Service Manual

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Service & Maintenance Manual

Model(s)

15/20MVL &

15/20MSP

Series

P/N - 3121231

December 20, 2013

Summary of content (174 pages)

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Service & Maintenance Manual Model(s) 15/20MVL & 15/20MSP Series P/N - 3121231 December 20, 2013
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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 . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . .
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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 Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Mast Chain Inspection Procedure . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS Traction Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Platform Control Console Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Horn Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Alarm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS 6.6 ELECTRICAL SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Basic Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Automatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 . . . . . . . . . . . .
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TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 3-1. 3-2. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 5-8. 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 3121231 TITLE PAGE NO. Torque Chart (SAE Fasteners - Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 Torque Chart (SAE Fasteners - Sheet 2 of 7)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS LIST OF TABLES TABLE NO. 1-1 1-2. 1-3. 1-4 1-5 1-6 1-7 2-1 2-2 2-3 3-1 3-2 3-3 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 viii TITLE PAGE NO. General Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 15MVL/MSP - Machine Maximum Wheel Loads (Lb.
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TABLE OF CONTENTS 6-40 6-41 6-42 6-43 6-44 6-45 6-46 6-47 6-48 6-49 6-50 6-51 6-52 6-53 6-54 6-55 3121231 Codes (100 - 199) Ground Control Module - Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36 Code (200 - 299) Platform Control Console - Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37 Codes (300 - 399) Traction Control Module - Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38 Machine Will Not Power UP. . . . . . . . . .
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TABLE OF CONTENTS NOTES: x – JLG Lift – 3121231
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SECTION 1 - MACHINE SPECIFICATIONS SECTION 1. MACHINE SPECIFICATIONS Table 1-1. General Machine Specifications 15MVL 20MVL Maximum Occupants: 15MSP 20MSP 500 lb. (230 kg) 400 lb. (180 kg) 1 Maximum Work Load (Capacity): (MVL-Std. Platform / MSP - Stockpicker Platform) 500 lb. (230 kg) Maximum Travel Grade (Gradeability): 350 lb. (160 kg) 20% (11.5°) (Platform STOWED ONLY) Maximum Travel Grade (Side Slope): 5° (Platform STOWED ONLY) Maximum Vertical Platform Height: 19 ft. 1 in. (5.
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SECTION 1 - MACHINE SPECIFICATIONS 1.1 CAPACITIES System Voltage Batteries (2) (STD) - AGM - 12 Volt/100 Amp Hour (@ 20 Hr. rate) - Sealed/Maintenance Free - Weight – 71-75 lb. (34 Kg) - Per Battery Batteries (4) (OPTION) - AGM - 6 Volt/220 Amp Hour (@ 20 Hr. rate) - Sealed/Maintenance Free - Weight – 66 lb. (30 Kg) - Per Battery All Models – 24 Volt DC Hydraulic System All Models – 5 qts. U.S. (4.7 L) Drive Motor GearBox (gear oil) Battery Charger – All Models – 10 oz.
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SECTION 1 - MACHINE SPECIFICATIONS Platform Size Machine Ground Clearance Oversized Standard - 26 in.- W x 28 in.- L (66cm x 71cm) PHP Retracted - 2 in. (5.1cm) PHP Extended - 0.75 in. (1.9cm) Stockpicker - 28 in.- W x 48 in.- L (71cm x 122cm) Base Footprint Extendible - 26 in.- W x 49 in.- L (66cm x 124cm) MVL/MSP - 29.25 in.- W x 52 in.- L (74cm) x (132cm) 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.
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SECTION 1 - MACHINE SPECIFICATIONS 1.4 LUBRICATION 1.5 CYLINDER SPECIFICATIONS NOTE: Also see Lubrication Interval Chart - Table 1-7, Lubrication Intervals for Various Components in this section of the manual. NOTE: All dimensions are given in inches (in), with the metric equivalent, centimeters (cm), given in parentheses. Table 1-6.
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SECTION 1 - MACHINE SPECIFICATIONS Table 1-7.Lubrication Intervals for Various Components ITEM 1 2 COMPONENT Hydraulic Oil Mast Chains NO/TYPE (a) LUBE POINTS INTERVAL (b) LUBE/METHOD Fill To Line on Reservoir 5 Qt. Reservoir HO - Check Hyd. Oil Level HO - Change Hyd. Oil 2 - Per Section Chain Lube - Brush or Spray 3 6 MONTHS MONTHS 1 YEAR 2 YEARS ✔ ✔ COMMENTS Check fluid level every day. (c) Change hydraulic oil every 2 years. Inspect, lubricate if dry or rusting.
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SECTION 1 - MACHINE 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 0.00604 0.00661 0.00909 0.01015 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 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 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 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.
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SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance 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 Table 2-2. MVL/MSP - Preventive Maintenance & Inspection Schedule.
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SECTION 2 - GENERAL Table 2-2. MVL/MSP - Preventive Maintenance & Inspection Schedule.
