Service Manual

ManualsBrandsJLG ManualsSpecial machinery10MSP

Service and Maintenance Manual

ANSI

Model

10MSP

Vertical Lift

P/N - 3121228

April 29, 2013

Summary of content (154 pages)

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Service and Maintenance Manual Model 10MSP Vertical Lift P/N - 3121228 April 29, 2013 ANSI ®
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NOTES:
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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS MAINTENANCE SAFETY PRECAUTIONS A. GENERAL C. MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial 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.
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INTRODUCTION - REVISION LOG REVISION LOG Original Issue of Manual . . . . . . . . . . . . . December 23, 2005 Manual Revised. . . . . . . . . . . . . . . . . . . . January 2, 2005 Manual Revised. . . . . . . . . . . . . . . . . . . . January 6, 2005 Manual Revised. . . . . . . . . . . . . . . . . . . . May 23, 2006 Manual Revised. . . . . . . . . . . . . . . . . . . . October 4, 2006 Manual Revised. . . . . . . . . . . . . . . . . . . . December 5, 2007 Manual Revised. . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. MAINTENANCE SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A A GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A B HYDRAULIC SYSTEM SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Pressure-Fit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS Tank Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Filter Screen Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Pump Remove/Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Pressure Adjust Valve Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION 5 - MAST COMPONENTS 5.1 MAST COMPONENTS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.2 MAST COVER - INSTALL/REMOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.3 PLATFORM ASSEMBLY - INSTALL/REMOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.4 MATERIAL TRAY - INSTALL/REMOVE. . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS 6.8 TROUBLESHOOTING TABLES INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 SPECIFICATIONS FOR VARIOUS COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS . . . . . . . . . . . . . . . 6-14 FAULT CODE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 MAIN POWER CIRCUIT TROUBLESHOOTING . . . . . . . . . . . . . .
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TABLE OF CONTENTS 6.12 MAIN POWER CIRCUIT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Machine Will Not Power Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 6.13 MAST TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Platform Will Not Lower Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS LIST OF TABLES TABLE NO. 1-1 1-2 1-3 1-4 1-5 1-6. 2-1 2-2 2-3 3-1 4-1 5-1 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 6-12 6-13 6-14 6-15 6-16 6-17 6-18 6-19 6-20 6-21 6-22 6-23 6-24 6-25 6-26 6-27 6-28 6-29 6-30 6-31 6-32 6-33 6-34 6-35 6-36 6-37 6-38 6-39 6-40 6-41 6-42 6-43 3121228 TITLE PAGE NO. 10MSP - Machine Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Platform Maximum Capacity . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS 6-44 6-45 6-46 6-47 6-48 viii Caster Wheels Not Operating Freely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40 Won’t Climb Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41 Machine Drive in Opposite Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42 Machine Won’t Drive Straight.. . . . . . . . . .
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SECTION 1 - MACHINE SPECIFICATIONS SECTION 1. MACHINE SPECIFICATIONS Table 1-1. 10MSP - Machine Operating Specifications 10MSP Maximum Occupants: 1 Maximum Work Load (Capacity): See Table 1-2 on Page 1-2 Maximum Travel Grade (Gradeability): (Platform STOWED ONLY) 20% (8.5°) Maximum Travel Grade (Side Slope): (Platform STOWED ONLY) 5° Tilt Alarm Cut Out Limit: (Any Direction) (Platform ELEVATED) Machine Height (Platform Stowed) 57 in. (1.45m) Maximum Vertical Platform Height: 10 ft. (3.
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SECTION 1 - MACHINE SPECIFICATIONS 1.1 CAPACITIES IES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFORMANCE ISSUES OR BATTERY CHARGER FAULT CODES. JLG ASSUMES NO RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES ARISING FROM THE USE OF NON APPROVED BATTERIES. System Voltage 24 Volt DC Battery Charger Microprocessor Controlled/SCR Circuit Monitor 120/240 Volt A.C.
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SECTION 1 - MACHINE SPECIFICATIONS 1.7 LUBRICATION Machine Height Platform Elevated - 13.74 ft. (4.19m)(Top of platform rails) Platform Stowed - 57 in. (1.44m) Machine Overall Length - 61 in. (1.55m) Width - 29.5 in. (75cm) standard 32.5 in. (82.5cm) with bumpers 35.0 in. (89cm) with roller guides 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.
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SECTION 1 - MACHINE SPECIFICATIONS Lubrication Points. (See Table Below) Table 1-6. Lubrication Intervals for Various Components ITEM COMPONENT 1 Hydraulic Oil 2 Swivel Raceways 3 Mast Chains NO/TYPE (a) LUBE POINTS INTERVAL (b) LUBE/METHOD 3 6 MONTHS MONTHS 1 YEAR Fill To Full Line on HO - Check Hyd. Oil Dipstick - 5 Qt. Level Reservoir HO - Change Hyd. Oil — 2 - Per Section ✔ ✔ MPG CL - Brush or Spray 2 YEARS ✔ COMMENTS Check fluid level every day.
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SECTION 1 - MACHINE SPECIFICATIONS 1.8 TORQUE SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Lubricated Torque (Dry) Tensile Clamp Load Stress Area Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraTM OR Vibra-TITE 111 or TITETM 131) 140) Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.
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SECTION 1 - MACHINE SPECIFICATIONS SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Clamp Load Stress Area Torque (Dry or Loctite® 263) K= 0.20 Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraOR Vibra-TITE TM 111 or TITETM 131) 140) K=.18 K=0.15 Size TPI Bolt Dia Sq In 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.0364 IN-LB [N.m] IN-LB [N.m] 40 48 32 40 32 36 24 32 20 28 In 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.
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SECTION 1 - MACHINE SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .17 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.16 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - MACHINE SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Tensile Stress Area Clamp Load See Note 4 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18 Torque (Dry) K = .20 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - MACHINE SPECIFICATIONS CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Size PITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) Torque (Lub) KN [N.m] [N.m] Torque Torque (Loctite® (Loctite® 262TM 242TM or 271TM OR VibraOR VibraTITETM 131) TITETM 111 or 140) [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.
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SECTION 1 - MACHINE SPECIFICATIONS CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Size PITCH Tensile Stress Area Clamp Load Torque (Dry or Loctite® 263TM) K = 0.20 Sq mm KN [N.m] Torque (Lub OR Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140) K= 0.18 Torque (Loctite® 262TM OR Vibra-TITE TM 131) K=0.15 [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.
