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JLG 10MSP Service Maintenance Manual
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JLG 10MSP Service Maintenance Manual

JLG 10MSP Service Maintenance Manual

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Service & Maintenance Manual
Model
10MSP
PVC 2202
31219980
January 25, 2022 - Rev A
ANSI
Copyright ©
AS/NZS MOL 70

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Summary of Contents for JLG 10MSP

  • Page 1 Service & Maintenance Manual Model 10MSP PVC 2202 31219980 January 25, 2022 - Rev A ANSI Copyright © AS/NZS MOL 70...
  • Page 3 2. Relieve system pressure by lowering the platform completely to direct any line pressure back into the return line to the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss. VE100247A 10MSP 31219980...
  • Page 4 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 SOLVENTS. • ENSURE REPLACEMENT PARTS OR COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS. 31219980 10MSP...
  • Page 5 REVISION LOG DATE REVISION DESCRIPTION January 25, 2022 Original Issue 10MSP 31219980...
  • Page 6 This Page is intentionally left blank...
  • Page 7 Batteries and Battery Charger ....................70 SECTION 4 CONTROL COMPONENTS........................... 79 Control Components Overview ..................... 79 Control Components Installation................... 80 Ground Control Module ....................... 86 Ground Control Module Programming................... 92 Platform Control Console ..................... 98 Object Detection System (If Equipped)................. 105 10MSP 31219980...
  • Page 8 Special Pin Extractor Tools For Electrical Connectors .............. 166 6.10 Fault Code Troubleshooting Tables ..................167 6.11 Main Power Circuit Troubleshooting ..................180 6.12 Mast Troubleshooting......................180 6.13 Hydraulic Leak Troubleshooting..................183 6.14 Base Frame Components Troubleshooting ................183 6.15 Drive System Troubleshooting .................... 184 31219980 10MSP...
  • Page 9 SECTION 1 MACHINE SPECIFICATIONS VE100009A OPERATING SPECIFICATIONS SPECIFICATIONS 10MSP Gross Machine Weight: (Platform Empty) 1260 lb (572 kg) Machine Height: (Platform Stowed) 57.4 in. (1.45 m) Maximum Tire Load: (Per Wheel) 710 lb (322 kg) 1.875 in. (47.6 mm) Machine Ground Clearance: Machine Turning Radius: (Circle) 65 in.
  • Page 10 The use of non approved batteries in your JLG equipment may result in performance issues or battery charger fault codes. JLG assumes no responsibility for service or performance issues arising from the use of non approved batteries.
  • Page 11 MACHINE SPECIFICATIONS SPECIFICATIONS 10MSP Manual Material Tray: 254 lb (115 kg) Power Material Tray: 198 lb (90 kg) Carry Deck Capacity: 254 lb (115 kg) Platform Entry Height: 13.9 in. (35.3 cm) (Ground to Platform Floor) Platform Height - Mast Fully Extended - (Ground to Platform Floor): 10 ft.
  • Page 12 Note: Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. Note: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same re- quired additives or be of comparable viscosities.
  • Page 13 Table 3. UCon Hydrolube HP-5046 Specs Specific Gravity, 20/20°F 1.082 Pour Point, °C(°F) <-50 (<58) Appearance Red Liquid Viscosity at 0°C (32°F) 340cST (1600SUS) at 40°C (104°F) 46cST (215SUS) at 65°C (150°F) 22cST (106SUS) Viscosity Index 1.7.2 Lubrication Specifications VE100010A 10MSP 31219980...
  • Page 14 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. THREAD LOCKING COMPOUND Description JLG PN Loctite® ND Industries 0100011 242™...
  • Page 15 0.3125 0.0524 3340 0.3125 0.0580 3700 0.3750 0.0775 4940 0.3750 0.0878 5600 0.4375 0.1063 6800 7/16 0.4375 0.1187 7550 0.5000 0.1419 9050 0.5000 0.1599 10700 9/16 0.5625 0.1820 11600 0.5625 0.2030 12950 0.6250 0.2260 14400 0.6250 0.2560 16300 10MSP 31219980...
  • Page 16 2300 3128 1974 2676 5000059K Note: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER 31219980 10MSP...
  • Page 17 0.3125 0.0580 5220 0.3750 0.0775 7000 0.3750 0.0878 7900 7/16 0.4375 0.1063 9550 0.4375 0.1187 10700 0.5000 0.1419 12750 0.5000 0.1599 14400 9/16 0.5625 0.1820 16400 0.5625 0.2030 18250 0.6250 0.2260 20350 0.6250 0.2560 23000 0.7500 0.3340 30100 10MSP 31219980...
  • Page 18 3200 4350 2665 3625 5000059K Note: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER 31219980 10MSP...
  • Page 19 0.0524 3340 5/16 0.3125 0.0580 3700 0.3750 0.0775 4940 0.3750 0.0878 5600 0.4375 0.1063 6800 7/16 0.4375 0.1187 7550 0.5000 0.1419 9050 0.5000 0.1599 10700 9/16 0.5625 0.1820 11600 0.5625 0.2030 12950 0.6250 0.2260 14400 0.6250 0.2560 16300 10MSP 31219980...
  • Page 20 1754 2385 1645 2237 5000059K Note: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER 31219980 10MSP...
  • Page 21 0.3125 0.0580 5220 0.3750 0.0775 7000 0.3750 0.0878 7900 7/16 0.4375 0.1063 9550 0.4375 0.1187 10700 0.5000 0.1419 12750 0.5000 0.1599 14400 0.5625 0.1820 16400 9/16 0.5625 0.2030 18250 0.6250 0.2260 20350 0.6250 0.2560 23000 0.7500 0.3340 30100 10MSP 31219980...
  • Page 22 2845 3870 2665 3625 5000059K Note: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER 31219980 10MSP...
  • Page 23 0.3125 0.0524 4720 0.3125 0.0580 5220 0.3750 0.0775 7000 0.3750 0.0878 7900 7/16 0.4375 0.1063 9550 0.4375 0.1187 10700 0.5000 0.1419 12750 0.5000 0.1599 14400 0.5625 0.1820 16400 9/16 0.5625 0.2030 18250 0.6250 0.2260 20350 0.6250 0.2560 23000 10MSP 31219980...