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SECTION 2 - GENERAL 2.3 SERVICING AND MAINTENANCE GUIDELINES structure and the component becomes less than 90 degrees. 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.
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SECTION 2 - GENERAL Hydraulic Lines and Electrical Wiring Mast Chain Inspection Procedure 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.
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SECTION 2 - GENERAL 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 2.4 LUBRICATION INFORMATION Hydraulic Oil 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.
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SECTION 3 - BASE COMPONENTS SECTION 3. BASE COMPONENTS 3.1 BASE ASSEMBLY COMPONENTS Figure 3-1. Base Components. 1. 2. 3. 4. 3121231 Base Mounted Beacon Battery Charger Cover Front Tie Down Lug Battery Charger Assembly 5. 6. 7. 8. Base Frame Front Caster Wheel Assembly Left Drive Motor Assy. Pot Hole Protection System – JLG Lift – 9. Drive Motor Cover 10. Rear Tie Down Lug 11. Right Drive Motor Assy.
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SECTION 3 - BASE COMPONENTS 3.2 BASE FRAME COVERS 3.3 DRIVE/ELEVATION CUT-OUT SWITCH INSTALLATION Drive Motor Cover - Installation Drive Motor Cover Installation 1. Cover 2. Attach Screws and Washers (a) 3. Set Cover Tab on Lower portion of Cover, in Slot on Base Frame NOTE: (a) Apply Loctite #242 to screw threads before tightening. Battery Charger Cover - Installation Drive/Elevation Switch Cut-Out Switch Installation 1. Mounting Screws (a) 2. Proximity Switch (b) 3. Switch Mounting Block 4.
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SECTION 3 - BASE COMPONENTS 3.4 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 replacing the machine into service.
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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.
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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.
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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. 6. Remove the Brake Housing (B1) and the Spacers (B4). 1. Drain the oil from the Gearbox (1) by removing the cover plugs in the cover. 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.
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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 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.
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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. 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.
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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. 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. 2.
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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). 9. Remove the three Planet Shafts (G6) from the Input Carrier. NOTE: Do not overstress these Retaining Rings when removing them. 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). 2. Remove Thrust Plate (G23). 3.
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SECTION 3 - BASE COMPONENTS Hub - Disassembly Hub Disassembly 1. Remove Main Wheel Bearing (G14). 2. Remove main Lip Seal (G16). NOTE: This part is held in the hub with a press fit. To 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. 3121231 NOTE: 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. 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). 2. Remove three Output Planet Shafts (G10).
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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. of the Thrust Washers (G25) & (G32) and the Planet Gear (G9). NOTE: Do not damage or scratch the seal surface of the spindle (G1) during assembly. 8. Before pressing the Output Planet Shaft (G10) into the Spindle (G1), make sure the Output Planet Gear (G9) spins freely. 2.
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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. 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: 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. 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.
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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. 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. 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.
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SECTION 3 - BASE COMPONENTS 3.6 POT HOLE PROTECTION SYSTEM 1 2 7 8 4 6 8 Pot-Hole-Protection System Components 1. 2. 3. 4. PHP Actuator (Platform) Right/Left PHP Limit Switch Right Side Counterbalance Left Side Counterbalance 5. 6. 7. 8. PHP Link (see detail illustration following) Left PHP Bar Right PHP Bar PHP Bar Pivot Pin and Retaining Ring 1. 2. 3. 4.
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SECTION 3 - BASE COMPONENTS 1 2 3 4 6 5 7 Actuator - Limit Switch - Counterweight Installation - (Machines Prior to S/N-0130013258) (Same both sides of machine) 1. 2. 3. 4. 5. PHP Actuator Actuator Attach Screw/Nut Limit Switch (a) Limit Switch Attach Screws (b) Shim, Adhesive-Backed (max. 2 per switch) (c) 6. 7. 8. 9.
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SECTION 3 - BASE COMPONENTS 3.7 BATTERY CHARGER - SERVICE PROCEDURES Battery Charge LED Indicator on Platform Control Console 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.
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SECTION 3 - BASE COMPONENTS Battery Charging Status Indicators CHARGING PROBLEM 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.
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SECTION 3 - BASE COMPONENTS Battery Charger Check/Change Charging Algorithm Battery Charger Removal/Installation 1. Remove the charger cover from the machine located under the platform, see Section 3.2 on page 3-2. 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. 2. Disconnect the positive (+) battery cable at the left side battery under the left rear upper cover.
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SECTION 4 - CONTROL COMPONENTS SECTION 4. CONTROL COMPONENTS 4.1 CONTROL COMPONENTS OVERVIEW 7 8 6 5 4 3 2 1 Figure 4-1. Control Components Location - MVL/MSP. 1. Pump/Motor/Tank Assembly 2. Alarm 3. Horn 3121231 4. Batteries (2-12V - standard) 5. Traction Control Module 6. Ground Control Module – JLG Lift – 7. Platform Control Console 8.
