other three holes are for a different gear ratio.
9. Using the appropriate retaining ring pliers put a
Retaining Ring (G18) into the groove of each Input
Planet Shaft (G6).
NOTE: NOTE: Do not overstress the Retaining Rings (G18).
3121231 – JLG Lift – 3-15
SECTION 3 - BASE COMPONENTS
Main Gear Box Sub-Assembly
Main Gear Box Sub-Assembly
1. Inspect seal surface of Spindle Sub-Assembly.
Remove any debris or burrs that may be present.
2. Apply a coating of grease to the Lip Seal (not
shown) in the Hub Sub-Assembly.
3. Place Spindle (G1) Sub-Assembly on table with carrier side up.
4. Carefully install the Hub Subassembly (seal side
down) onto the Spindle Sub-Assembly. This instal-
lation should be a slip fit and takes place in 3 stages.
Stage 1: The hub slides together until the gear teeth
of the hub hit the gear teeth of the 3 Output Planet
Gears (G9).
Stage 2: Find the Output Planet Gear (G9) that is
tight and turn it until you feel it go into mesh with the
hub gear teeth, apply slight downward pressure to
the hub and then find the next gear that is tight and
do the same.
Stage 3: Once all the Output Planet Gears (G9) are
in mesh apply pressure to the hub, it should push on
the rest of the way.
5. 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.
6. Using the appropriate pressing tool (T-174356),
press in the Input Ring Gear (G3) into the bore of
Hub Subassembly.
NOTE: Do not use excessive pressing force because it will be
reacted by the main wheel bearings.
7. 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).
8. Install the Input Sun Gear (G4) into the area
between the three Input Planet Gears (G5).
9. Apply a coating of grease to the Cover O-ring
(G20) and install it into the o-ring groove of the Hub
Subassembly.
NOTE: It may be helpful to stretch the o-ring (G20) out prior to
assembly to avoid pinching or shearing when the Cover
(G11) is assembled.
10. 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.
NOTE: Make sure that both the Cover Thrust Washer (G21) and the
Cover (G11) have good clean surfaces for the Loctite to
properly adhere.
11. Center the Cover (G11) in the hub bore so that the
"JLG" logo is up. Push it into the bore.
12. Install the Cover Retaining Ring (G19) into the
groove of the Hub Sub-assembly.
3-16 – JLG Lift – 3121231
Motor, Brake and Gear Box Assembly
SECTION 3 - BASE COMPONENTS
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.
WHEN MOUNTING THE BRAKE FRICTION PLATE TO THE MOTOR
FLANGE, CHECK THAT THE MOTOR HOUSING TO FLANGE
MOUNTING BOLTS ARE NOT CONTACTING THE BRAKE FRICTION PLATE UNDERNEATH. CONTACT INTERFERENCE COULD
CAUSE THE BRAKE FRICTION PLATE TO WARP WHEN TIGHTENED DOWN.
3. Place the Brake Disc (B2) on the motor shaft. Make
sure the splines are properly lined up and the Brake
Disc (B2) is down against the Brake Friction Plate
(B3).
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 Housing (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-lbs.
7. Remove and discard the 2 bolts in the Brake Con-
tainment Holes.
8. Pull the Brake Lead through the through the slot in
the motor flange. Make sure the leads are all the way
in the bottom of the slot.
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. If the Gearbox (1) is loose from the machine place it
onto the bench with the cover side down. If the
Gearbox (1) is attached to the machine, perform the
next step with extreme caution.
BEFORE MOUNTING THE DRIVE MOTOR/BRAKE ASSEMBLY TO
THE GEARBOX SPINDLE HUB BE CERTAIN THE BRAKE CAVITY
INSIDE THE GEARBOX IS CLEAN AND FREE OF ANY OIL RESIDUE.
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.
NOTE: The motor may need to 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-lbs.
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 3-4).
15. The wheel drive is now ready to be installed onto the
machine, reverse removal instructions (See Page 3-
5).
3121231 – JLG Lift – 3-17
SECTION 3 - BASE COMPONENTS
1
6
4
7
8
8
2
3.6 POT HOLE PROTECTION SYSTEM
Pot-Hole-Protection System Components
1. PHP Actuator (Platform)
2. Right/Left PHP Limit Switch
3. Right Side Counterbalance
4. Left Side Counterbalance
5. PHP Link (see detail illustration following)
6. Left PHP Bar
7. Right PHP Bar
8. PHP Bar Pivot Pin and Retaining Ring
1. PHP Counterweight/Bar Link
2. Flange Bearing
3. PHP Counterweight Link
4. Retaining Ring
PHP Link Installation (Item 5 in Component Illustration Above)
3-18 – JLG Lift – 3121231
SECTION 3 - BASE COMPONENTS
1
2
3
4
5
6
3
4
Actuator - Limit Switch - Counterweight Installation - (Machines Prior to S/N-0130013258)
(Same both sides of machine)
1. PHP Actuator
2. Actuator Attach Screw/Nut
3. Limit Switch (a)
4. Limit Switch Attach Screws (b)
5. Shim, Adhesive-Backed (max. 2 per switch) (c)
Pot-Hole Switch and Mounting Bracket - (Machines S/N-0130013258 to Present)
NOTE: (a) When the pothole is in the deployed position (bars down), adjust plunger just past "click", tighten screws to
frame.
(b) Apply Loctite #222 to screw threads before tightening.
(c) Add as required if switch is adjusted to maximum and plunger has not clicked to engage switch.
6. Left Side Torsion Spring (yellow)
7. Counterweight Attach Pin
8. Spacer
9. Pivot Pin and Retaining Ring
3121231 – JLG Lift – 3-19
SECTION 3 - BASE COMPONENTS
3.7 BATTERY CHARGER - SERVICE PROCEDURES
Battery Charger General Information
DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGER
IF MACHINE IS STILL UNDER WARRANTY. OPENING THE BATTERY CHARGER WHILE THE MACHINE IS UNDER WARRANTY
WILL VOID THE CHARGER WARRANTY. IF UNDER WARRANTY
REQUEST A REPLACEMENT CHARGER FROM THE FACTORY.
Battery Charger Maintenance Information
1. Make sure charger connections to battery terminals
are tight and clean.
2. Do not expose charger to oil or to direct heavy water
spraying when cleaning vehicle.
Battery Charge LED Indicator on Platform Control Console
On normal power-up and operation this series of ten
(10) LEDs visually indicates the amount of charge
remaining in the batteries.
The number of LEDs lit will change depending on the
level of charge in the batteries.
• (+) All Three (3) GREEN LEDs lit up indicate maximum battery charge.
• Four (4) YELLOW LEDs indicate a two thirds to one
third battery charge remaining.
• (–) Three (3) RED LED’s lit indicate minimum battery
charge remaining. The machine will continue to
operate at this charge level but will begin to indicate
battery low voltage warning indicators.
Battery Low Voltage Warning Indicators
The Platform Control Console and Ground Control Station
indicate battery low voltage at three (3) Warning Levels.
(See Table 3-2. following).
Table 3-2. Battery Low Voltage Warning Indicators.
WARNING
LEVEL
LEVEL-1 •3 LEDs/BARS Flashing
LEVEL-2 •2 LEDs/BARS Flashing
LEVEL-3 •1 LED/BAR Flashing with
NOTE: (a) To maximize battery life, it is recommended that the factory supplied batteries be charged continuously for a min-
PLATFORM CONTROL LED GROUND CONTROL LCD
imum of 4 hours or until 8 bars are lit on the ground station LCD Display before operating the machine. When drained
to Warning Level 2, batteries must be charged until 8 bars are lit on the ground station LCD display to clear the fault
code.
INDICATOR LOCATION
RESULT
with an audible beep.
• Machine will Operate - No
Control Functions Locked
Out.
with an audible beep.
• Platform Lift-UP Function
is Locked Out.
an audible beep.
• Drive and Platform Lift-UP
Functions Locked Out.
ACTION REQUIRED TO
CLEAR FAULT
Charge batteries to a level of
four (4) LEDs/BARS or more
before operating.
Charge batteries for a minimum of four (4) continuous
hours or more, or (8) LEDs/
BARS lit before operating. (a)
Charge batteries for a minimum of four (4) continuous
hours or more, or (8) LEDs/
BARS lit before operating. (a)
3-20 – JLG Lift – 3121231
SECTION 3 - BASE COMPONENTS
Battery Charging Status Indicators
The battery charging status indicators are located just
above the Charger AC input receptacle on the center
cover section at the rear of the machine. This LED indicator set is plugged directly into a connector on the back of
the battery charger and indicates current charging status.
When first plugged in, the charger will automatically turn
on and go through a short LED indicator self-test (all
LED’s will flash in an up-down sequence for two seconds),
then charging will begin.