  • Page 24 3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. 31219980 10MSP...
  • Page 25 0.0524 4720 5/16 0.3125 0.0580 5220 0.3750 0.0775 7000 0.3750 0.0878 7900 7/16 0.4375 0.1063 9550 0.4375 0.1187 10700 0.5000 0.1419 12750 0.5000 0.1599 14400 9/16 0.5625 0.1820 16400 0.5625 0.2030 18250 0.6250 0.2260 20350 0.6250 0.2560 23000 10MSP 31219980...
  • Page 26 3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. 31219980 10MSP...
  • Page 27 3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. 10MSP 31219980...
  • Page 28 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. *ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. 31219980 10MSP...
  • Page 29 3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. 10MSP 31219980...
  • Page 30 3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. 31219980 10MSP...
  • Page 31 Annual Machine Inspection. JLG Industries recommends this task be performed by a Factory-Trained Service Technician. JLG Industries, Inc. recognizes a Factory-Trained Service Technician as a person who has successfully completed the JLG Service Training School for the subject JLG product model. Reference the machine Service and Maintenance Manual and appropriate JLG inspection form for performance of this inspection.
  • Page 32 Service and Maintenance Manual and ap- Pre-Delivery Inspection Owner, Dealer, or User Qualified JLG Mechanic delivery. plicable JLG inspection form. In service for 3 months or 150 hours, whichever comes first; or out of service Service and Maintenance Manual and ap- Frequent Inspection...
  • Page 33 BASE ASSEMBLY 1, 7 1, 7 Hood and Covers Installation Static Strap 1, 5 1, 5 Drive and Caster Wheels Pot Hole Protection System Bubble Level (If Equipped) 1, 2, 7 1, 2, 7 Brake Release Cable (If Equipped) 10MSP 31219980...
  • Page 34 Cylinder Attachment Pins and Pin Retainers 1, 2 1, 2 Hydraulic Hoses, Lines, and Fittings 1, 9 1, 9 Hydraulic Reservoir, Cap, and Breather 5, 7 5, 7 Hydraulic Filter Hydraulic Fluid *** Electrical Connections Instruments, Gauges, Switches, Lights, Horn 31219980 10MSP...
  • Page 35 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 36 Should pressure washing be utilized to wash areas containing electrical/electronic 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 37 Chain side wear, noticeable when pin heads and outside plates show a definite wear pattern, is caused by misalignment of the sheave/chain anchors and must be corrected promptly. Do not repair chains; if a section of chain is damaged, replace the entire chain set. 10MSP 31219980...
  • Page 38 If any cracks are discovered, replace all chains, as seemingly sound plates are on the verge of cracking. Fatigue and ultimate strength failures on JLG Lifts are incurred as a result of severe abuse as design specs are well within the rated lifting capacity of these chains.
  • Page 39 1. Refer to Section — Hydraulic Oil Specifications, page 12 for recommended viscosity ranges. 2. JLG recommends fluid, UTTO (STD) 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152. 2.4.3 Changing Hydraulic Oil 1.
  • Page 40 This Page is intentionally left blank...
  • Page 41 1. Front Cover 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 10MSP 31219980...
  • Page 42 2. 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. 3. Lift to remove deck from machine. 3.2.2 Hood (Carry Deck) Frame 1. Carry Deck Support 2. Support Screws, Nuts, Washers 31219980 10MSP...
  • Page 43 Rear Bumper Cover The five screws that attach the drive motor cover to the rear bumper must be removed before the rear bumper cover can be removed. VE100019A 1. Bumper Cover 3. AC Input - Receptacle Assembly Cover 2. Screws/Washers 10MSP 31219980...
  • Page 44 The tires and rims installed on machines are to be inspected daily as part of the daily walk-around inspection. JLG requires that the daily walk-around inspection be performed at each operator change during a shift and at each shift change.
  • Page 45 (27 - 41 Nm) (88 - 108 Nm) (142 - 163 Nm) 4. Wheel bolts should be torqued after the first 50 hours of operation and after each wheel removal. Check torque every 3 months or 150 hours of operation. 10MSP 31219980...
  • Page 46 4. Spindle Shaft Seal Note: Base is shown cutaway for illustrative purposes only. (a) If replacing bearing, pack bearing completely full of grease before assembling, use (JLG PN-3020029 - Mobil SHC 460 Syn- thetic or equivalent). Tap in evenly until seated.
  • Page 47 3 o-clock plug location, then remove both plugs. 3. Slowly add oil at the 12 o-clock plug location until oil begins to seep out of the 3 o-clock plug location. Reinstall and tighten plugs to 6-8 ft.lbs. 10MSP 31219980...
  • Page 48 7. Remove the six hex head capscrews and washers attaching the drive assembly to the frame. 8. Carefully slide the drive motor assembly out of the base frame assembly for disassembly. Figure 2. Wheel Drive Assembly Installation (Right Side Shown) 31219980 10MSP...
  • Page 49 Note: The brake wires will have some silicone sealant at the slot through the motor flange. It is okay to pull the wire out of the mo- tor flange slot. The slot will have to be re-sealed during reassembly. 7. Remove the Brake Disc (B2) from the splined motor shaft. 8. Remove the Brake Friction Plate (B3) from the motor flange. 10MSP 31219980...
  • Page 50 11. Connect brush lead wire to brush holder; tighten to 30 in. lbs. If this is a wear indicator brush, connect brush wear indicator lead to spade terminal in brush housing. 12. Repeat steps 6 to 9 for the other 3 brushes. 31219980 10MSP...
  • Page 51 22. Ensure timing marks are still aligned. If not, loosen bolts, line up the marks, and then retighten bolts. 23. Remove the protective tape from the motor shaft. NOTICE Before mounting drive motor/brake assembly to drive hub spindle, ensure brake cavity is clean, dry, and free of oil residue. 10MSP 31219980...
  • Page 52 The screws will push against the outer race of the main bearing. This bearing will have to be replaced afterwards. 7. Using a screwdriver, remove Spiral Retaining Ring (G27). 8. Pull Hub Sub-assembly off of the Spindle Sub-assembly. 31219980 10MSP...
