JLG 15MVL Series Service Maintenance Manual
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JLG 15MVL Series Service Maintenance Manual

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Service & Maintenance Manual
Model(s)
15/20MVL &
15/20MSP
Series
P/N - 3121231
December 20, 2013

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Summary of Contents for JLG 15MVL Series

  • Page 1 Service & Maintenance Manual Model(s) 15/20MVL & 15/20MSP Series P/N - 3121231 December 20, 2013...
  • Page 2 NOTES:...

  • Page 3: Maintenance Safety Precautions

    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. 3121231 – JLG Lift –...

  • Page 4: Revision Log

    Manual Revised ......December 5, 2013 Manual Revised ......December 20, 2013 – JLG Lift – 3121231...

  • Page 5: Table Of Contents

    Hydraulic Lines and Electrical Wiring ......... . . 2-6 3121231 – JLG Lift –...
  • Page 6 Ground Control Module............4-3 – JLG Lift –...
  • Page 7 Pressure Check Valve Installation ..........4-28 3121231 – JLG Lift –...
  • Page 8 Procedure ..............6-5 – JLG Lift –...
  • Page 9 Code 35 - P2-Auxiliary #1 - Tie Down ......... . 6-32 Code 38 - Battery Voltage Low - Warning Level 2 - Two (2) LED/LCDs lit ....6-33 3121231 – JLG Lift –...
  • Page 10 Noise From Drive Assembly ..........6-47 – JLG Lift –...
  • Page 11 Hydraulic Diagram. (MVL/MSP) ...........6-52 3121231 – JLG Lift –...
  • Page 12 Codes 41 thru 46 - OSS - Sensor 1 through 6 - Fault Condition ......6-35 viii – JLG Lift – 3121231...
  • Page 13 Noise from Drive Assembly............6-47 3121231 – JLG Lift –...
  • Page 14 TABLE OF CONTENTS NOTES: – JLG Lift – 3121231...

  • Page 15: Section 1 - Machine Specifications

    15 - 21 sec. 21 - 26 sec. 2,235 lb. 2,235 lb. 2,280 lb. 2,280 lb. Gross Machine Weight (Platform Empty): (955 kg) (955 kg) (975 kg) (975kg) NOTE: (1) Standard unless equipped with 14 ft. limiter circuit. 3121231 – JLG Lift –...

  • Page 16: Capacities

    350 lb. 150 lb. 500 lb. (160 kg) (70 kg) (230 kg) BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COM- PATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE 20MVL 250 lb. 100 lb. 350 lb. DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND...

  • Page 17: Platform Size

    22 x 25 SB 28 x 26 GW 26 x 50 GW 28 x 48 SP w/Folding Tray NOTE: Platform Types: SB - with Sliding Bar Gate GW - with Gull Wing Gate SP - Stock Picker Platform 3121231 – JLG Lift –...

  • Page 18: Lubrication

    Mobil DTE 13 hydraulic oil. 1.6 SERIAL NUMBER LOCATIONS Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not con- For machine identification, a serial number plate is affixed tain the same required additives or be of comparable vis- to the machine.
  • Page 19 (c) Prior to checking hydraulic oil level, operate machine through one complete cycle of lift function (full up and down). Failure to do so will result in incorrect oil level reading on the hydraulic reservoir. 3121231 – JLG Lift –...
  • Page 20 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 REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND JLG P/N Loctite® P/N...
  • Page 21 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 Figure 1-2. Torque Chart (SAE Fasteners - Sheet 2 of 7)) 3121231 – JLG Lift –...
  • Page 22 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. Figure 1-3. Torque Chart (SAE Fasteners - Sheet 3 of 7) – JLG Lift – 3121231...
  • Page 23 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. Figure 1-4. Torque Chart (SAE Fasteners - Sheet 4 of 7) 3121231 – JLG Lift –...
  • Page 24 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. Figure 1-5. Torque Chart (METRIC Fasteners - Sheet 5 of 7)) 1-10 – JLG Lift – 3121231...
  • Page 25 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. Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 6 of 7) 3121231 – JLG Lift – 1-11...
  • Page 26 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. Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 7 of 7) 1-12 – JLG Lift – 3121231...

  • Page 27: Section 2 - General

    The Annual Machine Inspection must be performed by a operation, ensure that all the necessary inspections and qualified JLG equipment mechanic on an annual basis, no maintenance have been completed before placing the later than thirteen (13) months from the date of the prior machine into service.

  • Page 28: Preventive Maintenance And Inspection Schedule

    Owner, Dealer, or User Qualified JLG Service and Maintenance Man- Inspection rental delivery. Mechanic ual and applicable JLG inspec- tion form. Frequent In service for 3 months; or Out of service Owner, Dealer, or User Qualified JLG Service and Maintenance Man- Inspection for a period of more than 3 months;...
  • Page 29 2, 7, 9 2, 9 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 3121231 – JLG Lift –...

  • Page 30: Inspection And Maintenance Codes

    Grease and Lubricate to Specifications Function Test of All Systems Paint and Appearance Notify JLG of Change in Machine Ownership Change only when serviced, requires 10 oz. (296cc’s) to fill. Replace after system brush wear indicator warning is activated on Ground Control Station.

  • Page 31: Servicing And Maintenance Guidelines

    Torque Chart in Section 3121231 – JLG Lift –...

  • Page 32: Hydraulic Lines And Electrical Wiring

    (90 degrees) from the pin in-line position. Inspect chains carefully after long time use and heavy loading for this type of crack. If any cracks are dis- covered, replace all chains, as seemingly sound plates – JLG Lift – 3121231...
  • Page 33 Fatigue and ultimate ture) but tend to extend in an arc-like path, often parallel to strength failures on JLG Lifts are incurred as a result of the rolling grain of the material. severe abuse as design specs are well within the rated lift- ing capacity of these chains.