CHARGING
YELLOW(MIDDLE) LED ON
Charge Incomplete
1. The YELLOW ‘CHARGING’ LED will turn on and a
trickle current will be applied until a minimum voltage is reached.
Once a minimum battery voltage of 2 volts per cell is
detected, the charger will enter the bulk charging
constant-current stage and the YELLOW ‘CHARGING’ 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.
2. When the GREEN ‘CHARGED’ LED turns on, the
batteries are completely charged.
CHARGE COMPLETE
GREEN (TOP) LED ON
100% Complete
CHARGING PROBLEM
RED (BOTTOM) LED ON
See Flash Codes following
intervention to first resolve the problem and then to
reset the charger by interrupting AC power for at
least 10 seconds. Others may be simply transient
and will automatically recover when the fault condition 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. Indicates a high battery pack voltage.
[2 FLASH] Battery Voltage Low: auto-recover. Indicates either a battery pack failure, battery pack is not
connected to charger, or battery volts per cell is less
than 0.5 VDC. Check the battery pack and battery
pack connections.
[3 FLASH] Charge Time-out: Indicates the battery
did not charge within the allowed time. This could
occur if the battery is of a larger capacity than the
algorithm is intended for. It can also occur if the battery 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 minimum 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. Indicates charger has shutdown due to high internal
temperature which typically indicates there is not
sufficient airflow for cooling – see step 1 of Installation Instructions. Charger will restart and charge to
completion if temperature is within accepted limits.
The charger may now be unplugged from AC power
(always pull on plug and not cord to reduce risk of
damage to the cord). If left plugged in, the charger
will automatically restart a complete charge cycle if
the battery pack voltage drops below a minimum
voltage or 30 days has elapsed.
3. If a fault occurred anytime during charging, a fault
indication is given by flashing the RED ‘FAULT’ LED
with a code corresponding to the error.
There are several possible conditions that generate
errors. Some errors are serious and require human
[6 FLASH] Qui-Q Fault: Indicates that the batteries
will not accept charge current, or an internal fault
has been detected in the charger. This fault will
nearly always be set within the first 30 seconds of
operation. Once it has been determined that the batteries 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.
3121231 – JLG Lift – 3-21
SECTION 3 - BASE COMPONENTS
Battery Charger Check/Change Charging Algorithm
The charger comes pre-loaded with nine algorithms for
batteries as detailed in Table 3-3. If your specific battery
model is not listed, please contact JLG.
Each time AC power is applied with the battery pack NOT
CONNECTED, the charger enters an algorithm select/display mode for approximately 11 seconds.
During this time, the current Algorithm # is indicated on
the YELLOW ‘CHARGING’ LED. A single digit Algorithm #
is indicated by the number of blinks separated by a
pause. A two digit Algorithm # is indicated by the number
of blinks for the first digit followed by a short pause, then
the number of blinks for the second digit followed by a
longer pause.
To Check/Change The Charging Algorithm:
1. Disconnect the charger positive connector from battery 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 Algorithm # will advance after 3 seconds. Repeat until
desired Algorithm # is displayed. A 30 second timeout 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) – algorithm is now in permanent memory.
3. Remove AC power from the charger and reconnect
the charger positive connector to the battery pack. It
is highly recommended to check a newly changed
algorithm by repeating the above steps 1) and 3).
Table 3-3. Battery Charger Algorithm Settings.
ALGORITHM
SETTING
1Trojan T105
2Trojan T105 Tapped
3 T105 DV/DT CP
4 US Batter y USB2200
5Trojan 30/31XHS
6DEKA 8G31 Gel
7 J305 DV/DT CP
8 Concorde 10xAH AGM, Douglas DG12-100M, US
BATT 12V100AH AGM, Full River HGL100-12X,
Universal Battery UB121000
23 Douglas Flooded (Default)
25 JLG - P/N-0400242
43 Harris Batt. Discover EVGGC6A-A
BATTERY TYPE
Battery Charger Removal/Installation
1. Remove the charger cover from the machine located
under the platform, see Section 3.2 on page 3-2.
2. Disconnect the positive (+) battery cable at the left
side battery under the left rear upper cover.
3. Disconnect the AC input, LED Status Indicator, Drive
Cut-Out Interlock, and DC Voltage Output to battery
wiring connectors from the top and bottom of the
charger assembly.
4. Remove the two (2) screws and washers from the
top bracket securing the charger to the frame
mount. Only loosen the two (2) screws on the bottom of the bracket of the charger enough to slide the
charger out. Move the charger to a suitable work
surface.
NOTE: (a) The mounting bracket is slotted under these
screws, loosen only.
MVL/MSP Battery Charger Removal
1. Battery Charger Assembly
2. Attach Screws (Top)
3. Attach Screws (Bottom) (a)
4. 120/220 AC Voltage Input Cable
5. Charger LED Status Indicator harness
6. Drive Cut-Out Interlock Harness (P2)
7. DC Voltage Output to Battery +/– Posts
3-22 – JLG Lift – 3121231
SECTION 4. CONTROL COMPONENTS
8
123
456
7
4.1 CONTROL COMPONENTS OVERVIEW
SECTION 4 - CONTROL COMPONENTS
Figure 4-1. Control Components Location - MVL/MSP.
1. Pump/Motor/Tank Assembly 4. Batteries (2-12V - standard) 7. Platform Control Console
2. Alarm 5. Traction Control Module 8. Obstruction Sensor System (MSP - Option)
3. Horn 6. Ground Control Module
3121231 – JLG Lift – 4-1
SECTION 4 - CONTROL COMPONENTS
1
2
1
2
4.2 CONTROLS COVER INSTALLATION
Battery Cover Doors (Optional Hinged)
1. Left Side Cover 2. Mast Support Column
Center, Left and Right Lower Covers
1. Right Side Cover 2. Mast Support Column
Lower Left Cover (Front View) Center Cover, Lower Left and Right Covers (Rear View)
Note: Center Cover requires unplugging the Charger AC Receptacle
a n d L E D I n d ic a to r wi r e s w h en r em o v in g .
Lower Right Cover (Front View)
4-2 – JLG Lift – 3121231
SECTION 4 - CONTROL COMPONENTS
1
2
2
122
4.3 CONTROL COMPONENTS INSTALLATION
BEFORE REMOVING ANY COMPONENT FROM THE ELECTRICAL
SYSTEM, DISCONNECT THE POSITIVE TERMINAL FROM THE
LEFT SIDE BATTERY.
Ground Control Module
The Ground Control Module is located under the center
cover at the rear of the machine and is mounted on the
mast support column. All electrical components on the
machine operate directly or indirectly through the Ground
Control Module. The module is currently programmed at
the factory with the machines operating profile. If replacing a Ground Control Module the new module may
require some programming to enable any optional equipment. See Section 4.6, Ground Control Module - Programming.
Traction Control Module
The Traction Control Module is mounted below the
Ground Control Module on the mast support column.
The traction module controls the voltage to the drive
motors as regulated by the ground control module, from
signals received via the joystick controller located on the
platform control module.
There are no internal parts serviced on this module.
Traction Control Module Installation
1. Traction Control Module 2. Attach Screws/Washers
Note: See Figure 4-2. for wiring connection instructions.
Ground Control Module Installation
1. Ground Control Module 2. Attach Screws/Washers
Note: See Figure 4-2. for wiring connection instructions.
3121231 – JLG Lift – 4-3
SECTION 4 - CONTROL COMPONENTS
1
2
1
2
Platform Control Console Installation
The platform control console is located in the platform and
mounted on the right side platform rail.
For removal see below, for servicing information see Section 4.7, Platform Control Console - Service Procedures.
Horn Installation
Horn Installation
1. Horn Assembly 2. Attach Screws/Washers
Note: See Figure 4-2. for wiring connection instructions.
Alarm Installation
Platform Control Console - Installation
1. Console Mounting Bracket and Attach Pin
2. Platform Control Console
3. Platform Console to Junction Box Harness (a)
Note: (a) The other end of this harness is plugged into the plat-
form junction box mounted to the mast behind the platform
decal board. From the console the harness is tie strapped
to the platform rail, and run inside the mast through a large
hole in the mast to the platform junction box.
Alarm Installation
1. Alarm Assembly 2. Attach Screws/Washers
Note: See Figure 4-2. for wiring connection instructions.
4-4 – JLG Lift – 3121231
SECTION 4 - CONTROL COMPONENTS
1
2
3
4.4 BATTERIES - SERVICE PROCEDURES
Battery Replacement
JLG MACHINES EQUIPPED WITH DELTA-Q BATTERY CHARGERS
ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES.
APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE
THROUGH JLG’S AFTERMARKET PARTS DISTRIBUTION CENTERS 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 COMPATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE
DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND
MACHINE CYCLE TIMES. THE USE OF NON APPROVED BATTERIES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFORMANCE
ISSUES OR BATTERY CHARGER FAULT CODES. JLG ASSUMES
NO RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES
ARISING FROM THE USE OF NON APPROVED BATTERIES.
