Oshkosh Corporation JLG 20MVL Service And Maintenance Manual
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Oshkosh Corporation JLG 20MVL Service And Maintenance Manual

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Service and Maintenance Manual
Models
20MVL
20MSP
PVC 2002
31215825
January 23, 2019 - Rev A

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Summary of Contents for Oshkosh Corporation JLG 20MVL

  • Page 1 Service and Maintenance Manual Models 20MVL 20MSP PVC 2002 31215825 January 23, 2019 - Rev A...
  • Page 2 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 3: Hydraulic System Safety

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A. GENERAL This section contains the general safety precautions which must be observed during maintenance of the Mobile Elevat- ing Work Platform. It is of utmost importance that mainte- nance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others or damage to the equipment.
  • Page 4 INTRODUCTION REVISON LOG A - January 23, 2019 Original Issue 31215825...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................... . 1-A Hydraulic System Safety .
  • Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 3 - BASE COMPONENTS Base Assembly Components ............... . 3-1 Base Frame Covers .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Ground Control Station - Programming ............. 4-12 General .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Hydraulic Lift Cylinder - Removal, Inspection and rebuild ..........5-9 Lift Cylinder Removal .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Code 02 - Left PHP Bar - UP ..............6-19 Code 03 - Right PHP Bar - UP.
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 31215825...
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-1. Base Components................. . 3-1 3-3.
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 4-36. Typical Hydraulic Pressure Gauge Installation (Hydraulic Filter Removed)......4-21 4-37.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 6-5. Component Electrical Connections ..............6-9 6-6.
  • Page 14 LIST OF TABLES TABLE NO. TITLE PAGE NO. 1-1. 20MVL/MSP - Machine Maximum Wheel Loads (lb) and (PSI) - Per Wheel ......1-2 1-2.
  • Page 15 LIST OF TABLES TABLE NO. TITLE PAGE NO. 6-45 Platform (Mast) Won’t Stay Elevated ..............6-40 6-46 Platform (Mast) Descends Too Slowly .
  • Page 16 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 17: General Specifications

    SECTION 1 - GENERAL SPECIFICATIONS SECTION 1. GENERAL SPECIFICATIONS 1.1 MACHINE SPECIFICATIONS Maximum Wind Speed 0 mph (0 kph) SPECIFICATION 20MVL 20MSP Maximum Horizontal Manual Side Force Gross Machine Weight 2,360 lb 2,390 lb 45 lbs (200 N) (Platform fully extended with Maximum load) (Platform Empty) (1,050 kg) (1,085 kg)

  • Page 18: Machine Wheel Loads And Psi - Per Wheel

    SECTION 1 - GENERAL SPECIFICATIONS Machine Wheel Loads and PSI - Per Wheel Table 1-1. 20MVL/MSP - Machine Maximum Wheel Loads (lb) and (PSI) - Per Wheel 20MVL 20MSP Platform Type Average Maximum Average Maximum (Loaded to Max. Wheel Load Per Wheel (lb) Wheel Load Per Wheel (lb) (PSI) Per Wheel (PSI) Per Wheel...

  • Page 19: Machine Component Weights

    SECTION 1 - GENERAL SPECIFICATIONS Machine Component Weights Lubrication Specifications SPECIFICATION 20MVL 20MSP SPECIFICATIONS Platform Weight MPG - Multipurpose Grease having a minimum dripping point of 350° F. Excel- (Quick-Change Platforms) lent water resistance and adhesive qualities, and being of extreme pres- Front Slide Bar Entry Platform 55 lb (25 kg) sure type.
  • Page 20 SECTION 1 - GENERAL SPECIFICATIONS Table 1-5. Lubrication Intervals for Various Components INTERVAL (b) NO/TYPE (a) ITEM COMPONENT LUBE/METHOD COMMENTS LUBE POINTS MONTHS MONTHS YEAR YEARS Fill To Line on HO - Check Hyd. Oil Check fluid level every day. (c) ...

  • Page 21: Threadlocking Compound

    SECTION 1 - GENERAL SPECIFICATIONS THREADLOCKING COMPOUND JLG PN Loctite® ND Industries Description 0100011 242™ Vibra-TITE™ 121 Medium Strength (Blue) 1001095650 243™ Vibra-TITE™ 122 Medium Strength (Blue) 0100019 271™ High Strength (Red) Vibra-TITE™ 140 0100071 262™ Vibra-TITE™ 131 Medium - High Strength (Red) NOTE: Loctite®...

  • Page 22: Torque Charts

    SECTION 1 - GENERAL SPECIFICATIONS TORQUE CHARTS SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Tensile Clamp Torque Torque Size Bolt Dia (Loctite® 242™ or 271™ or (Loctite®...
  • Page 23 SECTION 1 - GENERAL SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load...
  • Page 24 SECTION 1 - GENERAL SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry) Area...
  • Page 25 SECTION 1 - GENERAL SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load...
  • Page 26 SECTION 1 - GENERAL SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...
  • Page 27 SECTION 1 - GENERAL SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...

  • Page 28: Metric Fastener Torque Chart

    SECTION 1 - GENERAL SPECIFICATIONS Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Tensile Stress Clamp Load Torque (Loctite® 262™ or 271™ or Size Pitch Torque (Lube) (Loctite®...
  • Page 29 SECTION 1 - GENERAL SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAPSCREWS M3 - M5* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp Load (Loctite®...
  • Page 30 SECTION 1 - GENERAL SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Torque (Loctite® 262™ or Tensile Clamp Load (Lube or Loctite® 242™ or 271™ Size Pitch (Dry or Loctite®...
  • Page 31 SECTION 1 - GENERAL SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAPSCREWS M6 AND ABOVE* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp (Loctite®...
  • Page 32 SECTION 1 - GENERAL SPECIFICATIONS 1-16 31215825...

  • Page 33: General

    SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule MAINTENANCE for items requiring inspection during the performance of these inspections. Reference the appropriate areas of this General manual for servicing and maintenance procedures.

