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JLG 20MSP Series Manuals
Manuals and User Guides for JLG 20MSP Series. We have
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JLG 20MSP Series manuals available for free PDF download: Service Maintenance Manual, Operation And Safety Manual
JLG 20MSP Series Service Maintenance Manual (174 pages)
Brand:
JLG
| Category:
Boom Lifts
| Size: 11.12 MB
Table of Contents
Table of Contents
5
Maintenance Safety Precautions
3
Hydraulic System Safety
3
Maintenance
3
Revision Log
4
Table of Contents
5
Section 1 - Machine Specifications
15
Capacities
16
Drive Motor Gearbox (Gear Oil)
16
Hydraulic System
16
System Voltage
16
Component Data
16
Batteries/Battery Charger
16
Hydraulic Pump/Pump Motor Assembly
16
Rear Wheel Drive Motors
16
Performance Data
16
Platform Capacities
16
Base Footprint
17
Machine Ground Clearance
17
Machine Height (Platform Stowed)
17
Platform Size
17
Lubrication
18
Hydraulic Oil
18
Lubrication Specifications
18
Cylinder Specifications
18
Serial Number Locations
18
Torque Requirements
18
Section 2 - General
27
Machine Preparation, Inspection, and Maintenance
27
Annual Machine Inspection
27
General
27
Pre-Delivery Inspection and Frequent Inspection
27
Pre-Start Inspection
27
Preparation, Inspection, and Maintenance
27
Preventative Maintenance
27
Preventive Maintenance and Inspection Schedule
28
Footnotes
30
Inspection and Maintenance Codes
30
Servicing and Maintenance Guidelines
31
Bearings
31
Bolt Usage and Torque Application
31
Cleanliness
31
Component Disassembly and Reassembly
31
Components Removal and Installation
31
Gaskets
31
General
31
Pressure-Fit Parts
31
Safety and Workmanship
31
Batteries
32
Hydraulic Lines and Electrical Wiring
32
Hydraulic System
32
Lubrication and Servicing
32
Mast Chain Inspection Procedure
32
Lubrication Information
34
Changing Hydraulic Oil
34
Hydraulic Oil
34
Hydraulic System
34
Lubrication Specifications
34
Section 3 - Base Components
35
Base Assembly Components
35
Base Frame Covers
36
Battery Charger Cover - Installation
36
Drive Motor Cover - Installation
36
Drive/Elevation Cut-Out Switch Installation
36
Drive and Caster Wheels
37
Caster Wheels - Installation
37
Tire Wear and Damage
37
Wheel and Tire Replacement
37
Wheel Installation
37
Wheel Drive Assembly - Servicing
38
Drive Motor Brush Wear - Warning Indication
38
Oil Type & Capacity
38
Roll and Leak Testing
38
Wheel Drive Assembly - Removal from Machine
39
Wheel Drive Disassembly - Main Components
40
Replacing Drive Motor Brushes
41
Gear Box Main Disassembly
43
Input Carrier Disassembly
44
Hub Disassembly
45
Spindle Disassembly
46
Spindle Sub-Assembly
47
Hub Sub-Assembly
48
Input Carrier Sub-Assembly
49
Main Gear Box Sub-Assembly
50
Motor, Brake and Gear Box Assembly
51
Pot Hole Protection System
52
Battery Charger - Service Procedures
54
Battery Charge LED Indicator on Platform Control Console
54
Battery Charger General Information
54
Battery Charger Maintenance Information
54
Battery Low Voltage Warning Indicators
54
Battery Charging Status Indicators
55
Battery Charger Check/Change Charging Algorithm
56
Battery Charger Removal/Installation
56
Section 4 - Control Components
57
Control Components Overview
57
Controls Cover Installation
58
Battery Cover Doors (Optional Hinged)
58
Center, Left and Right Lower Covers
58
Control Components - Installation
59
Ground Control Module
59
Traction Control Module
59
Alarm Installation
60
Horn Installation
60
Platform Control Console Installation
60
Batteries - Service Procedures
61
Battery Condition Testing
61
Battery - Installation - (2-12V Batteries)
62
Battery Installation - (4-6V Batteries) (Option)
64
Cover Removal/Installation
66
Power Selector/Estop Switch Installation
67
Activating Programming Mode
68
Programming Levels
68
Adjusting Programmable Setting
69
Entering Password
69
Programming Mode Selection
69
Selecting Programmable Item to Adjust
69
Service Programming Mode - (Level)
70
Operator Programming Mode - (Level)
71
Display/Controller Module Electrical Connections
74
Mounting Bracket - Install/Remove
74
Rear Cover - Install/Remove
74
Display/Controller Module - Install/Remove
75
Drive/Lift Mode Switch - Install/Remove
75
Horn Button Switch - Install/Remove
75
Key Switch - Install/Remove
75
E-Stop/Shutdown Switch - Install/Remove
76
Joystick Assembly - Install/Remove
76
Hydraulic Pressure Settings and Adjustment
77
Pump/Motor/Tank Installation
78
Fenner Brand Pump - Brush Replacement
79
General Installation and Disassembly
79
Inline Hydraulic Filter Installation
79
Motor Cap/Motor Installation
79
Motor Brush Installation
80
Brush Housing Final Assembly Tips
