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Service and Maintenance Manual

1. NIBE Figure 5 2 Mast Cut a Way View 5 Section 3 Lift Chain Anchor Bracket 6 Section 4 Lift Chain Anchor Bracket 1 Lift Cylinder 2 Oylinder Lift Point 3 Wide Chain Set 4 Narrow Chain Set JLG Lift 5 5 SECTION 5 MAST COMPONENTS NOTE 10 free of any metal chips or debris which may stick to lubricated chains When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Slide mast section 3 out the TOP of mast section 2 enough to allow removal of the sheave wheel assembly Remove countersunk flathead screws securing chain sheave wheel assembly attach bars on both side rails at TOP of mast section 3 and remove sheave wheel assembly Carefully slide mast section 3 out BOTTOM of sec tion 2 Remove slide pads shims and cable anchor plate if necessary MAST SECTION 2 REMOVAL NOTE 11 5 6 Since the lift cylinder rod is still attached to the anchor block at the top of the section 2 mast assem bly you will need to temporar
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3. Figure 5 7 Platform Junction Box to Ground Control Station Wiring Harness 3 Upper Powertrak Bracket 5 Lower Powertrak Bracket 1 Harness Sheave Wheel 4 Mid Powertrak Bracket Powertrak 2 Harness Spring Tensioner Shown Cutaway 3121187 JLG Lift 5 18 SECTION 5 MAST COMPONENTS 5 10 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT NOTE This procedure is to be performed with the mast mounted on the machine Mast Chain Cable Adjustment See Figure 5 8 The intention of this procedure is to assure equal load dis tribution between the individual chains of a mast section chain sets Adjust using the following procedure 1 Remove the mast cover from the platform See Sec tion 5 2 Mast Cover Install Remove With mast completely lowered step into the platform and bounce your weight up and down a few times to be certain platform is at the bottom of travel Be cer tain the chain sets are seated in their sheaves prop erly at the top of each mast section Then with no load in the platform check the side pro file of the top of the mast the mast sections should all be even at the top and not stepped See Figure 5 8 If adjustment is required adjust one mast section at a time starting from the front of the mast section 3 and work towar
4. Platform Junction Box Installation 1 Platform Junction Box 2 Junction Box Attach tor Spare Screws 6 Platform Aux 1 Foot 3 Platform Console Harness switch Platform Gate Inter Connector lock Connector 4 Ground Control Module Harness Connector 5 Platform Aux 2 Connec 7 Programmable Security Lock PSL Connector 1 2 N X E T EMEN O AAN SN i P kak ka 555 UH d 22 sha Z Mi 2 2 Z EZA N 1 Platform Junction Box to Junction Box to Ground Control Module Harness Installation 2 Spring Tensioner Clamp 3 Harness Power Trak Assembly Ground Control Harness Note See Figure 5 7 Section 5 Mast Components for more JLG Lift detailed installation 3121187 SECTION 4 CONTROL COMPONENTS Platform Interlock Switch Circuit The platform interlock circuit consists of the platform foot switch and the platform gate switches wired in series This circuit will inhibit the machines lift and drive functions and display a fault code on the Gro
5. Table 6 1 LCD Display Service Fault Code Conditions jen FAULT DESCRIPTION FOR TROUBLESHOOTING FAULT CONSOLE LCD SYMBOL SCREEN LCD TEXT SCREEN MACHINE CONDITION REFER TO 37 RESERVED RESERVED 2 LEDs BARS Flashing with D CHARGE BATTERY an audible beep i 2 ms Platform Lift UP Function is Locked Out y 1 LED BAR Flashing with CHARGE of audible beep 3 1 gt BATTERY 439 Drive Platform Lift UP Functions Locked Out 40 RESERVED RESERVED 41 RESERVED RESERVED 42 RESERVED RESERVED 43 RESERVED RESERVED 44 RESERVED RESERVED 45 RESERVED RESERVED 46 RESERVED RESERVED nmm GROUND MODULE Ground Control Module See Table 6 34 p Fault Condition Page 6 26 nn JOSSTICK MODULE Platform Control Console See Table 6 35 20 9 a Fault Condition Page 6 27 TRACTION MODULE Traction Control Module See Table 6 36 300 10 M 2200 Md E Fault Condition Page 6 28 400 RESERVED RESERVED 401 RESERVED RESERVED 3121187 JLG Lift 6 7 SECTION 6 TROUBLESHOOTING 6 5 TROUBLESHOOTING TABLES INDEX SPECIFICATIONS FOR VARIOUS COMPONENTS PAGE Ohm Ratings for Various 6 10 Amperage Draw f
6. Figure 4 1 Control Components Location 1 Ground Control Station 4 Platform Footswitch Interlock 7 Platform Junction Box to Ground Control Harness 2 Platform Control Console 5 Traction Control Module 3 Platform Gate Interlock Switches 6 Platform Junction Box Mounted inside lower gate hinge left and right side 3121187 JLG Lift 44 SECTION 4 CONTROL COMPONENTS 4 2 CONTROL COMPONENTS INSTALLATION IMPORTANT BEFORE REMOVING ANY COMPONENT FROM THE ELECTRICAL SYSTEM DISCONNECT THE POSITIVE TERMINAL FROM THE LEFT SIDE BATTERY Ground Control Module The face of the Ground Control Module is visible from the front of the machine and is located under the front cover It is mounted to a bracket on the base frame in front of the hydraulic pump All electrical components on the machine operate directly or indirectly through the Ground Control Module The module is currently programmed at the factory with the machines operating profile If replacing a Ground Control Module the new module may require some programming to enable any optional equipment For servicing and programming information for the Ground Control Modudle See Section 4 3 Ground Con trol Module Service Procedure and Section 4 4 Ground Control Module Programming 4 2 JLG Lift Ground Control Module Installation 1 Ground Control Station Mod 8
7. STEP ACTION SPEC YES NO gt 1 Isthe lift down valve stuck open m Repair or Clean Goto Step 2 Valve 2 Lift down valves could be open due to incorrect electrical signal Check Pump Valve Electrical Goto Step 3 Circuit 3 Oil could be passing around the lift cylinder bore packing Replace or Rebuild the Lift Cylinder Platform Mast Descends Too Slowly Overview Of Procedure The following procedure examines the mast some hydraulic components for obstructions and defects Table 6 42 Platform Mast Descends Too Slowly STEP ACTION SPEC YES NO 1 Checkmastslide pads shimmed to tight Reshim Mast Goto Step 2 2 Isthere an obstruction inthe mast Remove Obstruction Gowers 3 Theliftcylinder packing could be too tight in the bore of the cylinder Rebuild Goto Step 4 barrel Replace Cylinder P 4 Check ifthe lift down valve is opening completely m Clean or Replace Goto 5 Valve P 5 lstherearestricted hydraulic line smashed e Replace Hydrau Goto Steps lic Line 6 Check the flow valve in the cylinder valve block for a restriction i e m Clean or Replace m dirt Flow Valve 6 32 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING 6 11 HYDRAULIC LEAK TROUBLESHOOTING Miscellaneous Hydraulic Leak Troubleshooting Overview Of Procedure This series of steps gives remedies for various areas of the machine where leaks could occur Ta
8. 1 1 1 4 7 4 4 Platform Control Console 4 15 5 1 Mast Components cedar ab ere erect dede kanam aa NE Bae kes 5 1 5 2 Mast Cut a Way View 5 5 5 3 Lift Cylinder Component Cross Section 1 5 7 5 4 Mast Section Assembly Reference 5 10 5 5 Bottom of Mast Section 2 Slide Pad Installation 5 11 5 6 of Mast Section 2 Slide Pad Installation 5 12 5 T Platform Junction Box to Ground Control Station Wiring 5 18 5 8 Mast Chain and Sequence Cable Adjustment 5 20 6 1 Component Electrical 1 6 3 6 2 SSV 10 Overview of Electrical System Components 6 39 6 3 Electrical Diagram 1870182 6 40 6 4 Hydraulic Diagram 2792684 6 42 vi JLG Lift 3121187 TABLE OF 5 LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 SSV10 Machine Operating Specifications
9. 1 1 1 2 Platform Maximum 1 2 1 3 Hydraulic Oil Operating 2 1 1 3 1 4 Lubrication 1 3 1 5 Cylinder Specifications 1 4 1 6 Lubrication Intervals for Various 1 5 2 1 Maintenance and Inspection Requirements 2 2 2 2 SSV 10 Preventive Maintenance amp Inspection Schedule 2 3 2 3 Chain Stretch Tolerance 1 25 2 6 3 1 Battery Low Voltage Warning 3 19 4 1 Ground Control Module Field Programmable Settings and Factory Preset SSV 10 4 13 5 1 Mast Component 4 5 5 6 1 LCD Display Service Fault Code 6 4 6 2 Ohm Ratings for Various 1 6 10 6 3 Amperage Draw for Various Components 6 10 6 4 Special Pin Extractor Tools for Electrical Connectors
10. 6 18 6 20 Code 19 Alarm 6 18 6 21 Code 20 Beacon Short Circuit 6 18 6 22 Code 21 Beacon Short Disconnected 1 6 19 6 23 Code 22 Horn Short 6 19 6 24 Code 23 Horn Disconnected 7 12 4 6 20 6 25 Code 24 Auxiliary 1 Circuit Short 6 20 6 26 Code 25 Auxiliary 1 Circuit 6 21 6 27 Code 26 Auxiliary 2 Short 6 21 6 28 Code 27 Auxiliary 2 6 22 6 29 Code 30 Traction Module No Communication with Ground Control Module 6 23 6 30 Code 31 Platform Control Console No Communication with Ground Control Module 6 24 6 31 Code 32 Pump Motor Over 1 6 24 6 32 Code 34 Auxiliary 2 6 25 6 33 Code 35 Auxiliary 2 Tie Down 6 25 6 34 Codes 100 199 Ground Control Module F
11. 6 10 6 5 Machine In Drive Speed Cut Back Turtle Mode All The 6 11 6 6 Code 01 Low Battery 6 12 6 7 Code 04 Tilt Condition 4 4 0 1 6 13 6 8 Code 07 Left Drive Motor 6 13 6 9 Code 08 Right Drive Motor Disconnected 6 14 6 10 Code 09 Left Brake Disconnected 6 14 6 11 Code 10 Right Brake Disconnected 6 14 6 12 Code 11 Left Drive Motor Short 6 15 6 13 Code 12 Right Drive Motor Short Circuit 6 15 6 14 Code 13 Traction Module In Fold 6 15 6 15 Code 14 Pump Motor Disconnected 6 16 6 16 Code 15 Lift Down Valve 6 16 6 17 Code 16 Lift Down Valve Short 1 6 17 6 18 Code 17 Ground Control Module In Fold 6 17 6 19 Code 18 Alarm Short
12. 6 30 Mast Noisy When Lifting And 0 6 31 Platform Mast Won t Stay Elevated 6 32 Platform Mast Descends Too 1 6 32 HYDRAULIC LEAK TROUBLESHOOTING Miscellaneous Hydraulic Leak Troubleshooting 6 33 BASE FRAME COMPONENTS TROUBLESHOOTING Caster Wheels Not Operating 6 34 DRIVE SYSTEM TROUBLESHOOTING Won t Climb Grade x or RR C RE aad ha idea ede ERREUR 6 35 Machine Drives in Opposite 1 6 36 Machine Won t Drive 6 37 Noise From Drive 6 38 3121187 JLG Lift 6 9 SECTION 6 TROUBLESHOOTING 6 6 SPECIFICATIONS FOR VARIOUS COMPONENTS The following table contains specifications for machine components Table 6 2 Ohm Ratings for Various Components COMPONENT NOMINAL RESISTANCE TEMPERATURE RESISTANCE RANGE POSSIBLE Pump Motor 0 20hm 0 4ohm 77deg F 0 120hm 0 490hm Brake Coil 44 7ohm 520hm 68deg F 31 40hm 65 30hm Drive Motor Bodine 1to 3ohm Can change depending on the rotation of the N A armature and temperature
13. 20 5 7 Lift Cylinder Component 5 8 Gylinder Assembly us r be Luce SEM me bao ce e ioc 5 8 519 MAST ASSEMBLY ss RR m hh hoes 5 10 5 10 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT 5 19 Mast Chain Cable 4 5 19 Sequencing Cable 1 5 19 SECTION 6 TROUBLESHOOTING 67 GENERAL zuyupak qeq a ee dee we Mia eater iuc se ada cu eared 6 1 6 2 TROUBLESHOOTING INFORMATION 6 1 6 3 HYDRAULIC CIRCUIT 1 4 60 lt 6 1 6 4 ELECTRICAL CIRCUIT 1 4 4 1 6 1 General ERREUR ane DC EE CRT EE ERA 6 1 Ground Control Module LCD 6 2 6 5 TROUBLESHOOTING TABLES 6 8 Specifications For Various 6 8 Special Pin Extractor Tools For Electrical 6 8 Fault Code Troubleshooting Tables 1 6 8 M
14. 2 7 Lubrication Specifications 1 2 7 SECTION 3 BASE COMPONENTS 3 4 BASE ASSEMBLY COMPONENTS 1 3 1 3 2 BASE FRAME COVERS u REALE AU hd men ney GR RR Bae ha s 3 2 Front Cover Installation Original 1 3 2 Front Cover Installation Carry Deck Version 3 2 Carry Deck Support Frame Installation 3 2 Rear Bumper Cover Installation 1 3 2 Drive Motor Cover 3 8 3 8 DRIVE AND CASTER WHEELS 11 3 3 Rear Drive Motor Wheel Removal 3 3 Drive Motor Wheel Installation 3 3 Rear Drive Motor Wheel Installation 3 4 Front Caster Wheel Installation 3 4 3 4 DRIVE ELEVATION CUT OUT SWITCH INSTALLATION 3 5 3 5 PUMP MOTOR ASSEMBLY SERVICE PROCEDURE 3 6 General esr pese ped eI SPI Su reperum e erre Ripe 3 6 Pump Motor Assembly
15. 3121187 1 6 HYDRAULIC PRESSURE SETTINGS AND ADJUSTMENT Adjust system pressure so that platform will raise with maximum rated capacity in platform Perform pressure adjustment with oil at normal operating temperature If pressure is set when oil is cold platform may not raise rated load after oil has warmed The following pressure setting is the factory recom mended initial setting MODEL SSV 10 PRESSURE SETTING 1800 PSI Turning adjustment screw clockwise increases system pressure turning screw counterclockwise decreases system pressure See Figure 1 1 Hydraulic Pressure Adjustment Screw Machine Front Cover Removed te Aq Figure 1 1 Hydraulic Pressure Adjustment Screw Machine Front Cover Removed 1 Pressure Adjustment Screw 2 Remove Adjust Screw Cap 3 Pump Ground Station Mounting Bracket 4 Ground Control Station NOTE Machine front cover must be removed to access pump motor JLG Lift 1 3 SECTION 1 MACHINE SPECIFICATIONS Hydraulic Pressure Gauge Connection A CAUTION ONLY OPEN HYDRAULIC SYSTEM LINES WITH THE MAST FULLY LOWERED TO RELIEVE PRESSURE IN THE SYSTEM CAREFULLY LOOSEN REQUIRED FITTINGS WEAR SAFETY PROTECTION EQUIPMENT WHEN WORKING WITH HYDRAULIC SYSTEMS NOTE See Section 5 5 Hydraulic Line Disconnect Spe cial Tool for hydraulic line removal procedure Remove the hydraulic oil filter and install a t f
16. 2 4 Footnotes cei esee p Spo eb erp Pn epe UPS PUES 2 4 2 3 SERVICING AND MAINTENANCE 2 5 General nore vp Dese DES rebos Vat d SE madii d ot h WR 2 5 Safety and Workmanship 2 20 4 2 5 Gleanliless rr uuu rede ze ata Od oie e ED 2 5 Components Removal and 2 5 Component Disassembly and Reassembly 2 5 Pressure Fit ccn regu Rn Ga aus ee 2 5 B arlfIgSu J EE 2 5 Gaskets 2e a Satie ddr coe nd S NE 2 5 Bolt Usage and Torque Application 1 2 5 Hydraulic Lines and Electrical Wiring 2 6 Hydraulic System od Lee te p R e NR 2 6 Lubrication and Servicing 2 6 Batteries o e oce in RIEN ed tbe enr 2 6 Mast Chain Inspection 2 6 2 4 LUBRICATION INFORMATION 2 2 7 Hydraulic Systemic sci aici usuy VM eee ES be UI PP Wed 2 7 Hydraulic Oil 92 5 DL rep d cte edle eo v d ret ge ates usa a etg 2 7 Changing Hydraulic
17. 6 26 Codes 200 299 Platform Control Console Fault 6 27 Codes 300 399 Traction Control Module Fault 6 28 6 9 MAIN POWER CIRCUIT 6 29 Machine Will Not Power 2 6 29 6 10 5 6 30 Platform Will Not Lower 6 30 Platform Lift Up Down 6 30 Mast Noisy When Lifting And 0 2 4 6 31 Platform Mast Won t Stay 6 32 Platform Mast Descends Too Slowly 6 32 6 11 HYDRAULIC LEAK 6 33 Miscellaneous Hydraulic Leak Troubleshooting 6 33 6 12 BASE FRAME COMPONENTS TROUBLESHOOTING 6 34 Caster Wheels Not Operating 6 34 6 13 DRIVE SYSTEM 6 35 Wont Climb Grade e eyes aor c n 6 35 M
18. Figure 5 8 Mast Chain and Sequence Cable Adjustment Components 1 Mast Side Profile 3 Mast Section 1 6 Mast Section 4 9 Chain Lock Jam Nut Sections Even at Top 4 Mast Section 2 7 Chain Anchor Plate Inside 10 Threaded Chain End Stud 2 Sequence Cable Adjust Nut 5 Mast Section 3 8 Chain Adjust Nut 5 20 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING SECTION 6 TROUBLESHOOTING 6 1 GENERAL This section contains troubleshooting information to be used for locating and correcting most operating problems If a prob lem should develop which is not presented in this section or which is not corrected by listed corrective actions technically qualified guidance should be obtained before proceeding with any maintenance 6 2 TROUBLESHOOTING INFORMATION Troubleshooting procedures applicable to this machine are listed and defined starting with Section 6 5 TROUBLESHOOT ING TABLES Index in this section of the manual Each malfunction within an individual group or system is followed by a listing of probable causes which will enable determi nation of the applicable remedial action The probable causes and the remedial action should where possible be checked in the order listed in the troubleshooting tables It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems It should be recognized that the majority of the problems arising in the machine w
19. Emergency Stop Switch Installation EStop Power Selector Switch Connector Locations 1 Emergency Stop Button 4 Nut 1 LCD and Button Circuit Board 2 Button Seal 5 Emergency Stop Switch 2 Emergency Stop Switch Connector 3 Square Lock Washer 6 Switch Lock Release Lever 3 Main Power Selector Switch Connector Note Tighten nut enough to keep button from turning Note To release switch connectors push tab on top of connector Reattach wires to same terminals on new switch 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 3121187 JLG Lift 4 9 SECTION 4 CONTROL COMPONENTS 4 4 GROUND CONTROL MODULE PROGRAMMING General The Ground Control Module allows on board program ming of various component and control function personal ity settings Programming may be required under circumstances such as Replacement of the Ground Control or Traction Control Module some components or optional equipment may not be enabled under the standard default settings of the replacement unit Optional equipment has been added to the machine in the field and that function must be enabled before oper ation Customizing the machine to fit a specific application such as changing the LCD display language program ming operating speeds such as braking turning or lift ing s
20. Table 6 3 Amperage Draw for Various Components COMPONENT AMPERAGE Ground Control Module 95 Amps room temperature with rated load LEVEL SURFACE 15 GRADE 24V RATED LOAD 24V RATED LOAD Traction Control Module 71011 Amps 55 to 60 Amps 3 5 to 4 8 Amps per motor per motor 78 to 86 RPM 6 7 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS The following table contains pin extractor tools for machine electrical connector components Table 6 4 Special Pin Extractor Tools for Electrical Connectors COMPONENT DESCRIPTION JLG PART NUMBER ILLUSTRATION Ground Control Station Forremoval of electrical connector pins from the Ground Control Station connectors 7016618 Drive Motor For removal of electrical connector pins from the 7002841 Drive Motor main power connectors Drive Motor Brake For removal of electrical connector pins from the 7002842 ip Drive Motor Brake power 25 connectors 6 10 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING 6 8 FAULT CODE TROUBLESHOOTING TABLES Machine in Drive Speed Cut Back Turtle Mode AII The Time Overview of Procedure Under normal machine operation once the platform is elevated the machine s maximum drive speed is reduced to 1 4 the normal drive speed of when the platform is fully lowered This is detected with a drive speed cut back proximity switch mounted at the base of the mast assemb
21. Traction Control Module Installation Traction Control Module Module Mounting Screws Washers a Left Drive Motor Power Cable w Reverser Harness Power From Ground Control Station Right Drive Motor Power Cable Communication Cable from Ground Control Station Platform Control Console Installation c gt 1 Console 3 Level Mounting Bracket Note a Apply Loctite 242 to mounting screw threads on final 2 1 ie S ae m d Washers assembly 3 Platform Console to Junction Box Harness 4 Harness Connector Removal Nut Nole The other end of this harness is plugged into the plat form junction box mounted to the mast under the platform From the console the harness is run under the mast cover is tie strapped to the top platform attach support and run inside the mast down and out the bottom rectangular hole Then runs down along the outside of the mast and through a large hole in the mast to the platform junction box Platform Junction Box Install Remove 3121187 JLG Lift 4 3 SECTION 4 CONTROL COMPONENTS All the platform mounted switches and controls connect to the platform junction box before running to the Ground Control Module P2 P3 and P4 Connectors the Ground Control Module Harness is attached to the side of the mast assembly Junction Box to Ground Control Harness Remove Install
22. d ii Transformer Remove Install 1 Transformer 2 Capscrews Nuts Washers 4 JLG Lift DC Circuit Breaker Voltage Select Switch Remove Install 1 DC Circuit Breaker 3 DC Circuit Breaker 2 120 240 Voltage Selector Switch 3121187 SECTION 3 BASE COMPONENTS SOLDER CONNECTI E BLACK 1001 OHM SCREWCONNECTION SIN Ies WVARFLEX DC FUSE OR CIRCUIT BREAKER aF o9 w DC POS lt RED __ HEATSINK 15 6 16 17 1 51984 CIRCUIT BOARD HARNESS 4 4321 2 r WET SEALED SWITCH REMOTE LIGHTS A BLACK PIN 1 RED WHITE PIN2 GREEN 1 GREEN PINS WHITE FD PN4 BLACK Figure 3 3 SCR Dual Voltage Battery Charger Wiring Diagram 3121187 JLG Lift 3 25 SECTION 3 BASE COMPONENTS This page intentionally left blank 3 26 JLG Lift 3121187 SECTION 4 CONTROL COMPONENTS SECTION 4 CONTROL COMPONENTS 4 1 CONTROL COMPONENTS OVERVIEW 1274 an 557 CEL
23. lt Charge Incomplete CHARGING PROBLEM Bm acp BOTTOM LED ON Consult Troubleshooting Section Cf HB of the Service Manual or the Charger Lf z SCR Manual in Manual Storage Box A Wet VRLA Battery Charging Profile Switch The battery charger is equipped with a manually select able charge profile switch located on the rear panel This switch must be set properly to select the charging profile required for either WET gassing lead acid batteries or VRLA Valve Regulated Lead Acid gelled agm type lead acid batteries The machine is equipped from the factory with VRLA valve regulated lead acid batteries and the switch is set from the factory to VRLA If the factory batteries are replaced with wet gassing batteries set this switch to WET IMPORTANT AN IMPROPER PROFILE SETTING MAY DAMAGE THE BATTER IES AND SHORTEN THE BATTERY S LIFE e VRLA Q w P ES WET VRLA Battery Selector Switch Location 1 WET VRLA Battery Selector Switch 2 Battery Charger Rear Panel 3 AC Voltage Input Receptacle Z lt 3121187 SECTION 3 BASE COMPONENTS Battery Charger Installation 1 Remove the front cover from the machine See 1 2 3 4 Page 3 2 N 2 Disconnect the positive battery cable at the left E side battery Eug ACh 3 Remove the four 4 capscrews and washers on the
24. 1 3 6 Motor Remove Install Reference Marks 3 7 Motor Brush Cover 3 8 Brush Carrier Assembly 3 9 Brush Assembly 3 9 Tank Remove Install aie ttd y deed ob Oia d IN eus LITORA RH 3 9 Filter Screen 0 4 3 10 Pump 3 10 Pressure Adjust Valve 1 3 10 Pressure Check Valve 1 3 10 3 6 DRIVE MOTOR ASSEMBLY 1 3 11 Drive Motor Assembly Removal 1 3 11 Drive Motor Assembly 3 12 Drive Motor Boot 3 13 Drive Motor Brake 3 13 ii JLG Lift 3121187 TABLE OF 5 Brake Assembly Removal From 3 14 Brake Operation lia eee uer hae need R
25. JLG Lift 3 3 SECTION 3 BASE COMPONENTS Rear Drive Motor Wheel Installation Front Caster Wheel Installation o Drive Wheel Installation Front Caster Wheel Installation 1 Wheel Hub Cover 9 Washer 2 Cotter Pin 6 Wheel Hub a 1 Snap Ring 5 Spindle Axle Assy 3 Nut Lock Shield 7 Drive Motor Shaft a 2 Upper Bearing a 6 Caster Wheel b 4 Wheel Nut b 8 Shaft Key 3 Lower Bearing 7 Snap Ring c NOTE a Coat the drive motor shaft and the inside of the 4 Spindle Shaft Seal wheel hub with Loctite Moly Paste Lubricant 51049 NOTE Base shown cutaway for illustrative purposes only JLG P N 3020039 before assembly If replacing bearing pack bearing completely full of before tightening to 100 ft Ib c Lightly tap key into keyway on shaft check that flat on key is parallel with shaft before installing wheel JLG Lift Mobil SHC 460 Synthetic or equivalent tap in evenly until seated b Coat the axle shaft with Loctite Moly Paste lubricant before assembling wheel Axle bearings on wheel are maintenance free c After installing the wheel and just before installing the Snap Ring wipe the end of the axle clean and coat the end of the axle with Clear Varnish 3121187 SECTION 3 BASE COMPONENTS 3 4 DRIVE ELEVATION CUT OUT SWITCH INSTALLATION Drive Elevation Switch Cut Out Switch Installation
26. 1 Mounting Screws a 4 Mounting Holes 2 Proximity Switch b 5 Proximity Switch b 3 Switch Mounting Block NOTE Apply Loctite 242 to mounting screw threads on final assembly b The SSV 10 is designed with two 2 drive elevation cut out proximity switches in the event that if one fails the other will continue to operate Both are plugged into the wiring harness to the P2 connector on the Ground Control Station If either switch would fail the Ground Control Module will signal a fault condition 3121187 JLG Lift 3 5 SECTION 3 BASE COMPONENTS 3 5 PUMP MOTOR ASSEMBLY SERVICE PROCEDURE General The following is a complete tear down re assembly of the 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 serviceable internal to the pump electric motor is the motor brush kit NOTE During reassembly of the pump motor assembly apply a liberal coat of JLG recommended hydraulic fluid to all seals and o rings Also keep all internal metal parts clean and coated with hydraulic fluid to prevent surface corrosion JLG recommends replacing all seals and o rings when disassembling and reassembling the pump motor unit IMPORTANT DISCONNECT THE LEFT SIDE BATTERY POSITIVE BATTERY TERMINAL BEFORE REMOVING THE PUMP MOTOR FROM THE MACHINE Pump Motor Assembly Remove Install A WARNING BE CERTAIN THE MA