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SECTION 4 - CONTROL COMPONENTS 4.2 CONTROLS COVER INSTALLATION Battery Cover Doors (Optional Hinged) 2 2 1 1 1. Left Side Cover 1. Right Side Cover 2. Mast Support Column 2. Mast Support Column Center, Left and Right Lower Covers Lower Left Cover (Front View) Center Cover, Lower Left and Right Covers (Rear View) Lower Right Cover (Front View) Note: Center Cover requires unplugging the Charger AC Receptacle and LED Indicator wires when removing.
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SECTION 4 - CONTROL COMPONENTS 4.3 CONTROL COMPONENTS INSTALLATION Traction Control Module The Traction Control Module is mounted below the Ground Control Module on the mast support column. BEFORE REMOVING ANY COMPONENT FROM THE ELECTRICAL SYSTEM, DISCONNECT THE POSITIVE TERMINAL FROM THE LEFT SIDE BATTERY. 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.
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SECTION 4 - CONTROL COMPONENTS Platform Control Console Installation Horn 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. 1 2 Horn Installation 1. Horn Assembly 2. Attach Screws/Washers Note: See Figure 4-2. for wiring connection instructions. Alarm Installation 1 Platform Control Console - Installation 1.
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SECTION 4 - CONTROL COMPONENTS 4.4 BATTERIES - SERVICE PROCEDURES Battery Condition Testing NOTE: Batteries in storage should be kept at 12.5V or higher. 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.
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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.
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SECTION 4 - CONTROL COMPONENTS 9 1 (–) P1 P2 P5 P4 P3 (+) 3 2 (–) 4 (+) 5 (+) M1 (–) M2 (–) (+) 7 6 (+) (–) 8 1. Ground Control Module (a) 2. Left Side Battery (b) 3. 175 Amp Inline Fuse Ground Control Module Plugs: Notes: 4. Right Side Battery (b) ) 5. Traction Control Module (a) 6.
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SECTION 4 - CONTROL COMPONENTS Battery Installation - (4-6V Batteries) (OPTION) 1 1 (–) 2 (+) 6 2 5 3 (–) (+) 4 (+) (–) 1. Battery Cables (a)(b) 2. Upper Battery 3. Upper Battery Hold-down Strap 4. Upper Left Side Battery Tray (c) 5. Lower Battery NOTE: (a) See battery cable to battery terminal connection 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.
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SECTION 4 - CONTROL COMPONENTS 4.5 GROUND CONTROL MODULE - SERVICE PROCEDURE The MVL Series and MSP Ground Control Module allows for field replacement of two (2) components internal to the module. • Emergency Stop Switch 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, COMMUNICATE THROUGH 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 Cover Installation 1 1.
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SECTION 4 - CONTROL COMPONENTS Power Selector/EStop Switch Installation 6 5 4 3 2 2 1 1 Emergency Stop Switch Installation 1. Emergency Stop Button 2. Button Seal 3. Square Lock Washer 4. Nut 5. Emergency Stop Switch 6. Switch Lock/Release Lever Note: Tighten nut enough to keep button from turning. Reattach wires to same terminals on new switch. 3 Power Selector/EStop Switch - Connectors Location 1. LCD and Button Circuit Board 2. Emergency Stop Switch Connector 3.
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SECTION 4 - CONTROL COMPONENTS 4.6 GROUND CONTROL MODULE PROGRAMMING Activating Programming Mode 2 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.
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SECTION 4 - CONTROL COMPONENTS Entering Password Selecting Programmable Item to Adjust 4 00000 2 1 1 3 2 Selecting Programmable Item to Adjust 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. 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: • Reset Timers • EEPROM Defaults • Program • OSS Sensor 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.
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SECTION 4 - CONTROL COMPONENTS Operator Programming Mode - (Level-3) Tilt Sensor In the Operator Programming Mode the following items are shown on the main menu (also see Table 4-1): Allows viewing current tilt sensor individual X and Y direction degree reading. Program • 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.
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SECTION 4 - CONTROL COMPONENTS Table 4-1. MVL/MSP Ground Control Module - Field Programmable Settings and Factory Preset.
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SECTION 4 - CONTROL COMPONENTS 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.
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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. 2 1 2 3 4 5 6 1 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 4 - CONTROL COMPONENTS 4.8 PUMP-MOTOR ASSEMBLY - SERVICE PROCEDURE Hydraulic Pressure Gauge Connection Hydraulic Pressure settings and Adjustment 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. Adjust system pressure so that platform will raise with maximum rated capacity in platform.
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SECTION 4 - CONTROL COMPONENTS Pump/Motor/Tank Installation 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.
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SECTION 4 - CONTROL COMPONENTS General Installation and Disassembly FENNER BRAND PUMP - Brush Replacement The following is a complete disassembly/assembly of the MVL/MSP machines pump/motor assembly. No internal parts to the hydraulic pump are serviced by JLG except for a pump installation seal kit. Also the only parts serviceable internal to the pump electric motor is the motor brush kit.