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SECTION 1 - MACHINE SPECIFICATIONS Magni Coating (Ref 4150701)* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Size PITCH Tensile Stress Area Sq mm Torque Torque (Lub OR Loctite® Torque (Loctite® 262TM Clamp Load (Dry or Loctite® 242TM or 271TM OR Vibra-TITE TM See Note 4 263TM) OR Vibra-TITE TM 131) K = .17 111 or 140) K = .15 K = .16 kN [N.m] [N.m] [N.m] 11 3 0.5 5.03 3.5 0.6 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 7 1 28.90 18.0 21 20 19 8 1.25 36.60 22.
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SECTION 1 - MACHINE SPECIFICATIONS NOTES: 1-12 – JLG Lift – 3121228
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SECTION 2 - GENERAL SERVICE INFORMATION SECTION 2. GENERAL SERVICE INFORMATION 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.
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SECTION 2 - GENERAL SERVICE INFORMATION Table 2-1. Maintenance and Inspection Requirements. Type Frequency Primary Responsibility Service Qualification Reference Pre-Start Inspection Prior to use each day; or At each Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
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SECTION 2 - GENERAL SERVICE INFORMATION Table 2-2. 10MSP - Preventive Maintenance & Inspection Schedule.
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SECTION 2 - GENERAL SERVICE INFORMATION Table 2-2. 10MSP - Preventive Maintenance & Inspection Schedule.
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SECTION 2 - GENERAL SERVICE INFORMATION 2.3 SERVICING AND MAINTENANCE GUIDELINES all parts are clean before they are installed. New parts should remain in their containers until they are ready to be used. General Components Removal and Installation The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter.
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SECTION 2 - GENERAL SERVICE INFORMATION Bolt Usage and Torque Application Mast Chain Inspection Procedure 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.
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SECTION 2 - GENERAL SERVICE INFORMATION 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.
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SECTION 2 - GENERAL SERVICE INFORMATION 2.4 LUBRICATION INFORMATION 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. 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.
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SECTION 3 - BASE COMPONENTS SECTION 3. BASE COMPONENTS 3.1 BASE ASSEMBLY COMPONENTS Figure 3-1. Base Components. 1. Front Cover 2. Drive Motor Cover 3. Hydraulic Pump Motor/Reservoir 3121228 4. Battery Charger 5. Batteries 6. Limit Switches (Mast Activated) – JLG Lift – 7. Front Caster Wheels 8. Drive Motor Assemblies 9.
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SECTION 3 - BASE COMPONENTS 3.2 BASE FRAME COVERS Carry Deck Support Frame - Installation Front Cover - Installation (Carry Deck Version) 1 3 1 2 2 Carry Deck Support Frame Installation Carry Deck - Hood Removal. 1. Hood - Carry Deck 2. Attach Screw NOTE: 3. Rear Hold-Down Bracket -Located Under Hood - Slides Under Hood Support (a) The Carry Deck has a maximum capacity of 250 lb. (115k). (b) Unscrew the attach screw to release hood from the frame mount under the cover.
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SECTION 3 - BASE COMPONENTS Rear Bumper Cover - Installation Drive Motor Cover - Installation Five (5) of the Drive Motor cover screws must be removed to remove the rear bumper cover, see the Drive Motor Cover - Installation illustration. To gain access to those screws, elevate the platform. NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL THE PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING. To gain access to the drive motor cover and screws, elevate the platform.
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SECTION 3 - BASE COMPONENTS 3.3 DRIVE AND CASTER WHEELS 3. The tightening of the lug nuts should be done in stages. Following the recommended sequence, tighten lug nuts per wheel torque. Tire Wear and Damage Table 3-1. Wheel Torque Chart Inspect tires periodically for wear or damage. Tires with worn edges or distorted profiles require replacement. Tires with significant damage in the tread area or side wall, require immediate evaluation before placing the machine into service.
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SECTION 3 - BASE COMPONENTS 3.4 DRIVE/ELEVATION CUT-OUT SWITCH INSTALLATION 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. 5 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.
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SECTION 3 - BASE COMPONENTS Wheel Drive Assembly - Removal From Machine 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.
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SECTION 3 - BASE COMPONENTS 5 4 1 2 3 Wheel Drive Assembly - Installation (Right Side Shown) 1. Wheel Drive Assembly 2. Frame Mounting Surface 3. Mounting Bolts/Washers (a) NOTE: 3121228 4. Drive Wheel 5. Wheel Mounting Lugs (b) Installation same for left and right drive motor - (a) Apply Loctite #242 to threads before tightening. (b) Tighten to 120 ft. lbs.
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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. 6. Remove the Brake Housing (B1) and the Spacers (B4). NOTE: 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.
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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 PAGES FOLLOWING. 1. Wrap tape around the end of the motor shaft that interfaces with the gearbox to avoid damage to this area. 2. Remove the motor thru bolts. 3. Remove the motor flange/brake mount from the motor frame. 4.
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SECTION 3 - BASE COMPONENTS tipped 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. 22. Tighten the motor bolts to 65 in-lbs. 23.
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SECTION 3 - BASE COMPONENTS Gear Box Main Disassembly 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. NOTE: 2. Remove Cover (G11), Thrust Washer (G21) should remain in the inner counterbore of the Cover when removed. NOTE: To remove the cover the motor must be removed.
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SECTION 3 - BASE COMPONENTS Input Carrier Disassembly Input Carrier Disassembly 1. Remove Retaining Rings (G18) from each of the three Planet Shafts (G6). NOTE: 6. Remove the other Thrust Washer (G25) from each Planet Shaft (G6). 7. Remove Retaining Ring (G24) from Output Sun Gear (G8). Do not overstress these Retaining Rings when removing them. 8. Slide Output Sun Gear (G8) out from the center of the Input Carrier (G7). 2. Remove Thrust Plate (G23). 3.
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SECTION 3 - BASE COMPONENTS Hub - Disassembly Hub Disassembly 1. Remove Main Wheel Bearing (G14). NOTE: 2. Remove main Lip Seal (G16). 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. 3121228 NOTE: – JLG Lift – This Lip Seal (G16) is also held in with a press fit.
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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: 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).
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SECTION 3 - BASE COMPONENTS Spindle Sub-Assembly Spindle Sub-Assembly 1. Place the spindle (G1) on the bench with the carrier portion facing up. NOTE: 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). Do not damage or scratch the seal surface of the spindle (G1) during assembly. 8.
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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: 3-16 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. NOTE: The Seal has a thin outer shell that can be easily damaged if not installed with care.
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SECTION 3 - BASE COMPONENTS Input Carrier Sub-Assembly 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. 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.
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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. NOTE: 2. Apply a coating of grease to the Lip Seal (not shown) in the Hub Sub-Assembly. 7. Install the Input Carrier Subassembly into mesh.