  • Page 34: Lubrication Information

    SECTION 2 - GENERAL 2.4 LUBRICATION INFORMATION Hydraulic Oil For best performance, JLG recommends the use of ISO- Hydraulic System Vg grade 32, 46 oil with a viscosity range between 15-250 SUS at 100 degrees F (32-54 cST at 40 degrees C). Refer...

  • Page 35: Section 3 - Base Components

    2. Battery Charger Cover 6. Front Caster Wheel Assembly 10. Rear Tie Down Lug 3. Front Tie Down Lug 7. Left Drive Motor Assy. 11. Right Drive Motor Assy. 4. Battery Charger Assembly 8. Pot Hole Protection System 3121231 – JLG Lift –...

  • Page 36: Base Frame Covers

    (a) Apply Loctite #242 to mounting screw Battery Charger Cover - Installation threads on final assembly. Batttery Charger Cover Installation 1. Charger Cover 3. Rear Attach Screws 2. Front Attach Screws and Washers - Loosen and Washers Only - Cover Slotted – JLG Lift – 3121231...

  • Page 37: Drive And Caster Wheels

    (a) On assembly, apply Loctite 242 to threads. (b) As required; Place unit on a flat surface, shim a caster wheel that is consistently more than .015" off of flat surface. Figure 3-2. Wheel Lug Nut Tightening Sequence 3121231 – JLG Lift –...

  • Page 38: Wheel Drive Assembly - Servicing

    (repositioning the brush warn- ing sensors), and the Ground Control Station is pro- grammed to reset the Brush Wear - Warning Timer - see Section 4.6, Ground Control Module - Programming of this manual. – JLG Lift – 3121231...

  • Page 39: Wheel Drive Assembly - Removal From Machine

    5. Wheel Mounting Lugs (b) 3. Wheel Drive Assembly NOTE: Installation same for left and right drive motor - (a) Apply Loctite #242 to threads before tightening. (b) Tighten to 120 ft. lbs. (534 N-m) 3121231 – JLG Lift –...

  • Page 40: Wheel Drive Disassembly - Main Components

    8. Remove the Brake Friction Plate (B3) from the motor flange. 4. Cut the black wire tie (not shown) from the frame of the motor. 5. Remove the 3 Brake Bolts (7). – JLG Lift – 3121231...

  • Page 41: Replacing Drive Motor Brushes

    30 in-lbs. If this is a wear indicator brush, is oriented such that the spring touches the outer connect the brush wear indicator lead to the spade raceway of the armature bearing. terminal in the brush housing. 3121231 – JLG Lift –...
  • Page 42 ON THE OTHER SIDE OF THE FLANGE. THIS COULD CAUSE THE BRAKE FRICTION PLATE TO BECOME WARPED AND THE BRAKE TO NOT WORK PROPERLY. IF NECESSARY, ADD ANOTHER WASHER UNDER THE HEAD OF THE MOTOR HOUSING MOUNT- ING BOLTS. – JLG Lift – 3121231...

  • Page 43: Gear Box Main Disassembly

    Insert jacking screws (1/4- 20UNC, grade 8) with at least 1.5 inches of thread length into each of the three tapped holes to force the ring gear out. Be sure and alternate between the 3121231 – JLG Lift –...

  • Page 44: Input Carrier Disassembly

    6. Remove the other Thrust Washer (G25) from each Planet Shaft (G6). 7. Remove Retaining Ring (G24) from Output Sun Gear (G8). 8. Slide Output Sun Gear (G8) out from the center of the Input Carrier (G7). 3-10 – JLG Lift – 3121231...

  • Page 45: Hub Disassembly

    The Lip Seal will most likely become inner race of the bearing. Apply force to the push the damaged during removal. Try not to damage the hub bearing out. This bearing will need to be replaced bore. upon reassembly. 3121231 – JLG Lift – 3-11...

  • Page 46: Spindle Disassembly

    Planet Gears to avoid confusion. 4. Press out Bushing (G26) from the bore of each Planet Gear (G9). Bushings cannot be reused when removed 5. Remove the Main Bearing (G14) from the outside diameter of the Spindle (G1). 3-12 – JLG Lift – 3121231...

  • Page 47: Spindle Sub-Assembly

    6. Slide the Output Planet Gear (G9) into the window with the Tanged Thrust Washer (G32) until the bores line up. 7. Insert Output Planet Shaft (G10) into the Planet Shaft hole of the Spindle (1) and through the bores 3121231 – JLG Lift – 3-13...

  • Page 48: Hub Sub-Assembly

    NOTE: 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 mal- let before pressing. 3-14 – JLG Lift – 3121231...

  • Page 49: Input Carrier Sub-Assembly

    Gear (G8) cannot be pulled out of the Input Carrier (G7). 5. Place a Thrust Washer (G25) on each side of the Input Planet Gear (5). Line up the bores as well as you can visually. 3121231 – JLG Lift – 3-15...

  • Page 50: Main Gear Box Sub-Assembly

    11. Center the Cover (G11) in the hub bore so that the work it into the groove. "JLG" logo is up. Push it into the bore. 6. Using the appropriate pressing tool (T-174356), 12. Install the Cover Retaining Ring (G19) into the press in the Input Ring Gear (G3) into the bore of groove of the Hub Sub-assembly.

  • Page 51: Motor, Brake And Gear Box Assembly

    Brake Housing (B1). Tighten to 4-5 ft-lbs. 15. The wheel drive is now ready to be installed onto the 7. Remove and discard the 2 bolts in the Brake Con- machine, reverse removal instructions (See Page 3- tainment Holes. 3121231 – JLG Lift – 3-17...

  • Page 52: Pot Hole Protection System

    4. Left Side Counterbalance 8. PHP Bar Pivot Pin and Retaining Ring 1. PHP Counterweight/Bar Link 2. Flange Bearing 3. PHP Counterweight Link 4. Retaining Ring PHP Link Installation (Item 5 in Component Illustration Above) 3-18 – JLG Lift – 3121231...
  • Page 53 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. (c) Add as required if switch is adjusted to maximum and plunger has not clicked to engage switch. 3121231 – JLG Lift – 3-19...