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SECTION 4 - CONTROL COMPONENTS Motor Brush Installation Once brush housing has been removed, inspect the rotor commutator for excessive wear before installing a new brush set. The rotor commutator surface when new, is approximately 1/8 in. (3mm) in thickness. 1 3 1 2 3 4 2 5 Brush Housing Installation 1. Brush Housing 2. Brush Housing Screws 3. Mark Front of Motor and Brush Housing for reference when reassembling. New Brush Installation 1. Brush Terminal Screw 4. Brush Spring 2. Brush 5.
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SECTION 4 - CONTROL COMPONENTS Brush Housing Final Assembly Tips It is easier to install the brush housing assembly by sliding the rotor assembly completely out of the other end of the motor housing, then attach the brush housing first. After the brush housing is installed look into the motor housing from the opposite end to check that the positive (+) post wires and static winding wires are positioned, not to block the holes for the motor mounting bolts, inside the motor housing.
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SECTION 4 - CONTROL COMPONENTS MONARCH BRAND PUMP - Brush Replacement Motor Assembly - Remove/Install - Reference Marks 4 Pump Motor - Removal/Installation - Reference Marks • For reference when reassembling, mark motor cover, housing and valve body position before disassembling. 2 1. Motor Top Cover 2. Cover/Housing Reference Mark 3. Motor Housing 4. Housing/Motor Valve Body Reference Mark 5.
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SECTION 4 - CONTROL 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 1 3 4 5 3 Brush Assembly - Remove/Install 1. Brush Assembly (a) 2. Brush Carrier Socket 3.
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SECTION 4 - CONTROL COMPONENTS Tank Installation Pump Installation 4 4 3 2 3 2 2 1 1 2 Pump Installation 1. Pump Assembly 2. Pump Assembly Screws Tank Installation 1. Tank Assembly 2. Tank Screws (4) 3. Pump Shaft Seal 4. Pump End Head 3. O-Ring Seal 4. Use Screwdriver to pry tank away from pump head. Filter Screen Installation 2 1 Filter Screen Installation 1. Filter Screen 2. Pump Pick-Up Tube Pump O-Ring Installation 1. Pump Assembly 4-28 – JLG Lift – 2. O-Ring Seal 3.
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SECTION 4 - CONTROL COMPONENTS Pressure Adjust Valve Installation Pressure Check Valve Installation 7 5 6 6 4 3 4 2 3 1 2 5 1 Pressure Adjust Valve Installation 1. Adjust Valve Cap 2. Adjustment Screw 3. Valve Spring Pressure Check Valve Installation 4. Valve Ball 5. Adjust Valve Port 6. Extend (Pressure) Port (Shown Plugged) 1. Check Valve Assembly 2. O-Ring Seal 3. O-Ring Seal 4. Backing Ring Note: Adjust pressure per specification shown in Section-1 of this Service Manual. 3121231 5.
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SECTION 4 - CONTROL COMPONENTS 4.9 OBSTRUCTION SENSOR SYSTEM SERVICE PROCEDURE (MSP - OPTION) General The Obstruction Sensor System (OSS) Control Module is mounted between the rails of the mast platform header section under the platform decal billboard at the rear of the MSP model platform, see illustration below. The OSS Control Module communicates with the Ground Control Module through the platform electrical junction box also mounted on the mast behind the platform decal billboard.
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SECTION 4 - CONTROL COMPONENTS 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. The Ground Control Module can also display the following sensor detection information when in Level 2 password Service and Maintenance Settings mode.
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SECTION 4 - CONTROL COMPONENTS 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.
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SECTION 4 - CONTROL COMPONENTS 2 3 3 1 2 4 2 1 5 Transducer Sensor Installation (Typical) 1. Mounting Screws (a) 2. Bushings 3. Transducer Sensor (b) 4. DO NOT Pressure Wash Decal 5. Sensor Side Deflector 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) 2. Pop Rivet 3. Platform Side Frame Note: (a) One deflector required on each side of platform.
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SECTION 5 - MAST COMPONENTS SECTION 5. MAST COMPONENTS 5.1 MAST COMPONENTS OVERVIEW Figure 5-1. Mast Components. (MVL/MSP) 1. Mast Section - 1 2. Mast Section - 2 3. Mast Section - 3 3121231 4. Mast Section - 4 5. Mast Section - 5 6. Lift Cylinder 7. Lift Cylinder Mount 8. Slide Pads 9. Chain Anchor Plates – JLG Lift – 10. Lanyard Attach 11. Chain Guard 12. Sheave Assemblies 13. Chain/Equalizer Plate Assemblies 14.
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SECTION 5 - MAST COMPONENTS 5.2 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT 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 52. when the mast is retracted.