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SECTION 3 - BASE COMPONENTS Motor, Brake and Gear Box Assembly 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.
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SECTION 3 - BASE COMPONENTS 3.6 PUMP-MOTOR ASSEMBLY SERVICE PROCEDURE Hydraulic Pressure Settings and Adjustment Adjust system pressure so that platform will raise with maximum rated capacity in platform. General The following is a complete tear-down/re-assembly of the machines’ pump/motor assembly. No internal parts to the hydraulic pump are serviced by JLG except for a pump installation seal kit. Also the only parts serviceable internal to the pump electric motor is the motor brush kit.
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SECTION 3 - BASE COMPONENTS Hydraulic Pressure Gauge Connection After Filter Pressure Check 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. Reinstall the hydraulic oil filter and install a t-fitting between the hydraulic filter and the extend line to the cylinder.
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SECTION 3 - BASE COMPONENTS Pump-Motor Assembly - Remove/Install Pump-Motor Assembly - Remove/Install 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 AND PORTS WHEN DISCONNECTED. 1 2 3 Hydraulic Pump Mount and Mounting Screws 1. Hydraulic Pump/Motor/ Reservoir Assembly 2. Pump/Ground Control Station Mounting Bracket NOTE: 3.
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SECTION 3 - BASE COMPONENTS Motor/Brush Cover - Remove/Install 3 2 5 1 5 4 Motor/Brush Cover - Removal/Installation 1. Motor/Brush Cover (a) 2. Cover Screws (b) 3. Washers 4. Power Leads to Lead Clips (Soldered) 5. Power Lead Clip Attach Screws 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).
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SECTION 3 - BASE COMPONENTS Brush Carrier Assembly - Remove/Install 4 2 3 1 Brush Carrier Assembly - Remove/Install 1. Stator/Brush Carrier Screws (Pump Rear) 2. Stator/Brush Carrier Screws (Pump Front) (a) 3. Mark Brush Carrier Position on Motor Housing 4. Brush Carrier Assembly NOTE: (a) Removed previously with motor cover disassembly (shown for reference only). Brush Assembly - Remove/Install 2 Tank Remove/Install 1 2 3 4 5 3 Brush Assembly - Remove/Install 1. Brush Assembly (a) 2.
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SECTION 3 - BASE COMPONENTS Filter Screen Remove/Install Pressure Adjust Valve Remove/Install 5 5 4 3 2 1 4 3 2 1 Filter Screen - Remove/Install • Requires removal of tank assembly. 1. Filter Screen 2. Pump Pick-Up Tube 3. Tube Retainer Clip Pressure Adjust Valve - Remove/Install 4. Tube Attach Screw 5. O-Ring Note: Tubes shown shortened for illustrative purposes only. 1. Adjust Valve Cap 2. Adjustment Screw 3. Valve Spring 4. Valve Ball 5.
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SECTION 3 - BASE COMPONENTS 3.7 BATTERIES AND BATTERY CHARGER SERVICE PROCEDURES Battery Condition Testing NOTE: Batteries in storage should be kept at 12.5V or higher. Battery - Installation (2-12V Batteries) 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.
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SECTION 3 - BASE COMPONENTS Battery Installation - (4-6V Batteries) (OPTION) REAR 6 5 7 3 1 4 2 4 Battery Installation - 4-6V (Left Side Batteries Shown with Machine Covers Removed) 1. Batteries (Left Side) 2. Battery Hold-Down Brakets and Fasteners NOTE: FRONT 2 3 3. Drive Motor Cover Screw Bracket 4. Move Rear Battery Forward and Lift Out The carry deck, support frame will need to be removed to remove the batteries.
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SECTION 3 - BASE COMPONENTS Battery Charge LED Indicator on Platform Control Console • (+) 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.
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SECTION 3 - BASE COMPONENTS Battery Charger General Information the battery pack voltage drops below a minimum voltage or 30 days has elapsed. 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.
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SECTION 3 - BASE COMPONENTS teries and connections are not faulty, and Fault 6 is again displayed after interrupting AC power for at least 10 seconds, the charger must be brought to a qualified service depot. Battery Charger Maintenance Information 1. Make sure charger connections to battery terminals are tight and clean. 2. Do not expose charger to oil or to direct high pressure water spraying when cleaning vehicle.
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SECTION 3 - BASE COMPONENTS Battery Charger Removal/Installation 1. Remove the front cover (carry deck) from the machine. 2. Remove the carry deck support bracket from the base frame. 3. Disconnect the positive (+) battery cable at the left side battery. 4. Remove the two (2) screws and washers from the top bracket securing the charger to the base frame mast mount. Only loosen the two (2) screws on the bottom bracket of the charger enough to slide the charger out. 5.
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SECTION 3 - BASE COMPONENTS NOTES: 3-32 – JLG Lift – 3121228
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SECTION 4 - CONTROL COMPONENTS SECTION 4. CONTROL COMPONENTS 4.1 CONTROL COMPONENTS OVERVIEW 2 1 3 4 7 6 5 Figure 4-1. Control Components Location 1. Ground Control Station 2. Platform Control Console 3. Platform Gate Interlock Switches* 3121228 4. Platform Footswitch Interlock 5. Traction Control Module 6. Platform Junction Box – JLG Lift – 7. Platform Junction Box to Ground Control Harness * Mounted inside lower gate hinge left and right side.
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SECTION 4 - CONTROL COMPONENTS 4.2 CONTROL COMPONENTS INSTALLATION BEFORE REMOVING ANY COMPONENT FROM THE ELECTRICAL SYSTEM, DISCONNECT THE POSITIVE TERMINAL FROM THE LEFT SIDE BATTERY. Ground Control Module The face of the Ground Control Module is visible from the front of the machine and is located under the front cover. It is mounted to a bracket on the base frame in front of the hydraulic pump. All electrical components on the machine operate directly or indirectly through the Ground Control Module.
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SECTION 4 - CONTROL COMPONENTS Traction Control Module Platform Control Console Installation The Traction Control Module is mounted to the base frame beneath the platform, under the drive motor cover. This module controls the voltage to the drive motors as regulated by the Ground Control Module from signals received from the Joystick Controller located on the Platform Control Module. The platform control console is located in the platform and mounted on the right side of the mast assembly.
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SECTION 4 - CONTROL COMPONENTS Platform Junction Box - Install/Remove All the platform mounted switches and controls connect to the platform junction box before running to the Ground Control Module (P2, P3, and P4 Connectors), the Ground Control Module Harness is attached to the side of the mast assembly. Junction Box to Ground Control Harness Remove/Install 2 1 7 6 5 4 3 Platform Junction Box - Installation 1. Platform Junction Box 2. Junction Box Attach Screws 3.