  • Page 34: Preventive Maintenance And Inspection Schedule

    SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Service Type Frequency Reference Responsibility Qualification Pre-Start Prior to use each day; or User or User or Operator Operator and Safety Manual Inspection At each Operator change. Operator Service and Maintenance Pre-Delivery Prior to each sale, lease, or Qualified JLG...
  • Page 35 SECTION 2 - GENERAL Table 2-2. MVL/MSP - Preventive Maintenance & Inspection Schedule INTERVAL PRE-DELIVERY(b) ANNUAL (d) AREA ON MACHINE OR FREQUENT (c) (YEARLY) INSPECTION INSPECTION MAST ASSEMBLY Mast Sections 2, 5 2, 5 Chain Systems 3, 14 3,14, 25 Sequence Cable Systems 1, 2, 3 Covers or Shields...

  • Page 36: Inspection And Maintenance Codes

    SECTION 2 - GENERAL Table 2-2. MVL/MSP - Preventive Maintenance & Inspection Schedule (Continued) INTERVAL PRE-DELIVERY(b) ANNUAL (d) AREA ON MACHINE OR FREQUENT (c) (YEARLY) INSPECTION INSPECTION Hydraulic Fluid *** Electrical Connections Instruments, Gauges, Switches, Lights, Horn 5,23 5,23 GENERAL Operator and Safety Manual in Storage Box ANSI Manual of Responsibilities and AEM Safety Manual in Storage Box (ANSI Only)

  • Page 37: Servicing And Maintenance Guidelines

    SECTION 2 - GENERAL 2.3 SERVICING AND MAINTENANCE GUIDELINES Component Disassembly and Reassembly When disassembling or reassembling a component, complete General the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck The following information is provided to assist you in the use your work to assure that nothing has been overlooked.

  • Page 38: Hydraulic Lines And Electrical Wiring

    SECTION 2 - GENERAL Hydraulic Lines and Electrical Wiring Mast Chain Inspection Procedure Clearly mark or tag hydraulic lines and electrical wiring, as well Inspect mast chains for the following conditions: as their receptacles, when disconnecting or removing them Wear: Always inspect that segment of chain that operates from the unit.
  • Page 39 SECTION 2 - GENERAL Fatigue Cracks: Fatigue is a phenomenon that affects most Stress Corrosion Cracking: The outside link plates, which are heavily press-fitted to the pins, are particularly susceptible to metals, and is the most common cause of chain plate failures. Fatigue cracks are found through the link holes, perpendicular stress corrosion cracking.

  • Page 40: Lubrication Information

    SECTION 2 - GENERAL 2.4 LUBRICATION INFORMATION Hydraulic Oil For best performance, JLG recommends the use of ISO-Vg Hydraulic System grade 32, 46 oil with a viscosity range between 15-250 SUS at 100 degrees F (32-54 cST at 40 degrees C). Refer to Section 1 of The primary enemy of a hydraulic system is contamination.
  • Page 41 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 42: Base Components

    SECTION 3 - BASE COMPONENTS SECTION 3. BASE COMPONENTS 3.1 BASE ASSEMBLY COMPONENTS Figure 3-1. Base Components 1. Base Mounted Beacon 5. Base Frame 9. Drive Motor Cover 2. Battery Charger Cover 6. Front Caster Wheel Assembly 10. Rear Tie Down Lug 3.

  • Page 43: Base Frame Covers

    SECTION 3 - BASE COMPONENTS 3.2 BASE FRAME COVERS Battery Charger Cover - Installation Drive Motor Cover - Installation Figure 3-3. Battery Charger Cover Installation 1. Charger Cover 3. Rear Attach Screws and 2. Front Attach Screws and Washers - Loosen Only - Figure 3-2.

  • Page 44: Drive/Elevation Cut-Out Switch Installation

    SECTION 3 - BASE COMPONENTS 3.3 DRIVE/ELEVATION CUT-OUT SWITCH INSTALLATION WHEEL LUG NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BRO KE N LUG N UTS , AN D POSSIBL E SEPARATIO N OF WHEEL FROM THE AXLE.

  • Page 45: Caster Wheels - Installation

    SECTION 3 - BASE COMPONENTS 3.5 WHEEL DRIVE ASSEMBLY - SERVICING Caster Wheels - Installation The component parts of the left and right drive motor assem- blies 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...

  • Page 46: Oil Type & Capacity

    SECTION 3 - BASE COMPONENTS Oil Type & Capacity Drive Motor Brush Wear - Warning Indication This torque hub unit is shipped with ISO 68 viscosity oil The machines drive motors include brush wear sensors that (hydraulic fluid). It is designed to utilize the same oil through- activate a warning indicating the drive motor brushes will out its service life.

  • Page 47: Wheel Drive Assembly - Removal From Machine

    SECTION 3 - BASE COMPONENTS Wheel Drive Assembly - Removal From Machine Remove the drive wheel mounting lugs and remove the drive wheel(s). The electric wheel drive assemblies are mounted independent Disconnect the power harness terminals and brake har- of each other in the base frame at the rear of the machine. ness connector(s) from the drive motor.

  • Page 48: Wheel Drive Disassembly - Main Components

    SECTION 3 - BASE COMPONENTS Wheel Drive Disassembly - Main Components Figure 3-8. Drive Motor Disassembly - Main Components NOTE: If possible, remove the wheel drive assembly from the Remove the Brake Housing (B1) and the Spacers (B4). machine frame. NOTE: The brake wires will have some silicone sealant at the slot through the motor flange.

  • Page 49: Replacing Drive Motor Brushes

    SECTION 3 - BASE COMPONENTS Replacing Drive Motor Brushes THE MOTOR MUST BE DISASSEMBLED FROM THE GEAR- BOX AND DISCONNECTED FROM THE MACHINE CONTROL- LER BEFORE BEGINNING THIS PROCEDURE. SEE WHEEL DRIVE ASSEMBLY - REMOVAL FROM MACHINE AND WHEEL DRIVE DISASSEMBLY - MAIN COMPONENTS ON THE PREVIOUS PAGES.
  • Page 50 SECTION 3 - BASE COMPONENTS Tighten the motor bolts to 65 in-lbs. Look at the timing marks to make sure that they are still THE PERMANENT MAGNETS IN THE MOTOR FRAME ARE aligned. If not, loosen bolts, line up the marks, and then STRONG AND WILL TRY TO PULL THE ARMATURE IN THE retighten the bolts.

  • Page 51: Gear Box Main Disassembly

    SECTION 3 - BASE COMPONENTS Gear Box Main Disassembly Figure 3-10. Gear Box Main Disassembly NOTE: The Input Ring Gear (G3) is held in with a press fit on its out- Using a screwdriver, pry the end of the Retaining Ring (G19) out of the groove in the Hub Subassembly, then side diameter.

