JLG 10msp Service And Maintenance Manual
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JLG 10msp Service And Maintenance Manual

Vertical lift
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Service and Maintenance Manual
Model
10MSP
Vertical Lift
P/N - 3121228
October 24, 2017
ANSI
®
AS/NZS

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Summary of Contents for JLG 10msp

  • Page 1 Service and Maintenance Manual Model 10MSP Vertical Lift P/N - 3121228 October 24, 2017 ANSI ® AS/NZS...
  • Page 3 FORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS. • BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPONENTS. • KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE. • USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL- VENTS. 3121228 – JLG Lift –...
  • Page 4 Manual Revised ....... . . April 29, 2013 Manual Revised ......October 24, 2017 – JLG Lift – 3121228...

  • Page 5: Table Of Contents

    Hydraulic System................2-6 3121228 – JLG Lift –...
  • Page 6 Battery Condition Testing..............3-27 – JLG Lift –...
  • Page 7 MANUAL MATERIAL TRAY ................5-3 3121228 – JLG Lift –...
  • Page 8 Procedure ..................6-5 – JLG Lift –...
  • Page 9 Noise From Drive Assembly..............6-45 3121228 – JLG Lift –...
  • Page 10 Hydraulic Schematic -Power Tray (If Equipped) ............6-57 – JLG Lift –...
  • Page 11 Machine Will Not Power UP............... . . 6-37 3121228 – JLG Lift –...
  • Page 12 Noise from Drive Assembly ............... . . 6-45 viii – JLG Lift – 3121228...

  • Page 13: Section 1- Machine Specifications

    5.0 mph (8 kph) when the platform is stowed. Max. Platform Speeds (w/Max. Load) Platform Up: 13 sec Platform Down: 9 - 13 sec Gross Machine Weight (Machine + Maximum Capacity) 1950 lb (885 kg) 3121228 – JLG Lift –...

  • Page 14: Capacities

    SECTION 1 - MACHINE SPECIFICATIONS 1.1 CAPACITIES System Voltage JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES. • 24 V DC APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG' S...

  • Page 15: Platform Size

    • 7 ft (2.13 m) - w/ Height Limiter (if equipped) ity for mobile hydraulic system service. (to platform floor) NOTE: Aside from JLG recommendations, it is not advisable to mix Platform Maximum (Working) Height oils of different brands or types, as they may not contain the same required additives or be of comparable viscosi- •...

  • Page 16: Lubrication Specifications

    CL - Brush or Spray NOTE: Recommended lubricating intervals are based on normal use. If machine is subjected to severe operating conditions, such as a high number of cycles, location, corrosive/dirty environment, etc., user must adjust lubricating requirements accordingly. – JLG Lift – 3121228...

  • Page 17: Torque Specifications

    SECTION 1 - MACHINE SPECIFICATIONS 1.8 TORQUE SPECIFICATIONS Figure 1-8. Torque Chart - SAE Fasteners (Sheet 1 of 5) 3121228 – JLG Lift –...

  • Page 18: Torque Chart - Sae Fasteners (Sheet 2 Of 5)

    SECTION 1 - MACHINE SPECIFICATIONS Figure 1-9. Torque Chart - SAE Fasteners (Sheet 2 of 5) – JLG Lift – 3121228...

  • Page 19: Torque Chart - Sae Fasteners (Sheet 3 Of 5)

    SECTION 1 - MACHINE SPECIFICATIONS Figure 1-10. Torque Chart - SAE Fasteners (Sheet 3 of 5) 3121228 – JLG Lift –...

  • Page 20: Torque Chart - Metric Fasteners (Sheet 4 Of 5)

    SECTION 1 - MACHINE SPECIFICATIONS Figure 1-11. Torque Chart - METRIC Fasteners (Sheet 4 of 5) – JLG Lift – 3121228...

  • Page 21: Torque Chart - Metric Fasteners (Sheet 5 Of 5)

    SECTION 1 - MACHINE SPECIFICATIONS Figure 1-12. Torque Chart - METRIC Fasteners (Sheet 5 of 5) 3121228 – JLG Lift –...
  • Page 22 SECTION 1 - MACHINE SPECIFICATIONS NOTES: 1-10 – JLG Lift – 3121228...

  • Page 23: General Service Information

    Pre-Delivery Inspection and Frequent Inspection ciency to service, repair, and maintain the subject JLG product model. The Pre-Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic. JLG Indus- Reference the Preventive Maintenance Schedule and the tries, Inc.

  • Page 24: Preventive Maintenance And Inspection Schedule

    Pre-Delivery Inspection Prior to each sale, lease, or rental delivery Owner, Dealer, or User Qualified JLG Mechanic applicable JLG inspection form In service for 3 months or 150 hours, whichever Service and Maintenance Manual and Frequent Inspection comes first; or Out of service for a period of more...

  • Page 25: Preventive Maintenance & Inspection Schedule

    5, 7 Drive/Lift Mode Selector Switch (If Equipped) Control Enclosure and Protective Boot/Guards Remote Manual Decent (If Equipped) Object Detection System (If Equipped) Platform Gate Alarm (If Equipped) POWER SYSTEM Battery Fluid Level Motors Electrical Connections 3121228 – JLG Lift –...
  • Page 26 Grease and Lubricate to Specifications Function Test of All Systems Paint and Appearance Notify JLG of change in Machine Ownership Change only when serviced, fill half full. Replace after system brush wear indicator warning is activated. Drain and refill with fresh hydraulic fluid every two years.

  • Page 27: Servicing And Maintenance Guidelines

    ING. SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS If bearing is found to be serviceable, apply a light coat of A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 oil and wrap it in clean (waxed) paper.

  • Page 28: Gaskets

    Batteries Clean batteries using a non-metallic brush and a solution of baking soda and water. Rinse with clean water. After cleaning, thoroughly dry batteries and coat terminals with an anti-cor- rosion compound. – JLG Lift – 3121228...
  • Page 29 Fatigue and ultimate strength failures on ABNORMAL PROTRUSION OR JLG Lifts are incurred as a result of severe abuse as design TURNED PINS specs are well within the rated lifting capacity of these chains.

  • Page 30: Lubrication Information

    Hydraulic Oil Refer to Section 1 for recommended viscosity ranges. Hydraulic System JLG recommends Mobilfluid 424 hydraulic oil, which has The primary enemy of a hydraulic system is contamina- an SAE viscosity of 10W-30 and a viscosity index of 152.