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SECTION 5 - MAST COMPONENTS 7/16 in. (12mm) 1 7 2 3 4 5 6 8 9 10 11 Figure 5-2. MVL/MSP - Mast Chain and Sequence Cable Adjustment Components. 1. Sequence Cable Adjust Nut 2. Mast Section - 1 3. Mast Section - 2 3121231 4. Mast Section - 3 5. Mast Section - 4 6. Mast Section - 5 7. Check Mast Stowed Height 8. Chain Anchor Plate 9. Chain Adjust Nut – JLG Lift – 10. Chain Lock Nut 11.
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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.
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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. Cable Strands Unlayed 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. Cut To This Length 2. Sleeve 4.
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SECTION 5 - MAST COMPONENTS 6. Reclamp the assembly in the vise on the flats of the sleeve. Using the plug driver, a metal tube or pliers, bend the outer strands toward the center strands enough that the socket can be slipped over all the strands. 1. Inspection Hole 3. Four Threads or Less Showing 2. Install Socket and Tighten 8. Inspect for proper assembly prior to loading the cable. Strands visible through the inspection hole are your assurance of a proper assembly. 1.
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SECTION 5 - MAST COMPONENTS 5.4 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 - In-Line Style Fittings (continued) 5-8 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.
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SECTION 5 - MAST COMPONENTS Tool Use - Angled Style Fittings (continued) 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.
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SECTION 5 - MAST COMPONENTS 4. At the base end, remove and cap the extend and return hydraulic lines. 7. Remove the adjust and lock nuts from the chain studs at the bottom of mast section-3. 1 2 3 4 5 Hydraulic Extend and Return Lines 1. Cylinder Return Line 2. Cylinder Extend Line Chain Assembly - Bottom of Mast Section-3 3. Manual Descent Valve 1. Mast Section-4 2. Mast Section-3 3. Chain Assembly Stud (a) 5. Remove the mini covers from the tops of the mast sections. 4. Adjust Nut 5.
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SECTION 5 - MAST COMPONENTS 9. Remove the cylinder/anchor block attach pin - snap ring from the back of the top of mast section-2. 11. At the bottom of mast section-1, remove the cylinder mount bolts, and mount reinforcement plates. 1 2 3 4 Snap Ring Installation 1. Back of Mast Section-2 2. Cyl./Chain Anchor Block 3. Pin and Snap Ring 4. Cylinder Rod Lift Cylinder Mount Installation 10. Remove the cylinder rod pin from the cylinder/chain anchor block. 1. Cylinder/Mount Assembly 3.
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SECTION 5 - MAST COMPONENTS Cylinder Disassembly Lift Cylinder Component Inspection Cylinder Rod (See Figure 5-4.) 1. Before disassembling the cylinder, clean away all dirt and foreign substances from openings, particularly the head area. NOTE: Always protect the chrome surface of the cylinder rod during assembly and disassembly. Any damage to this surface will require replacement of the rod. 2. Extend the rod until the piston bottoms out against the cylinder head. 3.
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SECTION 5 - MAST COMPONENTS Cylinder Assembly (See Figure 5-4.) 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. 2. Lubricate the head and all seals with hydraulic fluid prior to installation. Install the seal, wiper, o-ring, back-up ring, and retraining ring to the cylinder head. 1 3. Lubricate the piston and all components with hydraulic fluid.
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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 5.6 MAST ASSEMBLY INSTALLATION Mast Removal 1. The following components must be removed from the machine before removing the mast assembly: • Rear Covers • Drive Motor Cover • Disconnect the Platform Control Console from the Mast mounted junction box • Platform Assembly 2. Disconnect the positive battery cable from the left side battery. 3. Unplug the platform control cable connector at the ground control module. 4.
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SECTION 5 - MAST COMPONENTS 5.7 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES slide pads and slide pad channels before assembly will help mast sections slide easier after slide pads have been properly shimmed. The MVL/MSP lift mast sections are constructed of extruded aluminum, protected with an anodized surface finish. The mast sections are interlocked into each other when assembled, by internally mounted slide pads at the top and bottom of each mast section.
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SECTION 5 - MAST COMPONENTS 5. Carefully slide mast section-5 out the BOTTOM of mast section-4 rails. Disassemble slide pads, shims and chain anchor plate from mast section-5, if necessary. Mast Section-4 - Removal 6. Remove chain adjust nuts from threaded ends of chains attached to the chain anchor plate (lower) on BOTTOM end of mast section-4. Push threaded ends of chains through anchor plate. 7. At TOP of mast section-4, pull chains out and allow to hang loose.
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SECTION 5 - MAST COMPONENTS Figure 5-6. Mast Chain Routing Diagram.
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SECTION 5 - MAST COMPONENTS Mast Assembly - MVL/MSP Mast Section 2 - Assembly Mast Section 1 - Assembly 1. Place mast section-1, rail (open) side up (See Figure 5-5. on page 5-16) on a clean, flat surface (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. 11. Lift cylinder installation into the bottom of Mast Section 1 and 2. d. When mast slide pads are shimmed properly, there should be no side to side movement of slide pad in rail channel.