  • Page 54: Battery Charger - Service Procedures

    4 hours or until 8 bars are lit on the ground station LCD Display before operating the machine. When drained to Warning Level 2, batteries must be charged until 8 bars are lit on the ground station LCD display to clear the fault code. 3-20 – JLG Lift – 3121231...

  • Page 55: Battery Charging Status Indicators

    RED ‘FAULT’ LED qualified service depot. with a code corresponding to the error. There are several possible conditions that generate errors. Some errors are serious and require human 3121231 – JLG Lift – 3-21...

  • Page 56: Battery Charger Check/Change Charging Algorithm

    Table 3-3. If your specific battery 2. Disconnect the positive (+) battery cable at the left model is not listed, please contact JLG. side battery under the left rear upper cover. Each time AC power is applied with the battery pack NOT 3.

  • Page 57: Section 4 - Control Components

    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. Horn 6. Ground Control Module 3121231 – JLG Lift –...

  • Page 58: Controls Cover Installation

    Center, Left and Right Lower Covers Lower Left Cover (Front View) Center Cover, Lower Left and Right Covers (Rear View) Lower Right Cover (Front View) Note: Center Cover requires unplugging the Charger AC Receptacle and LED Indicator wires when removing. – JLG Lift – 3121231...

  • Page 59: Control Components - Installation

    Traction Control Module Installation 1. Traction Control Module 2. Attach Screws/Washers Note: See Figure 4-2. for wiring connection instructions. Ground Control Module Installation 1. Ground Control Module 2. Attach Screws/Washers Note: See Figure 4-2. for wiring connection instructions. 3121231 – JLG Lift –...

  • Page 60: Platform Control Console Installation

    Alarm Installation 1. Alarm Assembly 2. Attach Screws/Washers Note: See Figure 4-2. for wiring connection instructions. – JLG Lift – 3121231...

  • Page 61: Batteries - Service Procedures

    YOUR LOCAL JLG SUPPORT OFFICE. 2. If an appropriate battery tester is unavailable, the BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COM- batteries can be tested by fully charging them with PATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE the charger that is installed on the machine.

  • Page 62: Battery - Installation - (2-12V Batteries)

    Battery Installation (Left Side Battery Shown) 1. Battery (a) 3. Battery Terminal Attach Nut/Washer (b) 2. Hold-Down Bar 4. Hold-Down Bar Wing-nut and Washer NOTE: (a) Mount with terminal posts inboard. (b) Apply battery terminal grease to prevent corro- sion. – JLG Lift – 3121231...
  • Page 63 P3 - Programmable Security Lock Harness (Option) (a) Notes: (a) Apply di-electric grease JLG Part Number 3020038 to wiring harness terminals, to prevent moisture from entering module. (b) Seal NEG (–) and POS (+) posts with battery grease to prevent corrosion.

  • Page 64: Battery Installation - (4-6V Batteries) (Option)

    Figure 4-2. support. There is a left side and a right side tray. Figure 4-3. Battery Cable to Battery Termi- nal Connections (4-6V) – JLG Lift – 3121231...
  • Page 65 7. Heat Sink Base/Main Board Assembly 2. Power Selector Switch Nut 5. Power Selector Switch 8. Cover Attach Screws 3. Emergency Stop Button 6. Main Board to LCD Ribbon Cable Connector Figure 4-4. Ground Control Module Components. 3121231 – JLG Lift –...

  • Page 66: Cover Removal/Installation

    (Slide cable into connector then push tabs back into connector) Note: Connector same at both ends of the ribbon cable. Disconnect the Ribbon Cable 1. Ribbon Cable Connector 3. Support for Cover 2. Ribbon Cable 4-10 – JLG Lift – 3121231...

  • Page 67: Power Selector/Estop Switch Installation

    Note: To release switch connectors, push tab on top of connector. Power Selector Switch Installation 1. Nut 2. Power Selector Switch 3. Align and insert tab on switch into slot on cover. Note: Re-attach wires to the same terminals on new switch. 3121231 – JLG Lift – 4-11...

  • Page 68: Activating Programming Mode

    Ground Control Module - Emergency Stop Button, and the Platform Control Console - Emergency Stop Button, are in the RESET position. THE LEVEL 1 JLG ENGINEERING SETTINGS ARE NOT DIS- Also, if machine is equipped with the (PSL) Program- PLAYED IN THE PROGRAMMABLE SETTINGS UNDER PASS- mable Security Lock option, see Section 3 - Pro- WORD LEVEL-2 OR LEVEL-3.

  • Page 69: Entering Password

    2. Press the Brake Release button (3) to enter selected TO EXIT Programming Mode after entering program- mode then move on to Selecting Programmable Item mable settings, power machine off with either the Main to Adjust. Power Selector Switch or Emergency Stop Button. 3121231 – JLG Lift – 4-13...

  • Page 70: Service Programming Mode - (Level)

    Section 4.9. ZEROING THE TILT SENSOR REQUIRES THE MACHINE TO BE RESTING ON A SURFACE CHECKED WITH A DIGITAL LEVEL MEASURING WITHIN 0.0 DEGREES LEVEL IN BOTH THE X AND Y AXIS DIRECTIONS. 4-14 – JLG Lift – 3121231...

  • Page 71: Operator Programming Mode - (Level)

    YES/NO Zero the On-Board Tilt Sensor YES/NO View Tilt Sensor Readings — — Brush Wear Sensor Timer Reset — BLANK/WORN Ancillary 1 Input Inhibit 0 - 4 Ancillary 2 Input Inhibit 0 - 4 3121231 – JLG Lift – 4-15...
  • Page 72 Notes: (a) MSP Models equipped with stock-picker platform and mid-gate interlock (drive inhibit) switch are factory preset to HIGH. (b) MSP Models equipped with 12 ft. or 14 ft. lift-limit-switch option are factory preset to HIGH. 4-16 – JLG Lift – 3121231...
  • Page 73 1. E-Stop/Shut Down Switch 5. Drive/Lift Mode Selector Switch 2. ON/OFF Key Switch (a) 6. Horn Button Switch 3. Joystick Assembly 7. Rear Cover 4. Display/Controller Module 8. Wiring Harness Connector NOTE: (a) No key switch on Australian spec. machines. 3121231 – JLG Lift – 4-17...