27. Figure 5 3 Lift Cylinder Component Cross Section 1 Cylinder Rod 6 Apply Anti Seize 10 Piston 2 Cylinder Head 7 Cylinder Tube 11 Wear Ring 3 Rod Wiper 8 Spacer 12 Piston O Ring 4 Rod Seal 9 Piston Seal 13 Piston Lock Nut a 5 O Ring Note Torque 100 120 ft 185 JLG Lift 5 7 SECTION 5 MAST COMPONENTS Lift Cylinder Component Inspection Cylinder Assembly Cylinder Rod There should be no scratches or pits deep enough to catch the fingernail Pits that go to the base metal are unacceptable Scratches that catch the fingernail but are not to the base metal less than 0 5 inch long and primarily in the circumferential direction are acceptable provided they cannot cut the rod seal 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 Cylinder Head Visually inspect the inside bore for scratches or polishing Deep scratches are unacceptable Polishing indicates uneven loading and when this occurs the bore should be checked for out of roundness If out of roundness exceed 0 007 this is unacceptable Check the condition of the dynamic seals wiper rod seals looking particularly for metallic particles embedded in the seal surface It is nor mal to cut the static seal on the retaining ring groove upon disassembly Remove the rod seal static o ring and bac
28. Platform Console Joystick Installation 4 Rubber Boot Gasket 5 Install Remove through the Access Hole in Bottom of Housing a b 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 con Sole 1 Joystick Assembly 2 Attach Screws 01 4 3 Nylon Washers Qty 4 3121187 SECTION 5 MAST COMPONENTS SECTION 5 MAST COMPONENTS 5 1 MAST COMPONENTS OVERVIEW 3121187 4 MUN I AL r em Nul ee A s Big Figure 5 1 Mast Components 1 Material Handling Tray 3 Mast Assembly 2 Platform Assembly 4 Platform Mast Cover JLG Lift 5 1 SECTION 5 MAST COMPONENTS 5 2 MAST COVER INSTALL REMOVE Mast Cover Installation 1 Mast Cover 2 Screws and Washers a 3 Platform Console Mount ing Screws Platform shown without right side rails for illustra tive purpos
29. That all battery and harness connectors secure and undamaged on Ground Control Module Batteries have sufficient charge Confirm that the static ground strap attached under base frame is secure and undamaged Table 6 34 Codes 100 199 Ground Control Module Fault Condition STEP ACTION SPEC YES NO 1 Recycle machine power 5 times allowing a 10 second interval between each power recycle Does fault clear Done Go to Step 2 2 Which code number is displaying Code 103 Goto Step 3 Replace Ground Control Code 119 Goto Step 5 Module 3 Confirmthatboth installed batteries are 12 Volt DC 12V DC GotoStep4 _Replacewith proper Batteries 4 SE voltage while charger is operating Is voltage within Nro Repair or Replace 31 Volts DC Module Battery Charger 6 26 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING Table 6 34 Codes 100 199 Ground Control Module Fault Condition 5 Removethe communications cable P5 connector atthe Ground Control Module and round connectoratthe Traction Control Module E Goto Step 6 Repair or Replace Check continuity of all three 3 wires in the communications cable p 5 from endto end P5 Pins 2 3 and 4 6 With communications cable still disconnected at both ends check i for continuity between Pins 2 3 and 4 atthe P5 connector end place Goto Step 7 7 Plug the communications cable on
30. 2 6 38 viii JLG Lift 3121187 SECTION 1 MACHINE SPECIFICATIONS 3121187 SECTION 1 MACHINE SPECIFICATIONS Table 1 1 SSV10 Machine Operating Specifications Maximum Occupants SSV10 1 Maximum Work Load Capacity See Table 1 2 on Page 1 2 Maximum Travel Grade Gradeability Platform STOWED ONLY 15 Maximum Travel Grade Side Slope Platform STOWED ONLY 5 Tilt Alarm Cut Out Limit Direction Platform ELEVATED 1 5 Machine Height Platform Stowed 57 in 1 44m Maximum Vertical Platform Height 108 3 09m Maximum Wheel Load Per Wheel 650 Ib 295 kg Maximum Drive SpeedsOperator Variable 0 5 3 7 mph 0 8 5 95 kph Platform Elevated mph 1 13kph Max Platform Speeds w Max Load Platform Up 13 sec Platform Down 11sec Gross Machine Weight Standard Equipment Platform Empty eee JLG Lift 1 1 SECTION 1 MACHINE SPECIFICATIONS 1 1 CAPACITIES System Voltage 24 Volt DC Hydraulic System 5 gts U S 4 7 L Drive Motor GearBox Gear Oil 6 oz 175cc 1 2 COMPONENT DATA Hydraulic Pump Pump Motor Assemhly Pump Motor
31. Checkresistance between the terminals on the lift down valve Repairor Replace Replacethe located atthe base of the lift cylinder Is reading within spec Wiring Harness nep 6 Ohms from Ground LiftDown Valve Control Module 3 With the terminals still removed from the lift down valve check continuity ofthe wires from pins 10 and 3 onthe P1 connectorto the 00 Ohms E lift down valve 9 6 16 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING Code 16 Lift Down Valve Short Circuit Check For These Obvious Conditions First Damaged wiring in the lift down valve wiring harness or a damaged lift down valve coil Table 6 17 Code 16 Lift Down Valve Short Circuit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the voltage Replace Ground across pins 10 and 3to the lift down valve coil Is reading within 0 2VDC Goto Step 2 C Hh I Modul specification Omio MOUIE 2 Remove the wire terminals at the lift down valve coil Check resis tance reading of the coil Is coil within specification 6 Ohms Go to Step 3 Replace Coil 3 With the terminals still removed from the lift down valve coil check continuity of the wires from pins 10 and 3 onthe P1 connectorto the 00 Ohms lift down valve iring Code 17 Ground Control Module In Fold Back Check For These Obvious Conditions First Has machine been operating on a continuous gra
32. 300 399 Traction Control Module Fault Condition Check For These Obvious Conditions First Damage to Traction Control Module wiring harness Confirm that the static ground strap attached under base frame is secure and undamaged Table 6 36 Codes 300 399 Traction Control Module Fault Condition STEP ACTION SPEC YES NO 1 Recycle machine power 5 times allowing a 10 second interval between each power recycle Does fault clear Done Go to Step 2 2 lsacode number displaying onthe Ground Control Station Replace Code 316 Go to Step 3 Traction Control Module Code 325 Go to Step 5 3 Confirmthatboth installed batteries are 12 Volt DC i 12VDC GotoStep4 _Replacewith proper Batteries 4 Se voltage while charger is operating Is voltage within Maximum M m Repair or Replace olts Module attery Charger 5 Check for shortin harness wires from Ground Control Station con nector P5 to Traction Module round din plug m Repairor Replace m Note This harness contains 6 wires only 3 are used See Figure 6 Wiring 3 Electrical Diagram 6 28 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING 6 9 MAIN POWER CIRCUIT TROUBLESHOOTING Machine Will Not Power Up Check For These Obvious Conditions First Battery voltage is 24 volts Sufficient Charge in Batteries to Operate Machine Positive and negative battery cable connections clean and tight at both the Batterie
33. From Inline Fuse Battery ule and To Traction Control Mod 2 Mounting Screws Washers ule 4 a 9 From Battery and To 3 P1 Connector b Traction Control Module 4 P2 Connector b 10 To Post on Hydraulic 5 P3 Connector b Pump 6 P4 Connector b 11 To Post on Hydraulic 7 P5 Connector b Post Note a Apply Loctite 242 to screw threads on final assembly b To help seal unit from dust and moisture apply electrical contact grease CG60 JLG Part 3020038 to all electrical connectors before assembly 3121187 SECTION 4 CONTROL COMPONENTS Traction Control Module Platform Control Console Installation The Traction Control Module is mounted to the base frame The platform control console is located in the platform and beneath the platform under the drive motor cover mounted on the right side of the mast assembly This module controls the voltage to the drive motors as regulated by the Ground Control Module from signals received from the Joystick Controller located on the Plat form Control Module There are no internal parts serviced on this module I Ti 2 7 For removal see below for servicing information see Sec tion 4 5 Platform Control Console Service Procedures d 4 2 amp amp
34. Top of Mast Section 2 Narrow Chain Set Installation 1 Anchor Block Attach Pin 3 Hole Through Anchor 2 Narrow Chain Set Block 4 Snap Ring 20 Slide mast section 2 back into section 1 until top and bottom ends are even JLG Lift 5 13 SECTION 5 MAST COMPONENTS MAST SECTION 3 ASSEMBLY 21 Lay the wide chain set attached to the top of mast section 1 into the open rail on mast section 2 Top of Mast Section 2 Slide Pad Installation 1 Wide Chain Set Attached to Mast Section 1 2 Mast Section 2 NOTE Before sliding mast sections together spray the slide pad channels with Krytox lubricant spray JLG P N 3020041 Be careful not to scratch or score the anodized finish in the slide pad channels 22 Carefully slide mast section 3 into section 2 until ends are even 23 At the bottom of mast section 3 install the slide pads between mast section 2 and 3 Shim per instructions in step 7 Mast Section 2 Assembly Bottom of Mast Section 3 Slide Pad Installation 1 Slide Pads 2 Shim Stock 3 Shim Pad Screws 5 14 24 25 26 27 Push mast section 3 out the top of mast section 2 approximately 1 ft 31cm Locate the lower chain anchor bracket one with the threaded attach holes horizontally aligned to outside of bracket Working at the bottom end of mast section 3 insert the threads stud ends of the wide c
35. c 5 Traction Control Module a 8 Power Cable To Right Drive Motor Brake a 3 175 Amp Fuse 6 Left Drive Motor Harness Reverser a 9 Hydraulic Pump Motor Tank Assembly b Ground Control P1 Horn Alarm Beacons Lift Down Valve Harness a P4 Platform Joystick Harness a Module Plugs P2 Elevation Speed Charger Limit Switch Harness a P5 Joystick Protocol Harness to P3 Programmable Security Lock Harness Option a Traction Control Module a Notes 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 c An quick disconnect is installed on the left battery POSITIVE cable for easier power disconnect when servicing machine See Figure 6 3 This section Troubleshooting for complete machine wiring schemalic Figure 6 1 Component Electrical Connections 3121187 JLG Lift 6 3 SECTION 6 TROUBLESHOOTING Table 6 1 LCD Display Service Fault Code Conditions PLATFORM FAULT CONSOLE FAULT DESCRIPTION CODE LEDs LCD SYMBOL SCREEN LCD TEXT SCREEN MACHINE CONDITION TROUBLESHOOTING FLASHING Machine In Drive Speed _ lt Cut Back Turtle Mode 7 X 000000 All The Time 9 Engage Brakes Z R Brakes Released Press Bro Release Button X 000000 DRIVE Disabled on Ground Control Station Unplu
36. quate lube generate tremendous friction between the pin and plates pin and bushing on leaf chain In extreme cases this frictional torque can actually turn the pins in the outside press fit plates Inspect for turned pins which can be easily spotted as the V flats on the pin heads are no longer in line Replace all chains showing evidence of turned or protruding pins Keep chains lubricated 3121187 SECTION 2 GENERAL SERVICE INFORMATION 3121187 Chain Anchors and Sheaves An inspection of the chain must include a close examination of chain anchors and sheaves Check chain anchors for wear breakage and misalignment Anchors with worn or broken fingers should be replaced They should also be adjusted to eliminate twisting the chain for an even load distribution Inspect the sheaves sheave bearings sheave grooves and pins for extreme wear replace as necessary A worn sheave can mean several problems as follows a Chains too tight b Sheave bearings pin bad c Bent misaligned chains 2 4 LUBRICATION INFORMATION Hydraulic System The primary enemy of a hydraulic system is contamina tion Contaminants enter the system by various means e g using inadequate hydraulic oil allowing moisture grease filings sealing components sand etc to enter when performing maintenance or by permitting the pump to cavitate due to insufficient system warm up or leaks in the pump supply The design and manufacturing tolerance
37. 1 SECTION 6 TROUBLESHOOTING Ground Control Module LCD Display i J X 00000 0 At power up during operation the LCD display on the Ground Control Module displays the current machine operating status The following illustration explains the symbol indications 1 2 5 N N CS HH pem X 00000 0 00 4 00 4 LCD Display Symbols 1 Battery Charge Indicator BCI 4 Fault Code Indicator 2 Function Display or Function Disable Indicators 5 Fault Code Text Message Display a 3 Hour Meter Display Note a When an Fault code is indicated the LCD screen will alternate between the text and symbol display modes 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 Disabled d DRIVE Disabled LIFT DOWN Disabled Battery Charger Plugged In 5 Drive Speed Cut Back Turtle A LIFT UP Disabled X e Mode Engaged 6 2 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING 1 Ground Control Module a 4 Right Side Battery b 7 Power Cable To Left Drive Motor Brake a 2 Left Side Battery b
38. 24 Volt DC motor Standard Duty Pump Displacement 098 cu in rev 1 6cc rev Pump Output Max 2 25 gpm 9 1400 psi 9 24 volts and 105 amps 9 43 centistrokes 200 SSU Reservoir Capacity 1 Gallon 3 78 L Rear Wheel Drive Motors Drive Motors 1 2 HP 24 Volt DC Variable 15 16 Parallel Drive Shaft Sealed Gear Box 32 1 Gear Ratio Brake Shaft and Drive Shaft Integral to Motor Brakes Friction Disk Spring Applied Electrically Released Batteries Battery Charger Batteries 12 Volt DC 2 in series 24 volt Nominal Capacity 100 Amp Hour Type M2 Marine Combination AGM Valve Regulated Leak Proof NonCorrosive Maintenance Free Weight 65 7 Ib 29 8 Kg Per Battery Battery Charger Microprocessor Controlled SCR Circuit Monitor 120 240 Volt A C Selectable 50 60 Hz input 24 volt 20 amp output with 2 amp finish Reset Circuit Breaker Automatic Charge Circuit Plug Interlock Circuit Wet VRLA Battery Switch NOTE The SSV 10 batteries require approximately five 5 hours to fully charge when drained to 80 discharge Only the RED LEDS on platform console lit 1 2 JLG Lift 1 3 PERFORMANCE DATA Platform Capacity Table 1 2 Platform Maximum Capacity MAXIMUM CAPACITY Max SPECIFICATION Platform Material Carry Total Wind Load TrayLoad Deck Capacity Speed ANSI CSA qun CE 3501 2501 25016 85016 Indoor Use Only 160kg 115kg 11
39. Component 3 Check the left and right drive motor brakes for loose hardware amp not Tighten or Adjust releasing properly per procedure inthis Goto Step 4 Service Manual 4 lstheelectrical signal and amperage draw to the drive motors Recheck Steps equal Check with machine on level surface See Table 6 3 1thru5 poro 5 Check the drive motor brushes do they need replaced Replace per procedure inthis GotoStep6 Service Manual 6 Inside the drive motor gear box checkif the drive shaft is exces Repair Replace gear box sively loose amp condition of drive shaft bearings components per procedure in this Are any gears broken or gear teeth excessively worn Service Manual 6 38 Lift 3121187 SECTION 6 TROUBLESHOOTING CHARGER AC BATTERY CHARGER ELEVATION SPEED PLATFORM LED INPUT CUTBACK SWITCHES CONSOLE LIGHT BOX Gp 9o SPARE ANALOGUE INPUT SPARE ANALOGUE SPARE INPUT ANALOGUE INPUT FOOT GROUND CONTROL SWITCH BOX SPARE ANALOGUE AUX INPUT INPUT 1 P1 P2 4 e e P3 P5 s y m P4 PLAT PLAT AUX AUX m E 1 2 o MAST JUNCTION BOX MAST POWERTRAK HARNESS CARRIER e TSTISITSITSITSITSITSITSITS SI
40. HA front of the charger securing it to the base frame charger mount 4 Lift charger up and lay on it s side to disconnect the 2999 wiring connectors from the back of the charger assembly Move the charger to a suitable work sur face O 2 or A 5 Battery Charger Rear Panel Connections 1 Wet VRLA Selector Switch 4 To Charging Status LED 2 AC 120 220Volt Input Indicators On Rear Bumper Socket Rear Bumper 5 DC Voltage Output to Battery 3 Drive Cut Out Wires to P2 Posts See Below Connector on Ground Control Station MACHINE FRONT 4 Battery Charger Remove Install 1 Battery Charger Assembly 2 Charger Capscrews Washers 4 O 3121187 JLG Lift 3 21 SECTION 3 BASE COMPONENTS Battery Charger Cover Installation Battery Charger Cover Remove Install 1 Charger Cover 2 Bottom Tray Screws Removal Optional 3 Screws Same on Both Sides General Component Installation Notes When removing components make note of the wiring con nections before disconnecting the wiring between the components within the charger a
41. Iberica S L Trapadella 2 Castellbisbal Sur 08755 Castellbisbal Barcelona Spain 2 34 93 772 4700 IL 34 93 771 1762 JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden 4 46 0 850 659 500 amp 46 0 850 659 534 www jlg com
42. NOTE a Slide brush assembly into socket until tab is in slot at 4 rear of socket Note a Lubricate o ring with clean hydraulic fluid before sliding tank over during installation 3121187 JLG Lift 3 9 SECTION 3 BASE COMPONENTS Filter Screen Remove Install Pressure Adjust Valve Remove Install Filter Screen Remove Install Requires removal of tank assembly 4 Tube Attach Screw 5 O Ring 1 Filter Screen 2 Pump Pick Up Tube 3 Tube Retainer Clip Note Tubes shown shortened for illustrative purposes only Pump Remove Install Pressure Adjust Valve Remove Install 1 Adjust Valve Cap 4 Valve Ball 2 Adjustment Screw 5 Adjust Valve Port 3 Valve Spring Note Adjust pressure per specification shown in Section 1 of this Service Manual Pressure Check Valve Remove Install Pump Remove Install Requires removal of tank assembly and pump pick up tube 1 Pump Assembly 2 Pump Assembly Screws 3 Motor to Pump Coupler 4 Pump Shaft Bearing 3 10 JLG Lift Pressure Check Valve Remove Install 1 Check Valve Assembly 2 Check Valve Port 3121187 SECTION 3 BASE COMPONENTS 3 6 DRIVE MOTOR ASSEMBLY SERVICING 1 Elevate the platform and remove the drive motor cover and set aside see Section 3 2 on page 3 2 The component parts of the left and right drive motor assemblies are identical The left drive moto
43. OUT aM SIGNAL IN JOYSTICK MODULE E BOARD UNUSED OPTION SECURITY LOCK OPTIONAL rn ON OFF BLUE 4666 COM WHITE EI 5 a E 88 835 g 3141855 d 9 2 2 EE E 331441 EE P JOYSTICK 12 12 4 7 I EM lt H ao 5 35 E aw 2 RE lt 3 HORN r gt jas 5 EM REP us 84 AVI ol ALARM br d 5 95 WHITE a Base 8 5 24VD Eh BEACON LP 5 B 33 5 5 UP pi Ml VALVE SPARE g 4 8 VDC 5 AUX OUTPUT 24VDC 5 MIMICKS BEACON B YELLOW RED 2 2 BLACK 3 _ AUX 2 OUTPUT 24VDC 5 WHITE D SHARED WITH OSS B mE BRAKE 4 1 BLACK E z 5 2 CA 5 oO 1870182 D Figure 6 3 Electrical Diagram 1870182_D 6 40 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING ES OUT YELLOW BLACK SO gt ES Y
44. Operate before operating LOW BATTERS Control Functions Locked Out LEVEL 2 42 LEDs BARS Flashing Charge batteries for a mini E with an audible beep mum of four 4 continuous z 00000 0 e Platform Lift UP Function hours or more or 8 LEDs CHARGE BATTERY f is Locked Out BARS lit before operating a 38 LEVEL 3 1 LED BAR Flashing with Charge batteries for a mini nomm p an audible beep mum of four 4 continuous GUI Drive and Platform Lift UP hours or more or 8 LEDs CHARGE t Functions Locked Out BARS lit before operating a BRTTERS 539 NOTE a To maximize battery life it is recommended that the factory supplied batteries be charged continuously for a minimum of 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 3121187 JLG Lift 3 19 SECTION 3 BASE COMPONENTS Battery Charger General Information IMPORTANT DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGER IF MACHINE IS STILL UNDER WARRANTY OPENING THE BAT TERY CHARGER WHILE THE MACHINE IS UNDER WARRANTY WILL VOID THE CHARGER WARRANTY IF UNDER WARRANTY REQUEST A REPLACEMENT CHARGER FROM THE FACTORY ALSO BEFORE REPLACING ANY COMPONENT USE THE CHARGER MANUFACTURERS TROUBLESHOOTING GUIDE SHIPPED WITH THE MACHINE TO CHECK THE INTERN
45. RIGHT MOTOR S 12 6 M que SHORTED boe Short Circuit X 000000 12 12 DRIVE Disabled 9 Traction Module TRACTION NOD 13 6 E rd lt gt IN FOLD BACK lt InFold Back 2 X 000000 13 DRIVE Disabled 9 PUMP MOTOR Pump Motor Disconnected See Table 6 15 2 1 8 lt gt DISCONNECTED Lift UP Disabled Page 6 16 X 000000 14 14 LiftDown Valve DOWN VALVE See Table 6 16 15 7 24 A lt gt DISCONNECTED A Disconnected Page 6 16 X 00000 0 15 15 Lift UP DOWN Disabled a DOUN VALVE Down Valve or Down Valve See Table 6 17 16 7 COT lt SHORT Circuit Short Page 6 17 i X 000000 416 416 Lift UP DOWN Disabled 9 GROUND MODULE 4 Ground Control Module 17 7 mum nmm i lt gt IN FOLD BACK a In Fold Back E bii X 000000 417 417 Machine Stopped 9 18 _ E 3 ALARM SHORT Alarm or See Table 6 19 X 000000 418 18 Alarm Circuit Short Page 6 18 ALARM DISCONNECTED 19 E lt gt Alarm Disconnected 000000 19 419 age D BEACON SHORT Beacon or See Table 6 21 20 21 Beacon Circuit Short Page 6 18 00000 0 20 20 BEACON DISCONNECTED 21 E gt Beacon Disconnected 2 22 X 00000 0 21 2 age 6 19 22 IS EE Horn or Horn Circuit Short L im X 000000 22 age o 3121187 JLG Lift 6 5 SECTION 6 TROUBLESHOOTING Table 6 1 LCD Display Service Fault Code Conditions 2 29 D
46. Replace Ground ifthe Auxiliary 1 open circuit detection is enabled Default NO Disable It Control Module 3 Check voltage atthe P1 connector onthe Ground Control Module Replace Ground between pin 9 and pin 2 Is reading within specification 2 4VDC Control Module Goto Step 4 4 Removethe wire terminals atthe Aux 1 component check conti nuity of each of the wires from pins 9 and 2 on the P1 connectorto d R bise the Aux 1 component epiace Wiring Code 26 Auxiliary 2 Short Circuit Check For These Obvious Conditions First Damaged wiring in the Auxiliary 2 Component wiring harness or a damaged Component Table 6 27 Code 26 Auxiliary 2 Short Circuit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the voltage Replace Ground across pins 8 and 1 to the Aux 2 component ls reading within 0 2VDC Goto Step 2 C ar Modul specification 2 Remove the wire terminals atthe Aux 2 component check conti nuity of each of the wires from pins 8 and 1 on the P1 connectorto 2 R iuge d the Aux 2 component end epiace Wiring 3121187 JLG Lift 6 21 SECTION 6 TROUBLESHOOTING Code 27 Auxiliary 2 Disconnected Check For These Obvious Conditions First Is machine equipped with a component on the Auxiliary 2 circuit Table 6 28 Code 27 Auxiliary 2 Disconnected STEP ACTION SPEC YES N
47. Short Circuit Check For These Obvious Conditions First Wiring harness from M1 connector on Traction Control Module to Left Drive Motor for damage Table 6 12 Code 11 Left Drive Motor Short Circuit STEP ACTION SPEC YES NO 1 Remove the M1 connector from the Traction Control Module and This circuit check both the pins to the drive motor for any voltage No Voltage should be Goto Step 2 Groundthe meterto the Ground Control Module Negative lug isolated Repair 2 Checkforcontinuity of both the pinsto ground or Replace Replace No Ground Components as Traction Required Control Module Code 12 Right Drive Motor Short Circuit Check For These Obvious Conditions First Wiring harness from M2 connector on Traction Control Module to Left Drive Motor for damage Table 6 13 Code 12 Right Drive Motor Short Circuit STEP ACTION SPEC YES NO 1 Remove the M2 connector from the Traction Control Module and This circuit check both the pins to the drive motor for any voltage No Voltage should be Goto Step 2 Ground the meter to the Ground Control Module Negative lug isolated Repair 2 Check for continuity of both the pins to the drive motor to ground or Replace Replace No Ground Components as Traction Required Control Module Code 13 Traction Module In Fold Back Check For These Obvious Conditions First Machine is operating o
48. a Apply Loctite 242 to screw threads before final assembly Pump Motor Removal Installation Reference Marks For reference when reassembling mark motor cover housing and valve body position before disassembling 1 Motor Top Cover 4 Housing Motor Valve Body 2 Cover Housing Reference Mark Reference Mark 5 Motor Valve Body 3 Motor Housing JLG Lift 3 7 SECTION 3 BASE COMPONENTS Motor Brush Cover Remove Install 3 AT 2 5 5 L d ges ms 9 USS Motor Brush Cover Removal Installation 1 Motor Brush Cover a 3 Washers 5 Power Lead Clip Attach Screws 2 Cover Screws b 4 Power Leads to Lead Clips Soldered IMPORTANT NOTE REMOVE THE MOTOR COVER CAREFULLY THE SHORT POWER LEADS INSIDE THE COVER FROM THE POSTS ARE SOL DERED TO ATTACH CLIPS WHICH ARE FASTENED TO THE BRUSH CARRIER ASSEMBLY WITH SCREWS ITEM 5 RAISE THE COVER STRAIGHT UP REMOVE THE SCREWS THEN HINGE THE COVER UP SEE CENTER ILLUSTRATION AND PRY THE CLIPS OFF OF THE BRUSH CARRIER ASSEMBLY TO COMPLETELY REMOVE THE MOTOR COVER NOTE a Once cover screws are removed you may need to tap lightly around the edge of the top cover to separate it from t