Replacement battery(s) must be of equivalent voltage and
amperage output as the OEM battery(s) in order for the
machine to operate to as manufactured specifications.
Battery replacement part weight must also be equivalent
to OEM per battery, in order to maintain machine stability
as manufactured. (See Section-1 of this manual for battery
specifications).
DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS
BATTERIES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION. DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.
Battery Condition Testing
NOTE: Batteries in storage should be kept at 12.5V or
higher.
Before testing for battery condition, the open circuit voltage 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 instructions of the battery tester manufacturer.
2. If an appropriate battery tester is unavailable, the
batteries can be tested by fully charging them with
the charger that is installed on the machine. Then
check the battery voltage of each battery - 4 hours after charging is complete. Batteries less than 12.72
volts should be replaced.
NOTE: If a faulty charger is suspected, the batteries can be
charged using a charger that supplies 2.45 volts/cell.
Charging should be terminated when the charge current drops below 1 amp.
Battery Disconnect (Option)
If equipped, the optional battery disconnect loop is
located on the left side of the mast assembly, just above
the rear cover assembly. Battery electrical power to the
machine is disconnected when the upper half of the connector is separated from the fixed lower half connector.
Use the wire handle provided on the front of the upper half
connector to disconnect it from the lower half. A lanyard
keeps the upper half attached to the machine when disconnected.
Battery Disconnect (Option)
1. Upper Half of Disconnect
2. Lower Half of Disconnect
3. Upper Half Pull Handle
3121231 – JLG Lift – 4-5
SECTION 4 - CONTROL COMPONENTS
Battery - Installation - (2-12V Batteries)
To gain access to the batteries, requires opening or
removal of the upper half of the rear covers, see Section
4.2, Controls Cover Installation.
Procedure for removal is same for both batteries.
On installation, batteries set in machine with the posts to
the inside. Left side battery (–) NEG post at front (shown
below), Right side battery (+) POS post towards machine
front.
Battery Installation (Left Side Battery Shown)
1. Battery (a)
2. Hold-Down Bar
NOTE: (a) Mount with terminal posts inboard.
(b) Apply battery terminal grease to prevent corrosion.
3. Battery Terminal Attach Nut/Washer (b)
4. Hold-Down Bar Wing-nut and Washer
4-6 – JLG Lift – 3121231
SECTION 4 - CONTROL COMPONENTS
(+)
(–)
4
(+)
(+)
(+)
(–)
(–)
(–)
(–)
(+)
1
7
6
8
2
3
5
P1P2P5
P4
P3
M1 M2
9
1. Ground Control Module (a) 4. Right Side Battery (b) ) 7. Power Cable To Right Drive Motor/Brake (a)
2. Left Side Battery (b) 5. Traction Control Module (a) 8. Pump/Motor/Tank Assembly (b)
3. 175 Amp Inline Fuse 6. Power Cable To Left Drive Motor/Brake (a) 9. Battery Disconnect (Option)
Ground Control P1 - Horn, Alarm, Beacons, Lift Down Valve Harness (a) P4 - Platform Junction Box Harness (a)
Module Plugs: P2 - PHP, Elevation/Speed, Charger Limit Switch Harness (a) P5 - Joystick Protocol Harness (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.
P3 - Programmable Security Lock Harness (Option) (a)
Figure 4-2. Component Electrical Connections. (2-12V Batteries shown)
3121231 – JLG Lift – 4-7
SECTION 4 - CONTROL COMPONENTS
1
2
3
4
5
4
5
6
(+)
(–)
1
2
3
(+)
(–)
(+)
(–)
(+)
(–)
(+)
(–)
Battery Installation - (4-6V Batteries) (OPTION)
Tra y (c)
1. Ground Control Module
2. Upper Left Side Battery
3. Lower Left Side Battery
NOTE: (a) Label battery cables before removing to
ensure proper installation. The battery cables
connecting the batteries are identical, only the
cable connections to the GCM are different.
(b) All other connections to Ground Control Module same as in Figure 4-2.
Figure 4-3. Battery Cable to Battery Termi-
nal Connections (4-6V)
4. Lower Right Side Battery
5. Upper Right Side Battery
6. 175 Amp Inline Fuse
(Left Side Batteries Shown with Machine Covers Removed)
1. Battery Cables (a)(b)
2. Upper Battery
3. Upper Battery Hold-down
Strap
NOTE: (a) See battery cable to battery terminal connec-
tion illustration - Figure 4-3.
(b) Apply battery terminal grease to prevent corrosion.
(c) Three bolts hold the battery tray to the mast
support, two shown and one on the back of the
support. There is a left side and a right side tray.
Battery Installation - 4-6V
4. Upper Left Side Battery
5. Lower Battery
4-8 – JLG Lift – 3121231
SECTION 4 - CONTROL COMPONENTS
1
4
5
8
7
2
6
4.5 GROUND CONTROL MODULE - SERVICE PROCEDURE
DO NOT ATTEMPT TO DISASSEMBLE THE GROUND CONTROL
MODULE IF MACHINE IS STILL UNDER WARRANTY. OPENING
THE GROUND CONTROL MODULE WHILE THE MACHINE IS
UNDER WARRANTY WILL VOID THE WARRANTY. IF UNDER
WARRANTY REQUEST A REPLACEMENT MODULE FROM THE
FACTORY.
The MVL Series and MSP Ground Control Module allows
for field replacement of two (2) components internal to the
module.
• Emergency Stop Switch
• Power Selector Switch (Key)
ELECTROSTATIC DISCHARGE CAN DAMAGE COMPONENTS ON
THE INTEGRATED CIRCUIT BOARD. PLACE THE GROUND CONTROL MODULE ON A NON-CONDUCTIVE SURFACE WHEN OPENING.
1. Cover/LCD Assembly 4. Emergency Stop Switch 7. Heat Sink Base/Main Board Assembly
2. Power Selector Switch Nut 5. Power Selector Switch 8. Cover Attach Screws
3. Emergency Stop Button 6. Main Board to LCD Ribbon Cable Connector
Figure 4-4. Ground Control Module Components.
3121231 – JLG Lift – 4-9
SECTION 4 - CONTROL COMPONENTS
1
1
2
3
1
1
1
1
Cover Removal/Installation
THE MAIN CIRCUIT BOARD AND THE SMALLER LCD CIRCUIT
BOARD MOUNTED TO THE COVER ASSEMBLY, COMMUNICATE
THROUGH A RIBBON CABLE. REMOVE THE COVER CAREFULLY
ONCE THE COVER SCREWS ARE REMOVED FROM THE BACK OF
THE MODULE.
Release Ribbon Cable
1. Ribbon Cable Connector Tabs
(Push tabs away from connector to release
cable then slide cable out of connector)
Note: Connector works same at both ends of the ribbon cable.
Cover Installation
1. Remove the (6) Hex Socket Screws from the Heat Sink/
Base. One screw is under the Warranty/Tamper Label.
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.
Disconnect the Ribbon Cable
1. Ribbon Cable Connector 3. Suppor t for Cover
2. Ribbon Cable
4-10 – JLG Lift – 3121231
Power Selector/EStop Switch Installation
1
2
4
5
6
1
2
3
231
Emergency Stop Switch Installation
1. Emergency Stop Button 4. Nut
2. Button Seal 5. Emergency Stop Switch
3. Square Lock Washer 6. Switch Lock/Release Lever
Note: Tighten nut enough to keep button from turning.
Reattach wires to same terminals on new switch.
SECTION 4 - CONTROL COMPONENTS
Power Selector/EStop Switch - Connectors Location
1. LCD and Button Circuit Board
2. Emergency Stop Switch Connector
3. Main Power Selector Switch Connector
Note: To release switch connectors, push tab on top of connector.
Power Selector Switch Installation
1. Nut
2. Power Selector Switch
3. Align and insert tab on switch into slot on cover.
Note: Re-attach wires to the same terminals on new switch.
3121231 – JLG Lift – 4-11
SECTION 4 - CONTROL COMPONENTS
1
2
4.6 GROUND CONTROL MODULE PROGRAMMING
General
The MVL/MSP machine Ground Control Module allows
on-board programming of various component and control
function personality settings.
Programming may be required under circumstances such
as:
• Replacement of the Ground Control or Traction Control
Module some components or optional equipment may
not be enabled under the standard default settings of
the replacement unit.
• Optional equipment has been added to the machine in
the field and that function must be enabled before operation.
• Customizing the machine to fit a specific application,
such as changing the LCD display language, programming operating speeds such as braking, turning or lifting speeds.