  • Page 31: Base Assembly Components

    6. Limit Switches (Mast-Activated) 2. Drive Motor Cover 5. Batteries (2 - 12V; OR 7. Front Caster Wheels 3. Hydraulic Pump Motor/Reservoir (4 - 6V, two on each side) 8. Drive Motor Assemblies 9. Rear Bumper Cover 3121228 – JLG Lift –...

  • Page 32: Base Components (Sn 0130032507 To Present)

    4. Battery Charger 7. Front Caster Wheels 2. Drive Motor Cover 5. Batteries (4 - 6V, two on each side) 8. Drive Motor Assemblies 3. Hydraulic Pump Motor/Reservoir 6. Limit Switches (Mast-Activated) 9. Rear Bumper Cover – JLG Lift – 3121228...

  • Page 33: Base Frame Covers

    Lift the hood slightly out of the frame gasket and slide deck forward till the rear hold-down bracket clears the support frame under the hood. Lift to remove deck from machine. 1. Carry Deck Support 2. Support Screws, Nuts, Washers 3121228 – JLG Lift –...

  • Page 34: Drive Motor Cover

    4. U-Style Tapped Nuts NOTE: (a) Apply Loctite #242 to threads before tightening. (b) Height of the platform stops is set by installing two 5/16" dia. wide plain steel flatwashers under the head of each stop, tighten securely. – JLG Lift – 3121228...

  • Page 35: Drive And Caster Wheels

    DO NOT use a lubricant on threads or nuts. and brand as originally installed on the machine or offered by JLG as an approved replacement. Please refer to the JLG Parts Tighten wheel bolts in the following sequence. Manual for the part number of the approved tires for a particu- lar machine model.

  • Page 36: Front) Caster Wheel Installation

    (a) If replacing bearing, pack bearing completely full to operate. Both are plugged into the wiring harness of grease before assembling, use (JLG P/N-3020029 - to the P2 connector on the Ground Control Station. If Mobil SHC 460 Synthetic or equivalent). Tap in evenly either switch fails, the Ground Control Module will until seated.

  • Page 37: Wheel Drive Assembly Servicing

    10 PSI for 20 minutes. NOTE: Due the small air volume inside this torque hub, it will pres- surize to 10 PSI very quickly. If the pressure becomes exces- sive in the unit, the seals will be destroyed. 3121228 – JLG Lift –...

  • Page 38: Drive Motor Brush Wear - Warning Indication

    Brush Wear - Warning Timer. Refer to Ground Control Mod- Carefully slide the drive motor assembly out of the base ule Programming in Section 4 of this manual. frame assembly for disassembly. – JLG Lift – 3121228...

  • Page 39: Wheel Drive Assembly Installation (Right Side Shown)

    2. Frame Mounting Surface 5. Wheel Mounting Bolts (b) 3. Mounting Bolts/Washers (a) NOTE: Installation same for left and right drive motor: (a) Apply Loctite #242 to threads before tightening. (b) Tighten to 120 ft.lbs. (534 Nm). 3121228 – JLG Lift –...

  • Page 40: Wheel Drive Main Components Disassembly

    This will keep the brake shaft. housing in one piece. Remove the Brake Friction Plate (B3) from the motor Cut the black wire tie (not shown) from the frame of the flange. motor. 3-10 – JLG Lift – 3121228...

  • Page 41: Replacing Drive Motor Brushes

    BEFORE MOUNTING DRIVE MOTOR/BRAKE ASSEMBLY TO TORQUE HUB SPIN- straightened paper clip) into small hole in the brush DLE, ENSURE BRAKE CAVITY IS CLEAN, DRY, AND FREE OF OIL RESIDUE. housing to keep brush held up in brush holder. 3121228 – JLG Lift – 3-11...

  • Page 42: Torque Hub Main Disassembly

    Using a screwdriver, remove Spiral Retaining Ring (G27). Remove Input Sun Gear (G4). Pull Hub Sub-assembly off of the Spindle Sub-assem- Remove Input Carrier Sub-assembly. bly. Remove Cover (11) and O-ring (G20). 3-12 – JLG Lift – 3121228...

  • Page 43: Input Carrier Disassembly

    Press out Bushing (G26) from the bore of each Planet remove the Planet Shafts (G6). Gear (G5). Bushings cannot be reused when removed. 3121228 – JLG Lift – 3-13...

  • Page 44: Hub Disassembly

    NOTE: This Lip Seal (G16) is also held in with a press fit. Remove the Lip Seal only if the hub or seal needs to be replaced. The Lip Seal will most likely become damaged during removal. Try not to damage the hub bore. 3-14 – JLG Lift – 3121228...

  • Page 45: Spindle Disassembly

    Remove the shaft Ball Bearing (G15) from the center bore. NOTE: The Output Planet Gears (G9) are very similar in size to the Input Planet Gears (5), tag or label the Planet Gears to avoid confusion. 3121228 – JLG Lift – 3-15...

  • Page 46: Spindle Sub-Assembly

    Using a flat plate or rod, press the Motor Shaft Seal with the Tanged Thrust Washer (G32) until the bores (G17) into the center bore so that it is flush with the face line up. of the Spindle (G1). 3-16 – JLG Lift – 3121228...

  • Page 47: Hub Sub-Assembly

    Seal (G16) so it is flush with the edge of the Flip the Hub (G2) over. hub. Using the appropriate pressing tool (T-174356), press the Main Bearing (G14) into the bore until it bottoms out. 3121228 – JLG Lift – 3-17...

  • Page 48: Input Carrier Sub-Assembly

    NOTE: Do not overstress the Retaining Rings (G18). Make sure that the Retaining Ring (G24) is correctly seated in the groove and that the Output Sun Gear (G8) cannot be pulled out of the Input Carrier (G7). 3-18 – JLG Lift – 3121228...

  • Page 49: Main Torque Hub Sub-Assembly

    Install Retaining Ring (G27) into the groove on the OD Center the Cover (G11) in the hub bore so that the "JLG" of the Spindle (G1) carrier. This is a Spiral Retaining Ring logo is up. Push it into the bore.

  • Page 50: Motor, Brake, And Torque Hub Assembly

    Remove and discard the 2 bolts in the Brake Contain- ment Holes. Pull the Brake Lead through the slot in the motor flange. Make sure the leads are all the way in the bottom of the slot. 3-20 – JLG Lift – 3121228...

  • Page 51: Pump Motor Assembly

    No internal parts to the temperature. If pressure is set when oil is cold, platform may hydraulic pump are serviced by JLG except for a pump installa- not raise rated load after oil has warmed. tion seal kit. The only internal serviceable part of the pump’s The factory-recommended (initial) pressure setting is electric motor is the motor brush kit.