  • Page 74: Display/Controller Module Electrical Connections

    Note: The (C) numbers shown after the description above repre- Platform Console - Rear Cover Installation sent the corresponding identification of the plug on the module’s circuit board. 1. Rear Cover 2. Cover Mounting Screws 4-18 – JLG Lift – 3121231...

  • Page 75: Display/Controller Module - Install/Remove

    Note: (a) Remove rear cover, unplug switch wire, press tabs to 1. Key Switch (a) 3. Attach Nut remove. 2. Notch 4. Key Note: (a) Remove mounting bracket on bottom of console to gain access to the key switch assembly. 3121231 – JLG Lift – 4-19...

  • Page 76: E-Stop/Shutdown Switch - Install/Remove

    Note: (a) Use a small straight blade screwdriver to extend the (b) Remove the key switch and e-stop switch to remove spring-loaded retainer hooks (6) out and release the switch joystick assembly through access hole in bottom of con- from the body. sole. 4-20 – JLG Lift – 3121231...

  • Page 77: Hydraulic Pressure Settings And Adjustment

    Installation (Hydraulic Filter Removed). 1. Remove Adjust Screw Cap 2. Pressure Adjustment Screw Note: Machine rear covers must be removed to access pump motor. Figure 4-6. Hydraulic Pressure Adjustment Screw. (Machine Rear Covers Removed) 3121231 – JLG Lift – 4-21...

  • Page 78: Pump/Motor/Tank Installation

    Pump/Motor/Tank Assembly Installation Figure 4-8. Typical Hydraulic Pressure Gauge 1. Pump/Motor/Tank Assembly 3. Detach and Cap Extend Installation (After Hydraulic Filter). 2. Attach Screws/Washers and Return Lines Note: See Figure 4-2. for wiring connection instructions. 4-22 – JLG Lift – 3121231...

  • Page 79: General Installation And Disassembly

    Motor Cap/Motor Installation MVL/MSP machines pump/motor assembly. No internal parts to the hydraulic pump are serviced by JLG except for a pump installation seal kit. Also the only parts service- able internal to the pump electric motor is the motor brush kit.

  • Page 80: Motor Brush Installation

    Brush Assembly Connections 1. Negative (–) Post 3. Brush Assemblies 2. Positive (+) Post 4. Spring Washer Note: Length of wires to brush assemblies shown exaggerated for illustrative purposes. 4-24 – JLG Lift – 3121231...

  • Page 81: Brush Housing Final Assembly Tips

    ONCE THE ROTOR ASSEMBLY IS IN PLACE, REMEMBER TO PUSH EACH BRUSH DOWN UNTIL THE BRUSH FACE IS IN CONTACT WITH THE COMMUTATOR ON THE ROTOR SHAFT AND THE BRUSH SPRING IS PUSHING DOWN ON TOP OF THE BRUSH. 3121231 – JLG Lift – 4-25...

  • Page 82: Monarch Brand Pump - Brush Replacement

    NOTE: (a) Once cover screws are removed, you may need to tap lightly around the edge of the top cover to separate it from the motor housing. Read the important note above before attempting to remove the cover. (b) These steel screws are threaded into the aluminum valve body, do not overtighten. 4-26 – JLG Lift – 3121231...

  • Page 83: Brush Carrier Assembly - Remove/Install

    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. 3121231 – JLG Lift – 4-27...

  • Page 84: Tank Installation

    4. Use Screwdriver to pry tank away from pump head. Filter Screen Installation Filter Screen Installation 1. Filter Screen 2. Pump Pick-Up Tube Pump O-Ring Installation 1. Pump Assembly 2. O-Ring Seal 3. O-Ring Seal 4-28 – JLG Lift – 3121231...

  • Page 85: Pressure Adjust Valve Installation

    6. Extend (Pressure) Port 3. O-Ring Seal 7. Return Port (Shown Plugged) 4. Backing Ring Note: Adjust pressure per specification shown in Section-1 of this Note: Extend (Pressure) and Return Ports Shown Plugged Service Manual. 3121231 – JLG Lift – 4-29...
  • Page 86 Control Module through the platform electrical junction box also mounted on the mast behind the platform decal An OSS Sensor replacement kit is available from the JLG billboard. Parts Department for individual sensors. The kit provides...

  • Page 87: Transducer Sensor Check

    1. Transducer Sensors #1 through #6 Note: (a)The LED Indicator will flash when an object is 2. Underside of MSP Platform detected at each sensor. Remove object and allow the LED to stop flashing before testing next sensor. 3121231 – JLG Lift – 4-31...

  • Page 88: Oss Component Installation

    1. Sensor Comm Channels (a) 3. Wire Harness to Junction Box Notes: (a) Apply Loctite 222 to threads. 2. Sensor Cables 4. LED Indicator Light (b) Drill out pop rivets to remove. Notes: (a) Channel 1-Sensor 1, Channel 2-Sensor 2, etc. 4-32 – JLG Lift – 3121231...
  • Page 89 Deflector must be even with, and not extend inside facing down. of the platform side frame. Secure Transducer Sensor Wiring 1. Nylon Tie Wraps (a) 2. Platform Floor Supports Note:(a)Secure ALL sensor wire cables to platform side frame. 3121231 – JLG Lift – 4-33...
  • Page 90 SECTION 4 - CONTROL COMPONENTS This page intentionally left blank. 4-34 – JLG Lift – 3121231...
  • Page 91 2. Mast Section - 2 5. Mast Section - 5 8. Slide Pads 11. Chain Guard Plate Assemblies 3. Mast Section - 3 6. Lift Cylinder 9. Chain Anchor Plates 12. Sheave Assemblies 14. Mast Mini Covers 3121231 – JLG Lift –...