  • Page 52: Input Carrier Disassembly

    SECTION 3 - BASE COMPONENTS Input Carrier Disassembly Figure 3-11. Input Carrier Disassembly Remove Retaining Rings (G18) from each of the three Slide Output Sun Gear (G8) out from the center of the Planet Shafts (G6). Input Carrier (G7). Remove the three Planet Shafts (G6) from the Input Car- NOTE: Do not overstress these Retaining Rings when removing rier.

  • Page 53: Hub Disassembly

    SECTION 3 - BASE COMPONENTS Hub Disassembly Figure 3-12. Hub Disassembly Remove Main Wheel Bearing (G14). Remove main Lip Seal (G16). NOTE: This part is held in the hub with a press fit. To remove have NOTE: This Lip Seal (G16) is also held in with a press fit. Remove the hub setting seal side up.

  • Page 54: Spindle Disassembly

    SECTION 3 - BASE COMPONENTS Spindle Disassembly Figure 3-13. Spindle Disassembly Place Spindle Sub-Assembly on bench with Planet Gears NOTE: This bearing is held in with a press fit. You will need to pry (G9) facing up. against the Spindle (1) to remove it. A new bearing should be used when the unit is reassembled.

  • Page 55: Spindle Sub-Assembly

    SECTION 3 - BASE COMPONENTS Spindle Sub-Assembly Figure 3-14. Spindle Sub-Assembly Place the spindle (G1) on the bench with the carrier por- Before pressing the Output Planet Shaft (G10) into the tion facing up. Spindle (G1), make sure the Output Planet Gear (G9) spins freely.

  • Page 56: Hub Sub-Assembly

    SECTION 3 - BASE COMPONENTS Hub Sub-Assembly Figure 3-15. Hub Sub-Assembly Put Hub (G2) on a table with the tapped holes facing Flip the Hub (G2) over. down. Using the appropriate pressing tool (T-174356), press Using a flat plate in conjunction with a pressing tool, the Main Bearing (G14) into the bore until it bottoms press in the Seal (G16) so it is flush with the edge of the out.

  • Page 57: Input Carrier Sub-Assembly

    SECTION 3 - BASE COMPONENTS Input Carrier Sub-Assembly Figure 3-16. Input Carrier Sub-Assembly Use the Input Planet Shaft (G6) as a pressing tool to Place the Input Planet Gear (G5) and Thrust Washers install the Planet Bushing (G26) into the bore of each (G25) onto the Input Planet Shaft (G6) sticking out from Planet Gear (G5).

  • Page 58: Main Gear Box Sub-Assembly

    SECTION 3 - BASE COMPONENTS Main Gear Box Sub-Assembly Figure 3-17. Main Gear Box Sub-Assembly NOTE: Do not use excessive pressing force because it will be Inspect seal surface of Spindle Sub-Assembly. Remove any debris or burrs that may be present. reacted by the main wheel bearings.

  • Page 59: Motor, Brake And Gear Box Assembly

    SECTION 3 - BASE COMPONENTS Motor, Brake and Gear Box Assembly Figure 3-18. Motor, Brake and Gear Box Assembly Place the Motor (2) shaft up on the bench. Install a wire tie around the brake leads and the motor housing. Position the wire tie so that it is approximately Place the Brake Friction Plate (B3) onto face of the motor 2 in.

  • Page 60: Pot Hole Protection System

    SECTION 3 - BASE COMPONENTS 3.6 POT HOLE PROTECTION SYSTEM Figure 3-19. Pot-Hole-Protection System Components 1. PHP Actuator (Platform) 5. PHP Link (see detail illustration following) 2. Right/Left PHP Limit Switch 6. Left PHP Bar 3. Right Side Counterbalance 7. Right PHP Bar 4.
  • Page 61 SECTION 3 - BASE COMPONENTS MAF28500 Figure 3-21. Pot-Hole Switch and Mounting Bracket 1. Limit Switch (a) 3. Counterweight Attach Pin 2. Limit Switch Attach Screws (b) NOTE: (a) When the pothole is in the deployed position (bars down), adjust plunger just past “click”, tighten screws to frame. (b) Apply Loctite #222 to screw threads before tightening.

  • Page 62: Battery Charger - Service Procedures

    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 CHAR- GER IF MACHINE IS STILL UNDER WARRANTY. OPENING THE BATTERY CHARGER WHILE THE MACHINE IS UNDER WAR RANTY WILL VOID THE CHARGER WARRANTY.

  • Page 63: Battery Charging Status Indicators

    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 RED (BOTTOM) LED ON See Flash Codes following 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.

  • Page 64: 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 nine algorithms for batter- Remove the charger cover from the machine located ies as detailed in Table 3-3. If your specific battery model is not under the platform, see Section 3.2 on page 3-2.
  • Page 65 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 66: Control Components

    SECTION 4 - CONTROL COMPONENTS SECTION 4. CONTROL COMPONENTS 4.1 CONTROL COMPONENTS OVERVIEW Figure 4-1. Control Components Location - MVL/MSP 1. Pump/Motor/Tank Assembly 4. Batteries (2-12V - standard) 7. Platform Control Console 2. Alarm 5. Traction Control Module 8. Obstruction Sensor System (MSP - Option) 3.

  • Page 67: Controls Cover Installation

    SECTION 4 - CONTROL COMPONENTS 4.2 CONTROLS COVER INSTALLATION Battery Cover Doors MAF31400 MAF31410 1. Right Side Cover 2. Mast Support Column 1. Left Side Cover 2. Mast Support Column Center, Left and Right Lower Covers MAF31430 MAF31440 MAF31420 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.

  • Page 68: Control Components - Installation

    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 ELECTRI- The traction module controls the voltage to the drive motors CAL SYSTEM, DISCONNECT THE POSITIVE TERMINAL FROM as regulated by the ground control module, from signals THE LEFT SIDE BATTERY.

  • Page 69: Platform Control Console Installation

    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. Figure 4-5.

  • Page 70: Batteries - Service Procedures

    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 Before testing for battery condition, the open circuit voltage should be taken from each battery. If the voltage of the batter- ies differs by 0.3 volts or more, the lower voltage battery JLG MACHINES EQUIPPED WITH DELTA-Q BATTERY CHAR- should be replaced.