  • Page 52: Hydraulic Pressure Gauge Connection

    1. Hydraulic Oil Filter 3. Pressure Gauge Assembly 2. T- Fitting 4. Cylinder Extend Line Figure 3-8. Typical Hydraulic Pressure Gauge Installation 1. Pressure Gauge Assembly 3. T- Fitting 2. Cylinder Extend Line 4. Cylinder Return Line 3-22 – JLG Lift – 3121228...

  • Page 53: Pump Motor Assembly Removal

    3. Motor Housing Once power cables and hydraulic lines are removed from this side of pump assembly, remove the mount- ing screws from the other side of the pump. Refer to the following illustration. 3121228 – JLG Lift – 3-23...

  • Page 54: Motor/Brush Cover Removal

    NOTE: (a) Once cover screws are removed, it may be necessary to tap lightly around the edge of the top cover to separate it from the motor housing. (b) These steel screws are threaded into the aluminum valve body. Do not overtighten. 3-24 – JLG Lift – 3121228...

  • Page 55: Brush Carrier Assembly Removal

    NOTE: (a) Slide brush assembly into socket until tab is in slot at 1. Tank Assembly 3. O-Ring Seal (a) rear of socket. 2. Tank Screws 4. Reference Mark NOTE: (a) Lubricate o-ring with clean hydraulic fluid before sliding tank over during installation. 3121228 – JLG Lift – 3-25...

  • Page 56: Filter Screen Removal

    Pump Removal 1. Check Valve Assembly 2. Check Valve Port Requires removal of tank assembly and pump pick-up tube. 1. Pump Assembly 3. Motor to Pump Coupler 2. Pump Assembly Screws 4. Pump Shaft Bearing 3-26 – JLG Lift – 3121228...

  • Page 57: Battery Replacement

    ANY WAY TO AFFECT STABILITY. 1. Battery (a) 3. Battery Posts JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED 2. Hold-Down Bracket and Screw 4. Drive Motor Cover Screw Brackets FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES.

  • Page 58: Battery Installation (4-6V)

    3. Left Front Battery 7. Battery Quick-Disconnect 4. 175 Amp Inline Fuse NOTE: Label battery cables before removing to ensure proper installation. All other connections to Ground Control Module are the same as in Figure 4-2. 3-28 – JLG Lift – 3121228...

  • Page 59: Battery Charge Led Indicator On Platform Control Console

    8 bars are lit on the ground station LCD Display before operating the machine. When drained to Warning Level 2, batteries must be charged until 8 bars are lit on the ground station LCD display to clear the fault code. 3121228 – JLG Lift – 3-29...

  • Page 60: Battery Charging Status Indicators

    RED (BOTTOM) LED ON STILL UNDER WARRANTY. OPENING THE BATTERY CHARGER WHILE THE See Flash Codes following MACHINE IS UNDER WARRANTY WILL VOID THE CHARGER WARRANTY. IF UNDER WARRANTY REQUEST A REPLACEMENT CHARGER FROM THE FACTORY. 3-30 – JLG Lift – 3121228...

  • Page 61: Battery Charger Check/Change Charging Algorithm

    SECTION 3 - BASE COMPONENTS Battery Charger Check/Change Charging Algorithm Battery Charger Removal/Installation The charger comes pre-loaded with these nine algorithms. JLG recommends using OEM batteries. Contact the battery manu- facturing dealer for the correct algorithm setting if it is not included on this chart.
  • Page 62 SECTION 3 - BASE COMPONENTS NOTES: 3-32 – JLG Lift – 3121228...

  • Page 63: Control Components

    2. Platform Control Console 5. Traction Control Module * Mounted inside lower gate hinge left and right side. 3. Platform Gate Interlock Switches * 6. Platform Junction Box Note: Some components hidden or removed for clarity. 3121228 – JLG Lift –...

  • Page 64: Control Components Location (Sn 0130032507 To Present)

    * Mounted inside lower gate hinge left and right side 4. Platform Footswitch Interlock 5. Traction Control Module Note: Some components hidden or removed for clarity 6. Platform Junction Box Figure 4-2. Control Components Location (SN 0130032507 to Present) – JLG Lift – 3121228...

  • Page 65: Control Components Installation

    7. P5 Connector (b) Note: (a) Apply Loctite #242 to screw threads on final assembly. (b) To help seal unit from dust and moisture, apply electrical contact grease CG60 (JLG P/N 3020038) to all electrical con- nectors before assembly. 3121228...

  • Page 66: Traction Control Module Installation

    Then it runs down along the out- side of the mast and through a large hole in the mast to the platform junction box. – JLG Lift – 3121228...

  • Page 67: Platform Junction Box Installation

    Note: Refer to Section 5 for more detailed harness hardware 2. Platform Console Harness Connector Connector) installation. 3. Ground Control Module Harness 5. Power Tray Connector (Option) Connector 6. Platform Aux #1 (Left Hand Lift) 7. Footswitch Connector 3121228 – JLG Lift –...

  • Page 68: Platform Interlock Switch Circuit

    Figure 4-4. Platform Interlock Switch Circuit (Prior to SN 0130032507 On machines from SN 0130032507 to present, the platform interlock circuit excludes the footswitch circuit. Figure 4-5. Platform Interlock Switch Circuit (SN 0130032507 to Present) – JLG Lift – 3121228...

  • Page 69: Component Electrical Connections

    Traction Control Module (a) Notes: (a) Apply dielectric grease JLG P/N 3020038 to wiring harness terminals to prevent moisture from entering module. (b) Seal NEG (–) and POS (+) posts with battery grease to prevent corrosion. (c) An quick-disconnect is installed on left battery (+) POSITIVE cable for easy power disconnect when servicing.

  • Page 70: Component Electrical Connections (4-6V Batteries)

    Traction Control Module (a) Notes: (a) Apply dielectric grease JLG P/N 3020038 to wiring harness terminals to prevent moisture from entering module. (b) Seal NEG (–) and POS (+) posts with battery grease to prevent corrosion. (c) An quick-disconnect is installed on left battery (+) POSITIVE cable for easy power disconnect when servicing.

  • Page 71: Ground Control Module

    Figure 4-8. Ground Control Module Components 1. Cover/LCD Assembly 4. Main Board to LCD - Ribbon Cable 2. Power Selector Switch Assembly 5. Heat Sink Base/Main Board Assembly 3. Emergency Stop Switch Assembly 6. Cover Attach Screws 3121228 – JLG Lift –...