49. down NOTE pig tail wire should be formed to rest against the nonme tallic insulator It must be spaced from any metallic surfaces other than the brush box by a minimum of 125 in 3mm 3 Nowinstall the brush retaining spring bracket Grasp the tip of the spring bracket such that the roll type spring will be on the brush side of the brush box and resting on top of the brush when the brush spring is completely installed 4 Push the spring bracket slowly into it s slot while let ting it s two attaching hooks slide on the wall of the brush box 5 Stop but do not release the spring bracket when it s hooks slip around the edge of the brush box 6 While still grasping the spring bracket with the pliers slowly bring the spring back out of the brush box until the hooks latch around the edge of the brush box 7 Now release the spring bracket and check that it is lying flat against the brush box wall If it is cocked it is improperly seated and will have to be reinstalled 3121187 IMPORTANT THE SPRING BRACKET MUST BE ALSO LIE COMPLETELY INSIDE THE BRUSH BOX AND NOT OUT OVER THE EDGE THE ROLL END OF THE SPRING MUST BE CENTERED ON THE TOP OF THE BRUSH SEE ILLUSTRATION FOLLOWING 8 Also apply slight pressure by pulling up on the spring bracket to be certain it is hooked securely around the brush box wall at the bottom of the brush box 9 Screw the brush caps back into the end shield using the largest possi
50. for proper chain specifications and allowable stretch tolerances Peening and wear of chain plate edges are caused by sliding over a chain worn contact face of a sheave or unusually heavy loads of the above require replacement of the chain and correction of the cause 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 2 6 Rust and Corrosion Rust and corrosion will cause a major reduction in the load carrying capacity of the chain because these are primary reasons for side plate crack ing The initial lubrication at the factory is applied in a hot dip tank to assure full penetration into the joint Do not steam clean or degrease chains At time of chain installa tion factory lube must be supplemented by a mainte nance program to provide a film of oil on the chains at all times If chains are corroded they must be inspected especially the outside plates for cracks in line with the pins If cracks are found replace the chain if no cracks are discovered lubricate the chains by dipping in heated oil and reinstall on the machine Keep chains lubricated Table 2 3 Chain Stretch Tolerance Chain Size Pin io Pin Allowable Stretch Measurement 50 pitch 12 or 24 pitches 24 in 12 in span 625 pitch 15 o
51. loosened Then re tighten the loosened jam nuts until tight against the top adjust nut Chain should have slight tension but should not be taut After all mast adjustments are complete if neces sary readjust the bumpers mounted on the base frame under the platform so the platform rests slightly above the base frame when it is lowered and empty Sequencing Cable Adjustment 1 NOTE After Retract mast completely and check each sequenc ing cable on outside of masts for excessive slack Adjust only to remove slack from cable Tighten nylock nut at the sequence cable bracket located at the top of the mast just enough to remove excessive slack from sequencing cable The springs should not be compressed more than 25 after adjusting 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 prop erly even or the the cable will have to be replaced due to stretching adjusting the mast chains and sequence cables cycle mast up and down several times to verify adjust ments are correct JLG Lift 5 19 SECTION 5 MAST COMPONENTS NE 4
52. onto the sheave pin on each side of the anchor block c Place sheave wheels for wide 544 chain on sheave pin one each side of anchor block d On the outside of each sheave wheel place a large thrust washer e Insert the key bar into the keyway on the end of the sheave wheel pin f Place a sheave pin support plate on each end of the shaft 9 Slide the whole anchor block sheave wheel assembly into top of mast section 2 Slide the anchor block onto the top of the cylinder rod Check that the hole in the cylinder rod aligns the the hole in the anchor block h Align the threaded holes in the sheave pin sup port bars with the mounting holes on each side of the top of mast section 2 mast and attach using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each 3121187 side Coat threads with Loctite 171 on final assembly 17 Locate and assemble the narrow chains set 444 and to the small triangular shape chain equalizer anchor plate using the pins washers and cotter keys 18 Lay out the chain 444 anchor plate assembly with anchor plate end towards mast be certain floor sur face is clean and free of any metal chip or debris which may Stick to lubricated chains or lay chains in a clean bucket 19 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
53. the Traction Control Module to Replace the round socket on the opposite end of the module Does this fix Done Ground Control problem Module Codes 200 299 Platform Control Console Fault Condition Check For These Obvious Conditions First Damage to Platform Control Console wiring harness Secure harness connections from Platform Control Console to Platform Junction Box to Ground Control Module Confirm that the static ground strap attached under base frame is secure and undamaged Table 6 35 Code 200 299 Platform Control Console Fault Condition STEP ACTION SPEC YES NO 1 Recycle machine power5 times allowing a 10 second interval between each power recycle Does fault clear Done Go to Step 2 2 Which 200 code numberis displaying Code 200 207 213 Goto Step 3 Replace Platform 3 Removethe 9 pin Platform Control Module connector from the side of the Platform Junction Box and the P4 connector at the Replace Repair or Ground Control Module Check continuity from the P4 connector Platform Repl Wirin pin 5 to Junction Box pin 3 and P4 pin 9 to Junction Box pin 4 Control Module 70 26 Wiring Is there continuity on these wires 4 Performthe Joystick Calibration Procedure in Section 4 5 of this Replace Service Manual Does this clear the fault code Done Platform Control Module 3121187 JLG Lift 6 27 SECTION 6 TROUBLESHOOTING Codes
54. when the springs are compressed Clean Slide Pads Note This noise is normal at the sequence cable sheave wheels Channels or Re when the mastis completely lowered However if the sequence shim Mast per Goto Step 5 cable chattering is happening no matter what position the mastis in Service M p it could be a resultofthe mast being shimmed to tight or dirt and Manua debris in the slide pad channels causing the mastto be tight 5 Isthebore of the lift cylinder dry Replace Packing orLiftCylinder 201051806 6 Arethe bearings in the lift pump motor and pump drive worn Repair or Replace Goto Step 7 Pump p 7 Arethehydraulic lines vibrating together Adjustthe Posi tion ofthe Lines 8 Checkifthe pump motor is loose to it s mounting plate Tighten pump mounting Goto Step 9 fasteners 9 Hydraulic oil could be cavatating inside the pump Repair or Replace Pump 3121187 JLG Lift 6 31 SECTION 6 TROUBLESHOOTING Platform Mast Won t Stay Elevated Overview Of Procedure The following procedure requests that the lift down dump and pump internal valves be checked to see if any are stuck open it also examines the lift down and dump valve circuits Also suggests that the lift cylinder packing could be leaking internally Check For These Obvious Conditions First Manual descent valve is closed tight Table 6 41 Platform Mast Won t Stay Elevated
55. with hydraulic fluid and allow to drain A high pressure rinse followed by a wipe with a lint free rag is preferable Clean all inter nal components of any foreign material 2 Lubricate the head and all seals with hydraulic fluid prior to installation Install the seal wiper o ring back up ring and retraining ring to the cylinder head 3 Lubricate the piston and all components with hydraulic fluid Install the seal and wear ring to the piston NOTE He check that seals are not twisted or pinched and are properly seated 4 Place the rod on a clean table Install the static pis ton o ring seal into the groove on the piston end of the rod 5 Install the head followed by the piston onto the rod noting the proper orientation of each component Torque the piston nut to 100 120 ft Ibs 6 When the rod assembly is ready to be installed into the tube liberally apply an anti seize lubricant to the cylinder head surface which slides into the cylinder tube 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 it s groove 3121187 SECTION 5 MAST COMPONENTS Lift Down Valve and Manual Release Installation 1 Lift Down Valve a 3 Solenoid Retaining Nut 5 O Ring with Backing Rings a 7 Solenoid O
56. 1 Bumper Cover 3 AC Input Receptacle 2 Screws Washers Assembly Cover A WARNING NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL THE PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVE MENT BY BLOCKING OR OVERHEAD SLING 3121187 SECTION 3 BASE COMPONENTS Drive Motor Cover Installation To gain access to the drive motor cover and screws ele vate the platform Drive Motor Cover Installation 1 Cover 2 Screws Washers a 3 Platform Stop a b 4 U Style Tapped Nuts NOTE Apply Loctite 242 to threads before tightening a Height of the platform stops is set by installing two 2 5 16 dia wide plain steel flatwashers under the head of each stop tighten securely 3121187 3 3 DRIVE AND CASTER WHEELS Rear Drive Motor Wheel Removal Drive Wheel Removal Tool 1 Wheel Puller Tool a 2 Puller Hex Head Screw b NOTE First remove the Hub Cover Cotter Pin Shield and Nut a JLG Tool Part Number 2915027 b Tighten in against the end of the drive motor shaft until the wheel comes loose 3 Interface with back of wheel spokes Drive Motor Wheel Hub Installation Drive Wheel Hub Installation 1 Rear Drive Wheel 2 Keyed Hub Insert NOTE Apply loctite 271 to threads torque to 19 ft Ib 3 Hub Screws a
57. 17 Drive Lift Mode Switch Install Remove 4 17 Horn Button Switch InstalllRemove 4 17 Key Switch Install Remove 4 17 E Stop ShutDown Switch Install Remove 4 18 Joystick Assembly Install Remove 4 18 SECTION 5 MAST COMPONENTS 5 1 MAST COMPONENTS OVERVIEW 5 1 5 2 MAST COVER 2 5 2 5 3 PLATFORM ASSEMBLY INSTALL REMOVE 5 2 5 4 MATERIAL TRAY 5 3 5 5 HYDRAULIC LINE DISCONNECT SPECIAL 5 8 TOOL USO hac i eee aman dos ete Ld es tts tipa ea Re Mute 5 8 5 6 MAST ASSEMBLY 0 1 0 5 4 io REL Wee 5 4 Mast e ber te em teet er oy Bert pe Poet tr Re ees 5 4 5 7 MAST DISASSEMBLY 5 5 Mast Disassembly 1 4 24 4 5 5 5 8 CYLINDER 5
58. 2 sa mak Um Deere SNR DEN e Y E ER 1 8 Hydtra lic Oil noL ERE RE eU setis E TE 1 3 Lubrication Specifications 1 3 1 6 HYDRAULIC PRESSURE SETTINGS AND ADJUSTMENT 1 8 Hydraulic Pressure Gauge 1 4 After Filter Pressure 1 4 1 7 CYLINDER SPECIFICATIONS 1 4 2 1 4 1 8 SERIAL NUMBER LOCATIONS 0 1 4 SECTION 2 GENERAL SERVICE INFORMATION 2 1 MACHINE PREPARATION INSPECTION AND 2 1 General s s adc eut REG eto e Zi eee Ra ace EAE S de id 2 1 Preparation Inspection and 2 1 Pre Start lrispectioft ize REM rU RUNE en E TRUE 2 1 Pre Delivery Inspection and Frequent 2 1 Annual Machine 2 2 1 Preventative 1 2 2 1 3121187 JLG Lift TABLE OF 5 2 2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE 2 2 Maintenance and Inspection Table Codes
59. 207 96201 7760 06067 9 56 osio 078 807 086 SIG 55961 Zee Sze IIZ ese 02996 79780 0 862 68 vec 9c POL 890 00 9 bec veel 20590120 8L 582 ISZOL 9Z tez 86c 1626 bec egt 6 poz 0559 09 90 LL 8006 866 602 97 LEZ 8 68 8 284 99190 9821 8L 96 0 2 9628 vec 88 6vL 689 1 69 601 c9cG 60970 L 99 9 68 ecl 9L cego 9EL 801 88 vS8v 9070 007271 0c z 1 v9 9L oer 60L orl 5 6 54 66 GZ SOLb 0960 l coL yges 46 L8 601 587 L8 89 89 Gl GCve GLOCO zi 0c 9L 96 cc8v 601 98 Gl 46 cecer Gl L9 98v 89 4806 00 00 vl 89 96 GZ 19 8r 89 6866 tS ve 0 50 062020 ezoso Ve 9 6 89 514 9 8v 8 Le ly bree 69610 9 26 LEOZ Lv ve ra LESZ 6c c 6L 9c 879 4vVV O 0 6 0 9 2262 Lt 0 Gz ve lyric 9 ZZ 8l z 6 5 Leel0 8l 6L 69 Lo vl 6L 887 9 OL vl 240 40600 05690 8c v 8L 8L L 9 26 6 LL 916 80800 0c 9 8 218 Y 9 686 80900 eqs 1 u f G 806 5 00 9870 Ol r S 66S Y 9 77600 9 E r S zg Y 807 95600 29 70 8 2 2 2 ZZ 85200 0 ze T Z tac 2980 L H zz 161 8
60. 3 220 0 1060 792 845 1170 27 3 459 286 0 1540 1160 1240 1690 30 3 5 561 349 5 2100 1570 1680 2310 33 3 5 694 432 5 2600 2140 2280 2860 36 4 817 509 0 3660 2750 2930 4020 42 4 5 1120 698 0 5860 4400 4690 6440 Note Thesetorque values do not apply to cadmium plated fasteners METRIC CLASS 8 8 METRIC CLASS 10 9 Figure 1 6 Torque Chart Metric Class Fasteners JLG Lift 3121187 SECTION 2 GENERAL SERVICE INFORMATION SECTION 2 GENERAL SERVICE INFORMATION 2 1 MACHINE PREPARATION INSPECTION AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition For maximum service life and safe operation ensure that all the necessary inspections and maintenance have been completed before placing the machine into service Preparation Inspection and Maintenance It is important to establish and conform to a comprehen sive inspection and preventive maintenance program The following table outlines the periodic machine inspections and maintenance recommended by JLG Industries Inc Consult your national regional or local regulations for fur ther requirements for aerial work platforms The frequency of inspections and maintenance must be increased as environment severity and frequency of usage requires Pre Start Inspection It is the User s or Operator s primary responsibil
61. 5kg 390kg Australia Indoor Use Only 1 Operators Platform 2 Platform Load Operator 3 Platform Swing In Entry Gate 4 Material Handling Tray 5 Storage Hook 6 Ext Cord Wrap Hooks 7 Lanyard Attach Point 8 Carry Deck Hood NOTE Distribute weight evenly in platform and material tray when loading Reference the capacity decal located on the machines mast cover in the operators plat form Platform Size 19 5 in W x 27 in L 49 5cm x 68 5cm Material Tray Size 26 3 in W x 25 6 in L 67cm x 65cm Platform Height Fully Elevated 10 ft 3 09m To floor of platform Platform Maximum Working Height Platform fully elevated Operator height 16 ft 4 92m approximately Machine Height Platform Elevated 13 74 ft 4 19m Top of platform rails Platform Stowed 57 in 1 44m Machine Overall Length 60 in 1 52m Width 29 5 in 74 93cm Platform Entry Height Floor to Platform Floor 13 5 in 34 3cm Machine Underclearance 1 875 in 47 6mm Machine Turning Radius Outside 65 in 165cm 3121187 SECTION 1 MACHINE SPECIFICATIONS 1 4 TORQUE REQUIREMENTS When maintenance becomes necessary or a fastener has loosened refer to the applicable Torque Chart Figure 1 4 Figure 1 5 and Figure 1 6 in this section of the man ual to determine proper torque values for various size fas teners 1 5 LUBRICATION Hydraulic Oil Hydraulic oils must have
62. 91070 8v 11 Z ce 172 L zi eoo 9 079p Y WN Dy WN WN WN WN py WN WN WN WN 291 SE LLZ 272 T LLZ 272 b QVOTANVID agon 97 QVOT adaon QVO 2 HO1Vd 190 201 anoHoL spun anoHoL EWO peg pus al M3U9S dV2 QV3H 1390S 108 Ferne 2 DEEST e ES PEA SLNN EAE 2 9 51709 AVS KINO S109 HV ki 9NIZ SANTA Figure 1 5 Torque Chart ANSI to METRIC Conversion 1 7 JLG Lift 3121187 SECTION 1 MACHINE SPECIFICATIONS CLASS 8 8 METRIC BOLTS amp CLASS 8 METRIC NUTS VALUES FOR ZINC PLATED YELLOW CHROMATE FASTENERS ONLY CLASS 10 9 METRIC BOLTS amp CLASS 10 METRIC NUTS DRY OR Loctite CLAMP pay on LOCTITE SIZE PITCH AREA LOCTITE ii 2420R LOAD Loctite Lue 242 OR 263 271 263 271 5 3 13 3 5 6 6 78 4 22 3 0 2 2 2 4 3 3 4 7 8 78 5 47 4 4 3 3 3 5 4 8 5 8 14 2 8 85 8 9 6 6 7 1 9 7 6 1 20 1 12 5 15 11 12 17 7 1 28 9 18 25 19 20 28 8 1 25 36 6 22 8 37 27 29 40 10 1 5 58 0 36 1 72 54 58 79 12 1 75 84 3 52 5 126 95 101 139 14 2 115 71 6 200 150 160 220 16 2 157 97 8 313 235 250 344 18 2 5 192 119 5 430 323 344 473 20 2 5 245 152 5 610 458 488 671 22 2 5 303 189 0 832 624 665 915 24 3 35
63. AL AC AND DC CIRCUITS AND DETERMINE WHICH COMPONENT HAS FAILED A WIRING DIAGRAM FOR THIS MODEL DUAL VOLTAGE SCR CHARGER IS INCLUDED AT THE END OF THIS SECTION OF THE MANUAL SEE FIGURE 3 3 The battery charger allows for replacement of the follow ing internal components Consult your Illustrated Parts Manual for part numbers of these components which are available from the JLG Parts Department Transformer Printed Circuit Board e Shunt Assembly Interlock Relay SCR Rectifier AC Circuit Breaker DC Circuit Breaker AC Voltage Selector Switch Wet VRLA Charging Profile Selector Switch Replacement and troubleshooting of these components requires removal of the battery charger from it s mounting position on the machine Battery Charging Status Indicators The battery charging status LED indicators are located next to the charger AC input receptacle on the rear bumper of the machine This LED indicator set is plugged directly into a connector on the back of the battery charger and indicates current charging status When first plugged in the charger runs through a self diagnostic test lighting the LEDs in sequence then charg ing will begin The following descriptions indicate charg ing status after diagnostic test is complete 2 CHARGE COMPLETE GREEN LED ON HE 100 Complete a 3 20 JLG Lift MU 0 mus CHARGING L AMBER MIDDLE LED ON
64. Auxiliary 1 Circuit 6 21 Code 26 Auxiliary 2 Short 6 21 Code 27 Auxiliary 2 Disconnected 6 22 Code 28 RESERVED una ena y get d n aea SQ SY 6 22 Code 29 RESERVED eR od Ron 6 22 Code 30 Traction Module No Communication with Ground Control Module 6 23 Code 31 Platform Control Console No Communication with Ground Control Module 6 24 Code 32 Pump Motor Over 6 24 Gode 33 RESERVED i rete deo RN ac Ese Fen RD ET 6 25 Code 34 Auxiliary 2 6 25 Code 35 Auxiliary 2 Tie 6 25 Code 36 S RESERVED 4 rude D Wr se e RT eka 6 25 Code 37 RESERVED ES RA eV d PY Tu ER 6 25 Code 38 Battery Voltage Low Warning Level 2 Two 2 LED LCDs lit 6 26 Code 39 Battery Voltage Low Warning Level One 1 LED LCDs lit 6 26 Code 40 RESERVED iunc dd acta del VAR ACA Rt sp Dei B yas up A TR drca 6 26 Codes 41 thru 46 RESERVED 6 26 Codes 100 199 Ground Control Module Fault Condition
65. Control Module Replace Ground between pin 13 and pin 6 Is reading within specification 2 4V DC Control Module Goto Step 2 2 Removethe wire terminals atthe alarm check continuity of each of Replace th the wires from pins 13 and 6 on the P1 connector to the alarm end Code 20 Beacon Short Circuit Check For These Obvious Conditions First Damaged wiring in the beacon wiring harness or a damaged beacon unit Table 6 21 Code 20 Beacon Short Circuit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the voltage Replace Ground across pins 12 and 5 to the beacon Is reading within specification 0 2VDC GotoStep2 Control Module 2 Remove the wire terminals at the beacon check continuity of each ofthe wires from pins 12 and 5 onthe P1 connector to the beacon the R end eacon eplace Wiring 6 18 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING Code 21 Beacon Disconnected Check For These Obvious Conditions First 5 machine equipped with flashing amber beacon light Table 6 22 Code 21 Beacon Short Disconnected STEP ACTION SPEC YES NO 1 Ismachine equipped with a flashing amber beacon light Goto Step 3 Gotto Step 2 2 Atthe Ground Control Module enter the programming mode check ifthe Beacon light open circuit detection is enabled Disable It 3 Checkvoltag
66. ELLOW SHIELD B BLACK RS485B BLUE RS485A ORANGE AUX 1 SIGNAL B BROWN BLACK AUX RETURN BLACK REQ SECURITY LOCK SUPPLY 24v Dc RED SECURITY LOCK 516 1 BROWN SECURTY LOCK SIG OUT ORANGE BLACK SPARE RED BLACK SPARE BLUE BLACK ale gt gt ad ipd 8 HAE s 2 EIE ala 2 ue Ble 5 s g g 255 22 j s emn s s 218 8 5 gt 545 815 z 4 5 als 2le o alo x lt 213 s 5 gl e sem 5 215 5 IE EIE EIE 5 PLATFORM el Els aux 2 MO 218 3 5151 5 gt E 8 E z E 9 PLATFORM 3 0 20 AUX 1 erat AUX INPUT 1 P gt gt sl B BLACK B BLACK eile ON OFF BLUE ON OFF BLUE COM WHITE COM WHITE ols 2 lo ale 1 5 s 2 i 5 z o I i 1 gt 8 P3 5 feat s I i 1 GROUND STATION MODULE Boiss modii Eher ee L L L La Ska s La T las asas tA BLACK 16 ORANGE RED 49 8 VOLTAGE LOW REF AUX ANALOGUE INPUT SPARE ANALOGUE INPUT YELLOW RED 2 4 BLACK 15 g OLTAGE HIGH REF BLACK 14 ORANGE RED 49 7 YELLOW RED 2 3 13 TILT SWITCH RETURN INHIBITS LIFT DRIVE B TILT SWITCH B POWER BLACK ORANGE RED 49 6 B AUX 2 SIGNALSPARE DIGITAL INPUT 2 AUX 2 RETURN PROGRAMMABLE C
67. ERVAL AREA ON MACHINE PRE START a 3 MONTH 6 MONTH PRE DELIVERY b ANNUAL d INSPECTION PREVENTATIVE PREVENTATIVE ORFREQUENT c YEARLY MAINTENANCE MAINTENANCE INSPECTION INSPECTION MAST ASSEMBLY 7 Mast Sections 2 5 2 5 Chain Systems 14 3 14 14 25 Sequence Cable Systems 3 1 2 3 Covers and Shields 1 Sheave Systems 1 2 1 2 Bearings 1 2 Slide Pads 1 2 PLATFORM ASSEMBLY 7 Platform and Material Tray 1 1 Guard Rails 1 2 4 1 2 4 Gate 125 1 5 Floor 1 2 1 2 Lanyard Anchorage Point 1 4 1 4 CHASSIS ASSEMBLY 7 Hood and Covers Installation 1 7 1 7 Static Strap 1 1 Caster Wheels 1 2 1 2 1 2 Drive Wheels Axle Assembly 2 2 Gear Box Assembly Drive Motor Brushes FUNCTIONS CONTROLS 7 Platform Controls 5 6 7 5 6 7 Ground Controls 5 6 5 6 14 Function Control Locks Guards or Detents 5 5 Function Enable System 5 Emergency Stop Switches Ground amp Platform 5 Function Limit or Cutout Switch Systems 5 Brake Release 5 Manual Descent or Auxiliary Power 5 5 POWER SYSTEM Batteries 19 9 18 Battery Charger 5 HYDRAULIC ELECTRIC SYSTEM 9 Hydraulic Pump 1 2 9 1 2 5 9 Hydraulic Cylinder 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 9 25 Hydraulic Fluid 11 11 11 Electrical Connections 20 20 Instruments Gauges Switches Lights Horn 5 3121187 JLG Lift 2 3 SECTION 2 GE
68. ESCRIPTION FOR TROUBLESHOOTING FAULT CONSOLE CODE LEDs LCD SYMBOL SCREEN LCD TEXT SCREEN MACHINE CONDITION REFER TO FLASHING See Table 6 24 23 E Me Horn Disconnected X 000000 23 23 Page 6 20 RUX 1 SHORT ss DRM See Table 6 25 24 E3 Auxiliary 1 Circuit Short Pane 6 20 X 000000 424 24 0 AUX 1 Auxiliary 1 Circuit SeeTable 6 26 25 4 gt DISCONNECTED Disconnected Page 6 21 X 000000 25 25 AUX 2 SHORT 2 E3 BN Auxiliary 2 Circuit Short 2 27 26 26 age 6 21 RUX 2 Auxiliary 2 Circuit See Table 6 28 pt 1 27 ES 22 lt gt D CONNECTED Disconnected Page 6 22 28 RESERVED RESERVED 29 RESERVED RESERVED Traction Module 30 6 lt gt MODULE No Communication X 00000 0 430 no conns 30 with Ground Control Module 9 Platform Control Console 31 24 lt gt No Communication with sr X 000000 0 conns 431 Ground Control Module agea PUMP MOTOR Pump Motor Over Current See Table 6 31 32 7 E3 gt OVER CURRENT LIFT UP Disabled Page 6 24 X 00000 0 32 32 33 RESERVED RESERVED Auxiliary 1 Inhibit 4 4 797 25 LIFTUP IDOWNandDRIVE 27 X 000008 34 34 are Disabled agen Auxiliary 1 Tie Down 35 m h OX TE DOU 2 LIFTUP D0WNandDRIVE L 2 X 00000 0 35 4 35 are Disabled age o 36 RESERVED RESERVED 6 6 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING
69. Fault Code while performing Step 1 Replace Ground Control Module 3 ls the pump hydraulic pressure setting within specification as show Adjustto in Section 1 6 of this Service Manual See Section 1 6 Goto Step 4 Specification 4 Check pump motor brushes and rotor commutator for abnormal Replace as Replace wear v Required Pump Motor 6 24 Lift 3121187 SECTION 6 TROUBLESHOOTING Code 33 RESERVED Code 34 Auxiliary 2 Inhibit Check For These Obvious Conditions First Open Platform Gate No Pressure on the Platform Footswitch Table 6 32 Code 34 Auxiliary 2 Inhibit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the voltage Replace Ground across pins 8 and 1 to the Aux 2 component Is reading within 0 2VDC Goto Step 2 C Modul specification 2 Removethe wire terminals atthe Aux 2 component check conti nuity of each of the wires from pins 8 and 1 onthe P1 connectorto dins R the Aux 2 component end omponen LL Code 35 Auxiliary 2 Tie Down Check For These Obvious Conditions First Pressure on the Platform Footswitch during machine power up Table 6 33 Code 35 Auxiliary 2 Tie Down STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the voltage Replace Ground across pins 8 and 1 to the Aux 2 component Is re