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SECTION 4 - CONTROL COMPONENTS Platform Interlock Switch Circuit The platform interlock circuit consists of the platform footswitch and the platform gate switches wired in series. This circuit will inhibit the machines lift and drive functions and display a fault code on the Ground Control Station if the circuit is not closed during machine operation. The circuit utilizes the Auxiliary #1 plug on the Platform Junction Box (located under the platform).
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SECTION 4 - CONTROL COMPONENTS Figure 4-2. Component Electrical Connections. 1. Ground Control Module (a) 2. Left Side Battery (b) (c) 3. 175 Amp Fuse Ground Control Module Plugs: Notes: 4. Right Side Battery (b) 7. Power Cable To Right Drive Motor/Brake (a) 5. Traction Control Module (a) 8. Hydraulic Pump/Motor/Tank Assembly (b) 6.
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SECTION 4 - CONTROL COMPONENTS 4.3 GROUND CONTROL MODULE SERVICE PROCEDURE The Ground Control Module allows for field replacement of two (2) components internal to the module. • Emergency Stop Switch • Power Selector Switch (Key) 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.
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SECTION 4 - CONTROL COMPONENTS Cover Removal/Installation 1 THE MAIN CIRCUIT BOARD AND THE SMALLER LCD CIRCUIT BOARD MOUNTED TO THE COVER ASSEMBLY, ARE CONNECTED BY A RIBBON CABLE. REMOVE THE COVER CAREFULLY ONCE THE COVER SCREWS ARE REMOVED FROM THE BACK OF THE MODULE. 1 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. 1 1 Cover Installation 1.
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SECTION 4 - CONTROL COMPONENTS Power Selector/EStop Switch Installation 3 2 1 Emergency Stop Switch Installation EStop/Power Selector Switch Connector Locations 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. 1. LCD and Button Circuit Board 2. Emergency Stop Switch Connector 3.
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SECTION 4 - CONTROL COMPONENTS 4.4 GROUND CONTROL MODULE PROGRAMMING Activating Programming Mode General The 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.
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SECTION 4 - CONTROL COMPONENTS Programming Mode Selection Adjusting Programmable Setting 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.
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SECTION 4 - CONTROL COMPONENTS Service Programming Mode - (Level-2) In the Service Programming Mode the following items are shown on the main menu (Also See Table 4-1 on Page 413): • Reset Timers • Program • Tilt Sensor • OSS Sensor NOTE: There are two production modules available at this time, one for North/South American and European languages, and one for Asian languages. All programmable items between these modules are identical with the exception of language selection.
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SECTION 4 - CONTROL COMPONENTS Table 4-1. Ground Control Module - Field Programmable Settings and Factory Preset. (10MSP) Level-2: Service Level Settings Level-3: Operator Level Settings LEVEL 2 3 On LCD Display: FACTORY PRESET – 1 PROGRAMMABLE ITEM Back to Main Set Language NOTE: There are two production modules available at this time, one for North/South American and European Languages, and one for Asian Languages.
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SECTION 4 - CONTROL COMPONENTS Table 4-1. Ground Control Module - Field Programmable Settings and Factory Preset. (10MSP) Level-2: Service Level Settings Level-3: Operator Level Settings LEVEL 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4-14 On LCD Display: FACTORY PRESET 5 SEC.
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SECTION 4 - CONTROL COMPONENTS 4.5 PLATFORM CONTROL CONSOLE SERVICE PROCEDURES 6 5 General 4 3 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.
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SECTION 4 - CONTROL COMPONENTS Display/Controller Module Electrical Connections Mounting Bracket - Install/Remove 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. 1 2 1 2 3 4 5 6 Platform Console - Mounting Bracket 1. Mounting Bracket 2.
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SECTION 4 - CONTROL COMPONENTS Display/Controller Module - Install/Remove Horn Button Switch - Install/Remove 1 1 2 3 2 Platform Console - Horn Switch Installation 1. Horn Button Switch (a) 2. Lock Washer 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. 3. Nut Note: (a) Remove rear cover, unplug wire, remove nut and lock washer then slide switch out of console.
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SECTION 4 - CONTROL COMPONENTS E-Stop/ShutDown Switch - Install/Remove Joystick Assembly - Install/Remove 2 1 2 3 4 3 5 4 1 6 5 7 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 Platform Console - Joystick Installation 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.
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SECTION 5 - MAST COMPONENTS SECTION 5. MAST COMPONENTS 5.1 MAST COMPONENTS OVERVIEW Figure 5-1. Mast Components. 1. Material Handling Tray 2. Platform Assembly 3121228 3. Mast Assembly 4.
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SECTION 5 - MAST COMPONENTS 5.2 MAST COVER - INSTALL/REMOVE 5.3 PLATFORM ASSEMBLY - INSTALL/ REMOVE Mast Cover Installation 1. Mast Cover 2. Screws and Washers (a) 3. Platform Console Mounting Screws Platform shown without right side rails for illustrative purposes only. Platform Installation 1. Platform/Material Tray Assembly 2. Tie Straps for Platform Console Harness Note: (a) Apply Loctite #242 to threads before final tightening. 3. Countersunk Flat Head Socket Screws/Washers and Locknuts 4.
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SECTION 5 - MAST COMPONENTS 5.4 MATERIAL TRAY - INSTALL/REMOVE 5.5 PLATFORM - 7 FT. HEIGHT LIMIT SWITCH - OPTION 3 1 2 4 Material Tray Installation 1. Material Tray Assembly 2. Tray Bottom Stops (b) 3. Tray Release Bar (c) 4. Raise Platform (a) Note: (a) Raise the platform approximately 2 ft. (60cm) when sliding the tray off the bottom of the mounting rails. Tray will not clear beacon or hood without raising platform. (b) Remove stops to slide tray off the bottom of the mounting rails.
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SECTION 5 - MAST COMPONENTS 5.6 HYDRAULIC LINE - DISCONNECT SPECIAL TOOL Tool Use - In-Line Style Fittings 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. Step 1.
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SECTION 5 - MAST COMPONENTS Tool Use - Angled Style Fittings Step 4. Gently push hose assembly into coupling body (see directional arrow). Step 1. Prior to disconnection, ensure that system is not under pressure. Step 5. Maintaining slight pressure on the hose assembly, actuate the tool (see arrow). 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.