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SECTION 5 - MAST COMPONENTS 15. Slide mast section-2 out of mast section-1 approximately 8 in. (20cm). e. Slide the whole anchor block/cylinder assembly with sheave pin, wheels and pin support bars into top of mast section-2. 16. Assemble one of the narrow chains sets (#444) and to the small chain equalizer anchor plate using the pins, washers and cotter keys. Set aside. f.
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SECTION 5 - MAST COMPONENTS Mast Section 3 - Assembly NOTE: When sliding mast sections together, be careful not to scratch or score the anodized finish in the slide pad channels. 24. Carefully slide mast section-3 into section-2 until ends are even. 25. 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.
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SECTION 5 - MAST COMPONENTS pin keeper. Allow to hang out the top of mast section-3 for later assembly. 36. Insert the threaded the ends of chain assembly (attached to top of mast section-1), into the opening between mast section-2 and mast section-3. Slide the threaded ends through the holes in chain anchor bracket attached at the bottom of mast section-3. Loosely thread two (2) 3/8"-16UNC nuts onto stud threads on each chain and remove any slack in the chains. Chains will be adjusted later in assembly.
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SECTION 5 - MAST COMPONENTS threaded holes in sheave pin support bars with holes in mast rails. f. Attach to top of mast section-4 using two (2) 3/ 8"-16UNC x 1/2" long socket head-countersunkflathead cap screws, each side. Coat threads with Loctite #171 and tighten. 2 3 4 5 4 3 6 1 1 7 Mast Section 4 - Chain Anchor Bracket (Bottom of Mast) 1. Chain Anchor Bracket 2. Mast Section 4 Note: 3. Anchor Bolts/Washers (a) 4. Pot-Hole Actuator Bracket (a) Apply Loctite #242 to threads.
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SECTION 5 - MAST COMPONENTS 3. Complete the following steps to determine shim stock thickness required for section-5; tight, remove section-5, disassemble slide pad and reduce thickness of shim stock. NOTE: Always use the an even amount of shim material behind slide pads on both sides of the mast rails. This will keep mast sections centered in rail channels and prevent any distortion of the section. e.
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SECTION 5 - MAST COMPONENTS 6. Slide mast section-5 back into mast section-4 until bottom ends of masts are even. Check to make sure chain set attached to top of section-3 is seating properly in cable sheave wheels attached to top of mast section-4. (Mast section-3 may need to be restrained to keep it’s slide pads from pushing out the bottom of mast sections-2). 7.
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SECTION 5 - MAST COMPONENTS 5.8 MSP - STOCKPICKER PLATFORM - INSTALLATION 5 1 4 2 6 3 Figure 5-8. MSP - StockPicker Platform Installation. 1. Mast Platform Header Section 2. Nut 3. Washers 4. Hex Head Screws (2 inch) 5. Hex Head Screws (2-1/2 inch) 6. Platform Bumper Rest (a) Note: (a) Once mounted, adjust bumper rests on both sides evenly so the platform rests on the bumpers when in stowed position.
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SECTION 5 - MAST COMPONENTS 5.9 MSP - STOCKPICKER PLATFORM - MIDGATE INTERLOCK INSTALLATION 5.10 MAST BEACON - INSTALLATION 4 5 3 2 5 1 1 6 4 2 MSP - Platform - Mid-Gate Interlock Switch Installation 1. Pop Rivets 2. Interlock Switch 3. Spacer 3 4. Mounting Holes 5. Mid-Gate 6. Wire Harness Clamp 1 Mast Mounted Beacon Installation (MVL/MSP) 1. Beacon Mounting Bracket 2. Bracket Screws/Nuts/Washers 3. Beacon Screws/Nuts/Washers 4 4. Beacon Assembly 5.
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SECTION 5 - MAST COMPONENTS 5.11 GATE ALARM - INSTALLATION - OPTION (FOR SIDE ENTRY W/FOLDING MATERIAL TRAY PLATFORM ONLY) NOTE: Machine must have v6.11 or higher software in the Ground Control Module. Ground Control Module Programming settings required: • Set Ancillary 1 POL to HIGH (Up Arrow) • Set AUX 1 INHIBIT to 5 Switches and Wiring Proximity Switch Location 1. Platform Vertical Rail 2. Left Platform Gate 3. Lower Gate Stop 4.
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SECTION 5 - MAST COMPONENTS 5.12 MAST - 14 FT. HEIGHT LIMITING SWITCH -15MSP (OPTION) Ground Control Module Programming settings required: • Set Ancillary 2 POL to HIGH (Up Arrow) Proximity Switch Installation 1. Mounting Screws, Nuts and Washers 2. Switch Shim 3. Proximity Switch 4.
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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 A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS.