Programming Levels
There are three (3) password protected programming
levels, from highest to lowest, the levels are:
• Level-1: JLG Engineering Settings
• Level-2: Service and Maintenance Settings -
Level-2 Password: 91101
• Level-3: Operator Settings -
Level-3 Password: 33271
THE LEVEL 1 JLG ENGINEERING SETTINGS ARE NOT DISPLAYED IN THE PROGRAMMABLE SETTINGS UNDER PASSWORD LEVEL-2 OR LEVEL-3. LEVEL-1 SETTINGS MUST NOT BE
MODIFIED UNLESS DIRECTED BY JLG ENGINEERING DEPARTMENT PERSONNEL.
Activating Programming Mode
Activating Programming Mode
1. With machine power off, press and hold the Brake
Release Button (1) on the Ground Control Module.
2. While holding the Brake Release Button in, power
machine up by turning the Main Power Selector
Switch (2), to either the Ground Control or Platform
Control Mode.
3. Release the Brake Release Button (1) after machine is
powered up. The LCD display should now display five
zeros, one with a box around. Continue to next step
Entering Password.
NOTE: If machine did not power up, check that both the
Ground Control Module - Emergency Stop Button,
and the Platform Control Console - Emergency Stop
Button, are in the RESET position.
Also, if machine is equipped with the (PSL) Programmable Security Lock option, see Section 3 - Programmable Security Lock in your Operators Manual
for additional machine power-up steps.
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 modification to machine personality settings such as lift
speeds, drive speeds, as well as various switch polarity
settings, also enable various optional equipment if
installed. This level can also adjust Level-3 settings.
Level-3: Operator Settings allow the direct user to modify a few settings such as the language setting of text output to the Ground Control Module LCD screen, setting
machine sleep time, and enabling the detection of the
horn and beacon components.
4-12 – JLG Lift – 3121231
SECTION 4 - CONTROL COMPONENTS
12
3
00000
4
1
2
3
1
2
1
2
Entering Password
Entering Password
1. The Brake Release button (1) moves the box (around
digit) from left to right to select which digit to change.
2. Platform UP button (2) increases the numerical digit.
3. Platform DOWN button (3) decreases the numerical
digit.
4. Change all five digits (4) to match password level,
then press the Brake Release button (1) again.
Selecting Programmable Item to Adjust
Selecting Programmable Item to Adjust
1. Use the Platform UP/DOWN buttons (1) to scroll
through the list of programmable items available to
your programming level.
2. Once a programmable item to be adjusted is selected,
press the Brake Release button (2) to enter that settings’ adjustment mode.
Adjusting Programmable Setting
Programming Mode Selection
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.
Adjusting Programmable Setting
1. Adjust the programmable setting using the Platform
UP/DOWN buttons (1), see Table 4-1 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 programmable settings, power machine off with either the Main
Power Selector Switch or Emergency Stop Button.
3121231 – JLG Lift – 4-13
SECTION 4 - CONTROL COMPONENTS
00000.0
Service Programming Mode - (Level-2)
In the Service Programming Mode the following items are
shown on the main menu:
• Reset Timers • EEPROM Defaults
•Program • OSS Sensor
• Tilt Sensor
NOTE: There are two production modules available at this
time, one for North/South American and European
languages, and one for Asian languages. All programmable items between these modules are identical with the exception of language selection.
Reset Timers
This setting displays five (5) timers as described following:
• Trip Tim e: This timer displays 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.
• Trac tio n Ti me: Displays the amount of accumulated
DRIVE hours on the machine’s current drive components.
• 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.
• To t a l T i m e : Displays the total amount of time accumulated by the Traction, Lift UP and Lift DOWN Timers.
Of these five (5) timers, only the Trip Timer can be RESET
back to zero (00000.0).
• Brush Wear Sensor Timer: This timer must be reset
after the drive motor brushes are replaced and the
brush wear sensors are repositioned. When reset the
display will go from WORN to a blank display. Also the
25 hr./10 second countdown will stop and normal
machine operation will resume.
Program
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.
EEPROM Defaults
Resets programmable settings to factory default settings
for 10MSP and 15/20MVL/MSP models.
NOTE: New replacement Ground Control Modules are
shipped with the EEPROM Defaults set up for 15/20/
MSP/MVL model machines. If a the new replacement module is installed on a 10MSP model, the
EEPROM Defaults must be reset to the 10MSP
model EEPROM Defaults.
Select "EEPROM Defaults" from the menu and press the
Brake Release button. Select the CORRECT machine
model, then push Brake Release button to accept. Power
machine off and begin operation.
OSS Sensor
Displays current Obstruction Sensor System status
(Detection - YES/NO). Also if an object is detected, the
sensor(s) detecting the object and distance the object is
from the sensor is displayed.
Allows service personnel to program the Level-2 and
Level-3 items shown in Table 4-1.
Tilt Sensor
Allows service personnel to reset the Ground Control
Module’s internal digital Tilt Sensor to zero (0.0) degrees
in both the X and Y axis.
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.
1. Detection Indicator - Yes/No 3. Object distance from sensor
2. Sensor numbers 4. Signal strength
Note: This screen can be viewed while another person performs
the transducer sensor check, see Section 4.9.
OSS Sensor LCD Display Mode
4-14 – JLG Lift – 3121231
SECTION 4 - CONTROL COMPONENTS
Operator Programming Mode - (Level-3)
In the Operator Programming Mode the following items
are shown on the main menu (also see Table 4-1):
• Tilt Sensor
•Program
NOTE: There are two production modules available at this
time, one for North/South American and European
languages, and one for Asian languages. All programmable items between these modules are identical with the exception of language selection.
Table 4-1. MVL/MSP Ground Control Module - Field Programmable Settings and Factory Preset.
Level-2: Service Level Settings On LCD Display: YES =
Level-3: Operator Level Settings NO = ✕ LO W = ↓
LEVEL PROGRAMMABLE ITEM FACTORY PRESET SETTING RANGE
2 Back to Main
Set Language
NOTE: There are two production modules available,
3
2 Set Maximum Lift Up Speed 100% 0 - 100%
2 Set Maximum Lift Down Speed 100% 0 - 100%
2, 3 Set Sleep Time 5 MINS 0 - 60 MINS
2 Set Polarity Of Left Pot Hole Input 1 2 0 - Disabled / 1 - LOW / 2 - HIGH
2 Set Polarity Of Right Pot Hole Input 2 2 0 - Disabled / 1 - LOW / 2 - HIGH
2 Set Polarity Of Up Limit/Elevation Input HIGH HIGH/LOW
2 Set Polarity Of Charger Inhibit LOW HIGH/LOW
2, 3 Set Polarity Of The Keypad Code LOW HIGH/LOW
2 Set Polarity Of Ancillary Input 1 LOW (a) HIGH/LOW
2 Set Polarity Of Ancillary Input 2 LOW (b) HIGH/LOW
2 Load Sensing (LSS) OFF ON/OFF
2, 3 Enable Detection Of Horn Open Circuit NO YES/NO
2, 3 Enable Detection Of Beacon Open Circuit NO YES/NO
2 Enable Obstruction Sensor System (OSS) NO YES/NO
2 Enable Detection Of Aux. #1 Open Circuit NO YES/NO
2 Enable Detection Of Aux #2 Open Circuit NO YES/NO
3 Forward Alarm Disable NO YES/NO
3 OSS Diagnostic NO YES/NO
2 Zero the On-Board Tilt Sensor NO YES/NO
3 View Tilt Sensor Readings — —
2 Brush Wear Sensor Timer Reset — BLANK/WORN
2 Ancillary 1 Input Inhibit 0 0 - 4
2 Ancillary 2 Input Inhibit 0 0 - 4
one for North/South American and European
Languages, and one for Asian Languages.
Tilt Sensor
Allows viewing current tilt sensor individual X and Y direction degree reading.
Program
Allows the Operator to program Level-3 items shown in
Table 4-1 following.
✓ HIGH = ↑
15/20MVL/MSP Return to Programming Menu
1 - English 6 - Italian
2 - German 7 - Swedish
1
2
3 - Dutch 8 - Brazilian Portuguese
4 - French 9 - Finnish
5 - Spanish
1 - English 3 - Japanese
2 - Chinese
3121231 – JLG Lift – 4-15
SECTION 4 - CONTROL COMPONENTS
Table 4-1. MVL/MSP Ground Control Module - Field Programmable Settings and Factory Preset.