  • Page 92: Mast Chain/Cable Adjustment

    (jam) nut on each chain/ not be compressed more than 25% after adjusting. cable. 3. Run mast through several cycles to verify cable/ chain adjustments and ensure no interference exists between chain anchor brackets and mast. – JLG Lift – 3121231...
  • Page 93 10. Chain Lock Nut 2. Mast Section - 1 5. Mast Section - 4 8. Chain Anchor Plate 11. Threaded Chain End 3. Mast Section - 2 6. Mast Section - 5 9. Chain Adjust Nut 3121231 – JLG Lift –...

  • Page 94: Sequence Cable Replacement Kit

    THE MANUFACTURER OF THE DRUM/SOCKET CLAMP RECOM- sequence cable with the threaded (top) end attached MENDS THE USE OF THEIR CABLE CLAMP ASSEMBLY KIT (JLG same as the top end of the factory cable. Also included is P/N - 7023275) TO ASSEMBLE THE CLAMP TO THE WIRE ROPE.
  • Page 95 When done properly the outer strands will form a symmetrical basket. Do not straighten out the spiral lay of the strands, unlay any wires that make up the strand, or allow the strands to cross each other inside the sleeve. 3121231 – JLG Lift –...
  • Page 96 Tighten until four threads or fewer are visible. If more than four threads are visi- ble, proof load the cable and retighten the socket fit- ting. (There is no specific requirement for torque.) – JLG Lift – 3121231...

  • Page 97: Tool Use - In-Line Style Fittings

    Tool Use - In-Line Style Fittings SPECIAL TOOL The extend and return hydraulic line couplings and hose fittings on this machine require special tool JLG P/N- 7027247 to remove and install them. FULLY LOWER THE MAST TO RELIEVE PRESSURE IN THE SYS- TEM BEFORE REMOVING ANY HYDRAULIC LINES.
  • Page 98 Step 3. Insert the disconnect tool in the gap created Step 6. Release the tool and pull on hose assembly between the dust boot and hose fitting to complete disconnection. shoulder. – JLG Lift – 3121231...

  • Page 99: Lift Cylinder Removal

    Figure 5-3. Machine Positioned for Cylinder Removal. Step 6. Pull on hose assembly to complete discon- 1. Be Careful of Control Components in this Area nection. 2. Support Mast Here - Keep Mast Approximately Level 3121231 – JLG Lift –...
  • Page 100 Exposing Top of Mast Section-2 Extending Mast Sections 1. Sections-3, 4 and 5 Pushed Back 1. Mast Section-2 2. 1 ft. (31cm) Extended 2. Top of Mast Section-2 Exposed 5-10 – JLG Lift – 3121231...
  • Page 101 12. Slide the lift cylinder and mount assembly out of the bottom of mast section-1 and -2 and place on a suit- able work surface. Cylinder Rod Pin Installation 1. Cylinder Rod Pin 3. Cyl./Chain Anchor Block 2. Cylinder Rod 3121231 – JLG Lift – 5-11...

  • Page 102: Cylinder Disassembly

    The roughness of the bore should be between 10 and 20 μ inches RMS. Significant variation (greater than 8 μ inches difference) are unacceptable. In the event that an unacceptable condition occurs, the tube assembly should be repaired or replaced. 5-12 – JLG Lift – 3121231...

  • Page 103: Cylinder Assembly (See Figure)

    4. Rod Seal 9. Piston Seal 13. Piston Lock Nut (a) 5. O-Ring 4. Remove the plastic from under the hydraulic reser- voir tank cap. Note: (a) Torque 100 - 120 ft. lbs. 3121231 – JLG Lift – 5-13...
  • Page 104 5. Valve O-Ring (a) 3. Manual Release Assembly 6. Solenoid O-Ring (a) Notes: (a) Coat all o-rings with clean hydraulic fluid before assembling. (b) Mount with electrical terminals pointing to right side of machine. 5-14 – JLG Lift – 3121231...

  • Page 105: Mast Assembly Installation

    2. Mounting Bolt/Washer/Nut Locations (a) 2. Once assembly is complete cycle the mast up and down several times, then check the oil level in the Notes: (a) Apply Loctite #271 to bolt threads on final assembly. hydraulic reservoir. 3121231 – JLG Lift – 5-15...
  • Page 106 (REFERS TO BO TTO M END O F (REFERS TO CLO SED RAIL M AST SECTIO N W HICH SETS IN BACK O F M AST SECTIO N) M ACHINE’S BASE FRAM E) Figure 5-5. Mast Section - Assembly Reference. 5-16 – JLG Lift – 3121231...
  • Page 107 TOP of mast section-3. Remove chains. NOTE: When sliding mast sections apart, be careful not to scratch or score the anodized finish in the slide pad channels. 3121231 – JLG Lift – 5-17...
  • Page 108 SECTION 5 - MAST COMPONENTS Figure 5-6. Mast Chain Routing Diagram. - MVL/MSP 5-18 – JLG Lift – 3121231...