70. Ge 04 006 Or ce 9 Ge 0095 8 800 0S 0 vc 8 94 09 1 06 Ov Ge Sv 0004 Ge 8c ec 0 92 00 OL 2 0089 oe Sc Oc Sc 0 9 LZ ZL vL 6L 007 08600 Szieo vc L S 9 044 0 8L 9 OcAv 6L 9L L ZL OEE vcS0 0 8 141781 1441 14781 148471 1481 vl 079 68 OcL 89 08 6 98 AA v9 00 00520 8c bil L ogle 09 80 0984 SOL GL 96 0202 800 Oc LS 89 008 96 6r 686 000400 006120 oL 09 084 ce cv 0 092400 vc cv OZEL Le 06 7700 OP9L O 9 g Le Lv 096 06 006 007100 mE 6L Sc 0c6 L SL OL9 910100 OgeL o OV 9 mE LL EZ 008 9L 086 606000 ce OL L 009 2 6 ocr 990070 02 0 8v 6 OVS E mE 9 8 08 v0900 0 Or Tree Can zt D 592 E TU S 7m gt im O01 g NI OS anoo 0901 4 12 3 59 aji9o 1 amigo ano 811 woma QVOT CND H31Yd 13M 901 HLIM aINOHOL dWV 19 ANOYOL 12 ssauis VIG 3218 M383S dY3 0V3H 13830S 1108 Salas 0361 owyuann ESO TTE py 1709 8 3QV39 avs SLNN Z 9 S1709 S avs SM3U9S 4 9 311480 517109 31 14 9NIZ 804 S360 1VA Figure 1 4 Torque Chart ANSI Spec 3121187 JLG Lift 1 6 SECTION 1 MACHINE SPECIFICATIONS
71. JL Service and Maintenance Manual Model s SSV Series P N 3121187 February 15 2012 JG INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS MAINTENANCE SAFETY PRECAUTIONS A GENERAL C MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial A WARNING platform It is of utmost importance that maintenance per FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN sonnel pay strict attention to these warnings and precau THIS SECTION COULD RESULT IN MACHINE DAMAGE PERSON tions to avoid possible injury to themselves or others or NEL INJURY OR DEATH AND IS A SAFETY VIOLATION damage to the equipment A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe to operate A WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA TION The specific precautions to be observed during machine maintenance are inserted at the appropriate point in the manual These precautions are for the most part those that apply when servicing hydraulic and larger machine component parts Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of component weight and never attempt to move heavy parts without th
72. M2 Replace Traction connector wiring harness going to the right drive motor Is reading 110 3 ohms Module Go to Step 2 within spec 2 Repair or replace right drive motor wiring brushes or motor For brush replacement see Section 3 of this Service Manual E E Code 09 Left Brake Disconnected Check For These Obvious Conditions First Check left drive motor M1 connector at the Traction Control Module for secure and proper connection Table 6 10 Code 09 Left Brake Disconnected STEP ACTION SPEC YES NO 1 Checkresistance across positive and negative leads in M1 Replace Traction connector wiring harness going to the left drive motor brake assem See Table 6 2 Module Goto Step 2 bly Is reading within spec 2 Repair or replace left brake wiring or left brake assembly Code 10 Right Brake Disconnected Check For These Obvious Conditions First Check right drive motor M2 connector at the Traction Control Module for secure and proper connection Table 6 11 Code 10 Right Brake Disconnected STEP ACTION SPEC YES NO 1 Checkresistance across positive and negative leads in M2 Replace Traction connector wiring harness going to the right drive motor brake See Table 6 2 Module Goto Step 2 assembly Is reading within spec Repair or replace right brake wiring or right brake assembly 6 14 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING Code 11 Left Drive Motor
73. Motor Cover 3 Hydraulic Pump Motor Reservoir 4 Battery Charger 9 Batteries 6 Limit Switches Mast Activated 7 Front Caster Wheels 8 Drive Motor Assemblies 9 Rear Bumper Cover 3121187 JLG Lift 3 1 SECTION 3 BASE COMPONENTS 3 2 BASE FRAME COVERS Front Cover Installation Original 2 Cover Screws 3 places 1 Front Cover Front Cover Installation Carry Deck Version 2 2 Front Cover Carry Deck Installation 1 Front Cover Carry Deck a 2 Cover Latches 3 places b NOTE The Carry Deck has a maximum capacity of 250 Ib 115k b Lift each latch until straight out to release from the latch mount under the cover Lift the rear of the hood Slightly out of the frame gasket and pull out on each rear latch to clear the latch mount on the base frame Lift deck and slide deck forward and lift to remove deck from machine 3 2 JLG Lift Carry Deck Support Frame Installation Carry Deck Support Frame Installation 2 Support Screws 4 places Apply Loctite 242 1 Carry Deck Support Rear Bumper Cover Installation Five 5 of the Drive Motor cover screws must be removed to remove the rear bumper cover see the Drive Motor Cover Installation illustration To gain access to those screws elevate the platform Rear Bumper Cover Installation
74. NERAL SERVICE INFORMATION Table 2 2 SSV 10 Preventive Maintenance amp Inspection Schedule Continued INTERVAL AREA ON MACHINE PRE START a 3 MONTH 6 MONTH PRE DELIVERY b ANNUAL d INSPECTION PREVENTATIVE PREVENTATIVE ORFREQUENT c YEARLY MAINTENANCE MAINTENANCE INSPECTION INSPECTION GENERAL Operation amp Safety Manual in Storage Box 21 21 21 ANSI amp EMI Handbooks in Storage Box 21 21 21 Capacity Decals Installed Secure Legible 21 21 21 All Decals Placards Installed Secure Legible 21 21 21 Walk Around Inspection Performed 22 Annual Machine Inspection Due 21 No Unauthorized Modifications or Additions 21 21 All Relevant Safety Publications Incorporated 21 21 22 General Structural Condition and Welds 2 4 2 4 All Fasteners Pins Shields and Covers 1 2 Grease and Lubricate to Specifications 22 22 Function Test of All Systems 22 22 Paint and Appearance 7 7 Stamp Inspection Date on Frame 22 Notify JLG of Machine Ownership 22 KKK Change only when serviced requires 6 oz 175cc s to fill Replace every 200 400 hours Traction Time Depending on Application Drain and refill with fresh hydraulic fluid every two years Maintenance and Inspection Table Codes 1 03 0 cs OD n n n c c nb uuu umo Gon or c Check for proper and secure installation Visual inspection for damag
75. O 1 Is machine equipped with acomponentonthe Auxiliary 2 circuit Goto Step 3 Gotto Step 2 2 Atthe Ground Control Module enter the programming mode check Replace Ground ifthe Auxiliary 2 open circuit detection is enabled Default NO Disable It Control Module 3 Check voltage atthe P1 connector on the Ground Control Module Replace Ground between pin 8 and pin 1 Is reading within specification 2 4VDC Control Goto Step 4 4 Removethe wire terminals atthe Aux 2 component check conti nuity of each of the wires from pins 8 and 1 onthe P1 connectorto 2 n R ji the Aux 2 component ep ace vviring Code 28 RESERVED Code 29 RESERVED 6 22 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING Code 30 Traction Module No Communication with Ground Control Module Check For These Obvious Conditions First Check if the communications cable connections P5 connector on the Ground Control Module and round plug on the Traction Control Module are seated properly in their sockets at each end Check the Positive RED and Negative BLACK power cable connections from the Ground Control Module to the Traction Control Module are tight and secure at both ends Table 6 29 Code 30 Traction Module No Communication with Ground Control Module STEP ACTION SPEC YES NO 1 Checkthe voltage reading atthe main power Positive Negative Repair o
76. OLSLL 052 90S 09cL 089L 00082 09181 00S cL zi Ocec 00SSLL 5092 706 082 08606 SZS 00LL 09 OOLY9 OSSLL 9 088 00 40L 0022 0 9 004 0004 00996 008 026 Ovcl 00965 06 07 005221 cL list 042 00696 0004 O9EL 028 00248 S4LL 6001 Ove 0 OO8ES 0696 0 2 08 00968 0801 00044 406 08 099 088 004 7 09980 09211 cL 81 1 Ortz 0089 1 00 0 0L 096 082 00 89 0r8 009 008 00607 0 9 0 2 9 6 00699 00LL 962 Ord 000 00 66 Gel 9 oes 004 00 06990 0007 cL 598 00909 066 289 089 006 00919 65 9 6 4 08 0r9 00986 09090 8 469 006065 S ves 004 099 00857 006 SCV 066 0 7 OOVCE 06090 05 80 vL 8 2 996 00297 099 68 09 009 009 GLY 986 oze oer 00 6 02970 6 00 00 9 026 ocr 009 lt 0 894 Occ 00 00862 0 4 0 00940 9 596 OOvVEES ocr LOE 082 08 00 06 480 Orc 004 094 OOELZ OL Occ 0098 S9c voc 08 Orc 000 c 06 esl 07 00 lt 9 09500 05290 8 g s 0 2 009cc Orc 08 07 Occ 0S 0c 49 04 oorr 09200 LL GOL 00 lt 04 06 027 06528 SEL 601 06 0 0466 06000 52980 8L 91 6 SSL 0028 59 OSL 00 9 86 08 009LL OcS8LO cL 0666 GEL 801 06 OcL 00 08 49 06 0070 66910 00050 Oc zi 06 och 96 08 04 6 98 89 99 GL 0406 60 L Gl 08 1 06 OL 09 08 OOZOL 09 04 Or GS 0464 48 0 5 60 Oc 9UL OL 08901 08 9 SG 04 0996 GS Sv Ge 05 0089 90 0 vL 065 08 8 GS Sv
77. OMPONENT DATA 2 ee shrek eh iae n Ute oe d aetna MUN ELE 1 2 Hydraulic Pump Pump Motor 1 2 Rear Wheel Drive 0 1 2 Batteries Battery Charger 1 1 2 1 3 PERFORMANCE DATAS tawna A ee Reg D Bae ee a as ad 1 2 Platform Capacity sve scies 1 2 5126 25 25 Er 1 2 Material Tray Size iei creer Ip a We Irt ue P s 1 2 Platform Height Fully 1 2 Platform Maximum Working Height Platform fully elevated Operator height 1 2 Machine Height Platform Elevated 1 2 Machine Height Platform Stowed 1 1 2 Machine Overall 1 2 Machine Overall 1 2 Platform Entry Height Floor to Platform 1 2 Machine 2 4 1 2 Machine Turning Radius 1 2 1 4 TORQUE REQUIREMENTS 1 8 1 5 LUBRICATION
78. ORE MAKING ADJUSTMENTS LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPO NENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACH MENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS INTRODUCTION REVISION LOG REVISION LOG Original Issue of Manual July 15 2004 Manual October 25 2004 Manual August 1 2005 Manual June 18 2007 Manual 15 2012 Lift 3121187 TABLE OF 5 TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO MAINTENANCE SAFETY PRECAUTIONS Dc GENERALI ML LU a Rc B HYDRAULIC SYSTEM SAFETY scene tasha EM Dui cR REVISI N LOG NAE v PO B SECTION 1 MACHINE SPECIFICATIONS Ja GARAGES US ras ret Ros A deed eee Da ae M rtc 1 2 System Voltage puente ch e pco on dpi e red Cu eet 1 2 Hydraulic Syston c Doy EH tnde de d ie pets p a ene 1 2 Drive Motor GearBox Gear Oil 1 2 1 2 C
79. P ACTION SPEC YES NO 1 Atthe Traction Control Module check if the left drive motor power Switch the Left lead is plugged into the M1 socket and Right Drive NOTE The left drive motor power lead uses a reverser har Go to Step 2 Motor Power ness between the module and the power lead to the Leads atthe motor Traction Module 2 Remove the Right Drive Motor power lead at the Traction Control Module M2 and check if the WHITE wire is connected to the posi Rewire as tive terminal and the BLACK wire is connected to the negative Goto Step 3 NGCOSS3r terminal Reference Figure 6 3 Electrical Diagram y 1870182 D 3 Remove the Left Drive Motor power lead atthe Traction Control Module M1 and check if the BLACK wire is connected to the posi tive terminal and the WHITE wire is connected to the negative Consult Rewire as terminal The Left Motor Power lead is reversed fromthe Right Factory Necessary Motor lead due to the reverser harness Reference Figure 6 3 Electrical Diagram 1870182 D 6 36 Lift 3121187 SECTION 6 TROUBLESHOOTING Machine Won t Drive Straight Overview Of Procedure The following procedure examines the drive motor assembly weldments attaching the drive motors to the base frame Also internal components of the drive motors gear box and a check of the components between the gear box and the drive wheels Check For These Obvious Conditions First Battery voltage 24 vo
80. Ring 2 Valve Solenoid b 4 Manual Release Assembly 6 Valve 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 3121187 JLG Lift 5 9 SECTION 5 MAST COMPONENTS 5 9 MAST ASSEMBLY Assembly procedures for all mast sections is basically the same carefully slide the mast sections together until mast ends are even When sliding the mast sections together be careful not to scratch the anodized surface in the wear pad channels Assemble the hardware to the bottom of mast section first slide this section out the top of previous section and assemble hardware to the top of mast Always install slide pad shims with slide pads inserted into the slide pad channels ends of mast sections even Apply ing Krytox spray JLG P N 3020041 onto the slide pads and slide pad channels before assembly will help mast sections slide easier after slide pads have been properly shimmed CLOSED RAIL REFERS TO CLOSED RAIL BACK OF MAST SECTION REFERS TO BOTTOM END OF MAST SECTION WHICH SETS IN MACHINE S BASE FRAVE Figure 5 4 Mast Section Assembly Reference 5 10 JLG Lift 3121187 SECTION 5 MAST COMPONENTS MAST SECTION 1 ASSEMBLY 1 Place mast section 1 rail open side up See Figure 5 4 on a clean flat surface preferably a table or work bench capable of supporting the weight o
81. ST IS FULLY LOWERED BEFORE REMOV ING ANY HYDRAULIC LINES FROM THE PUMP UNIT WEAR PRO TECTIVE GEAR WHEN WORKING AROUND PRESSURIZED HYDRAULIC LINES REMOVE CONNECTIONS CAREFULLY AND CAP ALL LINES AND PORTS WHEN DISCONNECTED NS Hydraulic Pump Assembly Components 1 Hydraulic Pump Motor Res 4 Hydraulic Extend Pressure ervoir Assembly Line to Lift Cylinder b 2 Power Cable from 9 Hydraulic Return Line from Ground Control Station a Lift Cylinder b 3 4 Power Cable from Ground Control Station a NOTE a Shown with protective cover removed b Completely lower platform before loosening any hydraulic lines to remove any pressure remaining in the lines Take proper caution and wear protective gear any time you are opening a hydraulic line Once power cables and hydraulic lines are removed from this side of pump assembly remove the mounting screws from the other side of the pump see the follow ing illustration 3 6 JLG Lift 3121187 3121187 SECTION 3 BASE COMPONENTS Zl w SS SN ESSE N V ANM Motor Remove Install Reference Marks Hydraulic Pump Mount and Mounting Screws Hydraulic Pump Motor Reser 3 Pump Mounting Screws a voir Assembly Pump Ground Control Station Mounting Bracket N NOTE
82. Section 1 and the cylinder into Section 2 Bottom of Mast Section 2 Cylinder Assembly Installation 1 Cylinder Assembly 3 Cyl Mount Reinforcement 2 Shim Stock a Plate 4 Cyl Mount Bolts and Washers b Nole a Thickness as required both sides to center cylinder mount in mast assembly b Apply Loctite 242 to threads 13 At the bottom of mast section 1 check for side to side clearance of the cylinder mount Use mounting shims of equal thickness on each side to center the mount in the closed rail portion as necessary 14 Install the mount reinforcement plates and mount bolt and washers Apply Loctite 242 to threads of mounting bolts before final assembly 3121187 SECTION 5 MAST COMPONENTS 15 Slide mast section 2 out of mast section 1 approxi mately one foot Top of Mast Section 2 Chain Anchor Sheave Wheel Installation 1 Anchor Block 6 Sheave Pin Support 2 Sheave Pin Plates a 3 Narrow Spacer Tube a T Key 4 Sheave Wheels Wide a 8 Support Plate Screws b 9 Thrush Washers a 9 Align Pin Holes Note a Install one on both sides of anchor block b Apply Loctite 242 to threads on final assembly 16 Assemble the chain sheave wheel assembly to the chain assembly anchor block which will attach to the cylinder rod and to mast section 2 using following steps a Insert sheave pin through anchor block assem bly b Load one 1 narrow spacer tube
83. TIS PUMP MOTOR So SECURITY LOCK 0 5 45 AUX QuTPUT T E AUX REVERSER ES HARNESS ALARM OUTPUT m ae Fr 1 imum 6 1 BEACON 1 TRACTION l BASE MTD MODULE BATTERIES o a p BEACON 2 LIFT MAST MTD LEFT DRIVE MOTOR RIGHT DRIVE MOTOR CYLINDER Figure 6 2 SSV 10 Overview of Electrical System Components 3121187 Lift 6 39 SECTION 6 TROUBLESHOOTING YELLOW JUNCTION BOX ES QUT YELLOW BLACK 9 ORANGE ES YELLOW KEY 4 C4 lt EE RS485A AUX 1 SIGNAL B BROWN BLACK o 16 AUX 1 RETURN BLACK RED E STOP 4 SEC LOCK SUPPLY 24V DC RED 9 SEC LOCK 516 OUT ORANGE BLACK C5 SHIELD SPARE RED BLACK PARI UE BLACK HORN 1 BLACK BLACK LEFT GATE 9 PROX SWITCH _ 9 SELECT SIGNAL
84. Traction Control Module defective or connections nottight Tighten Connec If possible swap out with another Traction Control Module tions or Replace s Traction Control nbs Module 9 Inside the drive motor gear box checkif the drive shaft is exces Repair Replace gear box sively loose amp condition of drive shaft bearings components per procedure in this Are any gears broken or gear teeth excessively worn Service Manual 3121187 JLG Lift 6 37 SECTION 6 TROUBLESHOOTING Noise From Drive Assembly Overview Of Procedure The following procedure examines the drive motor assembly weldments attaching the drive motors to the base frame Also internal components of the drive motors gear box and a check of the components between the gear box and the drive wheels Check For These Obvious Conditions First Battery voltage 24 volts Fully charge batteries Nothing is lodged between one of the wheels and the base frame A caster wheel on the front of the machine is seized up creating resistance Table 6 48 Noise from Drive Assembly STEP ACTION SPEC YES NO 1 Check forthe following on the drive assembly drive attachment Repair Replace Goto Step 2 weldment is bent has broken welds orloose hardware Tighten weldment 2 Checkforthe following on the drive assembly drive motor hard Repair Replace ware is hardware loose flange bearing bad Tighten Goto Step 3
85. UE DEOR S MUTO a a ERN S 3 14 Checking Adjusting Armature Plate Gap Setting 3 15 Brake Assembly Installation lille III 3 15 Drive Motor Brush 3 16 Brush Removal u zv da Es Rete x iu EROR Y NEAR PY Ue lunas 3 16 Brush Reassembly c eer lI ree erg uQ k e P p a 3 17 3 7 BATTERIES AND BATTERY CHARGER SERVICE PROCEDURES 3 18 Battery Condition Testing 3 18 Battery 2 2 3 18 Battery 1 3 18 Battery Charge LED Indicator on Platform Control Console 3 19 Battery Low Voltage Warning 3 19 Battery Charger General Information 2 3 20 Battery Charging Status 3 20 Wet VRLA Battery Charging Profile 3 20 Battery Charger 3 21 Battery Charger Cover Installation 1 3 22 General Component Installation 3 22 AC Line Fuse Installa
86. UT OUT B AUX SIGNAL PROGRAMMABLE CUT OUT AUX RETURN ORANGE RED 49 5 BLACK 12 ORANGE RED 49 4 BLACK 54 ORANGE RED 49 2 BLACK 9 has 555 28 258 BLACK 10 ORANGE RED 49 3 BLACK 8 ORANGE RED 49 1 T PHP 9 NOT USED 1870182 D Figure 6 3 Electrical Diagram 1870182 D 3121187 JLG Lift 6 41 SECTION 6 TROUBLESHOOTING 6 42 CYLINDER 2 7 x L m 1 i WV ht I i i d Y i 10 x 6 8 i PUMP 5 i E i i 1 Tank 2 Filter Screen 3 Pump 4 Pump Motor 1 2792684_A Figure 6 4 Hydraulic Diagram 2792684_A 5 Pressure Adjust Valve 9 Check Valve 6 Extend Line 10 Pressure Compensator Flow Control Valve 7 Hydraulic Filter 11 Manual Decent Valve 8 Return Line 12 Lift Cylinder JLG Lift 3121187 CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Batteries also contain other harmful chemicals known to the State of California WASH HANDS AFTER HANDLING An Oshkosh Corporation Co
87. achine Drives in Opposite 6 36 Machine Won t Drive Straight 6 37 Noise From Drive Assembly 7 6 38 3121187 JLG Lift V TABLE OF 5 LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Hydraulic Pressure Adjustment 1 1 3 1 2 Typical Hydraulic Pressure Gauge Installation Hydraulic Filter 1 4 1 3 Typical Hydraulic Pressure Gauge Installation After Hydraulic 1 4 1 4 Torque Chart ANSI Spec 1 6 1 5 Torque Chart ANSI to METRIC 2 1 1 7 1 6 Torque Chart Metric Class 1 8 3 1 Base Components irure ed ces pane DECRE GENE eters 3 1 3 2 Brake Assembly Components 2 4 3 14 3 3 SCR Dual Voltage Battery Charger Wiring Diagram 3 25 4 1 Control Components Location 2 4 1 4 2 Component Electrical 4 6 4 3 Ground Control Module
88. ading within 0 2VDC Goto Step 2 C ah Modul specification onto Mogule 2 Remove the wire terminals atthe Aux 2 component check conti nuity of each of the wires from pins 8 and 1 onthe P1 connectorto bin ui R diae the Aux 2 component end omponen epiac Code 36 RESERVED Code 37 RESERVED 3121187 JLG Lift 6 25 SECTION 6 TROUBLESHOOTING Code 38 Battery Voltage Low Warning Level 2 Two 2 LED LCDs To maximize battery life it is recommended that the factory supplied batteries be charged continuously for a minimum of 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 Failure to do so will result in a fault code 39 Code 39 Battery Voltage Low Warning Level 3 One 1 LED LCDs lit To maximize battery life it is recommended that the factory supplied batteries be charged continuously for a minimum of 4 hours or until 8 bars are lit on the ground station LCD Display before operating the machine When drained to Warning Level 1 batteries must be charged until 8 bars are lit on the ground station LCD display to clear the fault code Code 40 RESERVED Codes 41 thru 46 RESERVED Codes 100 199 Ground Control Module Fault Condition Check For These Obvious Conditions First
89. ain Power Circuit 6 9 Mast 6 9 Hydraulic Leak 0 6 9 Base Frame Components 0 6 9 Drive System Troubleshooting 1 6 9 6 6 SPECIFICATIONS FOR VARIOUS 6 10 6 7 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS 6 10 6 8 FAULT CODE TROUBLESHOOTING TABLES 1 6 11 Machine in Drive Speed Cut Back Turtle Mode All The Time 6 11 Code 01 Low Battery 6 12 Code 02 RESERVED i ze er RERO wis Sea upa kya chapara b aera 6 12 Cod 03 RESERVED Dev wa die Va pas Sol eid Nie Rb S 6 12 Code 04 Tilt 6 18 05 RESERVED cet eeu eder eS ER VES a ORA RE ERIT 6 13 JLG Lift 3121187 TABLE OF 5 Code06 RESERVED 24 4 et 6 13 Code 07 Left Drive Motor 6 13 Code 08 Right Drive Motor Di
90. ance of equipment Always be conscious of component weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that ade quate support is provided WARNING NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING Cleanliness The most important single item in preserving the long ser vice life of a machine is to keep dirt and foreign materials out of the vital components Precautions have been taken to safeguard against this Shields covers seals and fil ters are provided to keep the wheel bearings mast sec tions and oil supply clean however these items must be maintained on a scheduled basis in order to function properly At any time when oil lines are disconnected clear adja cent areas as well as the openings and fittings them selves As soon as a line or component is disconnected cap or cover all openings to prevent entry of foreign mat ter Clean and inspect all parts during servicing or mainte nance and assure that all passages and openings are unobstructed Cover all parts to keep them clean Be sure all parts are clean before they are installed New parts should remain in their containers until they are ready to be used Components Removal and Installation Use adjustable lifting devices whenever possibl
91. anti wear qualities at least to API Service Classification GL 3 and sufficient chemical stabil ity for mobile hydraulic system service JLG Industries recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity of 10W 30 and a viscosity index of 152 For cold weather applications i e when temperatures remain consistently below 20 F 7 C JLG recom mends using Mobil DTE 13 hydraulic oil Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not con tain the same required additives or be of comparable vis cosities If use of hydraulic oil other than Mobilfluid 424 is desired contact JLG Industries for proper recommenda tions Table 1 3 Hydraulic Oil Operating Range HYDRAULIC SYSTEM OPERATING SAE VISCOSITY TEMPERATURE RANGE GRADE 0 F to 180 F 10W 18 C to 483 C 0 F to 210 F 10W 20 10W 30 18 C to 499 C 50 F to 210 F 20W 20 10 C to 99 C Lubrication Specifications Table 1 4 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 F Excellent water resistance and adhesive qual ities and being of extreme pressure type Timken OK 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API service classification GL 5 or MIL Spec MIL L 2105 HO Hydraulic Oil ISO Vg grade 32 46 CL ChainLube Use a good quality chain lubricant
92. arged using a charger that supplies 2 45 volts cell Charging should be terminated when the charge current drops below 1 amp Battery Replacement Replacement battery s must be of equivalent voltage and amperage output as the OEM battery s in order for the machine to operate to as manufactured specifications Battery replacement part weight must also be equivalent to OEM 65 Ib 30Kg per battery in order to maintain machine stability as manufactured A WARNING DO NOT REPLACE ITEMS CRITICAL TO STABILITY SUCH AS BATTERIES WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFI CATION DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABIL ITY 3 18 JLG Lift Battery Installation To gain access to the batteries requires removal of the front cover and rear drive motor cover See Section 3 2 on page 3 2 Procedure for removal is same for both batteries On installation batteries set in machine with the posts to the outside Left side battery POS post at front shown below Right side battery NEG post towards machine front A WARNING NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL THE PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVE MENT BY BLOCKING OR OVERHEAD SLING Battery Installation Left Side Battery Shown 1 Battery a b 3 Battery Posts 2 Hold Down Bracket and 4 Drive Motor Cover Screw Screw Brackets NOTE Once hold down bracket item 2 is removed remove the cables fr