  • Page 71: Battery - Installation - (2-12V Batteries)

    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.
  • Page 72 SECTION 4 - CONTROL COMPONENTS (–) (+ ) (–) (+ ) (+ ) (–) (–) (+ ) (+ ) (–) 1. Ground Control Module (a) 4. Right Side Battery (b) 7. Power Cable To Right Drive Motor/Brake (a) 2. Left Side Battery (b) 5.

  • Page 73: Battery Installation - (4-6V Batteries) (Option)

    SECTION 4 - CONTROL COMPONENTS Battery Installation - (4-6V Batteries) (OPTION) (–) (–) (+ ) 1. Battery Cables (a)(b) 4. Upper Left Side 2. Upper Battery Battery Tray (c) 3. Upper Battery Hold 5. Lower Battery down Strap 1. Ground Control Module 4.
  • Page 74 SECTION 4 - CONTROL COMPONENTS 4.5 GROUND CONTROL MODULE - SERVICE The MVL Series and MSP Ground Control Module allows for field replacement of two (2) components internal to the mod- PROCEDURE ule. • Emergency Stop Switch • Power Selector Switch (Key) DO NOT ATTEMPT TO DISASSEMBLE THE GROUND CON- TROL MODULE IF MACHINE IS STILL UNDER WARRANTY.

  • Page 75: Cover Removal/Installation

    SECTION 4 - CONTROL COMPONENTS Cover Removal/Installation THE MAIN CIRCUIT BOARD AND THE SMALLER LCD CIR- CUIT BOARD MOUNTED TO THE COVER ASSEMBLY, COM- MUNICATE THROUGH A RIBBON CABLE. R EMOVE THE CO V E R C A R E F UL LY O N CE T H E CO V E R S C RE WS A RE REMOVED FROM THE BACK OF THE MODULE.

  • Page 76: Power Selector/Estop Switch Installation

    SECTION 4 - CONTROL COMPONENTS Power Selector/EStop Switch Installation Figure 4-17. Emergency Stop Switch Installation 1. Emergency Stop Button 4. Nut Figure 4-19. Power Selector/EStop Switch - Connectors 2. Button Seal 5. Emergency Stop Switch 1. LCD and Button Circuit Board 3.

  • Page 77: Ground Control Station - Programming

    SECTION 4 - CONTROL COMPONENTS 4.6 GROUND CONTROL STATION - PROGRAMMING Activating Programming Mode General The MVL/MSP machine Ground Control Module allows on- board programming of various component and control func- tion personality settings. Programming may be required under circumstances such as: •...

  • Page 78: Entering Password

    SECTION 4 - CONTROL COMPONENTS Entering Password Selecting Programmable Item to Adjust 00000 Figure 4-23. Selecting Programmable Item to Adjust Figure 4-21. Entering Password 1. Use the Platform UP/DOWN buttons (1) to scroll through the list of programmable items available to your pro- 1.

  • Page 79: Service Programming Mode - (Level-2)

    SECTION 4 - CONTROL COMPONENTS Note: When entering this mode the LCD will display in real time the Service Programming Mode - (Level-2) current X and Y degree readings of the tilt sensor. The read- In the Service Programming Mode the following items are ing being displayed is based on the previous zero setting and shown on the main menu: may not reflect level of the machines current resting surface.

  • Page 80: Operator Programming Mode - (Level-3)

    SECTION 4 - CONTROL COMPONENTS Tilt Sensor Operator Programming Mode - (Level-3) Allows viewing current tilt sensor individual X and Y direction In the Operator Programming Mode the following items are degree reading. shown on the main menu (also see Table 4-1): Program •...
  • Page 81 SECTION 4 - CONTROL COMPONENTS Table 4-1. MVL/MSP Ground Control Module - Field Programmable Settings and Factory Preset  Level-2: Service Level Settings On LCD Display: YES = HIGH =  Level-3: Operator Level Settings NO = LOW = LEVEL PROGRAMMABLE ITEM FACTORY PRESET SETTING RANGE...

  • Page 82: Platform Control Console - Service Procedures

    SECTION 4 - CONTROL COMPONENTS 4.7 PLATFORM CONTROL CONSOLE - SERVICE PROCEDURES General DO NOT ATTEMPT TO DISASSEMBLE THE PLATFORM CON- TROL BOX IF MACHINE IS STILL UNDER WARRANTY. OPEN- ING THE PLATFORM CONTROL BOX WHILE THE MACHINE IS UNDE R WARRANTY WIL L VOID TH E WARRANTY. IF UNDER WARRANTY REQUEST A REPLACEMENT BOX FROM THE FACTORY.

  • Page 83: Display/Controller Module Electrical Connections

    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 run- ning to the platform junction box mounted to the mast under the platform.

  • Page 84: Display/Controller Module - Install/Remove

    SECTION 4 - CONTROL COMPONENTS Display/Controller Module - Install/Remove Horn Button Switch - Install/Remove Figure 4-31. Platform Console - Horn Switch Installation 1. Horn Button Switch (a) 3. Nut Figure 4-29. Platform Console - Display Module 2. Lock Washer 1. Display/Controller 2.

  • Page 85: E-Stop/Shutdown Switch - Install/Remove

    SECTION 4 - CONTROL COMPONENTS E-Stop/ShutDown Switch - Install/Remove Joystick Assembly - Install/Remove Figure 4-33. Platform Console - E-Stop Switch Installation Figure 4-34. Platform Console - Joystick Installation 1. Loosen Switch Set 5. Barrel Seal 1. Joystick Assembly 4. Rubber Boot/Gasket Screw 6.

  • Page 86: Pump-Motor Assembly - Service Procedure

    SECTION 4 - CONTROL COMPONENTS 4.8 PUMP-MOTOR ASSEMBLY - SERVICE Hydraulic Pressure Gauge Connection PROCEDURE Hydraulic Pressure settings and Adjustment ONLY OPEN HYDRAULIC SYSTEM LINES WITH THE MAST FULLY LOWERED TO RELIEVE PRESSURE IN THE SYSTEM. Adjust system pressure so that platform will raise with maxi- CAREFULLY LOOSEN REQUIRED FITTINGS, WEAR SAFETY mum rated capacity in platform.