Level-2: Service Level Settings On LCD Display: YES =
✓ HIGH = ↑
Level-3: Operator Level Settings NO = ✕ LO W = ↓
LEVEL PROGRAMMABLE ITEM FACTORY PRESET SETTING RANGE
2 Ancillary 1 Anti-Tie-down 0 0-1
2 Ancillary 2 Anti-Tie-down 0 0-1
2 Mode Select Delay (active before time-out) 5 Sec. 0 - 60 Seconds
2 Invert Lif t Direction NO YES/NO
2 Lift Lock Delay 5 Sec. 0 - 60 Seconds
2 Acceleration (platform lowered) 80 1 - 100
2 Deceleration (platform lowered) 80 1 - 100
2 Tur n Acceleration (platform lowered) 50 1 - 100
2 Tur n Deceleration (platform lowered) 50 1 - 100
2 Maximum Forward Speed (platform lowered) 100 1 - 100
2 Minimum Forward Speed (platform lowered) 40 1 - 100
2 Maximum Reverse Speed (platform lowered) 50 1 - 100
2 Minimum Reverse Speed (platform lowered) 20 1 - 100
2 Maximum Tur n Speed (platform lowered) 20 1 - 100
2 Minimum Tur n Speed (platform lowered) 15 1 - 100
2 Minimum Forward Speed (platform elevated) 13 1 - 100
2 Minimum Reverse Speed (platform elevated) 13 1 - 100
2 Minimum Turn Speed (platform elevated) 5 1 - 100
2 Motor Compensation 50 mOhms 0 - 500 mOhms
2 EPPROM Reset — Resets GCM to default factory settings
Notes: (a) MSP Models equipped with stock-picker platform and mid-gate interlock (drive inhibit) switch are factory preset to HIGH.
(b) MSP Models equipped with 12 ft. or 14 f t. lift-limit-switch option are factory preset to HIGH.
4-16 – JLG Lift – 3121231
4.7 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. 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
SECTION 4 - CONTROL COMPONENTS
Remove Platform Control Console
First remove the platform control console completely from
the platform assembly. See Section 4.3, Control Components - Installation.
Figure 4-5. Platform Control Console Components.
1. E-Stop/Shut Down Switch 5. Drive/Lift Mode Selector Switch
2. ON/OFF Key Switch (a) 6. Horn Button Switch
3. Joystick Assembly 7. Rear Cover
4. Display/Controller Module 8. Wiring Harness Connector
NOTE: (a) No key switch on Australian spec. machines.
3121231 – JLG Lift – 4-17
SECTION 4 - CONTROL COMPONENTS
3
6
2
5
1
4
1
2
1
2
Display/Controller Module Electrical Connections
The internal switches and joystick controller of the platform console plug directly into the Display/Controller
Module. This module then relays the signals from these
switches to the Ground Control Box through the communications cable running to the platform junction box
mounted to the mast under the platform.
Mounting Bracket - Install/Remove
Platform Console - Mounti 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)
2. Communications Cable to
Platform Junction Box (C6)
3. ON/OFF Key Switch (C3)
Note: The (C) numbers shown after the description above repre-
sent the corresponding identification of the plug on the
module’s circuit board.
4. E-Stop/Shut-Down Switch (C4)
5. Drive/Lift Mode Select
Switch - (C7)
6. Joystick - (C8)
Platform Console - Rear Cover Installation
1. Rear Cover 2. Cover Mounting Screws
4-18 – JLG Lift – 3121231
SECTION 4 - CONTROL COMPONENTS
1
2
1
2
123
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
Horn Button Switch - Install/Remove
Platform Console - Horn Switch Installation
1. Horn Button Switch (a)
2. Lock Washer
Note: (a) Remove rear cover, unplug wire, remove nut and lock
washer then slide switch out of console.
3. Nut
Key Switch - Install/Remove
(No key switch on Australian specification machines.)
Platform Console - Drive/Lift Mode Select Switch
1. Switch Assembly (a) 2. Locking Tabs
Note: (a) Remove rear cover, unplug switch wire, press tabs to
remove.
3121231 – JLG Lift – 4-19
Note: (a) Remove mounting bracket on bottom of console to
Platform Console - Key Switch Installation
1. Key Switch (a)
2. Notch
gain access to the key switch assembly.
3. Attach Nut
4. Key
SECTION 4 - CONTROL COMPONENTS
1
2
4
5
3
7
6
2
3
4
5
1
E-Stop/ShutDown Switch - Install/Remove Joystick Assembly - Install/Remove
Platform Console - E-Stop Switch Installation
1. Loosen Switch Set Screw
2. Turn Switch 90°
3. Pull Spring-Loaded Release
Lever Out
4. Remove Barrel Assembly
5. Barrel Seal
6. Switch to Body Retainer
Hooks (a)
7. Switch Retainer Slots
1. Joystick Assembly
2. Attach Screws (Qty.-4)
3. Nylon Washers (Qty.-4)
Note: (a) Remove the console mounting bracket.
Note: (a) Use a small straight blade screwdriver to extend the
spring-loaded retainer hooks (6) out and release the switch
4-20 – JLG Lift – 3121231
from the body.
Platform Console - Joystick Installation
4. Rubber Boot/Gasket
5. Install/Remove through the
Access Hole in Bottom of
Housing. (a) (b)
(b) Remove the key switch and e-stop switch to remove
joystick assembly through access hole in bottom of console.
SECTION 4 - CONTROL COMPONENTS
1
2
231
4
4.8 PUMP-MOTOR ASSEMBLY - SERVICE PROCEDURE
Hydraulic Pressure settings and Adjustment
Adjust system pressure so that platform will raise with
maximum rated capacity in platform.
The following pressure setting are factory recommended
(initial) settings;
MODEL PRESSURE SETTING
15MVL/15MSP 2600 PS I
20MVL 1800 PSI
20MSP 2800 PSI
Turning adjustment screw clockwise increases system
pressure, turning screw counterclockwise decreases
system pressure. (See Figure 4-6., Hydraulic Pressure
Adjustment Screw. (Machine Rear Covers Removed))
Perform pressure adjustment with oil at normal operating
temperature. If pressure is set when oil is cold, platform
may not raise rated load after soil has warmed.
Hydraulic Pressure Gauge Connection
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.
Remove the hydraulic oil filter and install a t-fitting
between the pump and the extend line to connect a
hydraulic pressure gauge as shown in Figure 4-7., Typical
Hydraulic Pressure Gauge Installation (Hydraulic Filter
Removed).
CHECK, and if necessary, ADJUST the hydraulic pressure
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.
1. Pressure Gauge Assembly 3. T- Fitting
2. Extend Line 4. Retu rn Line
Figure 4-7. Typical Hydraulic Pressure Gauge
Installation (Hydraulic Filter Removed).
1. R em o ve A dj u s t S c re w Ca p 2. Pressure Adjustment Screw
Note: Machine rear covers must be removed to access pump motor.
Figure 4-6. Hydraulic Pressure Adjustment Screw.
(Machine Rear Covers Removed)
3121231 – JLG Lift – 4-21
SECTION 4 - CONTROL COMPONENTS
1
2
3
4
132
2
After Filter Pressure Check
Reinstall the hydraulic oil filter and install the t-fitting
between the hydraulic filter and the extend line to the cylinder. Recheck the hydraulic pressure and compare with
the previous readings when filter was removed. If a significant drop in pressure reading has occurred, replace the
hydraulic filter and recheck the "after filter" pressure reading.
Pump/Motor/Tank Installation
BE CERTAIN THE MAST IS FULLY LOWERED BEFORE REMOVING ANY HYDRAULIC LINES FROM THE PUMP UNIT. WEAR PROTECTIVE GEAR WHEN WORKING AROUND PRESSURIZED
HYDRAULIC LINES. REMOVE CONNECTIONS CAREFULLY AND
CAP ALL LINES.
1. Hydraulic Oil Filter 3. Pressure Gauge Assembly
2. T- F it tin g 4. Extend Line
Pump/Motor/Tank Assembly Installation
Figure 4-8. Typical Hydraulic Pressure Gauge
Installation (After Hydraulic Filter).
1. Pump/Motor/Tank Assembly 3. Detach and Cap Extend
2. Attach Screws/Washers and Return Lines
Note: See Figure 4-2. for wiring connection instructions.
4-22 – JLG Lift – 3121231
SECTION 4 - CONTROL COMPONENTS
12
3
1
2
1
234
General Installation and Disassembly
The following is a complete disassembly/assembly of the
MVL/MSP machines pump/motor assembly. No internal
parts to the hydraulic pump are serviced by JLG except
for a pump installation seal kit. Also the only parts 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.
The motor and motor brushes can be serviced without
removing the complete pump/motor unit. However components on the bottom end of the unit will require removal
of the complete pump/motor unit. See Pump/Motor/Tank
Installation instructions following.
Inline Hydraulic Filter Installation
FENNER BRAND PUMP - Brush Replacement
Motor Cap/Motor Installation
Motor Cap Installation
1. Cap Assembly Screws 2. Cap Assembly
Pump/Motor/Tank Assembly Installation
1. Valve Body Extend Line Fitting 3. Extend Line to Lift Cylinder
2. Inline Hydraulic Filter
1. Motor Assembly 3. Pump End Head
2. Motor Assembly Screws 4. Motor to Pump Coupler
Motor Installation
3121231 – JLG Lift – 4-23
SECTION 4 - CONTROL COMPONENTS
1
2
3
1
2
3
3
4
1
234
5
Motor Brush Installation
Brush Housing Installation
1. Brush Housing
2. Brush Housing Screws
3. Mark Front of Motor and Brush Housing for reference
when reassembling.