93. ault Condition 6 26 6 35 Code 200 299 Platform Control Console Fault 6 27 6 36 Codes 300 399 Traction Control Module Fault 6 28 6 37 Machine Will Not Power 4 2 6 29 6 38 Platform Will Not Lower Manually 4 6 30 6 39 Platform Lift Up and Down Jerky 0 6 30 6 40 Mast Noisy when Lifting and Lowering 2 6 31 6 41 Platform Mast Won t Stay 6 32 6 42 Platform Mast Descends 1 6 32 3121187 JLG Lift vii TABLE OF 5 6 43 Hydraulic Leak 0 1 6 33 6 44 Caster Wheels Not Operating 6 34 6 45 Won t Climb Grade neck ate tak BMW UE TES EE 6 35 6 46 Machine Drive in Opposite Direction 6 36 6 47 Machine Won t Drive 6 37 6 48 Noise from Drive Assembly 2
94. ay Controller Module a Note a Unplug all connections on the back of the module before removing from console 2 Mounting Screws Drive Lift Mode Switch Install Remove Platform Console Drive Lift Mode Select Switch 2 Locking Tabs Note a Remove rear cover unplug switch wire press tabs to remove 1 Switch Assembly a 3121187 Horn Button Switch Install Remove Platform Console Horn Switch Installation 1 Horn Button Switch a 3 Nut 2 Lock Washer Nole a Remove rear cover unplug wire remove nut and lock washer then slide switch out of console Key Switch Install Remove Platform Console Key Switch Installaiton 1 Key Switch a 3 Attach Nut 2 Notch 4 Key Note a Remove mounting bracket on bottom of console to gain access to the key switch assembly JLG Lift 4 17 SECTION 4 CONTROL COMPONENTS E Stop ShutDown Switch Install Remove Joystick Assembly Install Remove Platform Console E Stop Switch Installation 1 Loosen Switch Set Screw 5 Barrel Seal Turn Switch 909 6 Switch to Body Retainer 3 Pull Spring Loaded Hooks a Release Lever Out T Switch Retainer Slots 4 Remove Barrel Assembly N Note a Use a small straight blade screwdriver to extend the spring loaded retainer hooks 6 out and release the switch from the body 4 18 JLG Lift
95. b Ground Control P1 Horn Alarm Beacons Lift Down Valve Harness a P4 Platform Joystick Harness a Module Plugs P2 Elevation Speed Charger Limit Switch Harness a P5 Joystick Protocol Harness to P3 Programmable Security Lock Harness Option a Traction Control Module a Notes 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 c An quick disconnect is installed on the left battery POSITIVE cable for easier power disconnect when servicing machine See Section 6 Figure 6 3 Troubleshooting for complete machine wiring schematic 4 6 JLG Lift 3121187 SECTION 4 CONTROL COMPONENTS 4 3 GROUND CONTROL MODULE SERVICE PROCEDURE IMPORTANT DO NOT ATTEMPT TO DISASSEMBLE THE GROUND CONTROL MODULE IF MACHINE IS STILL UNDER WARRANTY OPENING THE GROUND CONTROL MODULE WHILE THE MACHINE IS UNDER WARRANTY WILL VOID THE WARRANTY IF UNDER WARRANTY REQUEST A REPLACEMENT MODULE FROM THE FACTORY The Ground Control Module allows for field replacement of two 2 components internal to the module Emergency Stop Switch Power Selector Switch Key IMPORTANT ELECTROSTATIC DISCHARGE CAN DAMAGE COMPONENTS ON THE INTEGRATED CIRCUIT BOARD PLACE THE GROUND CON TROL MODULE ON A NON CONDUCTIVE SURFACE WHEN OPEN ING Figure 4 3 Groun
96. ble 6 43 Hydraulic Leak Troubleshooting STEP ACTION SPEC YES NO 1 Oilleaking around the lift cylinder rod Replace the Seal a atthe end of the _ Piston and Cylinder Barrel 2 Oilleaking around the cylinder extend or return line fittings u Tighten or Replace Fittings 3 Oilleaking around the hydraulic lines Tighten or Replace Hydraulic Lines 4 Oilleaking around the lift down valve EX Tighten Cartridge E in Pump Case 5 Oilleaking around the Red manual descent valve __ Replace Lift u Down Valve Note Do not overtighten the nut on the solenoid in step 5 3121187 JLG Lift 6 33 SECTION 6 TROUBLESHOOTING 6 12 BASE FRAME COMPONENTS TROUBLESHOOTING Caster Wheels Not Operating Freely Check For These Obvious Conditions First s machine operating on a smooth level surface Table 6 44 Caster Wheels Not Operating Freely STEP ACTION SPEC YES NO 1 Isthecaster rotating freely Lubricate or Goto Step 2 Replace Caster Housing 2 lsthe wheel spinning freely e Lubricate or Goto Step 3 Replace Wheel 3 15 debris stuck in the rubber wheel m Remove Debris or __ Replace Wheel 6 34 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING 6 13 DRIVE SYSTEM TROUBLESHOOTING Won t Climb Grade Overview Of Procedure The following procedure checks the drive motor and attached components for component failure misadjustme
97. ble screwdriver Correct Incorrect Brush Installation 1 Correct 2 Incorrect 10 Reinstall the drive motor s to the machine and reconnect the power source IMPORTANT NEW BRUSHES MAY BE SEATED BY RUNNING THE DRIVE MOTOR AT NO LOAD PROPER SEATING IS REQUIRED FOR LOWEST BRUSH NOISE LEVEL JLG Lift 3 17 SECTION 3 BASE COMPONENTS 3 7 BATTERIES AND BATTERY CHARGER SERVICE PROCEDURES Battery Condition Testing NOTE Batteries in storage should be kept at 12 5V or higher Before testing for battery condition the open circuit volt age should be taken from each battery If the voltage of the batteries differs by 0 3 volts or more the lower voltage battery should be replaced Battery Testing Can Be Performed In Two Ways 1 The batteries can be tested using a battery tester capable of testing 12V 100Ah AGM VRLA Valve Regulated Lead Acid batteries using the instruc tions of the battery tester manufacturer 2 If an appropriate battery tester is unavailable the batteries can be tested by fully charging them with the charger that is installed in the machine Then check the battery voltage of each battery 4 hours after charging is complete Batteries less than 12 72 volts should be replaced NOTE Ifa faulty charger is suspected the batteries can be ch
98. bly 8 Wiring Harness Connector 4 5 3121187 JLG Lift 4 15 SECTION 4 CONTROL COMPONENTS Display Controller Module Electrical Mounting Bracket Install Remove Connections The internal switches and joystick controller of the plat form console plug directly into the Display Controller Module This module then relays the signals from these switches to the Ground Control Box through the commu nications cable running to the platform junction box mounted to the mast under the platform Platform Console Mounting Bracket 1 Mounting Bracket 2 Bracket Screws a Note Apply Loctite 242 to screw threads on final assembly Rear Cover Install Remove p eec Platform Console Circuit Board Connections 1 Horn Switch C5 4 E Stop ShutDown Switch 2 Communications Cable to C4 Platform Junction Box 5 Drive Lift ModeSelect C6 Switch C7 3 ON OFF Key Switch C3 6 Joystick C8 Platform Console Rear Cover Installation Note The C numbers shown after the description above repre 1 Rear Cover 2 Cover Mounting Screws sent the corresponding identification of the plug on the module s circuit board 4 16 JLG Lift 3121187 SECTION 4 CONTROL COMPONENTS Display Controller Module Install Remove Platform Console Display Module 1 Displ
99. cap screws each side Coat threads with Loctite 171 and tighten 3121187 JLG Lift 5 15 SECTION 5 MAST COMPONENTS MAST SECTION 4 ASSEMBLY 33 Lay the narrow chain set attached to the cylinder attach anchor block at the top of mast section 2 into the open rail on mast section 3 Top of Mast Section 3 Narrow Chain Set Layout 2 Chain Anchor Block 3 Mast Section 3 1 Narrow Chain Set Attached to Chain Anchor Block on Mast Section 2 NOTE Before sliding mast sections together spray the slide pad channels with Krytox lubricant spray JLG P N 3020041 Be careful not to scratch or score the anodized finish in the slide pad channels 34 Carefully slide mast section 4 into section 3 until ends are even 35 At the bottom of mast section 4 install the slide pads between mast section 3 and 4 Shim per instructions in step 7 Mast Section 2 Assembly Apply Loctite 242 to the threads of the pad screws on final assembly Bottom of Mast Section 4 Slide Pad Installation 1 Slide Pads 2 Shim Stock 3 Shim Pad Screws Apply Loctite 242 36 37 38 39 Slide mast section 4 out the top of mast section 3 approximately 1 ft 81cm Locate the lower chain anchor bracket one with the threaded attach holes in a triangular shape pattern Working at the bottom end of mast section 4 insert the threa
100. ct lubricate if dry or rusting Key to Lubricants MPG Multipurpose Grease HO Hydraulic Oil See Section 1 5 Lubrication in Service Manual GEAR OIL Good Quality Worm Gear Oil SAE 90 AGMA 5 EP Compounded CL Chain Lube Use a good quality chain lubricant Notes a Be certain to lubricate like items on each side of the machine b 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 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 3121187 JLG Lift SECTION 1 MACHINE SPECIFICATIONS 8 AVS S AGVYD AVS S1e9uejsej p zejd uinipeo oj Ajdde jou op sanjea nbio 9joN OLE 00084 48066 80 0990 0956 000 OOtC 26 09 0006 007 28 0088 L 00S L cL zi 006 0060 Sg v 06646 O9 C 09 6 00596 5004 64 7 09 06 0008 0SOr L 9 00SL L 000 S9LC 064765 O
101. d Control Module Components 1 Cover LCD Assembly 2 Power Selector Switch Assembly 3 Emergency Stop Switch Assembly 4 Main Board to LCD Ribbon Cable 5 Heat Sink Base Main Board Assembly 6 Cover Attach Screws Cover Removal Installation 3121187 JLG Lift 4 7 SECTION 4 CONTROL COMPONENTS IMPORTANT THE MAIN CIRCUIT BOARD AND THE SMALLER LCD CIRCUIT BOARD MOUNTED TO THE COVER ASSEMBLY ARE CON NECTED BY A RIBBON CABLE REMOVE THE COVER CARE FULLY ONCE THE COVER SCREWS ARE REMOVED FROM THE BACK OF THE MODULE Release Ribbon Cable 1 Ribbon Cable Connector Tabs Push tabs away from connector to release cable then slide cable out of connector Note Connector works same at both ends of the ribbon cable Cover Installation 1 Remove the 6 Hex Socket Screws from the Heat Sink Base One screw is under the Warranty Tamper Label Reconnecting Ribbon Cable 1 Ribbon Cable Connector Release Tabs 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 8 JLG Lift 3121187 SECTION 4 CONTROL COMPONENTS Power Selector EStop Switch Installation
102. de or rough terrain for a long period of time Table 6 18 Code 17 Ground Control Module In Fold Back STEP ACTION SPEC YES NO 1 Allow Ground Control Module to cool for 30 minutes Does the Replace Ground machine operate OK after cooling Control Module Table 6 3 Amperage Draw for Various Components NOTE If this is a recurring problem compare current draw of your machine with Ground Control Module specifications in 3121187 JLG Lift 6 17 SECTION 6 TROUBLESHOOTING Code 18 Alarm Short Circuit Check For These Obvious Conditions First Damaged wiring in the alarm wiring harness or a damaged alarm Table 6 19 Code 18 Alarm Short Circuit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the voltage Replace Ground across pins 13 and 6tothe alarm Is reading within specification 0 2V DC Goto Step 2 Control Module 2 Removethe wire terminals atthe alarm check continuity of each of Replaceth the wires from pins 13 and 6 onthe P1 connectorto the alarm end p Code 19 Alarm Disconnected Check For These Obvious Conditions First Damaged wiring in the alarm wiring harness or a damaged alarm Activate a function to check if alarm beeps Table 6 20 Code 19 Alarm Disconnected STEP ACTION SPEC YES NO 1 Check voltage atthe P1 connector on the Ground
103. drain hole approximately 1 8 inch 3mm size on the BOTTOM of the new boot This will allow any accumulated condensation to drain out and not remain trapped there Drive Motor Brake Location A brake assembly is mounted to the end of the drive motor housing The brakes are ENGAGED brakes on when the machine is parked and are RELEASED electri cally brakes off when the joystick is enabled and pushed in any direction The brakes can also be RELEASED elec trically using the manual brake release button on the ground control station NOTE The brakes are intended only as a parking brake to keep the machine from moving while at rest The brakes are not used to stop the machine during driving operations this braking is controlled by the drive motors themselves Under normal driving conditions once released the brakes are not engaged again until the machine comes to a complete stop Drive Motor Brake Location 1 Drive Motor Brake 3 Motor Brake Power Cable 2 Boot Shown Cutaway JLG Lift 3 13 SECTION 3 BASE COMPONENTS Brake Assembly Removal From Motor 1 Elevate the platform to gain access to the drive motor covers Remove the drive motor cover See Drive Motor Cover Installation on Page 3 3 Remove the drive wheel See Rear Drive Motor Wheel Installation on Page 3 4 Disconnect the drive motor brake power connector from it s wiring harness connector Remove the drive moto
104. ds stud ends of the narrow chain set now laying between mast section 3 and 4 into the holes of the lower chain anchor bracket Loosely thread two 2 3 8 16UNC nuts onto the stud threads on each chain Slide the anchor plate into the closed rail at the bot tom of mast section 4 and attach the anchor plate to the bottom of mast section 4 with three 3 1 4 20UNC x 3 4 long bolts Apply Loctite 242 to threads on final assembly 1 Lower Chain Anchor Bracket Bottom of Mast Section 4 Chain Anchor Installation 4 Chain Adjust and Jam 2 Anchor Bracket Screws a Nuts 3 Narrow Chain Set Studs Note a Apply Loctite 242 to threads on final assembly 40 41 42 5 16 JLG Lift Slide the top of mast section 4 back in even with the top of mast section 3 Insert slide pads into the top end mast rails between section 3 and 4 one on each side of the mast with beveled surface facing inward towards section 3 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts through holes in outside rail on top of mast section 2 and into the slide pad inserts Thread in enough to hold pad in place 3121187 SECTION 5 MAST COMPONENTS 43 Shim per instructions in step 7 Mast Section 2 Assembly Apply Loctite 242 to attach screw threads on final assembly Top of Mast Section 4 Slide Pad Installation 1 Slide Pads 2 S
105. ds the platform only mast section 3 and 4 are adjustable To adjust elevate the platform until the chain anchor adjust and jam nuts are accessible at the front and bottom of each mast section A WARNING NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCK ING OR OVERHEAD SLING 6 3121187 Start with the mast section which needs adjustment and loosen the bottom jam nut on each chain NOTE 10 11 Tighten to raise mast section or loosen to lower mast section the adjusting nut against the anchor plate on each chain Adjust the nut the amount required to raise or lower the top of the mast section to match the side profile shown in Figure 5 8 when the mast is retracted It is more important that the threaded ends studs are equal side to side on a mast section than it is that the tension in the chains is equal The chain equalizers will always assure equal tension but if the adjustment isn t equal as described the chains may tend to pull to one side or the other The threaded end of the chain may need to be restrained while tightening the adjust nut to keep the chain from twisting Retract the mast all the way and check if the top of the mast sections appear as shown in Figure 5 8 Repeat steps 1 through 7 for remaining mast sec tions Once mast section adjustment is completed apply loctite 242 to the threads under the jam nuts that were
106. e cracks distortion excessive wear Check for proper adjustment Check for cracked or broken welds Operates properly Returns to neutral or off position when released Clean and free of debris Interlocks function properly Check for signs of leakage Decals installed and legible Check for proper fluid level Check for chafing and proper routing Check for proper tolerances Properly lubricated Torqued to proper specification No gouges excessive wear or cords showing Properly inflated and seated around rim No loose connections corrosion or abrasions Inspected per Service and Maintenance Manual a Prior to use each day or at each Operator change c In service for 3 months or Out of service for 3 months d Annually no later than 13 months from the date of the 18 Proper and authorized components 19 Fully charged or 20 21 Verify 22 Perform 23 Sealed properly 24 Overrides Platform controls 25 Footnotes b Prior to each sale lease or delivery or more or Purchased used prior inspection Lift 3121187 SECTION 2 GENERAL SERVICE INFORMATION 2 3 SERVICING AND MAINTENANCE GUIDELINES General The following information is provided to assist you in the use and application of servicing and maintenance proce dures contained in this chapter Safety and Workmanship Your safety and that of others is the first consideration when engaging in the mainten
107. e if mechanical assistance is required All slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted Should it be necessary to remove a component on an angle keep in mind that the capacity of an eyebolt or sim ilar bracket lessens as the angle between the supporting structure and the component becomes less than 90 degrees If a part resists removal check to see whether all nuts bolts cables brackets wiring etc have been removed and that no adjacent parts are interfering Component Disassembly and Reassembly When disassembling or reassembling a component com plete the procedural steps in sequence Do not partially disassemble or assemble one part then start on another Always recheck your work to assure that nothing has been overlooked Do not make any adjustments other than those recommended without obtaining proper approval Pressure Fit Parts When assembling pressure fit parts use an anti seize or molybdenum disulfide base compound to lubricate the mating surface Bearings When a bearing is removed cover it to keep out dirt and abrasives Clean bearings in nonflammable cleaning sol vent and allow to drip dry Compressed air can be used but do not spin the bearing Discard bearings if the races and balls or rollers are pit ted scored or burned If bearing is found to be serviceable apply a light coat of oil and wrap it in c
108. e adjusted is selected press the Brake Release button 2 to enter that settings adjustment mode Adjusting Programmable Setting RESET TIMERS Programming Mode Selection 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 3121187 5 nINS Adjusting Programmable Setting 1 Adjust the programmable setting using the Platform UP DOWN buttons 1 see Table 4 1 on Page 4 13 for range of settings for the item selected 2 Once parameter is set for the programmable item press the Brake Release button 2 this will enter the parameter and return you to the Programmable Settings Menu TO EXIT Programming Mode after entering program mable settings power machine off with either the Main Power Selector Switch or Emergency Stop Button JLG Lift 4 11 SECTION 4 CONTROL COMPONENTS Service Programming Mode Level 2 In the Service Programming Mode the following items are shown on the main menu Also See Table 4 1 on Page 4 13 Reset Timers Program Tilt Sensor 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 pro grammable items between these modules are ide
109. e aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that ade quate support is provided A WARNING SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON TROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER OPERATOR B HYDRAULIC SYSTEM SAFETY 1 It should be particularly noted that the machines hydraulic systems operate at extremely high and potentially dangerous pressures Every effort should be made to relieve any system pressure prior to dis connecting or removing any portion of the system 2 Relieve system pressure by activating the lift DOWN control with the platform completely lowered to direct any line pressure back into the return line to the reservoir Pressure feed lines to system compo nents can then be disconnected with minimal fluid loss 3121187 JLG Lift REMOVE ALL RINGS WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE DO NOT WEAR LONG HAIR UNRESTRAINED OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT OBSERVE AND OBEY ALL DANGER WARNING CAU TION AND OTHER INSTRUCTIONS ON MACHINE AND IN SERVICE MANUAL KEEP STANDING SURFACES AND HAND HOLDS FREE OF OIL GREASE WATER ETC NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVER HEAD SLING BEF
110. e atthe P1 connector onthe Ground Control Module Replace Ground between pin 12 and pin 5 Is reading within specification 2 4VDC Control Module Goto Step 4 4 Remove the wire terminals at the beacon check continuity of each ofthe wires from pins 12 and 5 onthe P1 connectorto the beacon the R han end eacon eplace Wiring Code 22 Horn Short Circuit Check For These Obvious Conditions First Damaged wiring in the horn wiring harness or a damaged horn unit Table 6 23 Code 22 Horn Short Circuit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the voltage Replace Ground across pins 14 and 7 to the horn Is reading within specification 0 2V DC Goto Step 2 Control Module 2 Remove the wire terminals atthe horn check continuity of each of i the wires from pins 14 and 7 onthe P1 connectorto the horn end 3121187 JLG Lift 6 19 SECTION 6 TROUBLESHOOTING Code 23 Horn Disconnected Check For These Obvious Conditions First s machine equipped with a horn unit Table 6 24 Code 23 Horn Disconnected STEP ACTION SPEC YES NO 1 Ismachine equipped with a horn unit Goto Step 3 Gotto Step 2 2 Atthe Ground Control Module enter the programming mode check ifthe horn open circuit detection is enabled Disable It ME 3 Check voltage atthe P1 connector on the Ground C
111. e shown with rear bumper cover assembly removed for illustrative purposes only 3121187 JLG Lift 3 11 SECTION 3 BASE COMPONENTS Drive Motor Assembly Components Drive Motor Assembly Components 1 Drive Shaft Bearing a 5 Electric Drive Motor d 2 Bearing Set Screws b 6 Drive Motor Brake 3 Motor Mount Bearing Frame c 7 Motor Brake Boot 4 Drive Gear Box 32 1 Ratio NOTE Once motor is mounted to motor mount bearing frame slide drive shaft bearing into frame till it is seated b Tighten bearing set screws once bearing is seated in motor mount bearing carrier c Apply Loctite 242 to threads of motor mount screws at final assembly d Electric Motor harness contains both the drive motor and the brake leads The motor leads are negative lead is BLACK and positive 4 lead is WHITE e Mount boot with electrical lead sleeve at top and condensation drain hole in boot on bottom 3 12 JLG Lift 3121187 SECTION 3 BASE COMPONENTS Drive Motor Boot Installation Drive Motor Boot Installation 1 Boot Shown Cutaway 3 Drain Hole a 2 Boot Clamp 4 Power Cable Sleeve Clamp NOTE 3121187 When removing loosen clamps slide boot clamp for ward on motor pull bottom of boot up over brake and slide up harness sleeve a If replacing the boot assembly with a new one check the bottom of the boot for a drain hole If none exists cut a
112. end Pull on hose assembly to complete disconnection SECTION 5 MAST COMPONENTS 5 6 MAST ASSEMBLY INSTALL REMOVE Mast Removal The following components must be removed from the machine before removing the mast assembly With Platform Elevated approx 4 ft 1 2m Remove Front Hood See Section 3 2 Drive Motors Cover See Section 3 2 Platform Material Tray Assembly See Section 5 3 Remove the bottom bolts and unhook the enable foot switch and entry gate interlock wire harness from the platform junction box With Platform Completely Lowered If necessary use Manual Descent Valve Remove Platform Control Console See Section 4 2 Mast Cover See Section 5 2 Platform Material Tray Assembly See Section 5 3 Battery Charger Assembly See Section 3 7 2 Unplug and remove the amber beacon mounted on the front of the mast assembly 3 Disconnect and cap the hydraulic extend and return lines from the hydraulic cylinder either on the vavel block at the bottom of the cylinder or at the pump assembly See Section 5 5 following for special tool instructions 4 Using an overhead crane or suitable lifting device capable of supporting the weight of the mast assem bly attach a sling strap to the mast 5 Remove the four 4 mast attach bolts with washers and nuts securing the mast to the mounting column NOTE When lifting the mast out of the base frame be care ful with the manual d
113. es only Note Apply Loctite 242 to threads before final tightening 5 2 JLG Lift 5 3 PLATFORM ASSEMBLY INSTALL REMOVE e hele 2 DS A 2 2 3 4 Spe AN SS er 4 lt gt o gt NS Platform Installation 1 Platform Material Tray Assembly 2 Tie Straps for Platform Console Harness 3 Countersunk Flat Head Socket Screws Washers and Locknuts 4 Hex Head Screws Wash ers and Locknuts a Platform shown without right side rails and plat form floor cutaway for illustrative purposes only Note a Raise platform and remove the hex head screw wash ers and nuts item 4 While under the platform unplug the wiring harness to the foot enable switch and the entry gate interlock switches from the platform junction box Using suitable lifting equipment carefully lift the plat form material tray assembly off the mast assembly 3121187 SECTION 5 MAST COMPONENTS 5 4 MATERIAL TRAY INSTALL REMOVE 5 Material Tray Installation 1 Material Tray Assembly 3 Tray Release Bar c 2 Tray Bottom Stops b 4 Raise Platform a Note a Raise the platform approximate