  • Page 109: Mast Assembly - Mvl/Msp

    Tighten the slide pad mounting bolts, be sure there are no air gaps between shims, Note: (a) Apply Loctite #242 to threads. shim and mast or shim and slide pad when tight- ened. 3121231 – JLG Lift – 5-19...
  • Page 110 14. Install the cylinder mounting reinforcement plates 1 each side and secure the cylinder assembly to the mast using the cylinder mounting screws and wash- ers. Apply Loctite #242 to the screw threads before final tightening. 5-20 – JLG Lift – 3121231...
  • Page 111 1" flatwasher, a roll pin (into the slot in each end of the pin), and then place a sheave pin support bar (rectangular plate with threaded holes on each side of pin bore hole). 3121231 – JLG Lift – 5-21...
  • Page 112 3. Spacer cotter keys. Note: (a) Apply Loctite #242 to threads. 35. Install the chain/anchor plate assembly into the top of mast section-3, using the remaining large pin and 5-22 – JLG Lift – 3121231...
  • Page 113 1. Support Bar Screws (a) 5. Narrow Washer 2. Pin Support Bars 6. Sheave Pin 3. Wide Spacers 7. Square Keys 4. Sheave Wheel Assys. Note: (a) Apply Loctite #242 to threads. 3121231 – JLG Lift – 5-23...
  • Page 114 Holding complete sheave wheel assembly, slide order to determine the correct shim stock required assembly into top of mast section-4 and align for proper fit. 5-24 – JLG Lift – 3121231...
  • Page 115 (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 Loctite #242 to threads. 3121231 – JLG Lift – 5-25...
  • Page 116 11. Install the mast chain guard to the top mast section Lanyard Attach Installation The mast assembly is now ready to install on the machines base frame. Sequence Cable Bracket Installation) (Bottom End) 5-26 – JLG Lift – 3121231...

  • Page 117: Msp - Stockpicker Platform - Installation

    2. Nut 4. Hex Head Screws (2 inch) 6. Platform Bumper Rest (a) Note: (a) Once mounted, adjust bumper rests on both sides evenly so the platform rests on the bumpers when in stowed position. 3121231 – JLG Lift – 5-27...

  • Page 118: Mast Beacon - Installation

    Note: (a) Guard on UL-EE specification machines only. MSP - Platform - Mid-Gate Interlock Switch Wiring Harness Routing 1. Interlock Switch 3. Connection at Junction Box 2. Wire Routing 4. Platform Junction Box Note: Decal billboard removed in above illustration. 5-28 – JLG Lift – 3121231...

  • Page 119: Material Tray Platform Only

    Proximity Switch Wire Harness Routing Platform Junction Box 1. Platform Upper Rail 3. Platform Junction Box 2. Mast Header 4. AUX 1 Connector Proximity Switch Wiring 1. Connector 3. Proximity Switches 2. Splice 3121231 – JLG Lift – 5-29...
  • Page 120 Location of Proximity Switch and Target (Right side of mast from rear) 1. Proximity Switch 2. Target Plate Target Plate Installation 1. Target Plate 2. Mounting Screws and Washers (a) NOTE: (a) Secure to mast using existing holes. 5-30 – JLG Lift – 3121231...
  • Page 121 IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. 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. IF ELECTRICAL/ ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.

  • Page 122: Multimeter Basics

    = kilo = 1,000 * (Displayed Number) m = milli = (Displayed Number) / 1,000 μ = micro = (Displayed Number) / 1,000,000 Example: 1.2 kΩ = 1200 Ω Example: 50 mA = 0.05 A – JLG Lift – 3121231...
  • Page 123 • Circuit power must be turned OFF before testing resistance • Disconnect component from circuit before testing • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with meter leads 3121231 – JLG Lift –...
  • Page 124 (See multi meter’s operation manual) • Use firm contact with meter leads • Use firm contact with meter leads • First test meter and leads by touching leads together. Meter should produce an audible alarm, indicating continuity – JLG Lift – 3121231...

  • Page 125: Continuity Measurement Over Long Distances

    One can find the continuity of two wires, here #1 and #2, at once by following steps 1 through 4. If there is a problem the third wire is used to troubleshoot the other wires. To find the problem, start at step 1 and use the entire procedure. 3121231 – JLG Lift –...

  • Page 126: Electrical Switch Testing

    Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a "prox switch". Inductive prox- imity 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 127: Automatic Switches

    Also, the technician can measure the volt- age at both power terminals with respect to battery ground. The difference between those two measurements is the voltage applied to the load. 3121231 – JLG Lift –...

  • Page 128: Ground Control Module Lcd Display

    In the LCD Display Symbols illustration item (2) above, the Function Display or Function Disable Indicators will vary as shown following: Both LIFT UP and LIFT DOWN DRIVE Disabled Disabled Drive Speed Cut-Back (Turtle) LIFT UP Disabled Mode Engaged LIFT DOWN Disabled Battery Charger Plugged In – JLG Lift – 3121231...
  • Page 129 P3 - Programmable Security Lock Harness (Option) (a) Notes: (a) Apply di-electric grease JLG Part Number 3020038 to wiring harness terminals, to prevent moisture from entering module. (b) Seal NEG (–) and POS (+) posts with battery grease to prevent corrosion.
  • Page 130 Page 6-21 DRIVE operation remaining to a 10 sec. shut down mode) Left Drive Motor See Table 6-11, Disconnected Page 6-21 DRIVE Disabled 00000.0 Right Drive Motor SeeTable 6-12, Disconnected Page 6-22 00000.0 DRIVE Disabled 6-10 – JLG Lift – 3121231...
  • Page 131 Alarm Circuit Short Page 6-25 00000.0 See Table 6-23, — Alarm Disconnected Page 6-26 00000.0 Beacon or See Table 6-24, — Beacon Circuit Short Page 6-26 00000.0 See Table 6-25, — Beacon Disconnected Page 6-27 00000.0 3121231 – JLG Lift – 6-11...
  • Page 132 P2-Auxiliary #1 - Tie Down See Table 6-37, — LIFT UP/DOWN and DRIVE Page 6-32 are Disabled 2 LEDs/BARS Flashing with an audible beep. See Page 6-33 Platform Lift-UP Function is 00000.0 Locked Out. 6-12 – JLG Lift – 3121231...
  • Page 133 Traction Control Module See Table 6-42, Fault Condition Page 6-38 00000.0 OSS Control Module See Table 6-38, — Low Internal Supply Page 6-34 00000.0 OSS Control Module See Table 6-38, — Amplifier Fault Page 6-34 00000.0 3121231 – JLG Lift – 6-13...