Once brush housing has been removed, inspect the rotor
commutator for excessive wear before installing a new
brush set.
The rotor commutator surface when new, is approximately
1/8 in. (3mm) in thickness.
New Brush Installation
1. Brush Terminal Screw 4. Brush Spring
2. Brush 5. (See Installation Note Below)
3. Brush Holder
Installation the same for all four (4) brush assemblies.
Note: Using a clean towel, push each brush (2) up into it’s holder
(3), slide the spring (4) over the side of the brush. This will hold
each brush in place and allow them to clear the rotor commutator
during reassembly.
Clean the rotor commutator with a non-conductive electrical
cleaner before assembling the brush housing to the motor housing.
Note: Length of wires to brush assemblies shown exaggerated for
4-24 – JLG Lift – 3121231
Brush Assembly Connections
1. Negative (–) Post 3. Brush Assemblies
2. Positive (+) Post 4. Spring Washer
illustrative purposes.
Brush Housing Final Assembly Tips
It is easier to install the brush housing assembly by sliding
the rotor assembly completely out of the other end of the
motor housing, then attach the brush housing first. After
the brush housing is installed look into the motor housing
from the opposite end to check that the positive (+) post
wires and static winding wires are positioned, not to block
the holes for the motor mounting bolts, inside the motor
housing.
After final assembly of the brush housing check that all
brush terminal screws are tight and the brush springs are
positioned properly before mounting the motor to the
pump/motor end head.
SECTION 4 - CONTROL COMPONENTS
Brush Final Positioning
ONCE THE ROTOR ASSEMBLY IS IN PLACE, REMEMBER TO
PUSH EACH BRUSH DOWN UNTIL THE BRUSH FACE IS IN
CONTACT WITH THE COMMUTATOR ON THE ROTOR SHAFT
AND THE BRUSH SPRING IS PUSHING DOWN ON TOP OF
THE BRUSH.
3121231 – JLG Lift – 4-25
SECTION 4 - CONTROL COMPONENTS
3
4
1
2
2
3
1
4
55
MONARCH BRAND PUMP - Brush Replacement
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 4. Housing/Motor Valve Body
2. Cover/Housing Reference Mark
Reference Mark 5. Motor Valve Body
3. Motor Housing
Motor/Brush Cover - Remove/Install
Motor/Brush Cover - Removal/Installation
1. Motor/Brush Cover (a)
2. Cover Screws (b)
REMOVE THE MOTOR COVER CAREFULLY, THE (SHORT) POWER LEADS INSIDE THE COVER FROM THE (+/—) POSTS ARE SOLDERED TO ATTACH CLIPS WHICH ARE FASTENED TO THE BRUSH CARRIER ASSEMBLY WITH SCREWS (ITEM-5). RAISE THE COVER
STRAIGHT UP - REMOVE THE SCREWS - THEN HINGE THE COVER UP (SEE CENTER ILLUSTRATION) AND PRY THE CLIPS OFF OF
THE BRUSH CARRIER ASSEMBLY TO COMPLETELY REMOVE THE MOTOR COVER.
NOTE: (a) Once cover screws are removed, you may need to tap lightly around the edge of the top cover to separate it from the motor housing.
Read the important note above before attempting to remove the cover.
(b) These steel screws are threaded into the aluminum valve body, do not overtighten.
3. Washers
4. Power Leads to Lead Clips (Soldered)
5. Power Lead Clip Attach Screws
4-26 – JLG Lift – 3121231
Brush Carrier Assembly - Remove/Install
1
2
3
4
1
4
2
3
3
5
SECTION 4 - CONTROL COMPONENTS
Brush Carrier Assembly - Remove/Install
1. Stator/Brush Carrier Screws (Pump Rear)
2. Stator/Brush Carrier Screws (Pump Front) (a)
NOTE: (a) Removed previously with motor cover disassembly (shown for reference only).
3. Mark Brush Carrier Position on Motor Housing
4. Brush Carrier Assembly
Brush Assembly - Remove/Install
Brush Assembly - Remove/Install
1. Brush Assembly (a)
2. Brush Carrier Socket
3. Brush Tab Slot
NOTE: (a) Slide brush assembly into socket until tab is in slot at
rear of socket.
4. Brush Terminal Screw
5. Brush Attach Terminal
3121231 – JLG Lift – 4-27
SECTION 4 - CONTROL COMPONENTS
1
2
2
3
4
1
2
1
2
234
Tank Install ation
Tank Installation
1. Tank Asse mbly 3. O-Ring Seal
2. Tank S cre w s (4 ) 4. Use Screwdriver to pry tank
away from pump head.
Pump Installation
Pump Installation
1. Pump Assembly 3. Pump Shaft Seal
2. Pump Assembly Screws 4. Pump End Head
Filter Screen Installation
1. Filter Screen 2. Pump Pick-Up Tube
Filter Screen Installation
Pump O-Ring Installation
1. Pump Assembly 2. O-Ring Seal 3. O-Ring Seal
4-28 – JLG Lift – 3121231
SECTION 4 - CONTROL COMPONENTS
1
2
3
4
6
5
1234567
Pressure Adjust Valve Installation Pressure Check Valve Installation
Pressure Adjust Valve Installation
1. Adjust Valve Cap 4. Valve Ball
2. Adjustment Screw 5. Adjust Valve Port
3. Valve Spring 6. Extend (Pressure) Port
(Shown Plugged)
Note: Adjust pressure per specification shown in Section-1 of this
Service Manual.
Pressure Check Valve Installation
1. Check Valve Assembly 5. Check Valve Port
2. O-Ring Seal 6. Extend (Pressure) Port
3. O-Ring Seal 7. Return Port
4. Backing Ring
Note: Extend (Pressure) and Return Ports Shown Plugged
3121231 – JLG Lift – 4-29
SECTION 4 - CONTROL COMPONENTS
1
2
3
4
4.9 OBSTRUCTION SENSOR SYSTEM SERVICE PROCEDURE (MSP - OPTION)
General
The Obstruction Sensor System (OSS) Control Module is
mounted between the rails of the mast platform header
section under the platform decal billboard at the rear of
the MSP model platform, see illustration below.
The OSS Control Module communicates with the Ground
Control Module through the platform electrical junction
box also mounted on the mast behind the platform decal
billboard.
The OSS Control Module circuit board monitors six (6)
channels each channel is wired to an individual transducer sensor mounted under the MSP model platform.
The sensors are mounted in a manner to provide a detec-
tion zone beneath the platform and detect if an object has
entered that zone when the platform is being lowered.
NOTE: The OSS only operates normally when the Ground
Control Module - Power Selector Switch (Key) is set
to PLATFORM CONTROL MODE.
When the Power Selector Switch (Key) is set to
GROUND CONTROL MODE the OSS will detect an
obstruction but will not stop platform downward
movement or sound the horn. However, the OSS
Control Module LED will flash if a sensor detects the
presence of an object.
An OSS Sensor replacement kit is available from the JLG
Parts Department for individual sensors. The kit provides
instructions and everything necessary to connect the new
sensor to the existing soldered wire ends.
If the OSS Control Module has failed it is recommended to
replace the complete OSS system. See Section 6 of this
manual for further OSS Troubleshooting instructions.
1. Mast Platform Header Section 3. Obstruction Sensor Control Module
2. Platform Electrical Junction Box 4. Tr ansduce r Sens or Arrangement
Figure 4-9. Obstruction Sensor System Components (Platform Cutaway)
4-30 – JLG Lift – 3121231
SECTION 4 - CONTROL COMPONENTS
1
2
3
00000.0
#5
#3
#1
#2
#4
#6
2
1
Transducer Sensor Check
Perform the following daily Pre-Start Inspection to check if
each transducer sensor is working properly.
1. Power up machine by setting the Power Selector
(Key) Switch to Ground Control Mode.
2. Raise the platform approximately four (4) to five (5)
feet.
3. Hold an object about the size of 8-1/2 x 11 inches
directly under one of the sensors. The OSS Control
Module (RED) LED will flash if the sensor is working
properly.
4. Remove object, allow the LED to stop flashing and
check the next sensor, repeat this for all six (6) sensors.
The Ground Control Module can also display the following
sensor detection information when in Level 2 password
Service and Maintenance Settings mode.
OSS Sensor
Displays current Obstruction Sensor System status
(Detection - YES/NO). Also if an object is detected, the
sensor(s) detecting the object and distance the object is
from the sensor is displayed.