114. escent valve extend and return lines protruding from the bottom front of the mast assembly 6 Carefully lift the mast off the base frame and place on a suitable work surface Mast Installation ALIS Mast Assembly Mounting Bolt Location 1 Mast Mounting Column a 2 Mounting Bolt Washer Nut Locations b Notes a Battery charger removed b Apply Loctite 271 to bolt threads on final assembly 1 Unplug the platform control cable P4 connector at the ground control module 5 4 JLG Lift To install the mast assembly reverse the Mast Removal instructions however perform the following additional steps during re assembly 1 Once assembly is complete cycle the mast up and down several times then check the oil level in the hydraulic reservoir 3121187 SECTION 5 MAST COMPONENTS 5 7 MAST DISASSEMBLY PROCEDURE The mast sections are constructed of extruded aluminum protected with an anodized surface finish The mast sec tions are interlocked into each other when assembled by internally mounted slide pads at the top and bottom of each mast section These slide pads run up and down in slide pad channels on each side of the mast The mast assembly contains the number of mast sections as shown following Table 5 1 Mast Component Features Model No of Mast Extend Retract Sections Device SSV 10 4 Chain Mast D
115. f slide pad in rail channel Mast sections should be snug in channels but still be able to slide in channel by hand Insert slide pads into the slide pad channels top of mast between section 1 and 2 one on each side of the mast with beveled surface facing in towards section 2 Before fastening and shimming the slide pad on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher Figure 5 6 Top of Mast Section 2 Slide Pad Installation 1 Slide Pads 3 Sequence Cable Bracket 2 Shim Stock 4 Slide Pad Bolts Washers a a Apply Loctite 242 to threads Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in mast section 1 outside rail top of mast and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Before installing the lift cylinder to mast section 1 and into mast section 2 extend the lift cylinder rod out the top of the lift cylinder approximately 1 ft 31cm JLG Lift NOTE To extend the hydaulic cylinder the protective caps on the extend and return ports will need to be tempo rarily removed Be careful not to nick or scour rod surface when extending also catch any oil draining out of cylinder to avoid spillage onto work area 12 Install the lift cylinder mount into the bottom of Mast
116. f the entire mast assembly Slide mast out over end of work surface far enough to allow access to the chain anchor attach hole near the top of the mast 2 Locate the two 2 single wide chain assemblies and attach to the large equalizer anchor plate if not already attached Lay out the chain anchor plate assembly with the anchor plate end towards top of the mast Be certain floor surface is clean and free of any metal chips or debris which may stick to lubri cated 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 Top of Mast Section 1 Upper Chain Anchor Plate Installation Mast Section 1 Shown Cut Away 1 Anchor Plate Pin 4 Long Spacer 2 Short Spacer 5 Pin Keeper 3 Chain Anchor Plate Assy 6 Keeper Screw a Note a Apply Loctite 242 to threads 3121187 MAST SECTION 2 ASSEMBLY NOTE Before sliding mast sections together spray the slide pad channels with Krytox lubricant spray JLG P N 3020041 Be careful not to scratch or score the anodized finish in the slide pad channels 4 Locate mast section 2 carefully slide mast section 2 closed rail into section 1 open rail Slide sections together until ends are even 5 Insert slide pads into the slide pad channels at bot tom end of mast between section 1 and 2 one on each
117. form Lowered 30 1 100 2 Minimum Turn Speed Platform Lowered 10 1 100 2 Minimum Forward Speed Platform Elevated 20 1 100 2 Minimum Reverse Speed Platform Elevated 20 1 100 2 Maximum Turn Speed Platform Elevated 10 1 100 2 Motor Compensation 130 mOhms 0 500 mOhms 4 14 JLG Lift 3121187 SECTION 4 CONTROL COMPONENTS 4 5 PLATFORM CONTROL CONSOLE SERVICE PROCEDURES General IMPORTANT DO NOT ATTEMPT TO DISASSEMBLE THE PLATFORM CONTROL BOX IF MACHINE IS STILL UNDER WARRANTY OPENING THE PLATFORM CONTROL BOX WHILE THE MACHINE IS UNDER WARRANTY WILL VOID THE WARRANTY IF UNDER WARRANTY REQUEST A REPLACEMENT BOX FROM THE FACTORY The platform control console allows for replacement of nine 9 components Emergency Stop Switch Key Switch Joystick Assembly Display Controller Module Drive Lift Mode Selector Switch Horn Button Switch Rear Cover Wiring Harness Connector Socket Mounting Bracket Remove Platform Control Console First remove the platform control console completely from the platform assembly See Section 4 2 Control Compo nents Installation Platform Control Console Installation Figure 4 4 Platform Control Console Components Display Controller Module 9 Adjustable Mounting Bracket Drive Lift Mode Selector Switch 1 E Stop Shut Down Switch 6 Horn Button Switch 2 ON OFF Key Switch 7 Rear Cover 3 Joystick Assem
118. g Charger Charger AC Pluggedin ac put Power Cord X 00000 0 DRIVE Disabled from Machine Type in Code At PSL Key Pad gt CODE See Operators Manual for X 000000 Proper Operation a LETT 59 516 X 000000 01 01 9 02 2 RESERVED RESERVED 03 2 RESERVED RESERVED Tilt Condition 04 3 25 nmm gt W vx Platform Elevated X 00000 0 404 404 DRIVE and Lift UP Disabled 9 05 RESERVED RESERVED 06 RESERVED RESERVED Left Drive Motor v Disconnected Puede X 000000 07 07 DRIVE Disabled 9 Right Drive Motor op ioeo 56 Disconnected X 000000 08 08 DRIVE Disabled Left Brake Disconnected LEFT BRAKE 09 EA 15222 lt gt DISCONNECTED 4 DRIVE Lift UP DOWN X 000000 409 Disabled agen 6 4 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING Table 6 1 LCD Display Service Fault Code Conditions jen FAULT DESCRIPTION FOR TROUBLESHOOTING FAULT CONSOLE CODE p LEDS o LCD SYMBOL SCREEN LCD TEXT SCREEN MACHINE CONDITION REFER TO Right Brake Disconnected RIGHT BRAKE A 10 lt gt DRIVE Lift UP DOWN X 000000 410 410 Disabled age 9 Left Drive Motor LEFT MOTOR 5 11 6 lt gt lt gt SHORTED lt Short Circuit X 000000 11 11 DRIVE Disabled 9 Right Drive Motor
119. hain set now laying between mast section 2 and 3 into the holes of the lower chain anchor bracket Loosely thread two 2 3 8 16UNC nuts onto the stud threads on each chain Slide the anchor plate into the closed rail at the bot tom of mast section 3 and attach the anchor plate to the bottom of mast section 3 with four 4 1 4 20UNC x 3 4 long bolts Apply Loctite 242 to threads on final assembly Bottom of Mast Section 3 Chain Anchor Plate Installation 1 Lower Chain Anchor 3 Wide Chain Set Studs Bracket 4 Chain Adjust and Jam 2 Anchor Bracket Screws Nuts Note JLG Lift 3121187 SECTION 5 MAST COMPONENTS 28 At the top of mast section 3 assemble the chain 29 sheaves for narrow chain assembly to top of mast section 3 as shown following 30 NOTE 31 32 Slide the top of mast section 3 back in even with the top of mast section 2 Insert slide pads into the top end mast rails between section 2 and 3 one on each side of the mast with beveled surface facing inward towards section 3 Same as Figure 5 6 Before fastening and shimming the slide pad on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in outside rail on top of mast section 2 and i
120. he motor housing Read the note above before attempting to remove the cover b These steel screws are threaded into the aluminum valve body do not overtighten JLG Lift 3121187 SECTION 3 BASE COMPONENTS Brush Carrier Assembly Remove Install A 2 M jf eS Tat xn JA LL We Ey N i 1 Es Brush Carrier Assembly Remove Install 1 Stator Brush Carrier Screws Pump Rear 3 Mark Brush Carrier Position on Motor Housing 2 Stator Brush Carrier Screws Pump Front a 4 Brush Carrier Assembly NOTE a Removed previously with motor cover disassembly shown for reference only Brush Assembly Remove Install Tank Remove Install HL p Lj Brush Assembly Remove Install 1 Brush Assembly a 4 Brush Terminal Screw Tank Remove Install 2 Brush Carrier Socket 5 Brush Attach Terminal For reassembly reference place a mark on tank and valve body 9 Brush Tab Slot 1 TankAssembly 3 O Ring Seal a 2 Tank Screws Qty 4 4 Reference Mark
121. him Stock 3 Slide Pad Attach Screws a Note a Apply Loctite 242 to attach screws on final assembly 44 Attach the sequencing cables and hardware to the side of the mast assembly Side of Mast Section 2 Lower Sequence Cable Bracket 1 Mast Section 2 5 Sheave Wheel Thrust 2 Lower Bracket Attach Washer Screws 6 Sequence Cable Sheave 3 Lower Bracket Wheel 4 Sheave Wheel Attach Bolt 7 Spacers Qty 4 3121187 Side of Mast Section 3 Lower Sequence Cable Bracket 1 Mast Section 3 5 Sheave Wheel Thrust 2 Lower Bracket Attach Washer Screws 6 Sequence Cable Sheave 3 Lower Bracket Wheel 4 Sheave Wheel Attach Bolt 7 Spacers Qty 4 Side of Mast Section 4 Lower Sequence Cable Bracket 1 Mast Section 4 3 Lower Bracket 2 Bracket Attach Screws 45 Install the platform junction box to ground control station wiring harness See Figure 5 7 including the platform junction box powertrack assembly har ness cable sheave assembly and harness spring tensioner to the side of the mast assembly Also ref erence Section 4 Platform Junction Box Install Remove 46 The mast assembly is now complete and ready to install onto the base frame JLG Lift 5 17 SECTION 5 MAST COMPONENTS
122. ice Level Settings OnLCD Display YES W HIGH T Level 3 Operator Level Settings NO X LOW FACTORY LEVEL PROGRAMMABLE ITEM PRESET SETTING RANGE 2 Backto Main _ Returnto Programming Menu 3 SetLanguage 1 1 English 6 Italian 2 German 7 Swedish NOTE There are two production modules available at this Een 1 MS lime one for North South American and European 5 Spanish Languages and one for Asian Languages 2 1 Engiish 3 Japanese 2 Chinese 2 Set Maximum Lift Up Speed 100 0 100 2 Set Maximum Lift Down Speed 100 0 100 2 Zero the On Board Tilt Sensor NO YES NO 2 3 Set Sleep Time 10 MINS 0 60 MINS 2 Set Polarity Of Left Pot Hole Input 1 0 0 DISABLED 1 LOW 2 HIGH 2 Set Polarity Of Right Pot Hole Input 2 0 0 DISABLED 1 LOW 2 HIGH 2 Set Polarity Of Up Limit elevation Input HIGH HIGH LOW 2 Set Polarity Of Charger Inhibit HIGH HIGH LOW 2 3 Set Polarity Of The Keypad Code LOW HIGH LOW 2 Set Polarity Of Ancillary Input 1 HIGH HIGH LOW 2 Set Polarity Of Ancillary Input 2 LOW HIGH LOW 2 3 Enable Detection Of Horn Open Circuit NO YES NO 2 3 Enable Detection Of Beacon Open Circuit NO YES NO 2 Enable Obstruction Sensor System 055 NO YES NO 2 Enable Detection Of Ancl 1 Open Circuit NO YES NO 2 Enable Detection Of Ancl 2 Open Circuit NO YES NO 3 Forward Alarm Disable NO YES NO 3 OSS Diagnostic NO YES NO 2 Load Sensing LSS OFF OFF CUTOUT PLAT CUTOUT ALL 2 Aux 1 Inhibit Active when Ancilliary 1 is setto HIGH 4 O Inhibit Lift 1 Inhib
123. ide Remove slide pads and shims from mast section 1 if necessary Mast disassembly should now be complete JLG Lift 3121187 SECTION 5 MAST COMPONENTS 5 8 CYLINDER DISASSEMBLY See Figure 5 3 1 NOTE NOTE 3121187 Before disassembling the cylinder clean away all dirt and foreign substances from openings particu larly the head area Always protect the chrome surface of the cylinder rod during assembly and disassembly Any damage to this surface will require replacement of the rod Extend the rod until the piston bottoms out against the cylinder head Compress the head retraining ring enough to allow the cylinder head to be removed Carefully slide the head rod piston assembly out of the cylinder tube A gentle tap on the head assembly may be required to remove the head from the cylin der tube Place the head rod piston assembly on a surface that will not damage the chrome Remove the piston locknut and separate the piston from the rod Slide the head off the rod from the piston end When removing the old seals use only blunt tools be sure there are no sharp edges that may damage the seal grooves during removal Scratching the groove may cause by pass Remove and discard all old seals 8 a 77 m 4 RO POOH QR LR 222224 12 13 IRN
124. ill be centered in the hydraulic and electri cal systems For this reason every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment In the remaining machine groups only those problems which are symptomatic of greater problems which have more than one probable cause and remedy are included This means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if the cir cuit is lacking hydraulic oil and electrical control power This can be ascertained by overriding the bypass valve mechani cally or electrically so that oil is available to the function valve then overriding the function valve mechanically If the function performs satisfactorily the problem exists with the control circuit 6 3 HYDRAULIC CIRCUIT CHECKS See Figure 6 4 The first reference for improper function of a hydraulic system where the cause is not immediately apparent should be the Hydraulic Diagram Circuit The best place to begin the problem analysis is at the power source pump Once it is deter mined that the pump is serviceable then a systematic check of the circuit components would follow NOTE For aid in troubleshooting refer to Figure 6 4 for HYDRAULIC DIAGRAM circuit 6 4 ELECTRICAL CIRCUIT CHECKS General The dr
125. ily uncap the extend and return hydraulic lines to allow mast section 2 to be extended in the next step Capture any hydraulic fluid that may flow out of the lines and recap the lines once section is extended Slide mast section 2 out TOP of mast section 1 far enough to allow access to the chain assembly anchor block sheave wheel assembly 12 13 14 NOTE 15 On the underside of the mast assembly remove the snap ring securing the anchor pin running through the small chain equalizer plate the cylinder anchor block and the cylinder rod Push or lightly tap the anchor pin up and remove Lay the small chain set aside Remove countersunk flathead screws securing chain anchor block sheave wheel assembly attach bars on both side rails at TOP of mast section 2 and remove the anchor block sheave wheel assembly When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 2 out the TOP of sec tion 1 Remove slide pads and shims if necessary MAST SECTION 1 DISASSEMBLY 16 17 18 Remove the four 4 large screws 2 each side attaching the lift cylinder mounting block to mast section 1 Slide the cylinder out of the mast section and move to a suitable work surface 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 as
126. isassembly Procedure 1 After the mast assembly has been removed from the machine lay the mast assembly down on a suitable work table with the platform mounting section on top facing up 2 Remove the sequencing cables platform junction box and hardware from the sides of the mast assem bly Also remove the extend and return hydraulic lines from the bottom of the lift cylinder MAST SECTION 4 REMOVAL Platform Mount 3 Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate lower on BOTTOM end of mast section 4 platform mounting section Push threaded ends of chain through anchor plate 4 At the TOP of mast section 3 pull chains out and allow to hang loose Be certain floor surface is clean and free of any metal chips or debris which may stick to lubricated chains NOTE When sliding mast sections apart be careful not to scratch or score the anodized surface in the slide pad channels 5 Carefully slide mast section 4 out the BOTTOM of mast section 3 rails Disassemble slide pads shims and chain anchor plate from mast section 4 if nec essary MAST SECTION 3 REMOVAL 6 Remove chain adjust nuts from threaded ends of chains attached to the chain anchor plate lower on BOTTOM end of mast section 3 Push threaded ends of chains through anchor plate 7 At TOP of mast section 2 pull chains out and allow to hang loose Be certain floor surface is clean and 3121187
127. isconnected 6 16 Code 15 Lift Down Valve 6 16 Code 16 Lift Down Valve Short 6 17 Code 17 Ground Control Module In Fold 6 17 Code 18 Alarm Short 6 18 Gode 19 Alarm Disconriected eren RARI BR aychaqa La 6 18 Code 20 Beacon Short 0 6 18 Code 21 Beacon Disconnected 6 19 Code 22 Horn Short Circuit 6 19 Code 23 Horn Disconnected 6 20 Code 24 Auxiliary 1 Circuit Short 6 20 Code 25 Auxiliary 1 Circuit 6 21 Code 26 Auxiliary 2 Short 4 6 21 Code 27 Auxiliary 2 6 22 Code 28 RESERVED Vy et Sandon ah Dore a o sace Wak pa k A RE 6 22 Code 29 RESERVED un sun esa Rua e ab EPUM MEG vi MER 6 22 Code 30 Traction Module No Communication with Gro
128. it Drive when Platform is elevated 2 Inhibit Drive regardless of Plat position 3 Inhibit Lift and Drive when Plat elevated 4 Inhibit Lift and Drive regardless of Plat position 2 Aux 2 Inhibit Active when Ancilliary 2 is setto HIGH 0 O Inhibit Lift 1 Inhibit Drive when Platform is elevated 2 Inhibit Drive regardless of Plat position 3 Inhibit Lift and Drive when Plat elevated 4 Inhibit Lift and Drive regardless of Plat position 2 Aux 1 Tie Down 1 0 Disabled 1 trip if low at start up 2 trip high at start up 2 Aux 2 Tie Down 0 0 Disabled 1 trip if low at start up 2 trip high at start up 2 Mode Select Delay 5 SEC 1 60 SECONDS 3121187 JLG Lift 4 13 SECTION 4 CONTROL COMPONENTS Table 4 1 Ground Control Module Field Programmable Settings and Factory Preset SSV 10 Level 2 Service Level Settings OnLCD Display YES W HIGH T Level 3 Operator Level Settings NO X LOW 4 FACTORY LEVEL PROGRAMMABLE ITEM PRESET SETTING RANGE 2 Acceleration Platform Lowered 40 1 100 2 Deceleration Platform Lowered 45 1 100 2 Turn Acceleration Platform Lowered 30 1 100 2 Turn Deceleration Platform Lowered 30 1 100 2 Maximum Forward Speed Platform Lowered 100 1 100 2 Minimum Forward Speed Platform Lowered 30 1 100 2 Maximum Reverse Speed Platform Lowered 100 1 100 2 Minimum Reverse Speed Platform Lowered 20 1 100 2 Maximum Turn Speed Plat
129. itting between the pump and the extend line to connect a hydraulic pressure gauge as shown in Figure 1 2 Typical Hydraulic Pressure Gauge Installation Hydraulic Filter Removed CHECK and if necessary ADJUST the hydraulic pressure to initial settings shown in table at the beginning of this section Cycle the hydraulic system several times with the maximum load capacity in the platform then recheck pressure setting When pressure has stabilized continue to After Filter Pressure Check following After Filter Pressure Check Reinstall the hydraulic oil filter and install a t fitting between the hydraulic filter and the extend line to the cyl inder Recheck the hydraulic pressure and compare with the previous readings when filter was removed If a signifi cant drop in pressure reading has occurred replace the hydraulic filter and recheck the after filter pressure read ing Figure 1 2 Typical Hydraulic Pressure Gauge Installation Hydraulic Filter Removed 1 Pressure Gauge Assembly 3 T Fitting 2 Cylinder Extend Line 4 Cylinder Return Line Figure 1 3 Typical Hydraulic Pressure Gauge Installation After Hydraulic Filter 1 Hydraulic Oil Filter 3 Pressure Gauge Assembly 2 T Fitting 4 Cylinder Extend Line 1 7 CYLINDER SPECIFICATIONS NOTE All dimensions are given in inches in with the met ric equivalen
130. ity to per form a Pre Start Inspection of the machine prior to use daily or at each change of operator Reference the Opera tor s and Safety Manual for completion procedures for the Pre Start Inspection The Operator and Safety Manual must be read in its entirety and understood prior to per forming the Pre Start Inspection Pre Delivery Inspection and Frequent Inspection The Pre Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic JLG Industries Inc recognizes a qualified JLG equipment mechanic as a person who by possession of a recog nized degree certificate extensive knowledge training or experience has successfully demonstrated the ability and proficiency to service repair and maintain the subject JLG product model The Pre Delivery Inspection and Frequent Inspection pro cedures are performed in the same manner but at differ ent times The Pre Delivery Inspection shall be performed prior to each sale lease or rental delivery The Frequent Inspection shall be accomplished for each machine in ser vice for 3 months out of service for a period of more than 3 months or when purchased used The frequency of this inspection must be increased as environment severity and frequency of usage requires 3121187 Reference the JLG Pre Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the perfor
131. ive system on the SSV Series machines requires a microprocessor controlled electrical circuit to operate smoothly and accurately All platform control console functions are relayed to various machine components i e platform up down drive functions etc through the Ground Control Module microprocessor box mounted under the front hood The Ground Control Module is pre programmed with factory pre set personality settings for each machine function To help diagnose any problems with components plugged into the Ground Control Module the module is designed with an internal fault code and text messaging system displayed on an LCD screen at the module The platform control console also will display LED Flash Codes using the Battery Charge LED strip on the console When operating normally the LED panel on the platform control console indicates the battery voltage status using ten 10 LEDs red yellow green If a malfunction to the machine s electrical components occurs the platform console LED s will flash a number of LEDs to help indicate the problem to the Operator in the platform The Fault Codes and LED Flash Codes are outlined in the following sub sections of this chapter NOTE For aid in troubleshooting electrical problem refer to Figure 6 3 for an ELECTRICAL DIAGRAM of the various circuits Also for a pictorial overview of the connected components See Figure 6 2 Pictorial Overview of the Electrical Sys tem 3121187 JLG Lift 6
132. ked to within 0 0 degrees with a digital level in both the X and Y directions See Ground Control Pro gramming Section 3 of Service Manual NOTE If frequent calibration of the internal Tilt Sensor is required replace the Ground Control Module Code 05 RESERVED Code 06 RESERVED Code 07 Left Drive Motor Disconnected Check For These Obvious Conditions First Check left drive motor M1 connector at the Traction Control Module for secure and proper connection Table 6 8 Code 07 Left Drive Motor Disconnected STEP ACTION SPEC YES NO 1 Checkresistance across positive and negative drive motor Replace Traction leads in M1 connector wiring harness going to the left drive motor Is 1to 3ohms Module Goto Step 2 reading within spec 2 Repairorreplace left drive motor wiring brushes or motor For brush replacement see Section 3 of this Service Manual E 2 3121187 JLG Lift 6 13 SECTION 6 TROUBLESHOOTING Code 08 Right Drive Motor Disconnected Check For These Obvious Conditions First Check right drive motor M2 connector at the Traction Control Module for secure and proper connection Table 6 9 Code 08 Right Drive Motor Disconnected STEP ACTION SPEC YES NO 1 Checkresistance across positive and negative leads in
133. kif LEDs are illuminated on the Platform Control Console Go To Step 2 Go to Step 3 2 Remove the 9 pin Platform Control Console connector fromthe side RepairorReplace of the Platform Junction Box and the P4 connector at the Ground Platform Control Repair or Replace Control Module Check continuity from the P4 connector pin 5 to C Wiring Junction Box pin 3 and P4 pin 9 to Junction Box pin 4 3 Removethe 9pin Platform Control Console connector fromthe side Repairor Replace ofthe Platform Junction Box Checkthe voltage across pins 1 and5 24V DC Platform Control Goto Step 4 inthe Junction Box connector Console 4 Checkvoltage across pins 10 and 2 on connector P4 atthe Ground Control Module 24V DC Goto Step 5 4 5 Checkcontinuity of P4 connector pin 10 to Platform Junction Box pin 1 Also P4 connector pin 2 to Platform Junction Box pin 5 es Repair or Replace Wires Code 32 Pump Motor Over Current Check For These Obvious Conditions First Platform overload condition Obstruction in mast system Pump Positive and Negative connections are secure and undamaged Crushed or kinked hydraulic lines Hydraulic leaks Table 6 31 Code 32 Pump Motor Over Current STEP ACTION SPEC YES NO 1 Check current draw of pump motor by elevating the platform to full Lessthan height and load pump by continuing to press the UP button 145Am Goto Step 2 Goto Step 3 Is reading within spec ps 2 Didunit give a 32