  • Page 87: After Filter Pressure Check

    SECTION 4 - CONTROL COMPONENTS After Filter Pressure Check Pump/Motor/Tank Installation Reinstall the hydraulic oil filter and install the t-fitting between the hydraulic filter and the extend line to the cylinder. Recheck BE CE RTA IN TH E M AS T IS FU L LY LO WE RE D BE F O RE the hydraulic pressure and compare with the previous read- REMOVING ANY HYDRAULIC LINES FROM THE PUMP UNIT.

  • Page 88: General Installation And Disassembly

    SECTION 4 - CONTROL COMPONENTS General Installation and Disassembly FENNER BRAND PUMP - Brush Replacement The following is a complete disassembly/assembly of the MVL/ Motor Cap/Motor Installation MSP machines pump/motor assembly. No internal parts to the hydraulic pump are serviced by JLG except for a pump installa- tion seal kit.

  • Page 89: Motor Brush Installation

    SECTION 4 - CONTROL COMPONENTS Motor Brush Installation Once brush housing has been removed, inspect the rotor com- mutator for excessive wear before installing a new brush set. The rotor commutator surface when new, is approximately 1/8 in. (3mm) in thickness. Figure 4-42.

  • Page 90: Brush Housing Final Assembly Tips

    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...

  • Page 91: Monarch Brand Pump - Brush Replacement

    SECTION 4 - CONTROL COMPONENTS MONARCH BRAND PUMP - Brush Replacement Motor Assembly - Remove/Install - Reference Marks Pump Motor - Removal/Installation - Reference Marks • For reference when reassembling, mark motor cover, housing and valve body position before disassembling. 1.

  • Page 92: Brush Carrier Assembly - Remove/Install

    SECTION 4 - CONTROL COMPONENTS Brush Carrier Assembly - Remove/Install Figure 4-47. Brush Carrier Assembly - Remove/Install 1. Stator/Brush Carrier Screws (Pump Rear) 3. Mark Brush Carrier Position on Motor Housing 2. Stator/Brush Carrier Screws (Pump Front) (a) 4. Brush Carrier Assembly Note: (a) Removed previously with motor cover disassembly (shown for reference only).

  • Page 93: Tank Installation

    SECTION 4 - CONTROL COMPONENTS Tank Installation Pump Installation Figure 4-51. Pump Installation 1. Pump Assembly 3. Pump Shaft Seal Figure 4-49. Tank Installation 2. Pump Assembly Screws 4. Pump End Head 1. Tank Assembly 3. O-Ring Seal 2. Tank Screws (4) 4.

  • Page 94: Pressure Adjust Valve Installation

    SECTION 4 - CONTROL COMPONENTS Pressure Adjust Valve Installation Pressure Check Valve Installation Figure 4-53. Pressure Adjust Valve Installation Figure 4-54. Pressure Check Valve Installation 1. Adjust Valve Cap 4. Valve Ball 1. Check Valve Assembly 5. Check Valve Port 2.
  • Page 95 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 96: Mast Components

    SECTION 5 - MAST COMPONENTS SECTION 5. MAST COMPONENTS 5.1 MAST COMPONENTS OVERVIEW Figure 5-1. Mast Components. (MVL/MSP) 1. Mast Section - 1 4. Mast Section - 4 7. Lift Cylinder Mount 10. Lanyard Attach 13. Chain/Equalizer - 2. Mast Section - 2 5.

  • Page 97: Mast Chains And Sequencing Cables Adjustment

    SECTION 5 - MAST COMPONENTS 5.2 MAST CHAINS AND SEQUENCING CABLES Tighten (to raise mast section), or loosen (to lower mast section) the adjusting nut against the anchor plate on ADJUSTMENT each chain/cable. Adjust the nut the amount required to raise or lower the top of the mast section to match the Mast Chain/Cable Adjustment side profile shown in Figure 5-2.
  • Page 98 SECTION 5 - MAST COMPONENTS 7/16 in. (12m m ) Figure 5-2. MVL/MSP - Mast Chain and Sequence Cable Adjustment Components 1. Sequence Cable Adjust Nut 4. Mast Section - 3 7. Check Mast Stowed Height 10. Chain Lock Nut 2.

  • Page 99: Sequence Cable Replacement Kit

    SECTION 5 - MAST COMPONENTS 5.3 SEQUENCE CABLE REPLACEMENT KIT Clamp Installation (Drum/Socket Type) 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 THE MANUFACTURER OF THE DRUM/SOCKET CLAMP REC- threaded (top) end attached same as the top end of the fac- OMMENDS THE USE OF THEIR CABLE CLAMP ASSEMBLY...
  • Page 100 SECTION 5 - MAST COMPONENTS Twist the sleeve from the clamp kit onto the rope until it is flat against the vise jaws at the mark made on the wire rope. 1. Cable Strands Unlayed Install the plug supplied with the kit by placing the plug in the center of the strands starting with the small tapered end of the plug.
  • Page 101 SECTION 5 - MAST COMPONENTS 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.

  • Page 102: Hydraulic Line - Disconnect - Special Tool

    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 PN-7027247 to remove and install them.

  • Page 103: Tool Use - Angled Style Fittings

    SECTION 5 - MAST COMPONENTS Tool Use - In-Line Style Fittings (continued) Tool Use - Angled Style Fittings Step 1. Prior to disconnection, ensure that sys- Step 4. Gently push hose assembly into cou- tem is not under pressure. pling body (see directional arrow). Step 2.

  • Page 104: Hydraulic Lift Cylinder - Removal, Inspection And Rebuild

    SECTION 5 - MAST COMPONENTS Tool Use - Angled Style Fittings (continued) 5.5 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILD H Y D R A U L I C C Y L I N D E R S A R E D E S I G N E D TO H O L D HYDRAULIC FLUID UNDER HIGH PRESSURE.
  • Page 105 SECTION 5 - MAST COMPONENTS At the base end, remove and cap the extend and return Remove the adjust and lock nuts from the chain studs at hydraulic lines. the bottom of mast section-3. Figure 5-4. Hydraulic Extend and Return Lines Figure 5-6.
  • Page 106 SECTION 5 - MAST COMPONENTS Remove the cylinder/anchor block attach pin - snap ring At the bottom of mast section-1, remove the cylinder from the back of the top of mast section-2. mount bolts, and mount reinforcement plates. Figure 5-8. Snap Ring Installation 1.