  • Page 72: Cover Removal/Installation

    (Slide cable into connector then push tabs back into connector) Note: Connector works the same at both ends of ribbon cable. Disconnect the Ribbon Cable 1. Ribbon Cable Connector 3. Support for Cover 2. Ribbon Cable 4-10 – JLG Lift – 3121228...

  • Page 73: Power Selector/Emergency Stop Switch Installation

    Power Selector Switch Installation 1. Selector Knob 3. Power Selector Switch 2. Nut 4. Align and insert tab into cover Note: Reattach wires to the same terminals on new switch. 3121228 – JLG Lift – 4-11...

  • Page 74: Ground Control Module Programming

    Level 3 Password: 33271 steps. Entering Password THE LEVEL 1: JLG ENGINEERING SETTINGS ARE NOT DISPLAYED IN THE PRO- GRAMMABLE SETTINGS UNDER PASSWORD LEVEL-2 OR LEVEL-3. LEVEL-1 SET- TINGS MUST NOT BE MODIFIED UNLESS DIRECTED BY JLG ENGINEERING DEPARTMENT PERSONNEL.

  • Page 75: Programming Mode Selection

    1. Use the Platform UP/DOWN buttons (1) to scroll through the list of programma- ble items available to your programming level. 2. Once a programmable item to be adjusted is selected, press the Brake Release button (2) to enter that settings’ adjustment mode. 3121228 – JLG Lift – 4-13...

  • Page 76: Service Programming Mode - Level 2

    Allows service personnel to program the Level 2 and Level 3 items shown in Table 4-1. Tilt Sensor Allows service personnel to reset the Ground Control Module’s internal digital Tilt Sensor to zero (0.0) degrees in both the X and Y axis. 4-14 – JLG Lift – 3121228...

  • Page 77: Field Programmable Settings And Factory Preset (Prior To Sn 0130032507)

    2=trip high at start-up Aux. 2 - Tie Down 0=Disabled 1=trip if low at start-up 2=trip high at start-up Mode Select Delay (Active before timeout) 5 SEC. 1 - 60 SECONDS Acceleration (Platform Lowered) 1 - 100 3121228 – JLG Lift – 4-15...
  • Page 78 1 - 100 Minimum Forward Speed (Platform Elevated) 1 - 100 Minimum Reverse Speed (Platform Elevated) 1 - 100 Minimum Turn Speed (Platform Elevated) 1 - 100 Motor Compensation 50 mOhms 0 - 500 mOhms 4-16 – JLG Lift – 3121228...

  • Page 79: Field Programmable Settings And Factory Preset (Sn 0130032507 To Present)

    1=trip if low at start-up 2=trip high at start-up Aux. 2 - Tie Down 0=Disabled 1=trip if low at start-up 2=trip high at start-up Mode Select Delay (Active before timeout) 5 SEC 1 - 60 SECONDS 3121228 – JLG Lift – 4-17...
  • Page 80 1 - 100 Minimum Forward Speed (Platform Elevated) 1 - 100 Minimum Reverse Speed (Platform Elevated) 1 - 100 Minimum Turn Speed (Platform Elevated) 1 - 100 Motor Compensation 25mOhms 0 - 500 mOhms 4-18 – JLG Lift – 3121228...

  • Page 81: Platform Control Console

    • Wiring Harness Connector Socket (8) • Mounting Bracket (9) Before servicing the Platform Control Console, remove it com- pletely from the platform assembly (refer to Section 4.2). Figure 4-9. Platform Control Console Installation 3121228 – JLG Lift – 4-19...

  • Page 82: Display/Controller Module Electrical Connections

    3. ON/OFF Key Switch (C3) Note: The (C) numbers shown after the description above rep- resent the corresponding identification of the plug on 1. Rear Cover 2. Cover Mounting Screws the module’s circuit board. 4-20 – JLG Lift – 3121228...

  • Page 83: Display/Controller Module

    3. Attach Nut 2. Notch 4. Key Note: (a) Remove rear cover, unplug switch wire, press tabs to remove. Note: (a) Remove mounting bracket on bottom of console to gain access to the key switch assembly. 3121228 – JLG Lift – 4-21...

  • Page 84: E-Stop/Shutdown Switch

    (b) Remove the key switch and e-stop switch to remove Note: (a) Use a small straight blade screwdriver to extend the joystick assembly through access hole in bottom of con- spring-loaded retainer hooks (6) out and release the sole. switch from the body. 4-22 – JLG Lift – 3121228...

  • Page 85: Object Detection System (If Equipped)

    Verify the base is clean. Apply adhesive replacing the object sensing pad may be required. (JLG PN 0100040) evenly over the base. Raise and properly support the platform. Note: Do not bend or manipulate the sensing pad. Doing so could damage the internal wiring.
  • Page 86 SECTION 4 - CONTROL COMPONENTS NOTES: 4-24 – JLG Lift – 3121228...

  • Page 87: Mast Components

    SECTION 5 - MAST COMPONENTS SECTION 5. MAST COMPONENTS 5.1 MAST COMPONENTS OVERVIEW Figure 5-1. Mast Components 1. Material Handling Tray 2. Platform Assembly (Manual Tray Shown) 3. Mast Assembly 4. Platform Mast Cover 3121228 – JLG Lift –...

  • Page 88: Mast Cover

    While under the platform, unplug the wiring harness to the footswitch enable and the entry gate interlock switches from the platform junction box. Using suitable lifting equipment, carefully lift the plat- form/material tray assembly off the mast assembly. – JLG Lift – 3121228...

  • Page 89: Foot Height Limit Switch (If Equipped)

    Proximity switch wire connects to AUX 2 input on the main harness. The ground control module AUX 2 setting must be pro- grammed to “HIGH”, and the AUX 2 INHIBIT setting must be set to “0” (refer to Section 4.4, Ground Control Module Programming). 3121228 – JLG Lift –...

  • Page 90: Power Tray Disassembly

    3. Power Unit (Behind Covers) 5. Screws/Nuts (3) 6. Pump Cover Note: Tray assembly removed for clarity. Remove three sets of screws/nuts (5) from pump cover (6), then remove cover. Retain cover and all hardware. – JLG Lift – 3121228...

  • Page 91: Power Tray Roller Assembly

    Remove the cover plate. Retain plate and all hardware. 1. Tray Weldment 5. Support Pin 2. Roller Assembly (4) (attached to tray) 3. Bolt 6. Bearing 4. Nut 7. Support Pad Figure 5-2. Power Tray Roller Assembly 3121228 – JLG Lift –...