81
Monarch Brand Pump - Brush Replacement
82
Motor Assembly - Remove/Install - Reference Marks
82
Motor/Brush Cover - Remove/Install
82
Brush Assembly - Remove/Install
83
Brush Carrier Assembly - Remove/Install
83
Filter Screen Installation
84
Pump Installation
84
Tank Installation
84
Pressure Adjust Valve Installation
85
Pressure Check Valve Installation
85
Transducer Sensor Check
87
Oss Component Installation
88
Mast Chain/Cable Adjustment
92
Sequencing Cable Adjustment
92
Sequence Cable Replacement Kit
94
Clamp Installation (Drum/Socket Type)
94
Remove Old Cable
94
Replacement Cable Installation
94
Tool Use - In-Line Style Fittings
97
Lift Cylinder Removal
99
Cylinder Disassembly
102
Lift Cylinder Component Inspection
102
Cylinder Assembly (See Figure)
103
Cylinder Installation
103
Mast Assembly Installation
105
Mast Installation
105
Mast Removal
105
Mast Assembly - Mvl/Msp
109
Msp - Stockpicker Platform - Installation
117
Mast Beacon - Installation
118
Material Tray Platform Only
119
Switches and Wiring
119
Multimeter Basics
122
Continuity Measurement over Long Distances
125
Basic Check
126
Electrical Switch Testing
126
Limit Switches
126
Automatic Switches
127
Switch Wiring - Low Side, High Side
127
Ground Control Module Lcd Display
128
Troubleshooting Tables Index
134
Base Frame Components Troubleshooting
135
Special Pin Extractor Tools for Electrical Connectors
136
Specifications for Various Components
136
Fault Code Troubleshooting Tables
137
Machine in Drive Speed Cut-Back (Turtle) Mode All the Time
137
Battery Voltage Low - Warning Level 3 - Three (3) Led/Lcds Lit
138
Obstruction Sensor System - Detection
138
Code 02 - Left Php Bar - up
139
Code 03 - Right Php Bar - up
139
Code 04 - Tilt Condition
140
Code 05 - Reserved
140
Code 06 - Drive Motor Brush Wear Warning Indicator
141
Code 07 - Left Drive Motor - Disconnected
141
Code 08 - Right Drive Motor - Disconnected
142
Code 09 - Left Brake - Disconnected
142
Code 10 - Right Brake - Disconnected
142
Code 11 - Left Drive Motor - Short Circuit
143
Code 12 - Right Drive Motor - Short Circuit
143
Code 13 - Traction Module - in Fold Back
143
Code 14 - Pump Motor - Disconnected
144
Code 15 - Lift down Valve - Disconnected
144
Code 16 - Lift down Valve - Short Circuit
145
Code 17 - Ground Control Module - in Fold Back
145
Code 18 - Alarm - Short Circuit
145
Code 19 - Alarm - Disconnected
146
Code 20 - Beacon - Short Circuit
146
Code 21 - Beacon - Disconnected
147
Code 22 - Horn - Short Circuit
147
Code 23 - Horn - Disconnected
148
Code 24 - Auxiliary #1 Circuit - Short Circuit
148
Code 25 - Auxiliary #1 Circuit - Disconnected
149
Code 26 - Auxiliary #2 - Short Circuit
149
Code 27 - Auxiliary #2 - Disconnected
150
Code 28 - Reserved
150
Code 29 - Reserved
150
Code 30 - Traction Module - no Communication with Ground Control Module
150
Code 31 - Platform Control Console - no Communication with Ground Control Module
151
Code 32 - Pump Motor - over Current
151
Code 33 - both Php Bars - up
152
Code 34 - P2-Auxiliary #1 - Inhibit
152
Code 35 - P2-Auxiliary #1 - Tie down
152
Code 38 - Battery Voltage Low - Warning Level 2 - Two (2) Led/Lcds Lit
153
Code 39 - Battery Voltage Low - Warning Level 3 - One (1) Led/Lcds Lit
153
Code 40 - Obstruction Sensor System - no Communication with Ground Control Module
154
Codes 41 Thru 46 - Oss - Sensor 1 through 6 - Fault Condition
155
Codes (100 - 199) Ground Control Module - Fault Condition
156
Codes (200 - 299) Platform Control Console - Fault Condition
157
Codes (300 - 399) Traction Control Module - Fault Condition
158
Main Power Circuit Troubleshooting
159
Machine will Not Power up
159
Mast Troubleshooting
160
Platform will Not Lower Manually
160
Platform Lift up and down - Jerky
160
Mast Noisy When Lifting and Lowering
161
Platform (Mast) Won't Stay Elevated
162
Platform (Mast) Descends too Slowly
162
Hydraulic Leak Troubleshooting
163
Miscellaneous Hydraulic Leak Troubleshooting
163
Caster Wheels Not Operating Freely
164
Pot Hole Protection (Php) Bars will Not Lower
164
Won't Climb Grade
165
Machine Drives in Opposite Direction
165
Machine Won't Drive Straight
166
Noise from Drive Assembly
167
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JLG 20MSP Series Operation And Safety Manual (108 pages)
Brand:
JLG
| Category:
Boom Lifts
| Size: 3.95 MB
Table of Contents
Table of Contents
7
Section - Paragraph, Subject
8
Contact
11
Section 1 - Safety Precautions
11
General
11
Pre-Operation
11
Operator Training and Knowledge
11
Workplace Inspection
12
Machine Inspection
12
Operation
13
General
13
Trip and Fall Hazard
13
Electrocution Hazards
15
Minimum Approach Distances (M.A.D.)