OSS Sensor LCD Display Mode
1. Detection Indicator - Yes/No 3. Object distance from sensor
2. Sensor numbers 4. Signal strength
Note: This screen can be viewed while another person performs
the transducer sensor check, see Section 4.9.
Transducer Sensor Check
1. Electronic Module LED Indicator (a)
2. Detection Zone
3. Place a pad of paper or similar size object, 6 to
12 in. (15 to 30cm) individually beneath each
transducer to check detection.
Note: (a)The LED Indicator will flash when an object is
detected at each sensor. Remove object and allow
the LED to stop flashing before testing next sensor.
Transducer Sensor Locations
1. Transducer Sensors #1 through #6
2. Underside of MSP Platform
3121231 – JLG Lift – 4-31
SECTION 4 - CONTROL COMPONENTS
1
5
2
3
4
1
2
3
2
3
4
1
OSS Component Installation
THE FOLLOWING ILLUSTRATIONS PROVIDE KEY INSTALLATION
INSTRUCTIONS FOR THE OSS TO OPERATE PROPERLY.
• The OSS Control Module must be electrically isolated
from the mast, see installation instructions below.
• The sensor shield tubes attached to the platform’s
under sides must be properly installed and undamaged
to prevent sensor detection of objects outside the platform parameter.
• The area under the platform floor must be free of any
objects or debris dangling from beneath the platform to
avoid false detection by the sensors.
• DO NOT allow high pressure spray to directly contact
the transducer sensor (circular) membrane, this will
damage the sensor.
OSS Control Module Connections
1. RED LED Detection Indicator 3. Junction Box Harness
2. Sensor Harness
OSS Control Module Installation
1. OSS Control Module 4. Insulating Bushing
2. Mounting Screw (a) 5. Decal Billboard (b)
3. Nylon Washer
Notes: (a) Apply Loctite 222 to threads.
(b) Drill out pop rivets to remove.
Internal View of OSS Control Module (Back Removed)
1. Sensor Comm Channels (a) 3. Wire Harness to Junction Box
2. Sensor Cables 4. LED Indicator Light
Notes: (a) Channel 1-Sensor 1, Channel 2-Sensor 2, etc.
4-32 – JLG Lift – 3121231
SECTION 4 - CONTROL COMPONENTS
1
3
4
5
2
2
1
2
1
2
3
Transducer Sensor Installation (Typical)
1. Mounting Screws (a) 4. DO NOT Pressure Wash Decal
2. Bushings 5. Sensor Side Deflector
3. Tra nsduc er Senso r (b)
Notes: (a) Apply Loctite 222 to screw threads and torque to
15 in. lb.
(b) Mount sensor with (circular) membrane
facing down.
Sensor Side Deflectors
1. Sensor Side Deflector (a) 3. Platform Side Frame
2. Pop Rivet
Note: (a) One deflector required on each side of platform.
Deflector must be even with, and not extend inside
of the platform side frame.
1. Nylon Tie Wraps (a) 2. Platform Floor Suppor ts
Note:(a)Secure ALL sensor wire cables to platform side
Secure Transducer Sensor Wiring
frame.
3121231 – JLG Lift – 4-33
SECTION 4 - CONTROL COMPONENTS
This page intentionally left blank.
4-34 – JLG Lift – 3121231
SECTION 5. MAST COMPONENTS
5.1 MAST COMPONENTS OVERVIEW
SECTION 5 - MAST COMPONENTS
Figure 5-1. Mast Components. (MVL/MSP)
1. Mast Section - 1 4. Mast Section - 4 7. Lift Cylinder Mount 10. Lanyard Attach 13. Chain/Equalizer -
2. Mast Section - 2 5. Mast Section - 5 8. Slide Pads 11. Chain Guard Plate Assemblies
3. Mast Section - 3 6. Lift Cylinder 9. Chain Anchor Plates 12. Sheave Assemblies 14. Mast Mini Covers
3121231 – JLG Lift – 5-1
SECTION 5 - MAST COMPONENTS
5.2 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT
Mast Chain/Cable Adjustment
The intention of this procedure is to assure equal load distribution between the individual chains of a mast section
chain sets. Also to step each front mast section up
approximately 7/16 in. (12mm) from the section behind it
to allow clearance for the individual mast section covers.
Adjust using the following procedure;
1. With mast retracted, step into the platform and
bounce your weight up and down a few times to be
certain platform is at the bottom of travel. Be certain
all chain/cable sets are seated in their sheaves properly at the top of each mast section.
2. Then with no load in the platform check the side profile of the top of the mast for the amount of adjustment necessary to obtain the 7/16 in. (12mm) step
for mast sections-3 and up. (See Illustration)
NOTE: Mast section-1 is fixed to the base and mast section-
2 is attached to the lift cylinder, these sections
require no adjustment.
3. Adjust one mast section at a time starting from the
back (section-3, section-4, etc.) of the mast and
work forward. (i.e. if three is OK, then jump to four,
etc.)
4. To adjust, elevate the platform until the chain/cable
anchor adjust nuts are accessible at the front and
bottom of each mast section.
6. Tighten (to raise mast section), or loosen (to lower
mast section) the adjusting nut against the anchor
plate on each chain/cable. Adjust the nut the
amount required to raise or lower the top of the mast
section to match the side profile shown in Figure 5-
2. when the mast is retracted.
NOTE: It is more important that the (threaded ends) studs
protruding on the adjustments are equal side to side
on a mast section, than it is that the tension in the
chains is equal. The chain equalizers will always
assure equal tension, but if the adjustment isn’t
equal as described, the chains may tend to pull to
one side or the other.
The threaded end of the chain/cable may need to be
restrained while tightening the adjust nut to keep the
chain/cable from twisting.
7. Retract the mast all the way and check if the top of
the mast sections appear as shown in Figure 5-2.
8. Repeat steps (1) through (7) for remaining mast sections.
9. Once mast section adjustment is completed, apply
loctite #242 to the threads under the (jam) nuts that
were loosened. Then re-tighten the loosened (jam)
nuts until tight against the top (adjust) nut. Chain/
cable should have slight tension but should not be
taut.
10. (MSP Only) After all mast adjustments are complete, if necessary adjust the bumpers on the underside of the stock-picker platform so the platform
rests slightly above the base frame when it is lowered and empty.
Sequencing Cable Adjustment
NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT
BY BLOCKING OR OVERHEAD SLING.
5. Start with the mast section which needs adjustment
and loosen the bottom (jam) nut on each chain/
cable.
5-2 – JLG Lift – 3121231
1. Retract mast completely, and check each sequencing cable on outside of masts for excessive slack.
Adjust only to remove slack from cable.
2. Tighten nylock-nut just enough to remove excessive
slack from sequencing cable. The springs should
not be compressed more than 25% after adjusting.
3. Run mast through several cycles to verify cable/
chain adjustments and ensure no interference exists
between chain anchor brackets and mast.
SECTION 5 - MAST COMPONENTS
2
1
7
3
6
8
9
10
11
5
4
7/16 in. (12mm)
Figure 5-2. MVL/MSP - Mast Chain and Sequence Cable Adjustment Components.
1. Sequence Cable Adjust Nut 4. Mast Section - 3 7. Check Mast Stowed Height 10. Chain Lock Nut
2. Mast Section - 1 5. Mast Section - 4 8. Chain Anchor Plate 11. Threaded Chain End
3. Mast Section - 2 6. Mast Section - 5 9. Chain Adjust Nut
3121231 – JLG Lift – 5-3
SECTION 5 - MAST COMPONENTS
5.3 SEQUENCE CABLE REPLACEMENT KIT
A sequence cable replacement kit is available from the
JLG Parts Department to service broken or worn
sequence cables. This kit consists of a replacement
sequence cable with the threaded (top) end attached
same as the top end of the factory cable. Also included is
a clamp (drum/socket type) to secure the bottom end of
the cable. Use the following procedure to install the
replacement cable and clamp kit.
Remove Old Cable
1. Remove the locking nut from the threaded end of
the cable at the top of the mast and then remove the
spring cap, spring, and spacer washers if installed.
2. Slide the threaded top end out of the upper anchor
bracket, then at the bottom end pull the cable out
though the sheave pulley/anchor bracket until it is
completely clear of the machine.
Replacement Cable Installation
1. Be certain the mast is completely retracted and at
the bottom of travel. Check the mast "Side Profile" at
the top of the mast as shown in Figure 5-2., adjust
mast sections to proper height if necessary.
2. To determine where the clamp will be installed at the
bottom of the replacement cable, temporarily
assemble the new replacement cable to the top
cable anchor bracket on the mast using the washers, spring, spring cap and lock nut previously disassembled. Thread the lock nut on until
approximately 1/8 in. (3mm) of threads are exposed.
3. At the bottom of the mast, thread the loose end of
the replacement cable through the proper sheave
pulley and through the hole in the sheave pulley/
anchor bracket on the mast section ahead of the
sheave pulley.