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SECTION 6 - TROUBLESHOOTING 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. for an ELECTRICAL DIAGRAM of the various circuits. Also for a pictorial overview of the connected components, See Figure 6-6.
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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. 1 2 00 00000.0 4 3 00 5 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 9 1 (–) P1 P2 P5 P4 P3 (+) 3 2 (–) 4 (+) 5 (+) M1 (–) M2 (–) (+) 7 6 (+) (–) 8 1. Ground Control Module (a) 2. Left Side Battery (b)(c) 3. 175 Amp Fuse 4. Right Side Battery (b)(c) Ground Control Module Plugs: Notes: 5. Traction Control Module (a) 6. Power Cable To Left Drive Motor/Brake (a) 7. Power Cable To Right Drive Motor/Brake (a) 8.
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SECTION 6 - TROUBLESHOOTING Table 6-1. LCD Display - Service Fault Code Conditions FAULT CODE PLATFORM CONSOLE LEDs FLASHING — — — — 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 09 6 LCD SYMBOL SCREEN 00000.0 10 11 6 12 6 13 6 00000.0 00000.0 00000.0 16 7 17 7 18 — 00000.0 00000.0 00000.
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SECTION 6 - TROUBLESHOOTING Table 6-1. LCD Display - Service Fault Code Conditions FAULT CODE PLATFORM CONSOLE LEDs FLASHING 22 — 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 39 LCD SYMBOL SCREEN 1 00000.0 40 — 00000.0 42 44 — 45 — 00000.0 00000.
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS Special Pin Extractor Tools for Electrical Connectors . . . . . . . . . . . .
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SECTION 6 - TROUBLESHOOTING Code 33 - Both PHP Bars - UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Code 34 - P2-Auxiliary #1 - Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Code 35 - P2-Auxiliary #1 - Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 6 - TROUBLESHOOTING 6.9 SPECIFICATIONS FOR VARIOUS COMPONENTS The following table contains specifications for MVL Series and MSP machine components. Table 6-2. Ohm Ratings for Various Components COMPONENT 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 Obstruction Sensor System - Detection Check For These Obvious Conditions First: • Look for an obstruction under platform, remove obstruction. • Check for any external damage to sensor(s) or wiring harness. • Are the O.S.S. side shield tubes secure to platform frame and not loose or protruding into the sensor detection area? • Are the isolation bushings in place and undamaged on both the O.S.S.
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SECTION 6 - TROUBLESHOOTING Code 02 - Left PHP Bar - UP Check For These Obvious Conditions First: • Obstruction under LEFT pot hole bar. • Obstruction around the actuator assembly at the base of the mast. Table 6-7. Code 02 - Left PHP Bar - UP STEP ACTION SPEC YES NO CHECK THE FOLLOWING WITH THE PLATFORM ELEVATED 3 TO 4 FEET (1 TO 1.5m) 1. Go to the 20 pin molex connector at the Ground Control Module, back probe to check for continuity of pin 10, (BLK #8 wire) with pin 20, (ORG/RED 491 wire).
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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 6-9. Code 04 - Tilt Condition STEP ACTION SPEC YES NO 1.
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SECTION 6 - TROUBLESHOOTING Code 06 - Drive Motor Brush Wear Warning Indicator Check For These Obvious Conditions First: • Did the Brush Wear Indication relay get wet. If so, dry the relay and wire terminals and reset the Brush Wear Warning Timer. • Program Ground Control Station module to reset the Brush Wear Warning Timer - see Section 4.6, Ground Control Module - Programming.
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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 6-12. 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 6-15. Code 11 - Left Drive Motor - Short Circuit STEP ACTION SPEC 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 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 6-18. 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 6-20. 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 19 - Alarm - Disconnected Check For These Obvious Conditions First: • Damaged wiring in the alarm wiring harness or a damaged alarm. • Activate a function to check if alarm beeps. Table 6-23. Code 19 - Alarm - Disconnected STEP ACTION SPEC YES NO 1. Check voltage at the P1 connector on the Ground Control Module between pin-13 and pin-6. Is reading within specification? 2 - 4V DC Replace Ground Control Module Go to Step 2 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 6-25. 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 6-27. 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 - Auxiliary #1 Circuit - Disconnected Check For These Obvious Conditions First: • Is machine equipped with a component on the Auxiliary #1 circuit. Table 6-29. Code 25 - Auxiliary #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 - Auxiliary #2 - Disconnected Check For These Obvious Conditions First: • Is machine equipped with a component on the Auxiliary #2 circuit. Table 6-31. Code 27 - Auxiliary #2 - Disconnected STEP ACTION SPEC YES NO 1. Is machine equipped with a component on the Auxiliary #2 circuit. — 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 31 - Platform Control Console - No Communication with Ground Control Module Check For These Obvious Conditions First: • Check the harness connection at the P4 connector on the Ground Control Module and the harness connection at the other end on the Platform Junction Box. Table 6-33. Code 31 - Platform Control Console - No Communication with Ground Control Module STEP ACTION SPEC YES NO 1. Check if LEDs are illuminated on the Platform Control Console.