  • Page 107: Cylinder Disassembly

    SECTION 5 - MAST COMPONENTS Cylinder Disassembly Lift Cylinder Component Inspection Cylinder Rod (See Figure 5-11.) There should be no scratches or pits deep enough to catch the Before disassembling the cylinder, clean away all dirt fingernail. Pits that go to the base metal are unacceptable. and foreign substances from openings, particularly the Scratches that catch the fingernail but are not to the base head area.

  • Page 108: Cylinder Assembly (See Figure 5-11.)

    SECTION 5 - MAST COMPONENTS Cylinder Assembly (See Figure 5-11.) 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 com- ponents of any foreign material.
  • Page 109 SECTION 5 - MAST COMPONENTS Figure 5-12. Lift Down Valve and Manual Release Installation 1. Lift Down Valve (a) 4. O-Ring with Backing Rings (a) 2. Valve Solenoid (b) 5. Valve O-Ring (a) 3. Manual Release Assembly 6. Solenoid O-Ring (a) NOTE: (a) Coat all o-rings with clean hydraulic fluid before assembling.

  • Page 110: Mast Assembly Installation

    SECTION 5 - MAST COMPONENTS 5.6 MAST ASSEMBLY INSTALLATION Mast Removal 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 •...

  • Page 111: Mast Assembly And Disassembly Procedures

    SECTION 5 - MAST COMPONENTS 5.7 MAST ASSEMBLY AND DISASSEMBLY ing silicone spray onto the slide pads and slide pad channels before assembly will help mast sections slide easier after slide PROCEDURES pads have been properly shimmed. The MVL/MSP lift mast sections are constructed of extruded Mast Disassembly Procedure - MVL/MSP aluminum, protected with an anodized surface finish.
  • Page 112 SECTION 5 - MAST COMPONENTS Mast Section-2 - Disassembly Carefully slide mast section-5 out the BOTTOM of mast section-4 rails. Disassemble slide pads, shims and chain Slide mast section-2 out TOP of mast section-1 far anchor plate from mast section-5, if necessary. enough to allow access to the chain assembly anchor Mast Section-4 - Disassembly block/sheave wheel assembly.
  • Page 113 SECTION 5 - MAST COMPONENTS Figure 5-15. Mast Chain Routing Diagram. - MVL/MSP 5-18 31215825...

  • Page 114: Mast Assembly Procedure - Mvl/Msp

    SECTION 5 - MAST COMPONENTS Mast Section 2 - Assembly Mast Assembly Procedure - MVL/MSP NOTE: When sliding mast sections together, be careful not to Mast Section 1 - Assembly scratch or score the anodized finish in the slide pad chan- Place mast section-1, rail (open) side up (See Figure 5-14.
  • Page 115 SECTION 5 - MAST COMPONENTS c. Check mast section for side play. If play exists Lift cylinder installation into the bottom of Mast Section add.015” shims dividing the thickness equally 1 and 2. between both sides of mast. Insert shims until the shims cannot be inserted halfway by hand with the mast pulled to the opposite side.
  • Page 116 SECTION 5 - MAST COMPONENTS Slide mast section-2 out of mast section-1 approxi- e. Slide the whole anchor block/cylinder assembly mately 8 in. (20cm). with sheave pin, wheels and pin support bars into top of mast section-2. Assemble one of the narrow chains sets (#444) and to f.
  • Page 117 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 chan- nels. Carefully slide mast section-3 into section-2 until ends are even.
  • Page 118 SECTION 5 - MAST COMPONENTS d. Holding complete sheave wheel assembly, slide assembly into top of mast section-3 and align threaded holes in sheave pin support bars with holes in mast rails. e. Attach to top of mast section-3 using two (2) 3/8”- 16UNC x 1/2”...
  • Page 119 SECTION 5 - MAST COMPONENTS Mast Section 4 - Assembly NOTE: When sliding mast sections together, be careful not to scratch or score the anodized finish in the slide pad chan- nels. Carefully slide mast section-4 into section-3 until ends are even.
  • Page 120 SECTION 5 - MAST COMPONENTS e. Holding complete sheave wheel assembly, slide Complete the following steps to determine shim stock assembly into top of mast section-4 and align thickness required for section-5; threaded holes in sheave pin support bars with NOTE: Always use the an even amount of shim material behind holes in mast rails.
  • Page 121 SECTION 5 - MAST COMPONENTS Figure 5-27. Mast Section 5 - Bottom End Components (Chain Anchor Bracket and Slide Pad Installation) 1. Chain Anchor Bracket 3. Slide Pad 5. Slide Pad Bolts/Washers (a) 2. Anchor Bracket Bolts/Washers(a) 4. Long Slide Pad NOTE: (a) Apply Medium strength Threadlocking Compound to threads.
  • Page 122 SECTION 5 - MAST COMPONENTS Figure 5-28. Lanyard Attach Installation Figure 5-29. Sequence Cable Bracket Installation) (Bottom End) 5-27 31215825...

  • Page 123: Msp - Stockpicker Platform - Installation

    SECTION 5 - MAST COMPONENTS 5.8 MSP - STOCKPICKER PLATFORM - INSTALLATION Figure 5-30. MSP - Stockpicker Platform Installation 1. Mast Platform Header Section 3. Washers 5. Hex Head Screws (2-1/2 inch) 2. Nut 4. Hex Head Screws (2 inch) 6.

  • Page 124: Msp - Stockpicker Platform - Mid-Gate Interlock Installation

    SECTION 5 - MAST COMPONENTS 5.9 MSP - STOCKPICKER PLATFORM - MID-GATE 5.10 MAST BEACON - INSTALLATION INTERLOCK INSTALLATION Figure 5-31. MSP - Platform - Mid-Gate Interlock Switch Installation 1. Pop Rivets 4. Mounting Holes Figure 5-33. Mast Mounted Beacon Installation (MVL/ 2.

  • Page 125: Gate Alarm - Installation - Option (For Side Entry W/Folding Material Tray Platform Only)

    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) •...