15
Tipping Hazard
16
Crushing and Collision Hazard
17
Towing, Lifting, and Hauling
18
Section 2 - Preparation and Inspection
19
2.1 Personnel Training
19
Operator Training
19
Training Supervision
19
Operator Responsibility
19
Preparation, Inspection, and Maintenance
20
Section - Paragraph, Subject Page
22
Pre-Start Inspection
22
Daily Walk-Around Inspection
23
Daily Walk-Around Inspection for
24
Pot-Hole-Protection Bars Lowered
25
Function Check
25
General
27
Machine Operation
28
Eration
28
Battery Low Voltage Warning Indicators
29
To Charge Batteries
30
Ground Control Station - Operation
33
Ground Control Station. (Machine Rear View)
34
Platform up
35
Machine Status LCD Display
36
LCD Display Fault Conditions
37
Platform Control Console
41
General
42
Platform Control Display Panel
43
Platform Emergency Stop Button
43
Drive/Lift Mode Selector Switch
45
Multifunction Joystick Control
46
Machine Operating Specifications
47
Lift Mode
48
Drive Speed Setting Controls
49
Parking Machine
50
Max. Capacity with Side Entry Platform
52
Stockpicking Platform Operation
54
Fall Protection - Lanyard Attachment
56
Quick-Change Platform Mounting
57
Tie down Procedures
58
Crane Hook Accessory
59
Machine Tie-Down
59
Fork-Lift Truck Transport
60
Forklift Truck Lifting Pockets and Machine Tie down Loop Locations
61
Locations - at Rear of Machine
62
PSL™ Box and Ground Control Locations
62
Machine Power up Using the PSL™
63
System Description
64
OSS Transducer Sensor Array Location
65
OSS Pre-Start Inspection
65
OSS - Pre-Start Inspection of Operation
66
Hanging a Rug Using the Rug Carrier Accessory Arms
67
General
67
Removing a Rug Using Rug Carrier Accessory Arms
69
3.15 Stock-Picker Hanger Accessory
71
Pre-Start Inspection
71
Loading and Transporting an Item Using the Hanger Accessory
71
MVL Series Decal Installation Chart
73
MVL Series Decal Installation Chart
74
MSP Decal Installation Chart
76
MSP Decal Installation Chart
77
Section 4 - Emergency Procedures
79
General Information
79
Emergency Operation
79
Operator Unable to Control Machine
79
Platform Caught Overhead
79
Incident Notification
79
Section 5 - General Specifications and Operator Maintenance
81
5.1 Introduction
81
5.2 General Specifications
82
Machine Specifications
82
Machine Wheel Loads and PSI - Per Wheel
84
15MVL/MSP - Machine Maximum
84
20MVL/MSP - Machine Maximum
85
Electrical Specifications
86
Platform Data
87
Machine Component Weights
88
Serial Number Locations
88
5.3 Operator Maintenance
89
Battery
89
Tires and Wheels
89
Section - Paragraph, Subject Page
87
Wheel Lug Nut Tightening Sequence
90
Lubrication
91
Location of Lubrication Points (See Table 5-5)
92
Lubrication Intervals for Various Components
93
Ground Control Station - Programming5-14
94
General
94
Programming Levels
94
Operator Programming Mode
94
Ground Control Module Setting Range and
96
Activating Programming Mode
97
Entering Password
98
Programming Mode Selection
98
Selecting Programmable Item to Adjust
99
Adjusting Programmable Setting
99
5.5 Drive Motor Brush Wear - Warning Indication
100
5.6 Supplemental Information
101
Section 6 - Inspection and Repair Log
103
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