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SECTION 5 - MAST COMPONENTS 5.7 MAST ASSEMBLY INSTALL/REMOVE Mast Removal The following components must be removed from the machine before removing the mast assembly: With Platform Elevated (approx. 4 ft. (1.2m)) Remove; • Front Hood (See Section 3.2) • Drive Motors Cover (See Section 3.2)) • Platform/Material Tray Assembly (See Section 5.3) Remove the bottom bolts and unhook the enable foot switch and entry gate interlock wire harness from the platform junction box. Step 4.
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SECTION 5 - MAST COMPONENTS 3. Disconnect and cap the hydraulic extend and return lines from the hydraulic cylinder either on the valve block at the bottom of the cylinder or at the pump assembly. (See Section 5.6 for special tool instructions). 4. Using an overhead crane or suitable lifting device capable of supporting the weight of the mast assembly, attach a sling strap to the mast. 5. Remove the four (4) mast attach bolts with washers and nuts securing the mast to the mounting column. 5.
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SECTION 5 - MAST COMPONENTS Mast Section-3 - Removal 1. Remove chain adjust nuts from threaded ends of chains attached to the chain anchor plate (lower) on BOTTOM end of mast section-3. Push threaded ends of chains through anchor plate. 2. At TOP of mast section-2, pull chains out and allow to hang loose.
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SECTION 5 - MAST COMPONENTS Mast Section-1 - Disassembly 1. Remove the four (4) large screws (2 each side) attaching the lift cylinder mounting block to mast section-1. Slide the cylinder out of the mast section and move to a suitable work surface. 2. At the top end of mast section-1, remove the pin attaching the chain anchor block to the mast and remove chain/anchor block assemblies from the mast and lay aside. 1 3. Remove slide pads and shims from mast section-1, if necessary.
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SECTION 5 - MAST COMPONENTS Lift Cylinder Component Inspection Cylinder Assembly Cylinder Rod (See Figure 5-3.) 1. Rinse the inside of the tube with hydraulic fluid and allow to drain. A high-pressure rinse followed by a wipe with a lint-free rag is preferable. Clean all internal components of any foreign material. There should be no scratches or pits deep enough to catch the fingernail. Pits that go to the base metal are unacceptable.
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SECTION 5 - MAST COMPONENTS 2 3 4 5 1 6 Lift Down Valve and Manual Release Installation 1. Lift Down Valve (a) 2. Valve Solenoid (b) 3. Manual Release Assembly 4. O-Ring with Backing Rings (a) 5. Valve O-Ring (a) 6. Solenoid O-Ring (a) Notes: (a) Coat all o-rings with clean hydraulic fluid before assembling. (b) Mount with electrical terminals pointing to right side of machine.
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SECTION 5 - MAST COMPONENTS 5.10 MAST ASSEMBLY Assembly procedures for all mast sections is basically the same, carefully slide the mast sections together until mast ends are even. (When sliding the mast sections together, be careful not to scratch the anodized surface in the wear pad channels). Assemble the hardware to the bottom of mast section first, slide this section out the top of previous section and assemble hardware to the top of mast.
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SECTION 5 - MAST COMPONENTS Mast Section 1 - Assembly Mast Section 2 - Assembly 1. Place mast section-1, rail (open) side up (See Figure 5-4.) on a clean, flat surface (preferably a table or work bench capable of supporting the weight of the entire mast assembly). Slide mast out over end of work surface far enough to allow access to the chain anchor attach hole near the top of the mast.
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SECTION 5 - MAST COMPONENTS c. Check mast section for side play. If play exists add .015" shims dividing the thickness equally between both sides of mast. Insert shims until the shims cannot be inserted halfway by hand with the mast pulled to the opposite side. rarily removed. Be careful not to nick or scour rod surface when extending, also catch any oil draining out of cylinder to avoid spillage onto work area. 9.
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SECTION 5 - MAST COMPONENTS 12. Slide mast section-2 out of mast section-1 approximately one foot. side. Coat threads with Loctite #171 on final assembly. 14. Locate and assemble the narrow chains set (#444) and attach to the small (triangular shape) chain equalizer anchor plate using the pins, washers and cotter keys. 15.
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SECTION 5 - MAST COMPONENTS Mast Section 3 - Assembly 4. Push mast section-3 out the top of mast section-2 approximately 1 ft. (31cm). 1. Lay the wide chain set attached to the top of mast section-1 into the open rail on mast section-2. 5. Locate the lower chain anchor bracket (one with the threaded attach holes horizontally aligned to outside of bracket). 6.
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SECTION 5 - MAST COMPONENTS 9. Slide the top of mast section-3 back in even with the top of mast section-2. 10. Insert slide pads into the top end mast rails between section-2 and -3, (one on each side of the mast), with beveled surface facing inward towards section3. (Same as Figure 5-6.) NOTE: Before fastening and shimming the slide pad on the top left side of the mast, install a sequence cable bracket against the mast under the flatwasher.
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SECTION 5 - MAST COMPONENTS Mast Section 4 - Assembly 4. Slide mast section-4 out the top of mast section-3 approximately 1 ft. (31cm). 1. Lay the narrow chain set attached to the cylinder attach anchor block at the top of mast section-2 into the open rail on mast section-3. 5. Locate the lower chain anchor bracket (one with the threaded attach holes in a triangular shape pattern). 6.
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SECTION 5 - MAST COMPONENTS 11. Shim per instructions in step 7, Mast Section 2 Assembly. Apply Loctite #242 to attach screw threads on final assembly. Side of Mast Section-3 - Lower Sequence Cable Bracket 1. Mast Section-3 2. Lower Bracket Attach Screws 3. Lower Bracket 4. Sheave Wheel Attach Bolt Top of Mast Section-4 - Slide Pad Installation 1. Slide Pads 2. Shim Stock 3. Slide Pad Attach Screws (a) 5. Sheave Wheel Thrust Washer 6. Sequence Cable Sheave Wheel 7. Spacers (Qty.
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SECTION 5 - MAST COMPONENTS Figure 5-7. Platform Junction Box to Ground Control Station Wiring Harness. 1. Harness Sheave Wheel 2. Harness Spring Tensioner 5-20 3. Upper Powertrak Bracket 4. Mid Powertrak Bracket (Powertrak Shown Cutaway) – JLG Lift – 5.
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SECTION 5 - MAST COMPONENTS 5.11 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT NOTE: This procedure is to be performed with the mast mounted on the machine. Mast Chain/Cable Adjustment (See Figure 5-8.) NOTE: It is more important that the (threaded ends) studs are equal side to side on a mast section, than it is that the tension in the chains is equal.