  • Page 134: Troubleshooting Tables Index

    Code 30 - Traction Module - No Communication with Ground Control Module ....6-30 Code 31 - Platform Control Console - No Communication with Ground Control Module ..6-31 6-14 – JLG Lift – 3121231...
  • Page 135 Noise From Drive Assembly ............6-47 3121231 – JLG Lift – 6-15...

  • Page 136: Specifications For Various Components

    Drive Motor For removal of electrical con- nector pins from the Drive Motor main power connectors. 7002842 Drive Motor Brake For removal of electrical con- nector pins from the Drive Motor Brake power connec- tors. 6-16 – JLG Lift – 3121231...

  • Page 137: Machine In Drive Speed Cut-Back (Turtle) Mode All The Time

    With the platform fully lowered, bars raised, check for continuity on the Left — Repair or Replace Left Side Side PHP bar limit switch, between pins-10 and 20 on the P2 connector at PHP Limit Switch the Ground Control Module. 3121231 – JLG Lift – 6-17...

  • Page 138: Obstruction Sensor System - Detection

    Control Module), or more before operating. Failure to do so, will eventually result in a fault Code 38 - Battery Voltage Low - Warning Level 2. NOTE: If battery is not charging properly, see Battery/Battery Charger Servicing - Section 3 of this Manual. 6-18 – JLG Lift – 3121231...

  • Page 139: Code 02 - Left Php Bar - Up

    Go to Step 3 Check the PHP limit switch(s) at both sides of the machine for damage, — Replace, Adjust or — adjustment and for continuity through switch to ground when bars are Repair Wiring down. 3121231 – JLG Lift – 6-19...

  • Page 140: Code 04 - Tilt Condition

    X and Y directions. (See Ground Control Programming, Sec- tion-3 of Service Manual). NOTE: If frequent calibration of the internal Tilt Sensor is required, replace the Ground Control Module. Code 05 - Reserved 6-20 – JLG Lift – 3121231...

  • Page 141: Code 06 - Drive Motor Brush Wear Warning Indicator

    M1 connector wiring harness going to the left drive motor. Is reading within Module spec? Repair or replace left drive motor wiring, brushes or motor. — — — (For brush replacement, see Section 3 of this Service Manual) 3121231 – JLG Lift – 6-21...

  • Page 142: Code 08 - Right Drive Motor - Disconnected

    Replace Traction Go to Step 2 tor wiring harness going to the right drive motor brake assembly. Is reading Module within spec? Repair or replace right brake wiring or right brake assembly. — — — 6-22 – JLG Lift – 3121231...

  • Page 143: Code 11 - Left Drive Motor - Short Circuit

    Replace Traction machine operate OK after cooling. Module NOTE: If this is a recurring problem compare current draw of your machine with Traction Control Module specifications in Table 6-3 - Amperage Draw for Various Components. 3121231 – JLG Lift – 6-23...

  • Page 144: Code 14 - Pump Motor - Disconnected

    With the terminals still removed from the lift down valve coil, check continu- .00 Ohms — Repair or Replace ity of the wires from pins 10 and 3 on the P1 connector to the lift down valve. Wiring 6-24 – JLG Lift – 3121231...

  • Page 145: Code 16 - Lift Down Valve - Short Circuit

    Remove the wire terminals at the alarm, check continuity of each of the — Replace the Alarm Repair or wires from pins 13 and 6 on the P1 connector to the alarm end. Replace Wiring 3121231 – JLG Lift – 6-25...

  • Page 146: Code 19 - Alarm - Disconnected

    Remove the wire terminals at the beacon, check continuity of each of the — Replace the Repair or wires from pins 12 and 5 on the P1 connector to the beacon end. Beacon Replace Wiring 6-26 – JLG Lift – 3121231...

  • Page 147: Code 21 - Beacon - Disconnected

    Remove the wire terminals at the horn, check continuity of each of the wires — Replace the Repair or from pins-14 and 7 on the P1 connector to the horn end. Horn Replace Wiring 3121231 – JLG Lift – 6-27...

  • Page 148: Code 23 - Horn - Disconnected

    Remove the wire terminals at the horn, check continuity of each of the wires — Replace the Repair or from pins-9 and 2 on the P1 connector to the component end. Component Replace Wiring 6-28 – JLG Lift – 3121231...

  • Page 149: Code 25 - Auxiliary #1 Circuit - Disconnected

    Remove the wire terminals at the Aux. #2 component, check continuity of — Replace the Repair or each of the wires from pins-8 and 1 on the P1 connector to the Aux. #2 Component Replace Wiring component end. 3121231 – JLG Lift – 6-29...

  • Page 150: Code 27 - Auxiliary #2 - Disconnected

    Does this fix problem? Control Module Unplug the P5 connector at the Ground Control Module. Check voltage 4.5v DC Done Replace Ground between pins 2 (– lead-in) and 5 (+ lead-in). Is voltage within spec. Control Module 6-30 – JLG Lift – 3121231...

  • Page 151: Code 32 - Pump Motor - Over Current

    Is the pump hydraulic pressure setting within specification as show in Sec- See Section 1.6 Go to Step 4 Adjust to tion 1.6 of this Service Manual? Specification Check pump motor brushes and rotor commutator for abnormal wear. — Replace as Replace Required Pump Motor 3121231 – JLG Lift – 6-31...

  • Page 152: Code 33 - Both Php Bars - Up

    Remove the P2 connector from the Ground Station Module; check continu- — Go to Step 3 Repair or ity of the individual wires in the platform harness. (P2 to platform junction Replace Platform box), Harness 6-32 – JLG Lift – 3121231...

  • Page 153: Code 38 - Battery Voltage Low - Warning Level 2 - Two (2) Led/Lcds Lit

    8 bars are lit on the ground station LCD Display before operating the machine. When drained to Warning Level 1, batteries must be charged until 8 bars are lit on the ground station LCD display to clear the fault code. 3121231 – JLG Lift – 6-33...