  • Page 92: Electrical And Hydraulic Components Removal

    BEFORE BEGINNING POWER UNIT DISASSEMBLY, DISCONNECT THE LEFT SIDE relay to the pump support plate. Retain all hard- BATTERY (+) POSITIVE BATTERY TERMINAL. ware. b. If replacing the relay, mount to the same location and attach with existing hardware. – JLG Lift – 3121228...

  • Page 93: Pulley System Disassembly

    To remove pump assembly, remove two sets of bolts/ washers (7) attaching assembly to the cover plate (4) Retain all hardware. Once pump assembly has been removed, transfer to a clean, flat surface, and keep upright. 3121228 – JLG Lift –...

  • Page 94: Pulley System Overview

    (14). 4. Pin/Circlip 9. Single Pulley Remove hydraulic fittings (15) from the cylinder. 5. Screw/Nut/Washer (2) 10. Bolt/Nut/Washer 11. Nut (Single Cable) 12. Nuts (Double Cable) Figure 5-4. Pulley System Overview – JLG Lift – 3121228...

  • Page 95: Power Tray Lift Cylinder

    Loosen piston head using 24 mm spanner and unscrew. fitted into its groove. Note: Clamp the rod assembly at rod end to protect chrome rod. Pull gland (6) off rod assembly. Change seals (2, 7, & 8). 3121228 – JLG Lift –...

  • Page 96: Power Tray Installation

    Insert double pulley wheel (2) into the mounting bracket at the top of the cylinder assembly. Ensure holes are aligned and double cable is set in grooves and routed along top of wheel. 5-10 – JLG Lift – 3121228...
  • Page 97 Install nuts (13) to each threaded end of the cables. Tighten nuts one at a time, evenly from cable ends. Route the threaded end of the single cable (7) down through the slot on the right side of the cylinder mount- ing bracket. 3121228 – JLG Lift – 5-11...

  • Page 98: Electrical And Hydraulic Components Installation

    Install the following components (if they were removed during disassembly) to the pump support plate (1) using retained hardware: a. Relay (2 & 3) b. Fuse (4 & 5) c. Hydraulic Pump (6 & 7) 5-12 – JLG Lift – 3121228...

  • Page 99: Covers And Tray Installation

    The extend and return hydraulic line couplings and hose fit- If the tray was removed and the rollers disassembled, (refer to tings on this machine require special tool JLG P/N 7027247 to Figure 5-2.), ensure they are reassembled and returned to the remove and install them.

  • Page 100: In-Line Style Fittings

    Step 3. Insert the disconnect tool in the gap cre- Step 6. Release the tool and pull on hose assem- ated between the dust boot and hose fit- bly to complete disconnection. ting shoulder. 5-14 – JLG Lift – 3121228...

  • Page 101: Angled-Style Fittings

    Step 6. Pull on hose assembly to complete dis- connection. Step 3. Insert the disconnect tool in the gap cre- ated between the dust boot and hose fit- ting shoulder. 3121228 – JLG Lift – 5-15...

  • Page 102: Mast Removal

    Mast Installation Reverse the Mast Removal instructions to reinstall mast. Once assembly is complete, cycle the mast up and down several times, then check the oil level in the hydraulic reservoir. 5-16 – JLG Lift – 3121228...

  • Page 103: Mast Disassembly

    (Be certain floor surface is clean and free of necessary. any metal chips or debris which may stick to lubricated chains) Note: When sliding mast sections apart, be careful not to scratch or score the anodized finish in the slide pad channels. 3121228 – JLG Lift – 5-17...

  • Page 104: Cylinder Disassembly

    7. Cylinder Tube 11. Wear Ring 3. Rod Wiper 8. Spacer 12. Piston O-Ring 4. Rod Seal 9. Piston Seal 13. Piston Lock Nut (a) 5. O-Ring Note: (a) Torque 100 - 120 ft. lbs. 5-18 – JLG Lift – 3121228...

  • Page 105: Lift Cylinder Component Inspection

    10 and 20 μ inches RMS. Significant variation (greater than 8 μ inches difference) are unacceptable. In the event that an unacceptable condition occurs, the tube assembly should be repaired or replaced. 3121228 – JLG Lift – 5-19...

  • Page 106: Manual Descent Valve

    6. Solenoid O-Ring (a) 1. Lift Cylinder 2. Release Cable Note: (a) Coat all o-rings with clean hydraulic fluid before assem- 3. External Release Knob bling. (b) Mount with electrical terminals pointing to right side of machine. 5-20 – JLG Lift – 3121228...

  • Page 107: Mast Assembly

    Note: When sliding the mast sections together, be careful not to scratch the anodized surface in the wear pad channels. Apply Krytox spray (JLG P/N-3020041) onto the slide pads and slide pad channels before assembly to help mast sections slide easier after slide pads have been properly shimmed.

  • Page 108: Mast Section 1

    Note: Before sliding mast sections together, spray the slide pad surface, preferably a table or work bench capable of sup- channels with Krytox lubricant spray (JLG P/N- 3020041). Be porting the weight of the entire mast assembly. (Refer to careful not to scratch or score the anodized finish in the slide Figure 5-7.) Slide mast out over end of work surface far...
  • Page 109 20UNC x 3/8" hex head bolts) and thread through holes in mast section 1 outside rail (top of mast) and into the slide pad inserts. Thread in enough to hold pad in place., Repeat step 4 in this section. 3121228 – JLG Lift – 5-23...
  • Page 110 Coat threads with Loctite #171 on final assembly. Locate and assemble the narrow chains set (#444) and attach to the small (triangular shape) chain equalizer anchor plate using the pins, washers and cotter keys. 5-24 – JLG Lift – 3121228...

  • Page 111: Mast Section 3

    1. Wide Chain Set Attached to Mast Section 1 2. Mast Section 2 Note: Before sliding mast sections together, spray the slide pad channels with Krytox lubricant spray. (JLG P/N- 3020041). Be careful not to scratch or score the anodized finish in the slide pad channels.
  • Page 112 Note: (a) Apply Loctite #242 to attach screws on final assem- bly. 1. Narrow Spacer Tube 5. Key 2. Sheave Pin 6. Sheave Pin Support Plates (a) 3. Sheave Wheels (Narrow) (a) 7. Support Plate Screws (b) 4. Wide Spacer Tube (a) 5-26 – JLG Lift – 3121228...