  • Page 53 9. Remove the three Planet Shafts (G6) from the Input Carrier. Note: The Planet Shafts (G6) are held in with a press fit. To avoid damage to the parts, use an arbor or hydraulic press to remove the Planet Shafts (G6). 10MSP 31219980...
  • Page 54 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. 31219980 10MSP...
  • Page 55 6. Flip over the Spindle (G1). 7. Press out the Motor Shaft Seal (G17) from the center bore. The seal cannot be reused when removed. 8. Remove the shaft Ball Bearing (G15) from the center bore. 10MSP 31219980...
  • Page 56 12. Install Input Ball Bearing (G15) into the Spindle (G1) bore. 13. Using a flat plate or rod, press the Motor Shaft Seal (G17) into the center bore so that it is flush with the face of the Spindle (G1). 31219980 10MSP...
  • Page 57 Note: The seal has a thin outer shell that can be easily damaged if not installed with care. It is a good idea to start the Seal into the bore with a rubber mallet before pressing. 3. Flip the Hub (G2) over. 4. Using the appropriate pressing tool (T-174356), press the Main Bearing (G14) into the bore until it bottoms out. 10MSP 31219980...
  • Page 58 8. Put the Thrust Plate (G23) onto the three Input Planet Shafts (G6). Use the three holes on the outermost bolt circle. The other three holes are for a different gear ratio. 9. Using the appropriate retaining ring pliers put a Retaining Ring (G18) into the groove of each Input Planet Shaft (G6). Note: Do not overstress the Retaining Rings (G18). 31219980 10MSP...
  • Page 59 Cover (G11) so that the steel face of the washer is out of the bore. Note: Make sure that both the Cover Thrust Washer (G21) and the Cover (G11) have good clean surfaces for the Threadlocking Compound to properly adhere. 10MSP 31219980...
  • Page 60 BASE COMPONENTS 11. Center the Cover (G11) in the hub bore so that the "JLG" logo is up. Push it into the bore. 12. Install the Cover Retaining Ring (G19) into the groove of the Hub Sub-assembly. 3.5.15 Motor, Brake, and Drive Hub Assembly VE100023A 1.
  • Page 61 The following is a complete tear down/reassembly of the machine’s pump/motor assembly. No internal parts to the hydraulic pump are serviced by JLG except for a pump installation seal kit. The only internal serviceable part of the pump’s electric motor is the motor brush kit.
  • Page 62 2. Check, and if necessary, adjust the hydraulic pressure to initial settings shown in table at the beginning of this section. 3. Cycle the hydraulic system several times with the maximum load capacity in the platform, then recheck pressure setting. When pressure has stabilized, continue to the steps in the following section. 31219980 10MSP...
  • Page 63 2. Recheck the hydraulic pressure and compare with the previous readings when filter was removed. If a significant drop in pressure reading has occurred, replace the hydraulic filter and recheck the “After Filter” pressure reading. VE100037A Figure 7. Typical Hydraulic Pressure Gauge Installation 1. Hydraulic Oil Filter 3. Pressure Gauge Assembly 2. T- Fitting 4. Cylinder Extend Line 10MSP 31219980...
  • Page 64 Once power cables and hydraulic lines are removed from this side of pump assembly, remove the mounting screws from the oth- er side of the pump. Refer to the following illustration. 31219980 10MSP...
  • Page 65 Note: (a) Apply Medium Strength Threadlocking Compound to screw threads before final assembly. Before disassembling, be sure to mark or identify motor cover, housing, and valve body position per the following illustration: 1. Motor Top Cover 4. Housing/Motor Valve Body 2. Cover/Housing 5. Motor Valve Body 3. Motor Housing 10MSP 31219980...
  • Page 66 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. 31219980 10MSP...
  • Page 67 Brush Assembly Removal 1. Brush Assembly (a) 4. Brush Terminal Screw 2. Brush Carrier Socket 5. Brush Attach Terminal 3. Brush Tab Slot Note: (a) Slide brush assembly into socket until tab is in slot at rear of socket. 10MSP 31219980...
  • Page 68 Note: (a) Lubricate o-ring with clean hydraulic fluid before sliding tank over during installation. 3.6.11 Filter Screen Removal Requires removal of tank assembly. 1. Filter Screen 4. Tube Attach Screw 2. Pump Pick-Up Tube 5. O-Ring 3. Tube Retainer Clip Note: Tubes shown shortened for illustrative purposes only. 31219980 10MSP...
  • Page 69 1. Pump Assembly 3. Motor to Pump Coupler 2. Pump Assembly Screws 4. Pump Shaft Bearing 3.6.13 Pressure Adjust Valve Removal VE100048A 1. Adjust Valve Cap 4. Valve Ball 2. Adjustment Screw 5. Adjust Valve Port 3. Valve Spring 10MSP 31219980...
  • Page 70 Then check battery voltage of each battery four hours after charging is complete. Batteries less than 6.72V should be replaced. Note: If a faulty charger is suspected, the batteries can be charged using a charger that supplies 2.45V/cell. Charging should be termi- nated when the charge current drops below 1A. 31219980 10MSP...
  • Page 71 The use of non approved batteries in your JLG equipment may result in performance issues or battery charger fault codes. JLG assumes no responsibility for service or performance issues arising from the use of non approved batteries.
  • Page 72 Note: The carry deck, support frame must be removed to remove the batteries. Once hold-down brackets (2) are removed, remove the cables from the batteries. Slide the rear battery forward to clear the bracket (3). Then lift battery out of base frame. 31219980 10MSP...
  • Page 73 The number of LEDs lit will change depending on the level of charge in the batteries. • (+) All Three GREEN LEDs lit up indicate maximum battery charge. • Four YELLOW LEDs indicate a two thirds to one third battery charge remaining. 10MSP 31219980...
  • Page 74 If ambient temperature is too high, then the charging power will also be reduced to maintain a maximum internal temperature. When the GREEN ‘CHARGED’ LED turns on, the batteries are completely charged. 31219980 10MSP...
  • Page 75 3.7.9 Battery Charger Check/Change Charging Algorithm The charger comes pre-loaded with these nine algorithms. JLG recommends using OEM batteries. Contact the battery manufacturing dealer for the correct algorithm setting if it is not included on this chart. ALGORITHM SETTING...