134. kup and rod wiper Damage to the seal grooves par ticularly on the sealing surfaces is unacceptable In the event that an unacceptable condition occurs the head should be replaced Piston Visually inspect the outside surface for scratches or pol ishing Deep scratches are unacceptable Polishing indi cates uneven loading and when this occurs the diameter should be checked for out of roundness If out of round ness exceeds 0 007 this is unacceptable Check the con dition of the dynamic seals and bearings looking particularly for metallic particles embedded in the bearing and in the piston seal surface Remove the seals and bearings Damage to the seal grooves particularly on the sealing surfaces is unacceptable In the event that an unacceptable condition occurs the piston should be replaced Tube Assembly Visually inspect the inside bore for scratches and pits There should be no scratches or pits deep enough to catch the fingernail Scratches that catch the fingernail but are less than 0 5 inch long and primarily in the circumfer ential direction are acceptable provided they cannot cut the piston seal The roughness of the bore should be between 10 and 20 inches RMS Significant variation greater than 8 inches difference are unacceptable In the event that an unacceptable condition occurs the tube assembly should be repaired or replaced 5 8 JLG Lift See Figure 5 3 1 Rinse the inside of the tube
135. l Module 2 While holding the Brake Release Button in power machine up by turning the Main Power Selector Switch 2 to either the Ground Control or Platform Control Mode 3 Release the Brake Release Button 1 after machine is powered up The LCD display should now display five zeros one with a box around Continue to next step Entering Password NOTE If machine did not power up check that both the Ground Control Module Emergency Stop Button and the Platform Control Console Emergency Stop Button are in the RESET position Also if machine is equipped with the PSL Program mable Security Lock option refer to the Operators Manual for additional machine power up steps 4 10 JLG Lift 3121187 SECTION 4 CONTROL COMPONENTS Entering Password Selecting Programmable Item to Adjust Entering Password 1 The Brake Release button 1 moves the box around digit from left to right to select which digit to change 2 Platform UP button 2 increases the numerical digit 3 Platform DOWN button 3 decreases the numerical digit 4 Change all five digits 4 to match password level then press the Brake Release button 1 again Programming Mode Selection SET SLEEP TINE ave Selecting Programmable Item to Adjust 1 Use the Platform UP DOWN buttons 1 to scroll through the list of programmable items available to your programming level 2 Once a programmable item to b
136. lean waxed paper Do not unwrap reusable or new bearings until they are ready to install Lubricate new or used serviceable bearings before instal lation When pressing a bearing into a retainer or bore apply pressure to the outer race If the bearing is to be installed on a shaft apply pressure to the inner race Gaskets Check that holes in gaskets align with openings in the mating parts If it becomes necessary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usage and Torque Application Use bolts of proper length A bolt which is too long will bottom before the head is tight against its related part If a bolt is too short there will not be enough thread area to engage and hold the part properly When replacing bolts use only those having the same specifications of the origi nal or one which is equivalent Unless specific torque requirements are given within the text standard torque values should be used on heat treated bolts studs and steel nuts in accordance with 3121187 JLG Lift 2 5 SECTION 2 GENERAL SERVICE INFORMATION recommended shop practices or the Torque Chart Figures in Section 1 of this Service Manual Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacles when disconnecting
137. lts Fully charge batteries Nothing is lodged between one of the wheels and the base frame e caster wheel on the front of the machine is seized up creating resistance Table 6 47 Machine Won t Drive Straight STEP ACTION SPEC YES NO 1 Checkforthefollowing onthe drive assembly drive attachment m Repair Replace Goto Step 2 weldments is bent has broken welds or loose hardware Tighten weldment 2 Checkforthefollowing onthe drive assembly drive motor mounting Repair Replace plates are bent are square with drive weldments or is hardware Tighten weldment Goto Step 3 loose g 3 Check forthe following on the drive assembly drive motor hard Repair Replace ware is hardware loose flange bearing bad loose slip clutch Tighten compo Goto Step 4 check torque settings or adjustment nent 4 Checkthe left and right drive motor brakes for loose hardware amp not Tighten or Adjust releasing properly per procedure inthis Goto Step 5 Service Manual 5 lsthe electrical signal and amperage draw to the drive motors Recheck Steps equal Check with machine on level surface See Table 6 3 1thru5 Goto Step 6 6 Checkthe drive motor brushes do they need replaced Replace per procedureinthis Goto Step 7 Service Manual 7 15 joystick control defective m Repair Replace Goto Sten 8 If possible swap out with another platform control Platform control 8 Isthe
138. ly 2 ft 60cm when sliding the tray off the bottom of the mounting rails tray will not clear beacon or hood without raising platform b Remove stops to slide tray off the bottom of the mounting rails c Once bottom stops are removed carefully lower the tray to bottom and slide off of the mounting rails and move clear of machine If tray is allowed to drop with stops removed damage to the amber beacon and hood could occur 5 5 HYDRAULIC LINE DISCONNECT SPECIAL TOOL The extend and return hydraulic lines on this machine require special tool JLG P N 7027247 to remove them A CAUTION FULLY LOWER THE MAST TO RELIEVE PRESSURE IN THE SYS TEM BEFORE REMOVING ANY HYDRAULIC LINES CAREFULLY LOOSEN REQUIRED FITTINGS WEAR SAFETY PROTECTION EQUIPMENT WHEN WORKING WITH HYDRAULIC SYSTEMS Push Type Hydraulic Line Removal SpecialTool JLG P N 7027247 Tool Use Use the 90 angled end of the tool on straight fittings use the flat end of the tool on angled fittings 1 3121187 JLG Lift Pull on hose to create a gap between the dust boot and the hose fitting shoulder Insert the disconnect too in the gap created between the dust boot and the hose fitting shoulder Gently push the hose assembly into the coupling body While maintaining slight pressure on the hose assembly actuate the tool Pull up on tool when using the straight end Pull the tool in towards line when using the angled
139. ly and a target mounted on the mast assembly When the mast is elevated and the target raised the proximity switch then cuts back the machine drive speed When machine is in the drive speed cut back mode a turtle is displayed on the Ground Control Module LCD display Check For These Obvious Conditions First Mast drive speed cut back proximity switch and target plate secure and undamaged Table 6 5 Machine In Drive Speed Cut Back Turtle Mode All The Time STEP ACTION SPEC YES NO 1 With the machine powered on and the platform fully lowered check Replace Ground Repairor Replace for continuity on the wires of the Cutback Proximity Switches Atthe urou Speed Cutback Ground Control Module P2 connector check continuity between Control Module Proximity pins 8 and 18 switch 1 and pins 9 and 19 switch 2 Switch 3121187 JLG Lift 6 11 SECTION 6 TROUBLESHOOTING Code 01 Low Battery Voltage Check For These Obvious Conditions First Battery cable ends loose or corroded at battery posts Charger DC output wires from charger to batteries damaged or disconnected Table 6 6 Code 01 Low Battery Voltage STEP ACTION SPEC YES NO 1 Does battery charger power up through diagnostic cycle when See Battery Bat plugged in to an AC outlet tery Charger Ser mni Go To Step 2 vicing Section 3 ofthis Manual 2 lsthe Abnormal RED LED lit when charger is i
140. mance of these inspections Reference the appropriate areas of this manual for servicing and maintenance proce dures Annual Machine Inspection The Annual Machine Inspection must be performed by a qualified JLG equipment mechanic on an annual basis no later than thirteen 13 months from the date of the prior Annual Machine Inspection JLG Industries Inc recog nizes a qualified JLG equipment mechanic 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 appropri ate JLG inspection form for performance of this inspec tion Reference the JLG Annual Machine Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the performance of this inspection Reference the appropriate areas of this man ual for servicing and maintenance procedures For the purpose of receiving safety related bulletins it is important that JLG Industries Inc has updated ownership information for each machine When performing each Annual Machine Inspection notify JLG Industries Inc of the current machine ownership Preventative Maintenance In conjunction with the specified inspections mainte nance shall be performed by a qualified JLG equipment mechanic JLG Industries Inc recognizes a qualified equipment mechanic as a person who by possession of a recognized degree certificate e
141. mpany Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 717 485 5161 JLG Worldwide Locations E 717 485 6417 3121187 JLG Industries Australia Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 61265 811111 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil f 55 19 3295 0407 55 19 3295 1025 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 44 0 161 654 1000 44 0 161 654 1001 JLG France SAS 2 1 de Fauillet 47400 Tonneins France 33 0 5 53 88 31 70 El 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany 4 49 0 421 69 350 20 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 pla JLG Industries Italia s r l Via 22 20010 Pregnana Milanese MI Italy 39 029 359 5210 39 029 359 5845 Oshkosh JLG Singapore E Ltd 29 Tuas Ave 4 Jurong Industrial Estate 639379 Singapore 65 6591 9030 El 65 6591 9031 Plataformas Elevadoras JLG
142. n a continuous grade or rough terrain Table 6 14 Code 13 Traction Module In Fold Back STEP ACTION SPEC YES NO 1 Allow machine to cool the traction module for 30 minutes Does the Replace Traction machine operate OK after cooling m 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 3121187 JLG Lift 6 15 SECTION 6 TROUBLESHOOTING Code 14 Pump Motor Disconnected Check For These Obvious Conditions First Check the Positive Negative cables from the Ground Control Module to the Pump Motor studs for loose or cor roded connections Table 6 15 Code 14 Pump Motor Disconnected STEP ACTION SPEC YES NO 1 Checkresistance across the positive and negative studs on Repairor Replace the pump motor SeeTable 6 2 7 Pump Motor or Motor Brushes Code 15 Lift Down Valve Disconnected Check For These Obvious Conditions First Inspect wire terminals on the lift down valve at the base of the lift cylinder for tight and secure connection Table 6 16 Code 15 Lift Down Valve Disconnected STEP ACTION SPEC YES NO 1 Check voltage atthe P1 connector on the Ground Control Module Replace Ground between 10 and pin 3 Is reading within spec 2 4VDC Control Module Goto Step 2 2
143. n charge mode Charge Batteries Until 10096 GotoStep3 Green LEDis lit Goto Step 4 3 Test Batteries See Battery Condition Section 3 of this Service See Battery Bat Manual tery Charger Ser v vicing Section Rapace Banery of this Manual 4 Check Battery Condition See Battery Condition in Section of this m Replace Batteries Service Manual Do the batteries pass condition tests as Necessary Code 02 RESERVED Code 03 RESERVED 6 12 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING Code 04 Tilt Condition Check For These Obvious Conditions First e If machine is on a tilt of more than 1 5 in either or both the X or Y direction this is normal operation DRIVE and LIFT UP are disabled when tilt is detected Check if Ground Control Module is mounted securely to the mast support column Table 6 7 Code 04 Tilt Condition STEP ACTION SPEC YES NO 1 Using a digital level check the actual level of the machines resting o surfacein boththe X andthe Y directions Does surface check within Xand Go to Step 2 4 machine specification 2 Atthe Ground Control Module enter the programming mode See Ground Control Programming Section 3 of Service Manual and 1 5 Replace Ground Goto Step 3 check the tilt sensor X and Y readings Are readings within machine XandY Direction Control Module p specification 3 Zero Tilt Sensor ona surface chec
144. naccurate unless a written record has been The drive motor brushes must be replaced depending on application every 200 400 hours Traction Time as indi cated on the Ground Control Module in programming mode See Section 4 Ground Control Module Program ming about accessing the machine timer hours NOTE If machine hourmeter hours cannot be determined accurately as noted above a visual inspection and measurement of the brushes must be made The brushes must be replaced before they are less than 405 inch 11mm in length Drive Motor Brush Location 1 Brush Location A WARNING DISCONNECT THE POWER LEADS FROM THE POWER SOURCE BEFORE INSPECTING OR REPLACING BRUSHES 2 Brush Caps shown removed 3 16 JLG Lift Brush Removal Removal of the brushes also requires the removal of the drive motor s from the machine See Drive Motor Assem bly Removal on Page 3 11 After removing the drive motor from the machine remove the brush assemblies using the following steps 1 Remove the clamp and protective rubber boot from the drive motor N Unscrew the large round brush caps from each side of the drive motor use as large a screw driver as possible e The brushes are retained by constant force roll type springs To remove the springs press inward on the end of the spring retaining bracket using the tip of a pair of long nose pliers or other appropriate tool The brushes should
145. nt due to wear Check For These Obvious Conditions First Batteries are Fully Charged 24 Volts Speed Control is Set to Maximum s Grade within the Maximum Allowable Specification of 2096 Grade Does the Travel Surface allow for Proper Drive Wheel Traction s Platform Load within the Maximum Rated Capacity Table 6 45 Won t Climb Grade STEP ACTION SPEC YES NO 1 Does machine drive straight on a level surface Refer to Machine Won t Drive Goto Step 2 Straight Table 6 47 2 Areboththeleftand right drive motor slip clutches located Repair Replace betweenthe drive motor and the drive wheels working properly Goto Step 3 or Adjust Slip Clutch 3 Dotheleftand right drive motor brakes release properly and allow Dragging the drive wheels to rotate freely Go to Step 4 Repair Replace or Adjust Brakes 4 Checkthe amperage output of the onthe drive motor leads They Controller will should not exceed 100 amps while pulling a grade Shut Drive Down andwillflasha7 601051905 LED Code 5 Checkthe condition ofthe drive motor brushes Worn down OK goto Step6 replace brushes or drive motor 6 Ifallabove is OK Drive motors are working properly Consult Fac __ __ tory 3121187 JLG Lift 6 35 SECTION 6 TROUBLESHOOTING Machine Drives in Opposite Direction Table 6 46 Machine Drive in Opposite Direction STE
146. nti cal with the exception of language selection Reset Timers This setting displays five 5 timers as described following Trip Time This timer shows total accumulated hours since last trip timer reset This is the hour meter reading displayed on the Ground Control Module LCD Display during normal machine operation Traction Time Displays the amount of accumulated DRIVE hours on the machine s current drive compo nents Lift UP Time Displays the amount of accumulated time the machine has operated the Lift UP function Lift DOWN Time Displays the amount of accumulated time machine has operated the Lift DOWN function Total Time Displays the total amount of time accumu lated by the Traction Lift UP and Lift DOWN Timers Of these five 5 timers the Trip Timer is the only timer which can be RESET back to 00000 0 Program Allows service personnel to program the Level 2 and Level 3 items shown in Table 4 1 on Page 4 13 Tilt Sensor Allows service personnel to reset the Ground Control Module s internal digital Tilt Sensor to zero 0 0 degrees in both the X and Y axis A DANGER previous zero setting and may not reflect level of the machines current resting surface 1 Position the machine on a level surface verified level in both the X and Y axis with a digital level 2 Select Zero Tilt Sensor from the menu and press the Brake Release button 3 The current tilt sensor readings are displayed T
147. nto the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Apply Loctite 242 to attach screw threads on final assembly Top of Mast Section 3 Narrow Chain Sheave Wheel Installation 1 Narrow Spacer Tube 5 Key 2 Sheave Pin 6 Sheave Pin Support 3 Sheave Wheels Narrow Plates a a 7 Support Plate Screws b 4 Wide Spacer Tube a Note a Install one on both sides of anchor block b Apply Loctite 242 to threads on final assembly a Slide the narrow spacer tube onto one of the remaining sheave pin b Place the narrow chain sheave wheel assem blies one on each side of the narrow spacer onto the sheave pin c Place one wide spacer tube on the outside of Top of Mast Section 3 Top Slide Pad Installation each sheave wheel on the sheave pin 1 Slide Pads 3 Slide Pad Attach Screws a d Insert key into the keyway on the end of the 2 Shim Stock 4 Upper Sequence Cable Bracket sheave pin e Place two 2 sheave pin support bars one each Note a Apply Loctite 242 to attach screws on final assembly end of sheave pin onto outside of spacer tubes f Holding complete sheave wheel assembly slide assembly into top of mast section 3 and align threaded holes in sheave pin support bars with holes in mast rails g Attach to top of mast section 3 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead
148. o zero both the X and Y direction sensor setting to the machines present resting surface press the Brake Release button 4 Select Back to Main Menu and press the Brake Release Button 5 Power machine off and begin operation Operator Programming Mode Level 3 In the Operator Programming Mode the following items are shown on the main menu Also See Table 4 1 on Page 4 13 Tilt Sensor Program NOTE There are two production modules available at this time one for North South American and European languages and one for Asian languages All pro grammable items between these modules are identi cal with the exception of language selection Tilt Sensor Allows viewing current tilt sensor individual X and Y direc tion degree reading Program Allows the Operator to program Level 3 items shown in Table 4 1 on Page 4 13 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 NOTE When entering this mode the LCD will display in real time the current X and Y degree readings of the tilt sensor The reading being displayed is based on the 4 12 JLG Lift 3121187 SECTION 4 CONTROL COMPONENTS Table 4 1 Ground Control Module Field Programmable Settings and Factory Preset SSV 10 Level 2 Serv
149. om the battery posts slide battery forward to clear brackets item 4 Then lift battery out of base frame b The carry deck support frame will need to be removed on machines equipped with the carry deck 3121187 SECTION 3 BASE COMPONENTS Battery Charge LED Indicator on Platform Control Console The number of LEDs lit will change depending on the level of charge in the batteries All Three 3 GREEN LEDs lit up indicate maxi mum battery charge Four 4 YELLOW LEDs indicate a two thirds to one third battery charge remaining Three 3 RED lit indicate minimum battery charge remaining The machine will continue to operate at this charge level but will begin to indicate battery low voltage warning indicators On normal power up and operation this series of ten 10 LEDs visually indicates the amount of charge remaining in the batteries Battery Low Voltage Warning Indicators The Platform Control Console and Ground Control Station indicate battery low voltage at three 3 Warning Levels See Table 3 1 following Table 3 1 Battery Low Voltage Warning Indicators WARNING ILU erant ACTION REQUIRED TO LEVEL PEUT CLEAR FAULT PLATFORM CONTROL LED GROUND CONTROL LCD LEVEL 1 3 LEDSs BARS Flashing Charge batteries to a level of anco with an audible beep four 4 LEDs BARS or more Z RPONOW e Machine will
150. on 1 Secure the brake assembly to the drive motor hous ing using four 4 hex cap screws with washers Torque evenly to 44 in lbs Reinstall the protective rubber boot over the drive motor housing secure the boot with the boot clamp Reconnect the drive motor brake power wiring con nector to wiring harness connector Install the drive motor cover 3 2 y 4 1 1 Magnetic Coil 2 Armature Plate 3121187 Gap Setting Brake Engaged magnet not energized springs engage plate against disk 3 Brake Disk Engaged 5 006 Gap 4 Mounting Plate Gap Setting Brake Disengaged magnet energized plate compresses springs disk rotates freely 1 Magnetic Coil 2 Armature Plate JLG Lift 5 Plate Engaged Springs Compressed 3 Brake Disk Free 4 Mounting Plate 3 15 SECTION 3 BASE COMPONENTS Drive Motor Brush Replacement Each drive motor contains two 2 brushes the brushes are located under the two 2 large round slotted brush caps on the front end of each drive motor NOTE When determining hourmeter hours on the Ground Control Module for brush replacement remember the hourmeter dis play can be RESET back to 00000 0 at any time more accurate reading can be obtained by entering the Ground Control Module programming mode and checking the Timer readings there Also if the machine s Ground Control Module has been replaced the current hourmeter hours will also be i
151. on in the mast assembly s there a restricted hydraulic line smashed Are the mast slide pads shimmed properly not too tight per Mast Assembly procedure in Service Manual Table 6 38 Platform Will Not Lower Manually STEP ACTION SPEC YES NO 1 Checkto see ofthe platform will lower from the Ground Control Sta Repairor Replace tion in Ground Control Mode the Manual z Descent Control 20105180 2 Valve 2 Checkto see if the lift down valve is opening completely a Goto Step 3 Replace the Lift Down Valve 3 Check the flow valve in the lift cylinder for a restriction Sm Clean or Replace Consult Factory Flow Valve Platform Lift Up And Down Jerky Overview Of Procedure The following procedure suggests areas on the machine which might attribute to erratic movement of the platform during lift up and down Check For These Obvious Conditions First If mast is not running smooth or has tight and rough spots refer to the Mast Section Rebuild Hydraulic oil level in reservoir tank at full level Hydraulic oil is not milky presence of water or foamy full of air Table 6 39 Platform Lift Up and Down Jerky STEP ACTION SPEC YES NO CONTROLS ELECTRICAL 1 Isplatform control console platform enable up or down pad defec Replace pad Goto Step 2 2 Loose connections ground and power Repair connection 3 Valve solenoid keep
152. ontacting surfaces Also if the brake becomes clogged with debris or dirt the brake may not release properly Figure 3 2 Brake Assembly Components 1 Magnetic Coil Housing 2 Armature Plate 3 Friction Brake Disk 4 Mounting Plate 5 Plate Springs 6 Shim Washers 7 Spacer 8 Mounting Plate Screws 3121187 SECTION 3 BASE COMPONENTS Checking Adjusting Armature Plate Gap Setting 1 First inspect that all parts of the brake assembly are tight and secure Tighten as necessary Inspect the brake for any debris which may be lodged in the air gap between the armature plate and magnetic coil when the brakes are ENGAGED brakes on on either side of the friction disk when the brake is RELEASED brakes off Clean and remove debris as necessary With the brakes ENGAGED measure the air gap between the armature plate and the magnetic coil housing The correct setting should be 006 how ever the brakes will operate properly if the measure ment is a minimum of 004 and a maximum of 010 See Gap Setting Illustration this Section If the air gap falls outside the maximum allowable setting of 010 the friction disk has worn To correct this replace the disk with a new one If the air gap is below the minimum allowable setting of 004 recheck the areas between the magnetic coil housing armature plate friction disk and mounting plate for debris Clean as necessary Brake Assembly Installati