  • Page 113: Mast Section 4

    Anchor Block on Mast Section 2 3. Mast Section-3 Note: Before sliding mast sections together, spray the slide pad channels with Krytox lubricant spray, (JLG P/N- 3020041). Be careful not to scratch or score the anodized finish in the slide pad channels.
  • Page 114 Apply Loctite #242 to attach screw threads on final assembly. 1. Mast Section 3 5. Sheave Wheel Thrust Washer 2. Lower Bracket Attach Screws 6. Sequence Cable Sheave Wheel 3. Lower Bracket 7. Spacers (Qty. 4) 4. Sheave Wheel Attach Bolt 5-28 – JLG Lift – 3121228...
  • Page 115 Note: If equipped, re-install the 7 ft height limiting switch and bracket to the mast (See Section 5.4, 7 Foot Height Limit Switch (If Equipped)). The mast assembly is now complete and ready to install onto the base frame. 3121228 – JLG Lift – 5-29...

  • Page 116: Platform Junction Box To Ground Control Station Wiring Harness

    Figure 5-8. Platform Junction Box to Ground Control Station Wiring Harness 1. Harness Sheave Wheel 3. Upper Powertrak Bracket 5. Lower Powertrak Bracket 2. Harness Spring Tensioner 4. Mid Powertrak Bracket (Powertrak Shown Cut- away) 5-30 – JLG Lift – 3121228...

  • Page 117: Mast Chains And Sequencing Cables Adjustment

    Fully retract the mast all the way and check if the top of the mast sections appear as shown in Figure 5-9. Repeat steps 1 through 7 for remaining mast sections. 3121228 – JLG Lift – 5-31...

  • Page 118: Mast Chain And Sequence Cable Adjustment Components

    9. Chain Lock (Jam) Nut (Sections Even at Top) 4. Mast Section 2 7. Chain Anchor Plate (Inside) 10. Threaded Chain End (Stud) 2. Sequence Cable Adjust Nut 5. Mast Section 3 8. Chain Adjust Nut 5-32 – JLG Lift – 3121228...

  • Page 119: Troubleshooting

    ENSURE THE MACHINE IS SHUT DOWN BEFORE PRESSURE-WASHING. SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELEC- TRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS.

  • Page 120: Multimeter Basics

    = kilo = 1,000 * (Displayed Number) m = milli = (Displayed Number) / 1,000 μ = micro = (Displayed Number) / 1,000,000 Example: 1.2 kΩ = 1200 Ω Example: 50 mA = 0.05 A – JLG Lift – 3121228...

  • Page 121: Voltage Measurement

    • Circuit power must be turned OFF before testing resis- tance • Disconnect component from circuit before testing • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with meter leads 3121228 – JLG Lift –...

  • Page 122: Continuity Measurement

    • Harness with at least three separate wires including the wire under test. • These wires must be able to be isolated from other wires, etc. • Jumper or method to connect contacts on one side of harness. • Meter that can measure resistance or continuity. – JLG Lift – 3121228...

  • Page 123: Procedure

    Cycle through all positions of the switch. The meter should read short only when the switch connects the two terminals and open otherwise. c. If the switch has more than one common contact repeat the process for that circuit. 3121228 – JLG Lift –...

  • Page 124: Limit Switches

    Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a "prox switch". Inductive proximity switches are actuated only by ferrous metal (metal that contains Iron, such as steel) near the switch. They do not require contact, and must be energized to actuate.

  • Page 125: Ground Control Module Lcd Display

    In the LCD Display Symbols illustration item 2 above, the Function Display or Function Disable Indicators will vary as shown: Both LIFT UP and LIFT DOWN DRIVE Disabled Disabled Drive Speed Cut-Back LIFT UP Disabled (Turtle) Mode Engaged LIFT DOWN Disabled Battery Charger Plugged In 3121228 – JLG Lift –...

  • Page 126: Component Electrical Connections With 2-12V Batteries (Prior To Sn 0130032507)

    P3 - Programmable Security Lock Harness (Option) (a) Module (a) NOTES: (a) Apply di-electric grease JLG Part Number 3020038 to wiring harness terminals, to prevent moisture from entering module. (b) Seal NEG (–) and POS (+) posts with battery grease to prevent corrosion.

  • Page 127: Component Electrical Connections With 4-6V Batteries (Sn 0130032507 To Present)

    P3 - Programmable Security Lock Harness (Option) (a) Module (a) NOTES: (a) Apply di-electric grease JLG Part Number 3020038 to wiring harness terminals, to prevent moisture from entering module. (b) Seal NEG (–) and POS (+) posts with battery grease to prevent corrosion.

  • Page 128: Lcd Display - Service Fault Code Conditions

    (Counts down 25 hr of DRIVE opera- (See Section 3.5 for further tion to a 10 sec shut down mode) instructions) Left Drive Motor Disconnected See Table 6-10 00000.0 DRIVE Disabled Right Drive Motor Disconnected SeeTable 6-11 00000.0 DRIVE Disabled 6-10 – JLG Lift – 3121228...
  • Page 129 Alarm or — See Table 6-21 Alarm Circuit Short 00000.0 — Alarm Disconnected See Table 6-22 00000.0 Beacon or — See Table 6-23 Beacon Circuit Short 00000.0 — Beacon Disconnected See Table 6-24 00000.0 3121228 – JLG Lift – 6-11...
  • Page 130 No Communication with See Table 6-32 00000.0 Ground Control Module Pump Motor Over Current See Table 6-33 LIFT UP Disabled 00000.0 — RESERVED RESERVED P2-Auxiliary #1 - Inhibit — See Table 6-32 Left Hand Enable Open 6-12 – JLG Lift – 3121228...
  • Page 131 — RESERVED RESERVED Ground Control Module See Table 6-38 Fault Condition 1 00 00000.0 1 00 Platform Control Console See Table 6-39 Fault Condition 00000.0 Traction Control Module See Table 6-40 Fault Condition 00000.0 3121228 – JLG Lift – 6-13...

  • Page 132: Specifications For Various Components

    For removal of electrical connector Drive Motor pins from the Drive Motor main 7002841 power connectors. For removal of electrical connector Drive Motor Brake pins from the Drive Motor Brake 7002842 power connectors. 6-14 – JLG Lift – 3121228...

  • Page 133: Fault Code Troubleshooting Tables

    Open: 4-5 VDC Replace the OSS Relay Ground. Is the reading within specification? (If reading is 0VDC when there is no weight on the Consult Factory Closed: 0 VDC Board Object Sensing Pad, replace the pad) 3121228 – JLG Lift – 6-15...

  • Page 134: Code 01 - Low Battery Voltage

    Section 3 of this Manual Check Battery Condition. See Battery Condition in Section 3 of this Service Manual. Do the Replace Batteries — — batteries pass condition tests? as Necessary Code 02 - RESERVED Code 03 - RESERVED 6-16 – JLG Lift – 3121228...