  • Page 76 3. Remove AC power from the charger and reconnect the charger positive connector to the battery pack. It is highly recommended to check a newly changed algorithm by repeating the above steps 1 and 3. 3.7.10 Battery Charger Removal/Installation 1. Battery Charger Assembly. 2. Charger Attach Screws (4): remove two on top, loosen two on bottom 31219980 10MSP...
  • Page 77 1. To AC 120/220Volt Input Socket (On Rear Bumper) 2. Drive Cut-Out Interlock Harness to P2 Connector on Ground Control Module 3. DC Voltage Output to Battery +/– Posts 4. To Charging Status LED Indicators (On Rear Bumper) 10MSP 31219980...
  • Page 78 This Page is intentionally left blank...
  • Page 79 Figure 8. Control Components Location 1. Ground Control Station 6. Platform Junction Box 2. Platform Control Console 7. Platform Junction Box to Ground Control Harness 3. Platform Gate Interlock Switches * 8. Left Hand Lift Cable (routed inside platform rails) 10MSP 31219980...
  • Page 80 2. Mounting Screws/Washers (a) 8. From Inline Fuse (Battery +) and To Traction Control Module (+) 3. P1 Connector (b) 9. From Battery (–) and To Traction Control Module (–) 4. P2 Connector (b) 10. To (+) Terminal on Hydraulic Pump 31219980 10MSP...
  • Page 81 6. P4 Connector (b) Note: (a) Apply Medium Strength Threadlocking Compound to screw threads on final assembly. (b) To help seal unit from dust and moisture, apply electrical contact grease CG60 (JLG PN 3020038) to all electrical connectors before assembly.
  • Page 82 Then it runs down along the outside of the mast and through a large hole in the mast to the platform junction box. 31219980 10MSP...
  • Page 83 VE100067A 1. Platform Junction Box 5. Power Tray Connector (Option) 2. Platform Console Harness Connector 6. Platform Aux #1 (Left Hand Lift) 3. Ground Control Module Harness Connector 7. Footswitch Connector 4. Platform Aux #2 (Gate Interlock Connector) 10MSP 31219980...
  • Page 84 1. Harness from Platform Junction Box to Ground Control Module 4. Platform Junction Box 2. Spring Extension and Clamp Set 5. Platform Junction Box to Platform Control Harness 3. Power Track Assembly Note: Refer to Section — Mast Components, page 107 for more detailed harness hardware installation. 31219980 10MSP...
  • Page 85 Section — Troubleshooting , page 155. VE100069A Figure 10. Platform Interlock Switch Circuit 4.2.7 Component Electrical Connections Note: Refer to Section — Troubleshooting , page 155 for complete machine wiring schematic. Figure 11. Component Electrical Connections (4-6V Batteries) 10MSP 31219980...
  • Page 86 P3 - Programmable Security Lock Harness (Option) (a) Note: (a) Apply dielectric grease JLG PN 3020038 to wiring harness terminals to prevent moisture from entering module. (b) Seal NEG (–) and POS (+) posts with battery grease to prevent corrosion.
  • Page 87 VE100070A Figure 12. 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 10MSP 31219980...
  • Page 88 VE100071A Cover Installation Remove the six Hex Socket Screws from the Heat Sink/Base. One screw is under the Warranty/Tamper Label. Disconnect the Ribbon Cable 1. Ribbon Cable Connector 3. Support for Cover 2. Ribbon Cable 31219980 10MSP...
  • Page 89 Note: Connector works the same at both ends of ribbon cable. Reconnect Ribbon Cable 1. Ribbon Cable Connector Release Tabs (Slide cable into connector then push tabs back into connector) Note: Connector works the same at both ends of ribbon cable. 10MSP 31219980...
  • Page 90 Note: Tighten nut enough to keep button from turning. Reattach wires to same terminals on new switch. VE100076A 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. 31219980 10MSP...
  • Page 91 CONTROL COMPONENTS Emergency Stop/Power Selector Switch Connector Locations 1. LCD and Button Circuit Board 3. Main Power Selector Switch Connector 2. Emergency Stop Switch Connector Note: To release switch connectors, push tab on top of connector. 10MSP 31219980...
  • Page 92 Level-1 settings must not be modified un- less directed by JLG engineering department personnel. Level 1: JLG Engineering Settings include voltage, amperage, and ohm output settings that are within the operating parameters of various machine components. This Level can adjust all programmable settings.
  • Page 93 1. Use Platform UP/DOWN buttons (1) to move the selection box (2) up or down to select item to program. 2. Press the Brake Release button (3) to enter selected mode then move on to Selecting Programmable Item to Adjust. 10MSP 31219980...
  • Page 94 OSS Sensor Note: There are two production modules available at this time, one for North/South American and European languages, and one for Asian languages. All programmable items between these modules are identical with the exception of language selection. 31219980 10MSP...
  • Page 95 Note: There are two production modules available, one for North/ South American and European languages, and one for Asian lan- guages. All programmable items between these modules are identical with the exception of language selection. Tilt Sensor Allows viewing current tilt sensor individual X and Y direction degree reading. 10MSP 31219980...
  • Page 96 2= Inhibit Drive regardless of Platform position 3= Inhibit Lift, Lower and Drive when Platform elevated 4= Inhibit Lift, Lower and Drive regardless of Platform position 5= Inhibit Lift, Lower and Drive when Platform Elevated + Activate Horn 31219980 10MSP...
  • Page 97 0 - 100 Minimum Turn Speed (Platform Lowered) 0 - 100 Minimum Forward Speed (Platform Elevated) Minimum Reverse Speed (Platform Elevated) 0 - 100 0 - 100 Minimum Turn Speed (Platform Elevated) Motor Compensation 25 mOhms 0 - 500 mOhms 10MSP 31219980...
  • Page 98 SETTING RANGE PRESET Zero the On-Board Tilt Sensor YES/NO — Brush Wear Sensor Timer Reset MAINTAIN/ RESET EPPROM Reset (Resets GCM to default factory settings) 10MSP / 15/20 MVL — OSS Sensor Reading Output — Total Time Displays Machine Hours —...
  • Page 99 The internal switches and joystick controller of the platform console plug directly into the Display/Controller Module. This module then relays the signals from these switches to the Ground Control Box through the communications cable running to the platform junction box mounted to the mast under the platform. 10MSP 31219980...