  • Page 154: Code 40 - Obstruction Sensor System - No Communication With Ground Control Module

    At the Ground Control Module (P-4 connector) check voltage between pin-8 24V (DC) Repair or Replace, Replace Ground and pin-2, place positive (+) lead on pin-8. Junction Box to Control Module Ground Control Module Wire Harness 6-34 – JLG Lift – 3121231...

  • Page 155: Codes 41 Thru 46 - Oss - Sensor 1 Through 6 - Fault Condition

    X=No — Go to Step 4 Replace the sensor showing the fault. Does this correct the problem. — Done Go to Step 5 Replace the complete OSS system, module and sensors. — — — 3121231 – JLG Lift – 6-35...

  • Page 156: Codes (100 - 199) Ground Control Module - Fault Condition

    Pins 2, 3, and 4 at the P5 connector end. Wires Plug the communications cable on the Traction Control Module to the round — Done Replace socket on the opposite end of the module. Does this fix problem? Ground Control Module 6-36 – JLG Lift – 3121231...

  • Page 157: Codes (200 - 299) Platform Control Console - Fault Condition

    P4, pin-9 to Junction Box pin-4. Is there continuity on these wires? Perform the Joystick Calibration Procedure in Section 4.5 of this Service — Done Replace Manual. Does this clear the fault code? Platform Control Module 3121231 – JLG Lift – 6-37...

  • Page 158: Codes (300 - 399) Traction Control Module - Fault Condition

    Check for short in harness wires from Ground Control Station connector P5 — Repair or Replace — to Traction Module (round din plug). Wiring Note: This harness contains 6 wires only 3 are used, (See Figure 6-7.) Elec- trical Diagram. 6-38 – JLG Lift – 3121231...

  • Page 159: Main Power Circuit Troubleshooting

    Check continuity of the wires running from the P4 connector on Ground — Replace Platform Repair or Replace Control Module to the Platform Junction Box; Control Console Wiring P4 connector, Pin-1 to Junction Box Pin-2 and P4 connector, Pin-10 to Junction Box Pin-1 3121231 – JLG Lift – 6-39...

  • Page 160: Mast Troubleshooting

    Go to Step 5 HYDRAULIC Is the hydraulic valve working properly. — Go to Step 6 Replace Valve Pump drive cavatating. — Replace Pump Go to Step 7 Lift cylinder — Rebuild or Replace — Cylinder 6-40 – JLG Lift – 3121231...

  • Page 161: Mast Noisy When Lifting And Lowering

    Do slide pads and slide pad channels need to be cleaned of dust, dirt, or — Clean Pads and Go to Step 2 other debris? Channels Do mast chains need to be lubricated per JLG specification in the Service — Lubricate as Go to Step 3 Manual? Required Are the chain/cable sheave wheels dry and need lubrication? —...

  • Page 162: Platform (Mast) Won't Stay Elevated

    Is there a restricted hydraulic line (smashed)? — Replace Hydraulic Go to Step6 Line Check the flow valve in the cylinder valve block for a restriction, i.e. dirt. — Clean or Replace — Flow Valve 6-42 – JLG Lift – 3121231...

  • Page 163: Hydraulic Leak Troubleshooting

    Oil leaking around the lift down valve. — Tighten Cartridge in — Pump Case Oil leaking around the (Red) manual descent valve. — Replace Lift Down — Valve Note: Do not overtighten the nut on the solenoid in step 5. 3121231 – JLG Lift – 6-43...

  • Page 164: Caster Wheels Not Operating Freely

    • Obstruction around the actuator assembly at the base of the mast. Table 6-51. Pot Hole Protection (PHP) Bars will not Lower. STEP ACTION SPEC Check the actuator assembly and cables for adjustment or damage. — Adjust or Replace Consult Factory 6-44 – JLG Lift – 3121231...

  • Page 165: Won't Climb Grade

    WHITE wire is connected to the negative (–) terminal. The Left Motor Power lead is reversed from the Right Motor lead due to the reverser harness. (Reference Figure 6-7., Electrical Diagram. (MVL/MSP) 3121231 – JLG Lift – 6-45...

  • Page 166: Machine Won't Drive Straight

    Inside the drive motor gear box check if; the drive shaft is excessively loose — Repair/Replace gear box & condition of drive shaft bearings. components per procedure in this Service Are any gears broken or gear teeth excessively worn. Manual 6-46 – JLG Lift – 3121231...

  • Page 167: Noise From Drive Assembly

    Inside the drive motor gear box check if; the drive shaft is excessively loose — Repair/Replace gear box & condition of drive shaft bearings. components per procedure in this Service Are any gears broken or gear teeth excessively worn. Manual 3121231 – JLG Lift – 6-47...
  • Page 168 SECTION 6 - TROUBLESHOOTING Figure 6-6. Overview of Electrical System Components. (MVL/MSP) (Sheet 1 of 2) 6-48 – JLG Lift – 3121231...
  • Page 169 SECTION 6 - TROUBLESHOOTING Figure 6-2. Overview of Electrical System Components. (MVL/MSP) (Sheet 2 of 2) 3121231 – JLG Lift – 6-49...
  • Page 170 SECTION 6 - TROUBLESHOOTING Australia Spec Key Switch Removed STANDARD - 2-12V BATTERY CONNECTION OPTIONAL - 4-6V BATTERY CONNECTION 1870202_F Figure 6-7. Electrical Diagram. (MVL/MSP) 6-50 – JLG Lift – 3121231...
  • Page 171 SECTION 6 - TROUBLESHOOTING REV. E: AUSTRALIA ONLY - R emoved platform module keyswitch (C3 connector) and replaced ground module key switch with non-keyed switch. 1870202_F Figure 6-3. Electrical Diagram. (MVL/MSP) 3121231 – JLG Lift – 6-51...
  • Page 172 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. Lift Cylinder Figure 6-8. Hydraulic Diagram. (MVL/MSP) 6-52 – JLG Lift – 3121231...
  • Page 174 JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu...

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