  • Page 135: Code 04 - Tilt Condition

    Code 06 - Drive Motor Brush Wear Warning Indicator • Replace Drive Motor Brushes (refer to Section 3.5 for brush replacement instructions). • Program Ground Control Station module to reset the Brush Wear Warning Timer (refer to Section 4.4 for reset instructions). 3121228 – JLG Lift – 6-17...

  • Page 136: Code 07 - Left Drive Motor - Disconnected

    0.1 to 0.3 ohms Replace Traction Module Go to Step 2 Repair or replace right drive motor wiring, brushes or motor. (For brush replacement, see Section 3 of this Service Manual) — — — 6-18 – JLG Lift – 3121228...

  • Page 137: Code 09 - Left Brake - Disconnected

    Is reading within spec? See Table 6-2 Replace Traction Module Go to Step 2 Repair or replace right brake wiring or right brake assembly. — — — 3121228 – JLG Lift – 6-19...

  • Page 138: Code 11 - Left Drive Motor - Short Circuit

    (Ground the meter to the Ground Control Module - Negative (–) lug.) Repair or Replace Check for continuity of both the pins to the drive motor to ground. Replace Components as No Ground Traction Required Control Module 6-20 – JLG Lift – 3121228...

  • Page 139: Code 13 - Traction Module - In Fold Back

    Table 6-17. Code 14 - Pump Motor - Disconnected STEP ACTION SPEC Check resistance across the positive (+) and negative (–) studs on the pump motor. Replace Ground Control Repair or Replace Pump See Table 6-2 Module Motor or Motor Brushes 3121228 – JLG Lift – 6-21...

  • Page 140: Code 15 - Lift Down Valve - Disconnected

    With the terminals still removed from the lift down valve coil, check continuity of the wires from pins 10 and 3 on the P1 connector to the lift down valve. .00 Ohms — Repair or Replace Wiring 6-22 – JLG Lift – 3121228...

  • Page 141: Code 17 - Ground Control Module - In Fold Back

    Remove the wire terminals at the alarm, check continuity of each of the wires from pins 13 Repair or and 6 on the P1 connector to the alarm end. — Replace the Alarm Replace Wiring 3121228 – JLG Lift – 6-23...

  • Page 142: Code 19 - Alarm - Disconnected

    Remove the wire terminals at the beacon, check continuity of each of the wires from pins 12 Replace the Repair or and 5 on the P1 connector to the beacon end. — Beacon Replace Wiring 6-24 – JLG Lift – 3121228...

  • Page 143: Code 21 - Beacon - Short Disconnected

    Remove the wire terminals at the horn, check continuity of each of the wires from pins-14 and Replace the Repair or 7 on the P1 connector to the horn end. — Horn Replace Wiring 3121228 – JLG Lift – 6-25...

  • Page 144: Code 23 - Horn - Disconnected

    Remove the wire terminals at the Aux. #1 component, check continuity of each of the wires Replace the Repair or from pins-9 and 2 on the P1 connector to the Aux. #2 component end. — Component Replace Wiring 6-26 – JLG Lift – 3121228...

  • Page 145: Code 25 - P1-Auxiliary #1 Circuit - Disconnected

    Remove the wire terminals at the Aux. #2 component, check continuity of each of the wires Replace the Repair or from pins-8 and 1 on the P1 connector to the Aux. #2 component end. — Component Replace Wiring 3121228 – JLG Lift – 6-27...

  • Page 146: Code 27 - P1-Auxiliary #2 - Disconnected

    Remove the wire terminals at the Aux. #2 component, check continuity of each of the wires Replace the Repair or from pins-8 and 1 on the P1 connector to the Aux. #2 component. — Component Replace Wiring Code 28 - RESERVED Code 29 - RESERVED 6-28 – JLG Lift – 3121228...

  • Page 147: Code 30 - Traction Module - No Communication With Ground Control Module

    — Done Module Unplug the P5 connector at the Ground Control Module. Check voltage between pins 2 (– Replace Ground Control lead-in) and 5 (+ lead-in). Is voltage within spec. 4.5v DC Done Module 3121228 – JLG Lift – 6-29...

  • Page 148: Code 31 - Platform Control Console - No Communication With Ground Control Module

    Check voltage across pins-10 and 2 on connector P4 at the Ground Control Module. 24V DC Go to Step 5 Module Check continuity of P4 connector, pin-10 to Platform Junction Box pin-1. Also P4 connector, — Repair or Replace Wires pin-2 to Platform Junction Box, pin-5. 6-30 – JLG Lift – 3121228...

  • Page 149: Code 32 - Pump Motor - Over Current

    Remove the P2 connector from the Ground Station Module; check continuity of the individual Repair or wires in the platform harness (P2 to platform junction box). — Go to Step 3 Replace Platform Harness Check continuity of Left Hand Lift. Replace Component or Consult Factory Repair Wires 3121228 – JLG Lift – 6-31...

  • Page 150: Code 35 - P2-Auxiliary #1 - Tie-Down

    Remove the P2 connector from the Ground Station Module; check continuity of the individual Repair or wires in the platform harness (P2 to platform junction box). — Go to Step 3 Replace Platform Harness Check continuity of platform gate switches. Replace Component or Consult Factory Repair Wires 6-32 – JLG Lift – 3121228...

  • Page 151: Code 37 - Auxiliary #2 - Tie-Down

    8 bars are lit on the ground station LCD Display before operating the machine. When drained to Warning Level 1, batteries must be charged until 8 bars are lit on the ground station LCD display to clear the fault code. Code 40 - RESERVED Codes 41 thru 46 - RESERVED 3121228 – JLG Lift – 6-33...

  • Page 152: Codes (100 - 199) Ground Control Module - Fault Condition

    Go to Step 7 Plug the communications cable on the Traction Control Module to the round socket on the Replace opposite end of the module. Does this fix problem? — Done Ground Control Module 6-34 – JLG Lift – 3121228...

  • Page 153: Code (200 - 299) Platform Control Console - Fault Condition

    P4 connector, pin-5 to Junction Box pin-3 and P4, pin-9 to Junction Box pin-4. Control Module Is there continuity on these wires? Perform the Joystick Calibration Procedure in Section 4.5 of this Service Manual. Does this Replace clear the fault code? — Done Platform Control Module 3121228 – JLG Lift – 6-35...

  • Page 154: Codes (300 - 399) Traction Control Module - Fault Condition

    Check for short in harness wires from Ground Control Station connector P5 to Traction Module (round din plug). — Repair or Replace Wiring — Note: This harness contains 6 wires but only 3 are used. Refer to the electrical schematics for fur- ther representation. 6-36 – JLG Lift – 3121228...