  • Page 100 2. Communications Cable to Platform Junction Box (C6) 5. Drive/Lift ModeSelect Switch (C7) 3. ON/OFF Key Switch (C3) 6. Joystick - (C8) Note: The (C) numbers shown after the description above represent the corresponding identification of the plug on the module’s cir- cuit board. 31219980 10MSP...
  • Page 101 CONTROL COMPONENTS 4.5.3 Mounting Bracket 1. Mounting Bracket 2. Bracket Screws (a) Note: (a) Apply Medium Strength Threadlocking Compound to screw threads on final assembly. 4.5.4 Rear Cover 1. Rear Cover 2. Cover Mounting Screws 10MSP 31219980...
  • Page 102 Note: (a) Unplug all connections on the back of the module before removing from console. 4.5.6 Horn Button Switch 1. Horn Button Switch (a) 3. Nut 2. Lock Washer Note: (a) Remove rear cover, unplug wire, remove nut and lock washer, then slide switch out of console. 31219980 10MSP...
  • Page 103 Note: (a) Remove mounting bracket on bottom of console to gain access to the key switch assembly. 4.5.8 E-Stop/ShutDown Switch 1. Loosen Switch Set Screw 5. Barrel Seal 2. Turn Switch 90° 6. Switch to Body Retainer Hooks (a) 10MSP 31219980...
  • Page 104 5. Install/Remove through the Access Hole in Bottom of Housing. (a) (b) 3. Nylon Washers (Qty.-4) Note: (a) Remove the console mounting bracket. (b) Remove the key switch and e-stop switch to remove joystick assembly through access hole in bottom of console. 31219980 10MSP...
  • Page 105 If the Object Detection System is not functioning properly, replacing the object sensing pad may be required. 1. Raise and properly support the platform. 2. Disconnect the object sensing pad harness connection. 3. Peel and remove the object sensing pad from the base. 4. Clean any glue residue from the base. 10MSP 31219980...
  • Page 106 4.6.2 Installation 1. Verify the base is clean. Apply adhesive (JLG PN 0100040) evenly over the base. Note: Do not bend or manipulate the sensing pad. Doing so could damage the internal wiring. 2. Carefully remove the protective backing from the sensing pad and install on the base. Apply pressure on the sensing pad to ensure contact with the adhesive.
  • Page 107 SECTION 5 MAST COMPONENTS MAST COMPONENTS OVERVIEW MAF39411 Figure 16. Mast Components 1. Material Handling Tray (Manual Tray Shown) 3. Mast Assembly 2. Platform Assembly 4. Platform Mast Cover 10MSP 31219980...
  • Page 108 Figure 17. Mast Cover 1. Mast Cover 3. Platform Console Mounting Screws 2. Screws and Washers (a) Note: Platform shown without right side rails for illustrative purposes only. (a) Apply Medium Strength Threadlocking Compound to threads before final tightening. 31219980 10MSP...
  • Page 109 7 FOOT HEIGHT LIMIT SWITCH (IF EQUIPPED) Machines may be equipped with an optional 7 ft height limit switch. While the standard maximum platform height is 10 ft, this option limits platform height to 7 ft for certain applications. 10MSP 31219980...
  • Page 110 Proximity switch wire connects to AUX 2 input on the main harness. The ground control module AUX 2 setting must be programmed to “HIGH”, and the AUX 2 INHIBIT setting must be set to “0” (re- fer to Section — Ground Control Module Programming, page 92). 31219980 10MSP...
  • Page 111 The Power Tray is hydraulically-powered via a small lift cylinder connected to a pulley system. The pump and hydraulic reservoir are a single unit mounted to the support plate. Electrical components communicate through a relay mounted above the pump. 10MSP 31219980...
  • Page 112 Covers and Tray Removal Before beginning removal procedures, fully lower the tray. VE100098A 1. Screws (3) 3. Screws/Nuts (4) 2. Mast Cover Bracket 4. Power Unit Top Cover 1. Remove three screws (1) from mast cover bracket (3). Retain hardware. 31219980 10MSP...
  • Page 113 MAST COMPONENTS 2. Remove four sets of screws/nuts (3) from power unit top cover (4). Remove cover. Retain cover and hardware. VE100099A 5. Screws/Nuts (3) 6. Pump Cover Note: Tray assembly removed for clarity. 10MSP 31219980...
  • Page 114 MAST COMPONENTS 3. Remove three sets of screws/nuts (5) from pump cover (6), then remove cover. Retain cover and all hardware. VE100100A 7. Screws/Nuts (2) VE100101A 8. Cover Plate Note: Tray assembly removed for clarity. 31219980 10MSP...
  • Page 115 6. Lift the tray out of the open end of the tracks and set aside. For tray and roller assembly breakdowns, refer to Figure — Power Tray Roller Assembly, page 115 VE100103A Figure 18. Power Tray Roller Assembly 1. Tray Weldment 5. Support Pin (attached to tray) 2. Roller Assembly (4) 6. Bearing 3. Bolt 7. Support Pad 4. Nut 10MSP 31219980...
  • Page 116 4. Hydraulic Reservoir 2. 35 Amp Fuse 5. Lift Cylinder 3. Hydraulic Pump 6. Pulley System Note: Some parts removed for clarity. NOTICE Before beginning power unit disassembly, disconnect the left side battery (+) posi- tive battery terminal. 31219980 10MSP...
  • Page 117 2. If it is necessary to remove or replace the fuse: a. Remove the bolts, nuts and washers attaching the fuse to the pump support plate (4). b. If replacing the fuse, mount to the same location and attach with existing hardware. 10MSP 31219980...
  • Page 118 5. To remove pump assembly, remove two sets of bolts/ washers (7) attaching assembly to the cover plate (4) Retain all hardware. 6. Once pump assembly has been removed, transfer to a clean, flat surface, and keep upright. 31219980 10MSP...
  • Page 119 Note: Some parts removed for clarity. 1. Remove four sets of bolts/nuts/washers (1) securing the cylinder mounting bracket (2) to the platform assembly. Retain all hardware. 2. Carefully lift out the pulley system and set it on a clean, flat surface. 10MSP 31219980...