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SECTION 5 - MAST COMPONENTS Figure 5-8. Mast Chain and Sequence Cable Adjustment Components. 1. Mast Side Profile (Sections Even at Top) 2. Sequence Cable Adjust Nut 5-22 3. Mast Section - 1 4. Mast Section - 2 5. Mast Section - 3 6. Mast Section - 4 7. Chain Anchor Plate (Inside) 8. Chain Adjust Nut – JLG Lift – 9. Chain Lock (Jam) Nut 10.
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SECTION 6 - TROUBLESHOOTING SECTION 6. TROUBLESHOOTING 6.1 GENERAL This section contains troubleshooting information to be used for locating and correcting most operating problems. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance. IT IS GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS.
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SECTION 6 - TROUBLESHOOTING the platform control console indicates the battery voltage status using ten (10) LEDs (red/yellow/green). If a malfunction to the machine’s electrical components occurs, the platform console LED’s will flash a number of LEDs to help indicate the problem to the Operator in the platform. The Fault Codes and LED Flash Codes are outlined in the following sub-sections of this chapter. NOTE: For aid in troubleshooting electrical problem, refer to Figure 6-7.
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SECTION 6 - TROUBLESHOOTING Voltage Measurement Resistance Measurement Figure 6-1. Voltage Measurement (DC) Figure 6-2. Resistance Measurement • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • First test meter and leads by touching leads together.
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SECTION 6 - TROUBLESHOOTING Continuity Measurement Current Measurement Figure 6-3. Continuity Measurement Figure 6-4.
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SECTION 6 - TROUBLESHOOTING Continuity Measurement Over Long Distances When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a particular wire in the harness. Requirements: • Harness with at least three separate wires including the wire under test. • These wires must be able to be isolated from other wires, etc.
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SECTION 6 - TROUBLESHOOTING 6.6 ELECTRICAL SWITCH TESTING Basic Check The following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected. 1. De-energize the circuit. 2. Isolate the switch from the rest of the circuit if possible. If not possible, keep in mind it may affect readings. 3. Access the terminals to the switch. 4.
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SECTION 6 - TROUBLESHOOTING Automatic Switches If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be energized to actuate. 1. Connect instrumentation to monitor and/or control the parameter the switch is measuring. 2. Observe switch state in control system with the Analyzer.
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SECTION 6 - TROUBLESHOOTING 6.7 GROUND CONTROL MODULE LCD DISPLAY At power-up and during operation the LCD display on the Ground Control Module displays the current machine operating status. The following illustration explains the symbol indications. LCD Display Symbols 1. Battery Charge Indicator (BCI) 2. Function Display or Function Disable Indicators 3. Hour Meter Display 4. Fault Code Indicator 5.
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SECTION 6 - TROUBLESHOOTING 1. Ground Control Module (a) 2. Left Side Battery (b) (c) 3. 175 Amp Fuse Ground Control Module Plugs: Notes: 4. Right Side Battery (b) 7. Power Cable To Right Drive Motor/Brake (a) 5. Traction Control Module (a) 8. Hydraulic Pump/Motor/Tank Assembly (b) 6.
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SECTION 6 - TROUBLESHOOTING Table 6-1. LCD Display - Service Fault Code Conditions FAULT CODE PLATFORM CONSOLE LEDs FLASHING — — — — LCD TEXT SCREEN FAULT DESCRIPTION/ MACHINE CONDITION TROUBLESHOOTING — 00000.0 Machine In Drive Speed Cut-Back (Turtle) Mode All The Time See Table 6-5, Page 6-17 00000.
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SECTION 6 - TROUBLESHOOTING Table 6-1. LCD Display - Service Fault Code Conditions FAULT CODE PLATFORM CONSOLE LEDs FLASHING 10 6 LCD SYMBOL SCREEN 00000.
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SECTION 6 - TROUBLESHOOTING Table 6-1. LCD Display - Service Fault Code Conditions FAULT CODE PLATFORM CONSOLE LEDs FLASHING 23 — LCD SYMBOL SCREEN 00000.0 24 See Table 6-24, Page 6-26 P1 - Auxiliary #1 Circuit Short See Table 6-25, Page 6-26 P1 - Auxiliary #1 Circuit Disconnected SeeTable 6-26, Page 6-27 26 P1 - Auxiliary #2 Circuit Short See Table 6-27, Page 6-27 27 P1 - Auxiliary #2 Circuit Disconnected See Table 6-28, Page 6-28 23 23 24 24 25 25 — 00000.
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SECTION 6 - TROUBLESHOOTING Table 6-1. LCD Display - Service Fault Code Conditions FAULT CODE PLATFORM CONSOLE LEDs FLASHING 37 — LCD SYMBOL SCREEN FAULT DESCRIPTION/ MACHINE CONDITION LCD TEXT SCREEN RESERVED FOR TROUBLESHOOTING REFER TO RESERVED 2 2 LEDs/BARS Flashing with an audible beep. Platform Lift-UP Function is Locked Out. See Page 6-32 39 1 1 LED/BAR Flashing with an audible beep. Drive and Platform Lift-UP Functions Locked Out.
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SECTION 6 - TROUBLESHOOTING 6.8 TROUBLESHOOTING TABLES INDEX SPECIFICATIONS FOR VARIOUS COMPONENTS PAGE Ohm Ratings for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Amperage Draw for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 6 - TROUBLESHOOTING Code 36 - RESERVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Code 37 - RESERVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Code 38 - Battery Voltage Low - Warning Level 2 - Two (2) LED/LCDs lit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 6 - TROUBLESHOOTING 6.9 SPECIFICATIONS FOR VARIOUS COMPONENTS The following table contains specifications for machine components. Table 6-2. Ohm Ratings for Various Components COMPONENT Pump Motor NOMINAL RESISTANCE @ TEMPERATURE RESISTANCE RANGE POSSIBLE 0.2ohm - 0.4ohm @ 77deg F 0.12ohm - 0.49ohm Table 6-3.
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SECTION 6 - TROUBLESHOOTING 6.11 FAULT CODE TROUBLESHOOTING TABLES Machine in Drive Speed Cut-Back (Turtle) Mode All The Time Overview of Procedure Under normal machine operation once the platform is elevated the machine’s maximum drive speed is reduced to 1/4 the normal drive speed of when the platform is fully lowered. This is detected with a drive speed cut-back (proximity) switch mounted at the base of the mast assembly and a target mounted on the mast assembly.
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SECTION 6 - TROUBLESHOOTING Code 01 - Low Battery Voltage Check For These Obvious Conditions First: • Battery cable ends loose or corroded at battery posts. • Charger DC output wires from charger to batteries damaged or disconnected. Table 6-6. Code 01 - Low Battery Voltage STEP ACTION SPEC YES NO 1. Does battery charger power up through diagnostic cycle when plugged in to an AC outlet? — Go To Step 2 See Battery/Battery Charger Servicing Section 3 of this Manual 2.