  • Page 155: Main Power Circuit Troubleshooting

    Check continuity of the wires running from the P4 connector on Ground Control Module to the Platform Junction Box; Replace Platform — Repair or Replace Wiring P4 connector, Pin-1 to Junction Box Pin-2 and Control Console P4 connector, Pin-10 to Junction Box Pin-1 3121228 – JLG Lift – 6-37...

  • Page 156: Mast Troubleshooting

    Check the flow valve in the lift cylinder for a restriction. Clean or Replace Flow — Consult Factory Valve If equipped with Remote Manual Descent, check cable assembly to ensure valve is actuated. Replace Remote Manual — Descent Assembly 6-38 – JLG Lift – 3121228...

  • Page 157: Platform Lift Up And Down Jerky

    ACTION SPEC HYDRAULIC Is the hydraulic valve working properly. — Go to Step 6 Replace Valve Pump drive cavatating. — Replace Pump Go to Step 7 Lift cylinder. Rebuild or Replace — — Cylinder 3121228 – JLG Lift – 6-39...

  • Page 158: Mast Noisy When Lifting And Lowering

    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 Do mast chains need to be lubricated per JLG specification in the Service Manual? — Lubricate as Required Go to Step 3...

  • Page 159: Platform (Mast) Won't Stay Elevated

    Is there a restricted hydraulic line (smashed)? — Replace Hydraulic Line Go to Step6 Check the flow valve in the cylinder valve block for a restriction, i.e. dirt. Clean or Replace Flow — — Valve 3121228 – JLG Lift – 6-41...

  • Page 160: Hydraulic Leak Troubleshooting

    Go to Step 2 Caster Housing Is the wheel spinning freely? Lubricate or Replace — Go to Step 3 Wheel Is debris stuck in the rubber wheel? Remove Debris or — — Replace Wheel 6-42 – JLG Lift – 3121228...

  • Page 161: Drive System Troubleshooting

    Rewire as — negative (–) terminal. The Left Motor Power lead is reversed from the Right Motor lead due to Factory Necessary the reverser harness. (Refer to appropriate electrical schematic at end of this section.) 3121228 – JLG Lift – 6-43...

  • Page 162: Machine Won't Drive Straight

    Inside the drive motor torque hub, check if the drive shaft is excessively loose & condition of Repair/Replace torque hub drive shaft bearings. — components per procedure in this Service Manual Are any gears broken or gear teeth excessively worn? 6-44 – JLG Lift – 3121228...

  • Page 163: Noise From Drive Assembly

    Inside the drive motor torque hub check if; the drive shaft is excessively loose & condition of Repair/Replace torque hub drive shaft bearings. — components per procedure in this Service Manual Are any gears broken or gear teeth excessively worn. 3121228 – JLG Lift – 6-45...

  • Page 164: Electrical Components Installation (With 2-12V Batteries)

    SECTION 6 - TROUBLESHOOTING Figure 6-8. Electrical Components Installation (with 2-12V Batteries) 6-46 – JLG Lift – 3121228...

  • Page 165: Electrical Components Installation (With 4-6V Batteries)

    SECTION 6 - TROUBLESHOOTING Figure 6-9. Electrical Components Installation (with 4-6V Batteries) 3121228 – JLG Lift – 6-47...

  • Page 166: Electrical Components Installation (Sn 0130032507 To Present)

    SECTION 6 - TROUBLESHOOTING Figure 6-10. Electrical Components Installation (SN 0130032507 to Present) 6-48 – JLG Lift – 3121228...
  • Page 167 SECTION 6 - TROUBLESHOOTING This page left blank intentionally 3121228 – JLG Lift – 6-49...

  • Page 168: Electrical Schematic - Sheet 1 Of 2 (Prior To Sn 0130032507)

    SECTION 6 - TROUBLESHOOTING Figure 6-11. Electrical Schematic - Sheet 1 of 2 (Prior to SN 0130032507) 6-50 – JLG Lift – 3121228...

  • Page 169: Electrical Schematic - Sheet 2 Of 2 (Prior To Sn 0130032507)

    SECTION 6 - TROUBLESHOOTING Figure 6-12. Electrical Schematic - Sheet 2 of 2 (Prior to SN 0130032507) 3121228 – JLG Lift – 6-51...

  • Page 170: Electrical Schematic - Sheet 1 Of 4 (Sn 0130032507 To Present)

    SECTION 6 - TROUBLESHOOTING Figure 6-13. Electrical Schematic - Sheet 1 of 4 (SN 0130032507 to Present) 6-52 – JLG Lift – 3121228...

  • Page 171: Electrical Schematic - Sheet 2 Of 4 (Sn 0130032507 To Present)

    SECTION 6 - TROUBLESHOOTING Figure 6-14. Electrical Schematic - Sheet 2 of 4 (SN 0130032507 to Present) 3121228 – JLG Lift – 6-53...

  • Page 172: Electrical Schematic - Sheet 3 Of 4 (Sn 0130032507 To Present)

    SECTION 6 - TROUBLESHOOTING Figure 6-15. Electrical Schematic - Sheet 3 of 4 (SN 0130032507 to Present) 6-54 – JLG Lift – 3121228...

  • Page 173: Electrical Schematic - Sheet 4 Of 4 (Sn 0130032507 To Present

    SECTION 6 - TROUBLESHOOTING Figure 6-16. Electrical Schematic - Sheet 4 of 4 (SN 0130032507 to Present 3121228 – JLG Lift – 6-55...

  • Page 174: Hydraulic Schematic

    8. Return Line 3. Pump 9. Check Valve 4. Pump Motor 10. Pressure Compensator - Flow Control Valve 5. Pressure Adjust Valve 11. Manual Descent Valve 6. Extend Valve 12. Lift Cylinder Figure 6-17. Hydraulic Schematic 6-56 – JLG Lift – 3121228...

  • Page 175: Hydraulic Schematic -Power Tray (If Equipped)

    SECTION 6 - TROUBLESHOOTING Figure 6-18. Hydraulic Schematic -Power Tray (If Equipped) 3121228 – JLG Lift – 6-57...
  • Page 176 SECTION 6 - TROUBLESHOOTING NOTES: 6-58 – JLG Lift – 3121228...
  • Page 178 +33 (0) 553 84 85 74 Email:german-parts@jlg.com +(852) 2639 5797 Email: emeaservice@jlg.com Email: pieces@jlg.com JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & JLG Industries Via Po. 22 Polaris Avenue 63 Services Vahutinskoe shosse 24b. 20010 Pregnana Milanese (MI)

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