  • Page 126: Load Sensing System (Lss)

    SECTION 5 - MAST COMPONENTS 5.12 LOAD SENSING SYSTEM (LSS) SEE DETAIL A DETAIL A 1001230530-B MAF30460B SECTION A - A 1. Coil Spring 5. Nut 2. Capscrew 6. Capscrew 3. Lock Nut 7. Lock Nut 4. Bolt 8. Washer Figure 5-34.

  • Page 127: Setting Spring Pre-Load

    SECTION 5 - MAST COMPONENTS Setting Spring Pre-Load Adjusting Switch Adjust the height of the coil springs (1) to 2.250 in by Load platform with 105% of the total rated capacity. tightening the capscrew (6) and lock nut (7) (using cen- Align center of bolt (4) with plunger.
  • Page 128 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 129: Troubleshooting

    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 guid- ance should be obtained before proceeding with any maintenance.

  • Page 130: Multimeter Basics

    SECTION 6 - TROUBLESHOOTING NOTE: For aid in troubleshooting electrical problem, refer to Figure 6-8. for an ELECTRICAL DIAGRAM of the various circuits. Also for a picto- rial overview of the connected components, See Figure 6-6. “Pictorial Overview of the MVL/MSP Electrical System”. 6.5 MULTIMETER BASICS A wide variety of multi-meters or Volt Ohm Meters (VOM) can be used for troubleshooting your equipment.
  • Page 131 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 • First test meter and leads by touching leads together. (See multimeter’s operation manual) Resistance should read a short circuit (very low resis- tance)
  • Page 132 SECTION 6 - TROUBLESHOOTING Continuity Measurement Current Measurement Figure 6-3. Continuity Measurement Figure 6-4. Current Measurement (DC) • Some meters require a separate button press to enable • Set up the meter for the expected current range audible continuity testing •...

  • Page 133: Continuity Measurement Over Long Distances

    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.

  • Page 134: Electrical Switch Testing

    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 function- ing properly when there is continuity between the correct terminals or contacts only when selected. De-energize the circuit.

  • Page 135: Automatic Switches

    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. Connect instrumentation to monitor and/or control the parameter the switch is measuring.

  • Page 136: Ground Control Module Lcd Display

    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. 00000.0 LCD Display Symbols 1.
  • Page 137 SECTION 6 - TROUBLESHOOTING (– ) (+ ) (– ) (+ ) (+ ) (– ) (– ) (+ ) (+ ) (– ) 1. Ground Control Module (a) 6. Power Cable To Left Drive Motor/ 9. Battery Disconnect (Option) 2.
  • Page 138 SECTION 6 - TROUBLESHOOTING Table 6-1. LCD Display - Service Fault Code Conditions PLATFORM FAULT CONSOLE FAULT DESCRIPTION/ LCD SYMBOL SCREEN LCD TEXT SCREEN TROUBLESHOOTING CODE LEDs MACHINE CONDITION FLASHING Machine In Drive Speed See Table 6-5, — — — Cut-Back (Turtle) Mode Page 6-18 00000.0...
  • Page 139 SECTION 6 - TROUBLESHOOTING Table 6-1. LCD Display - Service Fault Code Conditions PLATFORM FAULT CONSOLE FAULT DESCRIPTION/ LCD SYMBOL SCREEN LCD TEXT SCREEN TROUBLESHOOTING CODE LEDs MACHINE CONDITION REFER TO FLASHING Right Drive Motor SeeTable 6-11, Disconnected Page 6-22 00000.0 DRIVE Disabled Left Brake Disconnected...
  • Page 140 SECTION 6 - TROUBLESHOOTING Table 6-1. LCD Display - Service Fault Code Conditions PLATFORM FAULT CONSOLE FAULT DESCRIPTION/ LCD SYMBOL SCREEN LCD TEXT SCREEN TROUBLESHOOTING CODE LEDs MACHINE CONDITION REFER TO FLASHING See Table 6-24, — Beacon Disconnected Page 6-27 00000.0 See Table 6-25, —...
  • Page 141 SECTION 6 - TROUBLESHOOTING Table 6-1. LCD Display - Service Fault Code Conditions PLATFORM FAULT CONSOLE FAULT DESCRIPTION/ LCD SYMBOL SCREEN LCD TEXT SCREEN TROUBLESHOOTING CODE LEDs MACHINE CONDITION REFER TO FLASHING 1 LED/BAR Flashing with an audible beep. See Page 6-33 Drive and Platform Lift-UP 00000.0 Functions Locked Out.
  • Page 142 SECTION 6 - TROUBLESHOOTING Table 6-1. LCD Display - Service Fault Code Conditions PLATFORM FAULT CONSOLE FAULT DESCRIPTION/ LCD SYMBOL SCREEN LCD TEXT SCREEN TROUBLESHOOTING CODE LEDs MACHINE CONDITION REFER TO FLASHING Internal OSS Sensor #6 See Table 6-37, — Fault Condition Page 6-34 00000.0...

  • Page 143: Troubleshooting Tables Index

    SECTION 6 - TROUBLESHOOTING 6.8 TROUBLESHOOTING TABLES INDEX Specifications For Various Components Page Ohm Ratings for Various Components ..............6-17 Amperage Draw for Various Components .
  • Page 144 SECTION 6 - TROUBLESHOOTING Code 29 - Reserved ..................6-30 Code 30 - Traction Module - No Communication with Ground Control Module .

  • Page 145: Specifications For Various Components

    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 NOMINAL RESISTANCE @ TEMPERATURE RESISTANCE RANGE POSSIBLE Pump Motor 0.2ohm - 0.4ohm @ 77deg F 0.12ohm - 0.49ohm Table 6-3.

  • Page 146: Fault Code Troubleshooting Tables

    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.

  • Page 147: Code 02 - Left Php Bar - Up

    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 6-6. Code 02 - Left PHP Bar - UP STEP ACTION SPEC...

  • Page 148: Code 04 - Tilt Condition

    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) •...

  • Page 149: Code 06 - Drive Motor Brush Wear Warning Indicator

    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. •...

  • Page 150: Code 08 - Right Drive Motor - Disconnected

    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 6-11. Code 08 - Right Drive Motor Disconnected STEP ACTION SPEC...

  • Page 151: Code 11 - Left Drive Motor - Short Circuit

    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 6-14. Code 11 - Left Drive Motor - Short Circuit STEP ACTION SPEC...

  • Page 152: Code 14 - Pump Motor - Disconnected

    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 connec- tions. Table 6-17.