  • Page 120 6. Link 2. Lift Cylinder 7. Single Pulley 3. Double Pulley 8. Cable Bracket 4. Pin/Circlip 9. Single Pulley 5. Screw/Nut/Washer (2) 10. Bolt/Nut/Washer VE100466A Figure 20. Pulley System Overview 11. Nut (Single Cable) 12. Nuts (Double Cable) 31219980 10MSP...
  • Page 121 5. Remove and retain hardware (5) securing link (6) to cylinder (2). VE100467A 13. Bolt/Nut/Washer (3) 15. Fittings 14. Cylinder Mounting Bracket 6. Remove and retain three sets of bolts/nuts/washers (13) securing cylinder to the mounting bracket (14). 7. Remove hydraulic fittings (15) from the cylinder. 10MSP 31219980...
  • Page 122 7. Change seals (2, 7 and 8). Reassembly 1. Fit gland back onto rod. Ensure seals are not damaged by rod threads. 2. Apply Medium Strength Threadlocking Compound to rod thread and fit piston head. Torque to 61.2 ft. lbs. (83 Nm). 31219980 10MSP...
  • Page 123 1. Attach fittings to lift cylinder. Torque each fitting to 14 ft. lbs. (19 Nm). 2. Attach cylinder to mounting bracket and secure with reserved hardware. VE100468A 3. Route the threaded ends of the double cable (1) up through the slot on the left side of the cylinder mounting bracket. VE100469A 10MSP 31219980...
  • Page 124 4. 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. VE100470A 5. Install pin (3) and circlip (4). VE100471A 31219980 10MSP...
  • Page 125 VE100474A 9. Pull the threaded ends of the double cable (10) through holes on the cable bracket (12). Pull the threaded end of the single cable (11) through the hole on the cable bracket. 10MSP 31219980...
  • Page 126 1. Install the following components (if they were removed during disassembly) to the pump support plate (1) using retained hardware: a. Relay (2 and 3) b. Fuse (4 and 5) c. Hydraulic Pump (6 and 7) 2. Connect all tagged electrical wiring to relay, fuse, and hydraulic pump. 31219980 10MSP...
  • Page 127 6. Attach tray to cable bracket using retained hardware. 7. Slide cover plate down behind tray. Attach to the bottom bracket using retained hardware. 8. Attach pump cover using retained hardware. 9. Attach power unit top cover using retained hardware. 10MSP 31219980...
  • Page 128 11. Cycle the power tray several times; check for leaks around the bottom of the power unit and smooth operation. HYDRAULIC LINE DISCONNECT TOOL 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 129 Step 2. Pull on hose assembly to create a gap between the dust boot and hose fitting shoulder. VE100483A Step 3. Insert the disconnect tool in the gap created between the dust boot and hose fitting shoulder. VE100484A Step 4. Gently push hose assembly into coupling body (refer to directional arrow). 10MSP 31219980...
  • Page 130 Step 5. Maintaining slight pressure on the hose assembly, actuate the tool (refer to arrow direction). VE100486A Step 6. Release the tool and pull on hose assembly to complete disconnection 5.8.2 Angled-Style Fittings VE100487A Step 1. Prior to disconnection, ensure that system is not under pressure 31219980 10MSP...
  • Page 131 Step 2. Pull on hose assembly to create a gap between the dust boot and hose fitting shoulder. VE100489A Step 3. Insert the disconnect tool in the gap created between the dust boot and hose fitting shoulder VE100490A Step 4. Gently push hose assembly into coupling body (refer to directional arrow). 10MSP 31219980...
  • Page 132 5. Disconnect and cap the hydraulic extend and return lines from the hydraulic cylinder either on the valve block at the bottom of the cylinder or at the pump assembly. (Refer to Section — Hydraulic Line Disconnect Tool, page 128 for special tool instructions). 31219980 10MSP...
  • Page 133 Note: If equipped with the OPTIONAL 7 ft. height limiting proximity switch, if necessary, remove the fasteners attaching the bracket and switch to the left side of the mast assembly. (Refer to Section — 7 Foot Height Limit Switch (If Equipped), page 109). 10MSP 31219980...
  • Page 134 2. At the top end of mast section 1, remove the pin attaching the chain anchor block to the mast and remove chain/anchor block assemblies from the mast and lay aside. 3. Remove slide pads and shims from mast section 1, if necessary. 31219980 10MSP...
  • Page 135 Note: When removing the old seals use only blunt tools, be sure there are no sharp edges that may damage the seal grooves dur- ing removal. Scratching the groove may cause by-pass. 8. Remove and discard all old seals. 10MSP 31219980...
  • Page 136 Chrome should be present over the entire surface of the rod and the lack thereof is unacceptable. In the event that an unacceptable condition occurs, the rod should be repaired or replaced. 31219980 10MSP...
  • Page 137 7. Next dip the entire rod assembly into hydraulic fluid and stuff this assembly into the tube. Watch the seals as they pass over the rod port (if visible) to be sure they are not nicked or cut. 8. Install the head until the retaining ring seats in its groove. 10MSP 31219980...
  • Page 138 (b) Mount with electrical terminals pointing to right side of machine. 5.11.4 Remote Manual Descent (If Equipped) The Remote Manual Descent option connects to the manual descent valve. It is enacts the manual release assembly through an external release knob located at the rear of the machine. 31219980 10MSP...
  • Page 139 3. Always install slide pad shims with slide pads inserted into the slide pad channels, ensuring the ends of mast sections are even. 4. Apply Krytox spray (JLG PN-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 140 (Be certain floor surface is clean and free of any metal chips or debris which may stick to lubricated chains.) 3. Insert the chain/anchor plate assembly end into the top of mast section 1 and secure using the large anchor plate attach pin, spacers, and pin keeper. 31219980 10MSP...
  • Page 141 5.12.2 Mast Section 2 Note: Before sliding mast sections together, spray the slide pad channels with Krytox lubricant spray (JLG PN- 3020041). Be careful not to scratch or score the anodized finish in the slide pad channels. 1. Locate mast section 2 and carefully slide mast section 2 closed rail into section 1 open rail. Slide sections together until ends are even.