4. Grasp the cable and pull on the cable until the
spring at the top of the cable is slightly compressed.
Use a black marker to mark the cable on the top
side of the sheave pulley/anchor bracket. This will
determine where the clamp (drum/socket) sleeve
will be positioned on the cable.
Clamp Installation (Drum/Socket Type)
THE MANUFACTURER OF THE DRUM/SOCKET CLAMP RECOMMENDS THE USE OF THEIR CABLE CLAMP ASSEMBLY KIT (JLG
P/N - 7023275) TO ASSEMBLE THE CLAMP TO THE WIRE ROPE.
THE KIT CONSISTS OF VISE JAWS TO HOLD THE WIRE ROPE IN
A VISE PROPERLY WITHOUT DAMAGING ANY ROPE STRANDS
AND A PLUG DRIVER TO DRIVE THE PLUG INTO THE CENTER OF
THE WIRE ROPE AND IS ALSO USED TO FORM THE STRANDS OF
THE ROPE DURING ASSEMBLY.
NOTE: The tools in the clamp assembly kit may be fabri-
cated if necessary. The vise clamp consists of vise
jaws with a hole drilled 1/32 in. smaller than the
diameter of the wire rope you are working with (i.e. 1/
8 in. rope - 3/32 in. hole.)
The plug driver is a metal tube with a hole in the bottom to allow the strands of the wire rope to be
shaped after the plug has been tapped into the center of the wire rope.
1. Using the recommended vise jaws, clamp the wire
rope into a vise with the bottom edge of the black
mark made on the wire rope resting just above the
vise jaws.
1. Cable 3. Recommended Vise Jaws
2. Mark on Cable
DO NOT CUT THE CABLE AT THE MARKED POINT ON THE
CABLE THIS IS ONLY USED AS A REFERENCE FOR POSITIONING
THE CABLE SLEEVE WHICH WILL REST AGAINST THE ANCHOR
BRACKET ONCE INSTALLED.
5-4 – JLG Lift – 3121231
SECTION 5 - MAST COMPONENTS
2. Twist the sleeve from the clamp kit onto the rope
until it is flat against the vise jaws at the mark made
made on the wire rope.
1. Sleeve Installed on Cable
3. Use a suitable tool and cut the cable as shown in the
illustration following. For 1/8 in. cable the recommended length is 5/8 in. past the end of the sleeve.
1. Cable Strands Unlayed
5. Install the plug supplied with the kit by placing the
plug in the center of the strands starting with the
small tapered end of the plug. Use a metal tube
(plug driver) and hammer to drive the plug into the
sleeve while assuring that the strands are spaced
somewhat equally around the plug. Drive the plug
until it is firmly seated and no more than 1/3 of the
plug is visible from above the sleeve.
1. Cut To This Length 2. Sleeve
1. Plug Driver 3. Inser t Plug in this Position
2. Plug
4. Unlay the cable strands by gently forcing a screwdriver between the outer strands to unlay the cable.
When done properly the outer strands will form a
symmetrical basket. Do not straighten out the spiral
lay of the strands, unlay any wires that make up the
strand, or allow the strands to cross each other
inside the sleeve.
3121231 – JLG Lift – 5-5
SECTION 5 - MAST COMPONENTS
6. Reclamp the assembly in the vise on the flats of the
sleeve. Using the plug driver, a metal tube or pliers,
bend the outer strands toward the center strands
enough that the socket can be slipped over all the
strands.
1. Use Plug Driver, Metal Tube or Pliers
2. Shape Strands Around Plug
NOTE: When assembling stainless steel parts all threads
must be coated with a dry lubricant or an anti-seize
lubricant to prevent seizing.
7. Coat the threads of the socket and sleeve with lubricant and install the socket by twisting it over the
strands of the cable and engage the threads of the
sleeve with the socket. Tighten until four threads or
fewer are visible. If more than four threads are visible, proof load the cable and retighten the socket fitting. (There is no specific requirement for torque.)
1. Inspection Hole 3. Four Threads or Less Showing
2. Install Socket and Tighten
8. Inspect for proper assembly prior to loading the
cable. Strands visible through the inspection hole
are your assurance of a proper assembly.
NOTE: The end of the rope may not be visible in the inspec-
tion hole after loading.
9. Install cable on machine and adjust per instructions
shown previously in Section 5.2, MAST CHAINS
AND SEQUENCING CABLES ADJUSTMENT.
5-6 – JLG Lift – 3121231
SECTION 5 - MAST COMPONENTS
5.4 HYDRAULIC LINE - DISCONNECT SPECIAL TOOL
The extend and return hydraulic line couplings and hose
fittings on this machine require special tool JLG P/N7027247 to remove and install them.
FULLY LOWER THE MAST TO RELIEVE PRESSURE IN THE SYSTEM BEFORE REMOVING ANY HYDRAULIC LINES. CAREFULLY
LOOSEN REQUIRED FITTINGS, WEAR SAFETY PROTECTION
EQUIPMENT WHEN WORKING WITH HYDRAULIC SYSTEMS.
Tool Use - In-Line Style Fittings
Step 1. Prior to disconnection, ensure that system
is not under pressure.
Push Type Hydraulic Line Removal - SpecialTool
JLG P/N - 7027247
Instructions for tool use on both in-line and angled hose
fittings are shown on the pages following.
Step 2. Pull on hose assembly to create a gap
between the dust boot and hose fitting
shoulder.
Step 3. Insert the disconnect tool in the gap created
between the dust boot and hose fitting
shoulder.
3121231 – JLG Lift – 5-7
SECTION 5 - MAST COMPONENTS
Tool Use - In-Line Style Fittings (continued) Tool Use - Angled Style Fittings
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 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 6. Release the tool and pull on hose assembly
to complete disconnection.
Step 3. Insert the disconnect tool in the gap created
between the dust boot and hose fitting
shoulder.
5-8 – JLG Lift – 3121231
SECTION 5 - MAST COMPONENTS
Tool Use - Angled Style Fittings (continued)
Step 4. Gently push hose assembly into coupling
body (see directional arrow).
5.5 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILD
HYDRAULIC CYLINDERS ARE DESIGNED TO HOLD HYDRAULIC
FLUID UNDER HIGH PRESSURE. ENSURE ALL APPROPRIATE
MEASURES ARE TAKEN TO RELIEVE RESIDUAL PRESSURE IN
THE CYLINDER BEFORE DISCONNECTING LINES.
Lift Cylinder Removal
Removal of the hydraulic lift cylinder without removing the
mast from the machine requires laying the machine on it’s
back (hood side) with the platform end on top.
1. Remove the following components from the
machine before laying machine on it’s back:
•Rear Covers (See Section 4)
•Batteries (See Section 3)
• Drive Motor Cover (See Section 3)
2. Seal the vented cap on the hydraulic fluid reservoir
by removing the cap, covering the hole with a few
layers of plastic wrap or equivalent. Then install and
tighten the cap over the plastic wrap to prevent leakage of hydraulic oil from the reservoir while machine
is in a layed back position.
3. Use a forklift truck or overhead crane and carefully
lay the machine on it’s back, place a support under
the mast end, keeping mast close to level. (See Fig-
ure 5-3.)
Step 5. While maintaining slight pressure on the
hose assembly, actuate the tool (see arrow).
Figure 5-3. Machine Positioned for Cylinder
Removal.
Step 6. Pull on hose assembly to complete discon-
nection.
1. Be Careful of Control Components in this Area
2. Support Mast Here - Keep Mast Approximately Level
3121231 – JLG Lift – 5-9
SECTION 5 - MAST COMPONENTS
1
2
1
2
3
4
5
2
1
4. At the base end, remove and cap the extend and
return hydraulic lines.
Hydraulic Extend and Return Lines
1. Cylinder Return Line 3. Manual Descent Valve
2. Cylinder Extend Line
5. Remove the mini covers from the tops of the mast
sections.
7. Remove the adjust and lock nuts from the chain
studs at the bottom of mast section-3.
Chain Assembly - Bottom of Mast Section-3
1. Mast Section-4 4. Adjust Nut
2. Mast Section-3 5. Lock Nut (b)
3. Chain Assembly Stud (a)
Note: (a) Remove nuts and push studs through anchor plate.
6. Manually extend the mast assembly until the top of
mast section-2 is extended approximately one (1)
foot (31cm), to allow access to the sheave wheelanchor block at the top of mast section-2 and the lift
cylinder.
Extending Mast Sections
1. Mast Section-2 2. 1 ft. (31cm) Extended
8. Push mast sections-3, 4 and 5 back towards the
base assembly allowing the top of mast section-2 to
be completely exposed.
Exposing Top of Mast Section-2
1. Sections-3, 4 and 5 Pushed Back
2. Top of Mast Section-2 Exposed
5-10 – JLG Lift – 3121231
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