  • Page 153: Code 16 - Lift Down Valve - Short Circuit

    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 6-19. Code 16 - Lift Down Valve - Short Circuit STEP ACTION SPEC...

  • Page 154: Code 19 - Alarm - Disconnected

    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 6-22. Code 19 - Alarm - Disconnected STEP ACTION SPEC...

  • Page 155: Code 21 - Beacon - Disconnected

    SECTION 6 - TROUBLESHOOTING Code 21 - Beacon - Disconnected Check For These Obvious Conditions First: • Is machine equipped with flashing amber beacon light. Table 6-24. Code 21 - Beacon - Short Disconnected STEP ACTION SPEC Is machine equipped with a flashing amber beacon light. —...

  • Page 156: Code 23 - Horn - Disconnected

    SECTION 6 - TROUBLESHOOTING Code 23 - Horn - Disconnected Check For These Obvious Conditions First: • Is machine equipped with a horn unit. Table 6-26. Code 23 - Horn - Disconnected STEP ACTION SPEC Is machine equipped with a horn unit. —...

  • Page 157: Code 25 - Auxiliary #1 Circuit - Disconnected

    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 6-28. Code 25 - Auxiliary #1 Circuit - Disconnected STEP ACTION SPEC...

  • Page 158: Code 28 - Reserved

    SECTION 6 - TROUBLESHOOTING Code 28 - Reserved Code 29 - Reserved Code 30 - Traction Module - No Communication with Ground Control Module Check For These Obvious Conditions First: • Check if the communications cable connections, P5 connector on the Ground Control Module and round plug on the Traction Con- trol Module are seated properly in their sockets at each end.

  • Page 159: Code 32 - Pump Motor - Over Current

    SECTION 6 - TROUBLESHOOTING Table 6-31. Code 31 - Platform Control Console - No Communication with Ground Control Module Check voltage across pins-10 and 2 on connector P4 at the Ground Replace Ground 24V DC Go to Step 5 Control Module. Control Module Check continuity of P4 connector, pin-10 to Platform Junction Box —...
  • Page 160 SECTION 6 - TROUBLESHOOTING NOTE: In the procedures below, if you check continuity between pin 6 and 16 it should show open circuit, when the platform gates are closed and nothing is on the foot switch. When you step on the foot switch with the gates closed, you should see a closed circuit. Table 6-34.

  • Page 161: Code 35 - P2-Auxiliary #1 - Tie Down

    SECTION 6 - TROUBLESHOOTING Code 35 - P2-Auxiliary #1 - Tie Down Check For These Obvious Conditions First: • Pressure on the Platform Foot-switch during machine power up. NOTE: In the procedures below, if you check continuity between pin 6 and 16 it should show open circuit, when the platform gates are closed and nothing is on the foot-switch.

  • Page 162: Code 40 - Obstruction Sensor System - No Communication With Ground Control Module

    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 6-36.

  • Page 163: Codes (100 - 199) Ground Control Module - Fault Condition

    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 6-38.

  • Page 164: Codes (200 - 299) Platform Control Console - Fault Condition

    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. •...

  • Page 165: Main Power Circuit Troubleshooting

    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. •...

  • Page 166: Mast Troubleshooting

    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 6-42.

  • Page 167: Mast Noisy When Lifting And Lowering

    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 6-44. Mast Noisy when Lifting and Lowering STEP ACTION SPEC...

  • Page 168: Platform (Mast) Won't Stay Elevated

    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: •...

  • Page 169: Hydraulic Leak Troubleshooting

    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 6-47. Hydraulic Leak Troubleshooting STEP ACTION SPEC Oil leaking around the lift cylinder rod. Replace the Seal at the end of the —...

  • Page 170: Base Frame Components Troubleshooting

    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 6-48. Caster Wheels Not Operating Freely STEP ACTION SPEC Is the caster rotating freely? Lubricate or —...

  • Page 171: Drive System Troubleshooting

    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. Check For These Obvious Conditions First: • Batteries are Fully Charged (24 Volts) •...

  • Page 172: Machine Won't Drive Straight

    SECTION 6 - TROUBLESHOOTING Table 6-51. Machine Drive in Opposite Direction Remove the Left Drive Motor power lead at the Traction Control Module (M1) and check if the BLACK wire is connected to the positive (+) terminal and the WHITE wire is connected to the negative (–) ter- Consult Rewire as —...

  • Page 173: Noise From Drive Assembly

    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: •...
  • Page 174 SECTION 6 - TROUBLESHOOTING Figure 6-6. Overview of Electrical System Components (MVL/MSP) (Sheet 1 of 2) 6-46 31215825...
  • Page 175 SECTION 6 - TROUBLESHOOTING Figure 6-7. Overview of Electrical System Components (MVL/MSP) (Sheet 2 of 2) 6-47 31215825...
  • Page 176 SECTION 6 - TROUBLESHOOTING LIGHT JUNCTION BOX ES OUT YELLOW/BLACK ES IN YELLOW SHIELD B- BLACK RS485B BLUE RS485A ORANGE AUX #1 SIGNAL B- RED/BLACK AUX #1 RETURN BLUE/BLACK SUPPLY 24V DC RED DIGITAL RETURN BROWN E-STOP LSS LED ORANGE/BLACK LSS SWITCH - BROWN/BLACK LSS SWITCH + BLACK/RED JOYSTICK MODULE...
  • Page 177 SECTION 6 - TROUBLESHOOTING ES OUT YELLOW/BLACK ES IN YELLOW SHIELD B- BLACK RS485B BLUE RS485A ORANGE AUX #1 SIGNAL B- RED/BLACK AUX #1 RETURN BLUE/BLACK SUPPLY 24V DC RED DIGITAL RETURN BROWN LSS LED ORANGE/BLACK LSS SWITCH - BROWN/BLACK LSS SWITCH + BLACK/RED PLATFORM AUX #2...
  • Page 178 SECTION 6 - TROUBLESHOOTING 2792504_B 1. Tank 5. Pressure Adjust Valve 9. Check Valve 2. Filter Screen 6. Extend Line 10. Pressure Compensator - Flow Control Valve 3. Pump 7. Hydraulic Filter 11. Manual Decent Valve 4. Pump Motor 8. Return Line 12.
  • Page 179 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

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