  • Page 142 Catch any oil draining out of cylinder to avoid spillage onto work area. Replace caps when finished. VE100500A 1. Slide Pads 3. Sequence Cable Bracket 2. Shim Stock 4. Slide Pad Bolts/Washers 9. Install the lift cylinder mount into the bottom of mast section 1 and the cylinder into section 2. 31219980 10MSP...
  • Page 143 16. Assemble the chain/anchor plate assembly and the chain anchor block to the cylinder rod end using the anchor plate/block attach pin and snap ring. 17. Slide mast section 2 back into section 1 until top and bottom ends are even. 10MSP 31219980...
  • Page 144 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 PN- 3020041). Be careful not to scratch or score the anodized finish in the slide pad channels.
  • Page 145 3 with four 1/4 in. - 20UNC x 3/4 in. bolts. Apply Medium Strength Threadlocking Compound to threads on final assembly. VE100505A 1. Lower Chain Anchor Bracket 3. Wide Chain Set Studs 2. Anchor Bracket Screws 4. Chain Adjust and Jam Nuts 10MSP 31219980...
  • Page 146 Thread in enough to hold pad in place. 12. Shim per instructions in step 4 of Mast Section 2 Assembly. Apply Medium Strength Threadlocking Compound to attach screw threads on final assembly. 31219980 10MSP...
  • Page 147 2. Chain Anchor Block 3. Mast Section-3 Note: Before sliding mast sections together, spray the slide pad channels with Krytox lubricant spray, (JLG PN- 3020041). Be careful not to scratch or score the anodized finish in the slide pad channels.
  • Page 148 2. Anchor Bracket Screws (a) 4. Chain Adjust and Jam Nuts Note: (a) Apply Medium Strength Threadlocking Compound to threads on final assembly. 8. Slide the top of mast section 4 back in even with the top of mast section 3. 31219980 10MSP...
  • Page 149 Thread in enough to hold pad in place. 11. Shim per instructions in step 4 of Mast Section 2 Assembly. Apply Medium Strength Threadlocking Compound to attach screw threads on final assembly. 10MSP 31219980...
  • Page 150 7. Spacers (Qty. 4) 4. Sheave Wheel Attach Bolt VE100513A 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 31219980 10MSP...
  • Page 151 Note: If equipped, re-install the 7 ft height limiting switch and bracket to the mast (refer to Section — 7 Foot Height Limit Switch (If Equipped), page 109). 14. The mast assembly is now complete and ready to install onto the base frame. 10MSP 31219980...
  • Page 152 MAST COMPONENTS Figure 24. Platform Junction Box to Ground Control Station Wiring Harness 1. Harness Sheave Wheel 4. Mid Powertrak Bracket and Sheave Wheel 2. Harness Spring Tensioner 5. Lower Powertrak Bracket 3. Upper Powertrak Bracket 31219980 10MSP...
  • Page 153 Note: If slack cannot be adjusted out of the cable and adjust nut has completely compressed the spring, then either the mast side profile is not adjusted properly (even) or the cable will have to be replaced due to stretching. 10MSP 31219980...
  • Page 154 1. Mast Side Profile -(Sections Even at Top) 2. Sequence Cable Adjust Nut 6. Mast Section 4 9. Chain Lock (Jam) Nut 3. Mast Section 1 7. Chain Anchor Plate (Inside) 10. Threaded Chain End (Stud) 4. Mast Section 2 31219980 10MSP...
  • Page 155 Should pressure washing be utilized to wash areas containing electrical/electronic 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 156 Also check that the lead on the "COM" port goes to the ground or negative side of the signal and the lead on the other port goes to the positive side of the signal. 31219980 10MSP...
  • Page 157 Figure 26. Voltage Measurement (DC) • If meter is not auto ranging, set it to the correct range (refer to respective multimeter’s operation manual) • Use firm contact with meter leads 6.5.7 Resistance Measurement VE100552A Figure 27. Resistance Measurement 10MSP 31219980...
  • Page 158 Disconnect component from circuit before testing • Use firm contact with meter leads • First test meter and leads by touching leads together. Meter should produce an audible alarm, indicating continuity 6.5.9 Current Measurement VE100554A Figure 29. Current Measurement (DC) 31219980 10MSP...
  • Page 159 1. De-energize the circuit. 2. Isolate the switch from the rest of the circuit if possible. If not possible, keep in mind it may affect readings. 3. Access the terminals to the switch. 10MSP 31219980...
  • Page 160 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 161 In the LCD Display Symbols illustration item 2 above, the Function Display or Function Disable Indicators will vary as shown: DRIVE Disabled LIFT UP Disabled LIFT DOWN Disabled Both LIFT UP and LIFT DOWN Disabled Drive Speed Cut-Back (Turtle) Mode Engaged Battery Charger Plugged In 10MSP 31219980...
  • Page 162 P3 - Programmable Security Lock Harness (Option) (a) Note: (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 163 Table — Code 10 - Right Brake Disconnected DRIVE, Right Brake - Disconnected, page Lift UP/DOWN Disabled Refer to Table — Code 11 - Left Left Drive Motor Short Circuit Drive Motor - Short Circuit, page DRIVE Disabled 10MSP 31219980...
  • Page 164 Table — Code 25 - P1- P1 - Auxiliary #1 Circuit — Auxiliary #1 Circuit - Discon- Disconnected nected, page 174 Refer to Table — Code 26 - P1- P1 - Auxiliary #2 Circuit Short — Auxiliary #2 - Short Circuit, page 31219980 10MSP...
  • Page 165 Drive and Pump Motor - Over Current, page Platform Lift-UP Functions Locked Out. Obstruction Sensor - No Communication RESERVED — RESERVED RESERVED — RESERVED RESERVED — RESERVED RESERVED — RESERVED RESERVED — RESERVED RESERVED — RESERVED RESERVED 10MSP 31219980...
  • Page 166 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS The following table contains pin extractor tools for machine electrical connector components. Table 15. Special Pin Extractor Tools for Electrical Connectors COMPONENT DESCRIPTION JLG PART NUMBER ILLUSTRATION 7016618 Ground Control Station For removal of electrical connector pins from the Ground Control Station connectors.
  • Page 167 At the Ground Module, P4 connector, check the voltage between pin 7(Orange/Red) Open: 4-5 VDC Closed: Replace the OSS Relay and Ground. Is the reading within specification? (If reading is 0VDC when there is now Consult Factory 0 VDC Board eight on the Object Sensing Pad, replace the pad) 10MSP 31219980...