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SECTION 6 - TROUBLESHOOTING Code 04 - Tilt Condition Check For These Obvious Conditions First: • If machine is on a tilt of more than 1.5° in either or both the X or Y direction, this is normal operation. (DRIVE and LIFT UP are disabled when tilt is detected) • Check if Ground Control Module is mounted securely to the mast support column. Table 6-7. Code 04 - Tilt Condition STEP ACTION SPEC YES NO 1.
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SECTION 6 - TROUBLESHOOTING Code 08 - Right Drive Motor - Disconnected Check For These Obvious Conditions First: • Check right drive motor M2 connector at the Traction Control Module for secure and proper connection. Table 6-9. Code 08 - Right Drive Motor Disconnected STEP ACTION SPEC YES NO 1. Check resistance across positive (+) and negative (–) leads in M2 connector wiring harness going to the right drive motor. Is reading within spec? .1 to .3 ohms Replace Traction Module Go to Step 2 2.
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SECTION 6 - TROUBLESHOOTING Code 11 - Left Drive Motor - Short Circuit Check For These Obvious Conditions First: • Wiring harness from (M1) connector on Traction Control Module to Left Drive Motor for damage. Table 6-12. Code 11 - Left Drive Motor - Short Circuit STEP ACTION SPEC YES NO 1. Remove the M1 connector from the Traction Control Module and check both the pins to the drive motor for any voltage. (Ground the meter to the Ground Control Module - Negative (–) lug.) No Voltage Go to Step 2 2.
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SECTION 6 - TROUBLESHOOTING Code 14 - Pump Motor - Disconnected Check For These Obvious Conditions First: • Check the Positive (+)/Negative (–) cables from the Ground Control Module to the Pump Motor studs for loose or corroded connections. Table 6-15. Code 14 - Pump Motor - Disconnected STEP 1. ACTION Check resistance across the positive (+) and negative (–) studs on the pump motor.
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SECTION 6 - TROUBLESHOOTING Code 16 - Lift Down Valve - Short Circuit Check For These Obvious Conditions First: • Damaged wiring in the lift down valve wiring harness or a damaged lift down valve coil. Table 6-17. Code 16 - Lift Down Valve - Short Circuit STEP ACTION SPEC YES NO 1. At the Ground Control Module, P1 connector, check the voltage across pins 10 and 3 to the lift down valve coil. Is reading within specification? 0 - 2V DC Go to Step 2 Replace Ground Control Module 2.
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SECTION 6 - TROUBLESHOOTING Code 18 - Alarm - Short Circuit Check For These Obvious Conditions First: • Damaged wiring in the alarm wiring harness or a damaged alarm. Table 6-19. Code 18 - Alarm - Short Circuit STEP ACTION SPEC YES NO 1. At the Ground Control Module, P1 connector, check the voltage across pins-13 and 6 to the alarm. Is reading within specification? 0 - 2V DC Go to Step 2 Replace Ground Control Module 2.
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SECTION 6 - TROUBLESHOOTING Code 21 - Beacon - Disconnected Check For These Obvious Conditions First: • Is machine equipped with flashing amber beacon light. Table 6-22. Code 21 - Beacon - Short Disconnected STEP ACTION SPEC YES NO 1. Is machine equipped with a flashing amber beacon light. — Go to Step 3 Got to Step 2 2. At the Ground Control Module enter the programming mode, check if the Beacon light open circuit detection is enabled. — Disable It Replace Ground Control Module 3.
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SECTION 6 - TROUBLESHOOTING Code 23 - Horn - Disconnected Check For These Obvious Conditions First: • Is machine equipped with a horn unit. Table 6-24. Code 23 - Horn - Disconnected STEP ACTION SPEC YES NO 1. Is machine equipped with a horn unit. — Go to Step 3 Got to Step 2 2. At the Ground Control Module enter the programming mode, check if the horn open circuit detection is enabled. — Disable It Replace Ground Control Module 3.
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SECTION 6 - TROUBLESHOOTING Code 25 - P1-Auxiliary #1 Circuit - Disconnected Check For These Obvious Conditions First: • Is machine equipped with a component on the Auxiliary #1 circuit. Table 6-26. Code 25 - P1-Auxiliary #1 Circuit - Disconnected STEP ACTION SPEC YES NO 1. Is machine equipped with a component on the Auxiliary #1 circuit. — Go to Step 3 Got to Step 2 2. At the Ground Control Module enter the programming mode, check if the Auxiliary #1 open circuit detection is enabled.
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SECTION 6 - TROUBLESHOOTING Code 27 - P1-Auxiliary #2 - Disconnected Check For These Obvious Conditions First: • Is machine equipped with a component on the Auxiliary #2 circuit. Table 6-28. Code 27 - P1-Auxiliary #2 - Disconnected STEP ACTION SPEC YES NO 1. Is machine equipped with a component on the Auxiliary #2 circuit. — Go to Step 3 Got to Step 2 2. At the Ground Control Module enter the programming mode, check if the Auxiliary #2 open circuit detection is enabled.
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SECTION 6 - TROUBLESHOOTING Code 30 - Traction Module - No Communication with Ground Control Module Check For These Obvious Conditions First: • Check if the communications cable connections, P5 connector on the Ground Control Module and round plug on the Traction Control Module are seated properly in their sockets at each end. • Check the Positive (+) (RED) and Negative (–) (BLACK) power cable connections from the Ground Control Module to the Traction Control Module are tight and secure at both ends.
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SECTION 6 - TROUBLESHOOTING Code 31 - Platform Control Console - No Communication with Ground Control Module Check For These Obvious Conditions First: • Check the harness connection at the P4 connector on the Ground Control Module and the harness connection at the other end on the Platform Junction Box. Table 6-30. Code 31 - Platform Control Console - No Communication with Ground Control Module STEP ACTION SPEC YES NO 1. Check if LEDs are illuminated on the Platform Control Console.
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SECTION 6 - TROUBLESHOOTING Code 33 - RESERVED Code 34 - P2-Auxiliary #1 - Inhibit Check For These Obvious Conditions First: • Platform Gates Closed. • Pressure on the Platform Footswitch (after power up). NOTE: In the procedures below, if you check continuity between pin 6 and 16 it should show open circuit, when the platform gates are closed and nothing is on the foot switch. When you step on the foot switch with the gates closed, you should see a closed circuit. Table 6-32.