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SECTION 6 - TROUBLESHOOTING Code 33 - Both PHP Bars - UP Table 6-35. Code 33 - Both PHP Bars - UP STEP ACTION SPEC YES NO 1. Perform steps in Code 2, Left PHP Bar UP then, Code 3, Right PHP Bar UP. Do either of these steps correct the problem? — Done Go to Step 2 2. Perform steps in Table 6-5 - Machine In Drive Speed Cut-Back (Turtle) Mode All The Time, of this section.
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SECTION 6 - TROUBLESHOOTING Table 6-37. Code 35 - P2-Auxiliary #1 - Tie Down 3. Check continuity of gate switches and foot switch circuit.
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SECTION 6 - TROUBLESHOOTING Code 40 - Obstruction Sensor System - No Communication with Ground Control Module Check For These Obvious Conditions First: • Is machine equipped with an Obstruction Sensor System? • Are the electrical harness connectors from the OSS Module through the Platform Junction Box to the Ground Control Module tight and undamaged? Table 6-38. Code 40 - OSS - No Communication with Ground Control Module STEP ACTION SPEC YES NO — Got to Step 4 Go to Step 2 1.
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SECTION 6 - TROUBLESHOOTING Codes 41 thru 46 - OSS - Sensor 1 through 6 - Fault Condition Check For These Obvious Conditions First: • Is there an obstruction under the sensor showing the fault? • Is the faulted sensor mounted properly and securely to the platform base frame? Table 6-39. Codes 41 thru 46 - OSS - Sensor 1 through 6 - Fault Condition STEP ACTION SPEC YES NO — Got to Step 4 Go to Step 2 1. Is machine equipped with an OSS system? 2.
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SECTION 6 - TROUBLESHOOTING Codes (100 - 199) Ground Control Module - Fault Condition Check For These Obvious Conditions First: • That all battery and harness connectors secure and undamaged on Ground Control Module. • Batteries have sufficient charge. • Confirm that the static ground strap attached under base frame is secure and undamaged. Table 6-40. Codes (100 - 199) Ground Control Module - Fault Condition STEP 6-36 ACTION 1.
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SECTION 6 - TROUBLESHOOTING Codes (200 - 299) Platform Control Console - Fault Condition Check For These Obvious Conditions First: • Damage to Platform Control Console wiring harness. • Secure harness connections from Platform Control Console to Platform Junction Box to Ground Control Module. • Confirm that the static ground strap attached under base frame is secure and undamaged. Table 6-41. Code (200 - 299) Platform Control Console - Fault Condition STEP ACTION SPEC YES NO 1.
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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 6-42. Codes (300 - 399) Traction Control Module - Fault Condition STEP 6-38 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 6-44. Platform Will Not Lower Manually. STEP ACTION SPEC YES NO 1. Check to see of the platform will lower from the Ground Control Station in Ground Control Mode.
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SECTION 6 - TROUBLESHOOTING Mast Noisy When Lifting And Lowering Overview Of Procedure This procedure examines components of the mast itself and as well as it’s lifting components for dirt, debris, proper lubrication and operation. Table 6-46. Mast Noisy when Lifting and Lowering. STEP SPEC YES NO 1. Do slide pads and slide pad channels need to be cleaned of dust, dirt, or other debris? — Clean Pads and Channels Go to Step 2 2.
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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 6-47. 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 6-49. 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 6-50. Caster Wheels Not Operating Freely. STEP 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 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. Overview of Electrical System Components.
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SECTION 6 - TROUBLESHOOTING Figure 6-2. Overview of Electrical System Components.
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SECTION 6 - TROUBLESHOOTING Australia Spec Key Switch Removed STANDARD - 2-12V BATTERY CONNECTION OPTIONAL - 4-6V BATTERY CONNECTION 1870202_F Figure 6-7. Electrical Diagram.
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SECTION 6 - TROUBLESHOOTING REV. E: AUSTRALIA ONLY - R emoved platform module keyswitch (C3 connector) and replaced ground module key switch with non-keyed switch. 1870202_F Figure 6-3. Electrical Diagram.
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SECTION 6 - TROUBLESHOOTING 12 11 10 9 6 8 5 4 2 1 1. 2. 3. 4. Tank Filter Screen Pump Pump Motor 5. 6. 7. 8. 2792504_B Pressure Adjust Valve Extend Line Hydraulic Filter Return Line 9. 10. 11. 12. Check Valve Pressure Compensator - Flow Control Valve Manual Decent Valve Lift Cylinder Figure 6-8. Hydraulic Diagram.
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3121231 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 +55 19 3295 0407 +61 2 65 811111 +55 19 3295 1025 +61 2 65 813058 JLG Deutschland GmbH Max-Planck-Str.