  • Page 168 X and Y directions (refer to Section — Base Components, page 41 for ground — — — control programming). Code 05 - Obstruction Sensor - No Communication Check for These Obvious Conditions First: • “OSS Enable” is set to “1” 31219980 10MSP...
  • Page 169 Is reading within spec? Module Repair or replace left brake wiring or left brake assembly. — — — Code 10 - Right Brake - Disconnected Check for These Obvious Conditions First: 10MSP 31219980...
  • Page 170 Note: If this is a recurring problem compare current draw of your machine with Traction Control Module specifications in Table — Amperage Draw for Various Components, page 166 Code 14 - Pump Motor - Disconnected Check for These Obvious Conditions First: 31219980 10MSP...
  • Page 171 10 and 3 on the P1 connector to the lift down valve. Wiring Code 17 - Ground Control Module - In Fold Back Check for These Obvious Conditions First: • Has machine been operating on a continuous grade or rough terrain for a long period of time? 10MSP 31219980...
  • Page 172 Remove the wire terminals at the beacon, check continuity of each of the wires from Repair or Replace Replace the Beacon — Wiring pins 12 and 5 on the P1 connector to the beacon end. Code 21 - Beacon - Disconnected Check for These Obvious Conditions First: 31219980 10MSP...
  • Page 173 7 on the P1 connector to the horn end. Wiring Code 24 - P1-Auxiliary #1 Circuit - Short Circuit Check for These Obvious Conditions First: • Damaged wiring in the Auxiliary #1 Component wiring harness or a damaged Component. 10MSP 31219980...
  • Page 174 Go to Step 3 Got to Step 2 — At the Ground Control Module enter the programming mode, check if the Auxiliary #2 Replace Ground Con- Default = NO Disable It open circuit detection is enabled. trol Module 31219980 10MSP...
  • Page 175 Remove the 9 pin Platform Control Console connector from the side of the Platform Repair or Replace Go to Step 4 Junction Box. Check the voltage across pins-1 and 5 in the Junction Box connector. 24V DC Plat- form Control Console 10MSP 31219980...
  • Page 176 (P2 to platform junction box). Platform Harness Check continuity of Left Hand Lift. Replace Component Consult Factory or Repair Wires Code 35 - P2-Auxiliary #1 - Tie-Down Check for These Obvious Conditions First: 31219980 10MSP...
  • Page 177 Platform Harness Check continuity of platform gate switches. Replace Component Consult Factory or Repair Wires Code 37 - Auxiliary #2 - Tie-Down Check for These Obvious Conditions First: • Platform gate open while elevated during machine power up. 10MSP 31219980...
  • Page 178 Repair or Replace Go to Step 6 round connector at the Traction Control Module. Check continuity of all three (3) wires — Wire(s) in the communications cable from end to end. P5 - Pins 2, 3, and 4. 31219980 10MSP...
  • Page 179 Replace Traction Con- Go to Step 3 Code - 316 trol Module Go to Step 5 — Code - 325 Confirm that both installed batteries are 12 Volt DC. Replace with proper Go to Step 4 12V DC Batteries 10MSP 31219980...
  • Page 180 Check for These Obvious Conditions First: • Is there an obstruction in the mast assembly? • Is there a restricted (smashed) hydraulic line? • Are the mast slide pads shimmed properly (not too tight) per Mast Assembly procedure in Service Manual? 31219980 10MSP...
  • Page 181 Rebuild or Replace — — Cylinder 6.12.3 Mast Noisy When Lifting And Lowering Overview of Procedure This procedure examines components of the mast itself and as well as its lifting components for dirt, debris, proper lubrication and operation. 10MSP 31219980...
  • Page 182 Clean Pads and — Go to Step 2 Channels Do mast chains need to be lubricated per JLG specification in the Service Manual? — Lubricate as Required Go to Step 3 Are the chain/cable sheave wheels dry and need lubrication? Note: Plastic wheels will Lubricate or Replace howl on the sheave pin when they are dry.
  • Page 183 Note: Do not overtighten the nut on the solenoid in step 5. 6.14 BASE FRAME COMPONENTS TROUBLESHOOTING 6.14.1 Caster Wheels Not Operating Freely Check for These Obvious Conditions First: • Is machine operating on a smooth, level surface? 10MSP 31219980...
  • Page 184 7 LED Code Check the condition of the drive motor brushes. Worn down, replace OK, go to Step 6 — brushes or drive motor If all above is OK, Drive motors are working properly. Consult Factory. — — — 31219980 10MSP...
  • Page 185 Check the drive motor brushes, do they need replaced? Replace per procedure — Go to Step 7 in this Service Manual Is joystick control defective? If possible, swap out with another platform control. Repair/Replace Plat- — Go to Step 8 form control 10MSP 31219980...
  • Page 186 Inside the drive motor drive hub check if; the drive shaft is excessively loose & Repair/Replace drive hub components per pro- — condition of drive shaft bearings. Are any gears broken or gear teeth excessively worn. cedure in this Service Manual 31219980 10MSP...
  • Page 187 TROUBLESHOOTING VE100525A Figure 32. Electrical Components Installation (with 4-6V Batteries) 10MSP 31219980...
  • Page 188 TROUBLESHOOTING VE100526A Figure 33. Electrical Components Installation 31219980 10MSP...
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  • Page 190 TROUBLESHOOTING Figure 34. Electrical Schematic - Sheet 1 of 2 31219980 10MSP...
  • Page 191 TROUBLESHOOTING Figure 35. Electrical Schematic - Sheet 2 of 2 10MSP 31219980...
  • Page 192 4. Pump Motor 7. Hydraulic Filter 10. Pressure Compensator - Flow Control Valve 2. Filter Screen 5. Pressure Adjust Valve 8. Return Line 11. Manual Descent Valve 3. Pump 6. Extend Valve 9. Check Valve 12. Lift Cylinder 31219980 10MSP...
  • Page 193 TROUBLESHOOTING Figure 37. Hydraulic Schematic - Sheet 2 of 2 (Power Tray (If Equipped)) 10MSP 31219980...
  • Page 194 Blank page This Page is intentionally left blank...
  • Page 196 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...