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SECTION 6 - TROUBLESHOOTING Code 38 - Battery Voltage Low - Warning Level 2 - Two (2) LED/LCDs lit To maximize battery life, it is recommended that the factory supplied batteries be charged continuously for a minimum of 4 hours or until 8 bars are lit on the ground station LCD Display before operating the machine. When drained to Warning Level 2, batteries must be charged until 8 bars are lit on the ground station LCD display to clear the fault code. Failure to do so, will result in a fault code 39.
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SECTION 6 - TROUBLESHOOTING Table 6-34. Codes (100 - 199) Ground Control Module - Fault Condition 5. Remove the communications cable, P5 connector at the Ground Control Module and round connector at the Traction Control Module. Check continuity of all three (3) wires in the communications cable from end to end. P5 - Pins 2, 3, and 4. — Go to Step 6 Repair or Replace Wire(s) 6.
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SECTION 6 - TROUBLESHOOTING Codes (300 - 399) Traction Control Module - Fault Condition Check For These Obvious Conditions First: • Damage to Traction Control Module wiring harness. • Confirm that the static ground strap attached under base frame is secure and undamaged. Table 6-36. Codes (300 - 399) Traction Control Module - Fault Condition STEP 6-34 ACTION 1. Recycle machine power 5 times allowing a 10 second interval between each power recycle. Does fault clear? 2.
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SECTION 6 - TROUBLESHOOTING 6.12 MAIN POWER CIRCUIT TROUBLESHOOTING Machine Will Not Power Up Check For These Obvious Conditions First: • Battery voltage is 24 volts. (Sufficient Charge in Batteries to Operate Machine) • Positive (+) and negative (–) battery cable connections clean and tight at both the Batteries and the Ground Control Module lugs. • Main Power Selector Switch (key) positioned to either Platform or Ground Control Mode.
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SECTION 6 - TROUBLESHOOTING 6.13 MAST TROUBLESHOOTING Platform Will Not Lower Manually Check For These Obvious Conditions First: • Is there an obstruction in the mast assembly? • Is there a restricted hydraulic line (smashed)? • Are the mast slide pads shimmed properly (not too tight), per Mast Assembly procedure in Service Manual? Table 6-38. Platform Will Not Lower Manually STEP ACTION SPEC YES NO 1. Check to see if the platform will lower from the Ground Control Station in Ground Control Mode.
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SECTION 6 - TROUBLESHOOTING Table 6-39. Platform Lift Up and Down Jerky (Continued) STEP ACTION SPEC YES NO HYDRAULIC 5. Is the hydraulic valve working properly. — Go to Step 6 Replace Valve 6. Pump drive cavatating. — Replace Pump Go to Step 7 7.
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SECTION 6 - TROUBLESHOOTING Platform (Mast) Won’t Stay Elevated Overview Of Procedure The following procedure requests that the lift down, dump, and pump internal valves be checked to see if any are stuck open, it also examines the lift down and dump valve circuits. Also suggests that the lift cylinder packing could be leaking internally. Check For These Obvious Conditions First: • Manual descent valve is closed tight. Table 6-41. Platform (Mast) Won’t Stay Elevated. STEP ACTION SPEC YES NO 1.
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SECTION 6 - TROUBLESHOOTING 6.14 HYDRAULIC LEAK TROUBLESHOOTING Miscellaneous Hydraulic Leak Troubleshooting Overview Of Procedure This series of steps gives remedies for various areas of the machine where leaks could occur. Table 6-43. Hydraulic Leak Troubleshooting STEP ACTION SPEC YES NO 1. Oil leaking around the lift cylinder rod. — Replace the Seal at the end of the Piston and Cylinder Barrel — 2. Oil leaking around the cylinder extend or return line fittings.
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SECTION 6 - TROUBLESHOOTING 6.15 BASE FRAME COMPONENTS TROUBLESHOOTING Caster Wheels Not Operating Freely Check For These Obvious Conditions First: • Is machine operating on a smooth, level surface? Table 6-44. Caster Wheels Not Operating Freely. STEP 6-40 ACTION SPEC YES NO 1. Is the caster rotating freely? — Go to Step 2 Lubricate or Replace Caster Housing 2. Is the wheel spinning freely? — Go to Step 3 Lubricate or Replace Wheel 3.
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SECTION 6 - TROUBLESHOOTING 6.16 DRIVE SYSTEM TROUBLESHOOTING Won’t Climb Grade Overview Of Procedure The following procedure checks the drive motor and attached components for component failure, misadjustment due to wear.
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SECTION 6 - TROUBLESHOOTING Machine Drives in Opposite Direction Table 6-46. Machine Drive in Opposite Direction STEP 6-42 ACTION SPEC YES NO 1. At the Traction Control Module, check if the left drive motor power lead is plugged into the M1 socket. — Go to Step 2 Switch the Left and Right Drive Motor Power Leads at the Traction Module 2.
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SECTION 6 - TROUBLESHOOTING Machine Won’t Drive Straight Overview Of Procedure The following procedure examines the drive motor assembly weldments attaching the drive motors to the base frame. Also internal components of the drive motors, gear box and a check of the components between the gear box and the drive wheels. Check For These Obvious Conditions First: • Battery voltage 24 volts. (Fully charge batteries) • Nothing is lodged between one of the wheels and the base frame.
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SECTION 6 - TROUBLESHOOTING Noise From Drive Assembly Overview Of Procedure The following procedure examines the drive motor assembly weldments attaching the drive motors to the base frame. Also internal components of the drive motors, gear box and a check of the components between the gear box and the drive wheels. Check For These Obvious Conditions First: • Battery voltage 24 volts. (Fully charge batteries) • Nothing is lodged between one of the wheels and the base frame.
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SECTION 6 - TROUBLESHOOTING Figure 6-6. 10MSP - Overview of Electrical System Components.
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SECTION 6 - TROUBLESHOOTING Keyed Switch Removed for Australia Spec 1870201_G Figure 6-7.
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SECTION 6 - TROUBLESHOOTING 1870201 G Figure 6-3.
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SECTION 6 - TROUBLESHOOTING Figure 6-8. Hydraulic Diagram. (2792684_A) 1. Tank 2. Filter Screen 3. Pump 4. Pump Motor 6-48 5. 6. 7. 8. Pressure Adjust Valve Extend Line Hydraulic Filter Return Line – JLG Lift – 9. Check Valve 10. Pressure Compensator - Flow Control Valve 11. Manual Decent Valve 12.
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3121228 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +61 2 65 811111 +61 2 65 813058 +55 19 3295 1025 JLG Deutschland GmbH Max-Planck-Str.