153. ontrol Module Replace Ground between pin 14 and pin 7 Is reading within specification 2 4VDC Control Module Goto Step 4 4 Remove the wire terminals atthe horn check continuity of each of i the wires from pins 14 and 7 onthe P1 connectorto the horn end 2 Code 24 Auxiliary 1 Circuit Short Circuit Check For These Obvious Conditions First Damaged wiring in the Auxiliary 1 Component wiring harness or a damaged Component Table 6 25 Code 24 Auxiliary 1 Circuit Short Circuit STEP ACTION SPEC YES NO 1 Atthe Ground Control Module P1 connector check the voltage Replace Ground across pins 9 and 2 to the Aux 1 component Is reading within 0 2VDC Goto Step 2 C x Modul specification 2 Removethe wire terminals atthe Aux 1 component check conti nuity of each of the wires from pins 9 and 2 on the P1 connectorto Msi ui R 2 the Aux 2 component end omponen epiace Wiring 6 20 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING Code 25 Auxiliary 1 Circuit Disconnected Check For These Obvious Conditions First Is machine equipped with a component on the Auxiliary 1 circuit Table 6 26 Code 25 Auxiliary 1 Circuit Disconnected STEP ACTION SPEC YES NO 1 Is machine equipped with acomponentonthe Auxiliary 1 circuit Goto Step 3 Gotto Step 2 2 Atthe Ground Control Module enter the programming mode check
154. or Various Components 6 10 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS Special Pin Extractor Tools for Electrical Connectors 6 10 FAULT CODE TROUBLESHOOTING TABLES Machine in Drive Speed Cut Back Turtle Mode All The Time 6 11 Code 01 Low Battery 6 12 Gode 02 RESERVED LA RERUM 6 12 Gode 08 RESERVED u rA he eit eh DAE qe Mn eR RU Du e qnd 6 12 Gode 04 Tilt Condition i oe Clone e reine su descen ET AUS Ru 6 13 Code 05 RESERVED Rage ee Ua RA RAD EE RR eet 6 13 06 RESERVED 5 5 52 oim us A LEO ee a led 6 13 Code 07 Left Drive Motor 6 13 Code 08 Right Drive Motor Disconnected 6 14 Code 09 Left Brake Disconnected 6 14 Code 10 Right Brake 6 14 Code 11 Left Drive Motor Short Circuit 6 15 Code 12 Right Drive Motor Short 6 15 Code 13 Traction Module In Fold 6 15 Code 14 Pump Motor D
155. or removing them from the unit This will assure that they are correctly reinstalled Hydraulic System Keep the system clean If evidence of metal or rubber par ticles is found in the hydraulic system drain and flush the entire system Disassemble and reassemble parts on clean work sur face Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assem bly Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart See Figure 1 2 in Section 1 Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants are not available consult your local supplier for an equivalent that meets or exceeds the specifications listed Batteries Clean batteries using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroughly dry batteries and coat terminals with an anti corrosion compound Mast Chain Inspection Procedure Inspect mast chains for the following conditions Wear Always inspect that segment of chain that operates over a sheave As the chain flexes over the sheaves joints and plate edges very gradually wear Chain stretch can be measured using a manufacturers wear scale or steel tape When chains have elongated 3 they must be removed and replaced Refer to Table 2 3
156. peeds Programming Levels There are three 3 password protected programming levels from highest to lowest the levels are Level 1 JLG Engineering Settings Level 2 Service and Maintenance Settings Level 2 Password 91101 Level 3 Operator Settings Level 3 Password 33271 IMPORTANT THE LEVEL 1 JLG ENGINEERING SETTINGS ARE NOT DIS PLAYED IN THE PROGRAMMABLE SETTINGS UNDER PASS WORD LEVEL 2 OR LEVEL 3 LEVEL 1 SETTINGS MUST NOT BE MODIFIED UNLESS DIRECTED BY JLG ENGINEERING DEPART MENT 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 Level 2 Service and Maintenance Settings allow modi fication to machine personality settings such as lift speeds drive speeds as well as various switch polarity settings also enable various optional equipment if installed This level can also adjust Level 3 settings Level 3 Operator Settings allow the direct user to mod ify a few settings such as the language setting of text out put to the Ground Control Module LCD screen setting machine sleep time and enabling the detection of the horn and beacon components Activating Programming Mode pore Activating Programming Mode 1 With machine power off press and hold the Brake Release But ton 1 on the Ground Contro
157. pop out if not they can be removed by pulling outward on the spring brackets with a pair of long nose pliers after the inside ends are unhooked B Now pull the brush out of the brush box by it s wire pig tail NOTE If only inspecting the brushes it is not necessary to remove the pig tail terminal from it s connection to the brush box Loosen the screw securing the pig tail terminal end to the brush box and slide the terminal end out from under the screw completely removing the brush from the drive motor qom d E 1 3 Brush Component Installation 1 Roll Spring 4 Brush Box Insulator 2 Roll Spring Hooks 5 Brush 3 Brush Box 6 Pigtail Wire 3121187 SECTION 3 BASE COMPONENTS Brush Reassemhly CAUTION MAKE CERTAIN THAT THE GROUND WIRE IS SECURELY RECON NECTED TO THE GROUND TERMINAL IF REMOVED LEADS INTERNAL TO THE SHIELD MUST BE ROUTED AWAY FROM THE ARMATURE E G BE CLOSE TO THE INSIDE WALL OF THE ALUMINUM SHIELD TO PREVENT A SAFETY HAZARD AND OR DAMAGE TO THE MOTOR 1 Install the brush pig tail terminal end under the screw on the brush box in the same manner as the old brush that was removed and tighten the screw 2 Slide the body of the brush into the brush box be certain that the wire pig tail is aligned with the slot in the base of the brush box so that it can feed into the brush box slot as the brush wears
158. pplied with the machine consult local supplier for assistance in selecting the proper equivalent Avoid mixing petroleum and syn thetic base oils JLG Industries recommends changing the hydraulic oil annually Use every precaution to keep the hydraulic oil clean If the oil must be poured from the original container into another be sure to clean all possible contaminants from the service container While the unit is shut down a good preventive mainte nance measure is to make a thorough inspection of all hydraulic components lines fittings etc as well asa functional check of each system before placing the machine back in service Lubrication Specifications Specified lubricants as recommended by the component manufacturers are always the best choice however multi purpose greases usually have the qualities which meet a variety of single purpose grease requirements Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion Refer to Section 1 of this Service Manual for an expla nation of the lubricant key designations appearing in the Lubrication Chart JLG Lift 2 7 SECTION 2 GENERAL SERVICE INFORMATION This page intentionally left blank 2 8 JLG Lift 3121187 SECTION 3 BASE COMPONENTS SECTION 3 BASE COMPONENTS 3 1 BASE ASSEMBLY COMPONENTS Figure 3 1 Base Components 1 Front Cover 2 Drive
159. r See Drive Motor Assembly Removal on Page 3 11 Loosen the boot clamp and slide the protective rub ber boot off the end of the drive motor housing exposing the brake assembly Remove the four 4 hex cap screws securing the brake assembly to the end of the drive motor hous ing and remove the brake assembly from the end of the drive motor 1 Round Hex Screws 2 Brake Assembly 3 14 Brake Removal 3 Brake Power Leads 4 Motor Shaft to Brake Disc Spline Gear JLG Lift Brake Operation When the magnetic coil is not energized brake on the armature plate is pushed away from the magnetic coil sur face by heavy springs internally mounted in the magnetic coil housing This pressure forces the armature plate against the friction brake disk holding it tight between the armature plate and the mounting plate The internally splined friction brake pad is mated to an externally splined gear on the drive motor armature shaft The brake is not released until the magnetic coil is energized pulling the armature plate away from the friction brake disk A correctly adjusted brake will ideally have a measure ment of approximately 006 but will operate normally at 004 to 010 between the armature plate and magnetic coil housing surface when the brakes are ENGAGED brakes on Never allow any type of lubricant oil grease hydraulic fluid etc to come in contact with the brake friction disk or it s c
160. r 24 pitches 301 15 in span JLG Lift Fatigue Cracks Fatigue is a phenomenon that affects most metals and is the most common cause of chain plate failures Fatigue cracks are found through the link holes perpendicular 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 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 lift ing capacity of these chains Tight Joints joints in the leaf chain should flex freely On leaf chain tight joints are usually caused by rust corro sion or the inside plates walking off the bushing Limber up rusty corroded chains after inspecting care fully with a heavy application of oil preferably a hot oil dip Tap inside walking plates inward if walking persists replace the chain This type of problem is accelerated by poor lubrication maintenance practice and most tight joint chains have been operated with little or no lubrica tion Tight joints on leaf chain are generally caused by a Bent pins or plates b Rusty joints c Peened plate edges Oil rusty chains and replace chains with bent or peened chain components Keep chains lubricated Protruding or Turned Pins Chains operating with inade
161. r Replace cable connection on the Traction Control Module Positive or 24v DC Go to Step 2 Negative Cable 2 Remove the communications cable P5 connector atthe Ground Control Module andround connector atthe Traction Control Module EM Goto Step 3 Repair or Replace Check continuity of all three 3 wires in the communications cable p 5 from endto end P5 Pins 2 3 and 4 3 With communications cable disconnected at both ends check for Repair or Replace continuity between Pins 2 3 and 4 of the P5 connector end 7 Go to Step 4 4 Plugthe communications cable on the Traction Control Module to the round socket on the opposite end of the module Does this fix Done nan problem u 5 Unplugthe P5 connector atthe Ground Control Module Check volt Replace Ground age between pins 2 lead in and 5 lead in Is voltage within 4 5v DC Done spec Control Module 3121187 JLG Lift 6 23 SECTION 6 TROUBLESHOOTING Code 31 Platform Control Console No Communication with Ground Control Module Check For These Obvious Conditions First Check the harness connection at the P4 connector on the Ground Control Module and the harness connection at the other end on the Platform Junction Box Table 6 30 Code 31 Platform Control Console No Communication with Ground Control Module STEP ACTION SPEC YES NO 1 Chec
162. r is run in the 2 Disconnect the positive battery terminals from the reverse direction of the right motor left side battery 3 Raise the rear drive wheels of the machine off the ground use a fork truck or floor jack Place a block or safety stand under machine Drive Motor Assembly Removal The SSV 10 electric drive motor assemblies are mounted indepentent of each other in the base frame at the rear of 4 Remove the drive motor wheel s see Section 3 3 the machine on page 3 3 The drive motor assembly consists of the electric drive 5 Disconnect the drive motor power harness connec motor with a 32 1 ratio parallel drive gear box mounted on tor s from the traction module mounted just in front one end and a friction disk brake covered with a rubber of the drive motor location in the base frame boot mounted on the other end This assembly is mounted to a motor mounting plate bearing carrier which 6 Remove the four 4 hex head cap screws and lock is bolted to the machines base frame nuts from the drive assembly mounting frame 7 Carefully slide the drive motor assembly out of the base frame assembly for disassembly Drive Motor Assembly Installation 1 Frame Mounting Surface 4 Drive Motor Mounting Bolts 2 Drive Motor Assembly 5 Lock Nuts 1 on each mounting bolt 3 Motor Mounting Plate Bearing Carrier 6 Traction Control Module Location NOTE Installation same for left and right drive motor Bas
163. s and the Ground Control Mod ule lugs Main Power Selector Switch key positioned to either Platform or Ground Control Mode Emergency stop buttons on both the Ground Control Module and the Platform Control Console in the RESET position out Table 6 37 Machine Will Not Power UP STEP ACTION SPEC YES NO 1 Checkfor24V DC atthe positive and negative main power Replace the 175 cable connections onthe Ground Control Module Amp Inline Fuse 24V DC Goto Step 2 onthe Positive power cable 2 Checkcontinuity of the Emergency Stop wires running to the Plat Replace the form Control Console pins 10 and 1 onthe P4 connector at the Ground Control Goto Step 3 Ground Control Module Module 3 Remove the 9 pin Platform Control Console connector at the Plat Replacethe form Junction Box and check continuity between pins 1 and 2 to the Go to Step 4 Platform Control Emergency Stop Switch inthe Platform Control Console cable Console 4 Check continuity of the wires running from the P4 connector on Ground Control Module to the Platform Junction Box 22 Replace Platform Repair or Replace P4 connector Pin 1 to Junction Box Pin 2 and Control Console Wiring connector Pin 10 to Junction Box Pin 1 3121187 JLG Lift 6 29 SECTION 6 TROUBLESHOOTING 6 10 MAST TROUBLESHOOTING Platform Will Not Lower Manually Check For These Obvious Conditions First s there an obstructi
164. s of the compo nent working parts are very close therefore even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and gener ally results in faulty operation Every precaution must be taken to keep hydraulic oil clean including reserve oil in storage Cloudy oils indicate a high moisture content which per mits organic growth resulting in oxidation or corrosion If this condition occurs the system must be drained flushed and refilled with clean oil It is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities Good grade mineral oils with viscosities suited to the ambient temperatures in which the machine is operating are recommended for use NOTE Metal particles may appear in the oil of new machines due to the wear in of meshing compo nents Hydraulic Oil For best performance JLG recommends the use of ISO 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 to Section 1 5 of this Service Manual for recommended hydraulic oils Changing Hydraulic Oil Use of any of the recommended hydraulic oils eliminates the need for changing the oil on a regular basis If it is nec essary to change the oil use only those oils meeting or exceeding the specifications appearing in this manual If unable to obtain the same type of oil su
165. s opening and closing Repair Connec tion or Replace Goto Step 4 Valve 4 Problem internal to the Ground Control Module Replace Module Goto Step 5 6 30 JLG Lift 3121187 SECTION 6 TROUBLESHOOTING Table 6 39 Platform Lift Up and Down Jerky Continued STEP ACTION SPEC YES NO HYDRAULIC 5 Isthehydraulic valve working properly Goto Step 6 Replace Valve 6 Pump drive cavatating Replace Pump Goto Step 7 7 Liftcylinder __ Rebuild or Replace Cylinder Mast Noisy When Lifting And Lowering Overview Of Procedure This procedure examines components of the mast itself and as well as it s lifting components for dirt debris proper lubrica tion and operation Table 6 40 Mast Noisy when Lifting and Lowering STEP ACTION SPEC YES NO 1 Doslide pads and slide pad channels need to be cleaned of dust Clean Pads and Goto Step 2 dirt or other debris Channels 2 Domastchains needto be lubricated per JLG specification in the m Lubricate as Goto Sten 3 Service Manual Required P 3 Arethechain cable sheave wheels dry and need lubrication Lubricate or Note Plastic wheels will howl onthe sheave pin when they are dry m Replace Sheave Goto Step 4 Sheave wheels may seize to the sheave pin and the pin may turn in Pi p d Wheel p the pin retainer blocks dli ere 4 Arethesequence cables located on the side of mast chattering
166. sconnected 6 14 Code 09 Left Brake Disconnected 6 14 Code 10 Right Brake 6 14 Code 11 Left Drive Motor Short Circuit 6 15 Code 12 Right Drive Motor Short 6 15 Code 13 Traction Module In Fold 6 15 Code 14 Pump Motor Disconnected 6 16 Code 15 Lift Down Valve 6 16 Code 16 Lift Down Valve Short 6 17 Code 17 Ground Control Module In Fold 6 17 Code 18 Alarm Short 6 18 Code 19 Alarm Disconnected 6 18 Code 20 Beacon Short 6 18 Code 21 Beacon 6 19 Code 22 Horn Short 6 19 Code 23 Horn Disconnected 6 20 Code 24 Auxiliary 1 Circuit Short 6 20 Code 25
167. side of the mast with beveled surface facing out towards section 1 Figure 5 5 Bottom of Mast Section 2 Slide Pad Installation 1 Slide Pads 2 Shim Stock 3 Slide Pad Bolts Washers a Note Apply Loctite 242 to threads 6 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in mast section 2 inside rail into the slide pad inserts Thread in enough to hold pad in place 7 Shim slide pads using the following steps NOTE Always use the an even amount of shim material behind slide pads on both sides of the mast rails This will keep mast sections centered in rail chan nels and prevent any distortion of the mast section a Start with a 036 thick shim and a 075 thick shim per side at each slide pad b Slide shims into place between slide pad and mast rail Tighten the slide pad mounting bolts be sure there are no air gaps between shims shim and mast or shim and slide pad when tight ened JLG Lift 5 11 SECTION 5 MAST COMPONENTS NOTE Note 10 11 5 12 c Check mast section for side play If play exists add 015 shims dividing the thickness equally between both sides of mast Insert shims until the shims cannot be inserted halfway by hand with the mast pulled to the opposite side d When mast slide pads are shimmed properly there should be no side to side movement o
168. specified inthe Service and Owner Dealer or User Qualified JLG Service and Maintenance Man Maintenance Maintenance Manual Mechanic ual 2 2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE See Table 2 2 The preventive maintenance and inspection checks are listed and defined in the following table This table is divided into two basic parts the AREA to be inspected and the INTERVAL at which the inspection is to take place Under the AREA portion of the table the various systems along with the components that make up that system are listed The INTERVAL portion of the table is divided into five columns representing the various inspec tion time periods The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive Variances in interval times may occur due to climate and or conditions and depend ing on the location and use of the machine 2 2 JLG Lift 3121187 SECTION 2 GENERAL SERVICE INFORMATION Table 2 2 SSV 10 Preventive Maintenance amp Inspection Schedule INT
169. ssembly Only discon nect enough wiring to remove a component The battery charger manual supplied with the machine contains a wiring diagram for the charger as well as Figure 3 8 at the end of this section of the manual 3 22 JLG Lift 3121187 SECTION 3 BASE COMPONENTS AC Line Fuse Installation Wet VRLA Switch Installation AC Line Fuse Remove Install Wet VRLA Switch Remove Install 1 AC Line Fuse 3 Back of Charger 1 Wet VRLA Switch 2 Back of Charger 2 Cap Screw Lock Washer Nut Shunt Assembly Installation Interlock Relay Installation Interlock Relay Remove Install Shunt Assembly Remove Install 1 Interlock Relay 3 Back of Charger 1 Shunt Assembly 3 Spacers 2 2 Attach Screws 2 2 Cap Screws 2 3121187 JLG Lift 3 23 SECTION 3 BASE COMPONENTS SCR Rectifier Installation Either Side Printed Circuit Board Installation SCR Rectifier Remove Install Same Mounting on Both Sides 1 SCR Rectifier 3 Aluminum Mount Plate 2 Nut Lock Washer Transformer Installation H a ace Z ZZ TE TE TAA zb o bt 4 ZZZ Circuit Board Remove Install 1 Circuit Board 3 Board Screws Nuts Washers 2 2 Spacer 2 4 Charger Face Plate DC Breaker Voltage Select Switch Installation
170. t centimeters cm given in parenthe ses Table 1 5 Cylinder Specifications DESCRIPTION BORE STROKE ROD DIA in cm in cm in cm SSV 10 1 63 41 50 1 375 Lift Cylinder 4 10 105 4 3 49 1 8 SERIAL NUMBER LOCATIONS For machine identification a serial number plate is affixed to the machine The plate is mounted on the base frame between the front caster wheels under the front cover The serial number is also stamped on the front of the mast assembly near the amber beacon 1 4 JLG Lift 3121187 SECTION 1 MACHINE SPECIFICATIONS Table 1 6 Lubrication Intervals for Various Components b No TvPe 8 INTERVAL ITEM COMPONENT LUBE METHOD COMMENTS LUBE POINTS 3 6 1 2 MONTHS MONTHS YEAR YEARS 1 Fill To Full Line on HO Check Hyd Oil Check fluid level every day Hydraulic Oil Dipstick 5 Qt Level v Change hydraulic oil every 2 Reservoir HO Change Hyd Oil years 2 Drive Wheel u _ Bearings Permanently Sealed 3 Drive Wheel 1 Change only when serviced Gear Box 2 Gear Boxes Gear Oil requires 6 oz 175 cc s to fill 4 Caster Axles Permanently Sealed 5 Upper Permanently Sealed Swivel Raceways MPG Lower Repack if Serviced 6 MastChains 2 Per Section CL Brush or Spray Inspe
171. tion 3 23 Interlock Relay Installation 3 23 Wet VRLA Switch Installation 2 3 23 Shunt Assembly Installation 3 23 SCR Rectifier Installation Either Side 3 24 Transformer Installation 0 3 24 Printed Circuit Board Installation _ 3 24 DC Breaker Voltage Select Switch Installation 3 24 SECTION 4 CONTROL COMPONENTS 4 1 CONTROL COMPONENTS OVERVIEW 4 1 4 2 CONTROL COMPONENTS 4 2 Ground Control 4 2 Traction Control Module 1 4 3 Platform Control Console Installation 4 3 Platform Junction Box Install Remove 4 8 Junction Box to Ground Control Harness 4 4 Platform Interlock Switch 4 5 4 3 GROUND CONTROL MODULE SERVICE PROCEDURE 4 7 Cover Remo
172. und Control Module 6 23 Code 31 Platform Control Console No Communication with Ground Control Module 6 24 Code 32 Pump Motor Over 6 24 Gode 33 RESERVED iu eoe ec UU ics eU RR xoa Ch didnt 6 25 Code 34 Auxiliary 2 1 6 25 Lift 3121187 SECTION 6 TROUBLESHOOTING Code 35 Auxiliary 2 Tie 6 25 Gode 36 RESERVED n yu yn i qa n equ ipu ES 6 25 Code 37 RESERVED didus eve VL SPRUHE PE NEU SERV R ee ee 6 25 Code 38 Battery Voltage Low Warning Level 2 Two 2 LED LCDslit 6 26 Code 39 Battery Voltage Low Warning Level 3 One 1 LED LCDs lit 6 26 Codes 100 199 Ground Control Module Fault 6 26 Codes 200 299 Platform Control Console Fault 6 27 Codes 300 399 Traction Control Module Fault Condition 6 28 MAIN POWER CIRCUIT TROUBLESHOOTING Machine Will Not Power 1 4 1 6 29 MAST TROUBLESHOOTING Platform Will Not Lower Manually 1 4 6 30 Platform Lift Up And Down
173. und Control Station if the circuit is not closed during machine operation The circuit utilizes the Auxiliary 1 plug on the Platform Junction Box located under the platform From there the circuit is wired to the Ground Control Module P2 connector through the Platform Junction Box to Ground Control Module wiring harness For Ground Control Module P2 pin assignments see the machine wiring schematic in Section 6 Troubleshooting Platform Interlock Switch Circuit 4 Platform Interlock Switch Components 1 Platform Junction Box 4 Right Gate Interlock Switch Location 2 Platform Aux 1 Connector 5 Left Gate Interlock Switch Location Footswitch Platform Gate Interlock Connector 3 Platform Footswitch 3121187 JLG Lift 4 5 SECTION 4 CONTROL COMPONENTS Ol Figure 4 2 Component Electrical Connections 1 Ground Control Module a 4 Right Side Battery b 7 Power Cable To Left Drive Motor Brake a 2 Left Side Battery b c 5 Traction Control Module a 8 Power Cable To Right Drive Motor Brake a 3 175 Amp Fuse 6 Left Drive Motor Harness Reverser a 9 Hydraulic Pump Motor Tank Assembly
174. val Installation I 4 7 Power Selector EStop Switch 4 9 4 4 GROUND CONTROL MODULE 4 10 icc 4 10 Programming Levels 20r da PET ex I E 4 10 Activating Programming Mode 2 4 10 Entering Password oiseau e REVOIR ee UE RU EP 4 11 Programming Mode Selection 1 4 11 Selecting Programmable Item to Adjust 4 11 Adjusting Programmable Setting 4 11 Service Programming Mode Level 2 4 12 Operator Programming Mode 3 4 12 4 5 PLATFORM CONTROL CONSOLE SERVICE PROCEDURES 4 15 icc 4 15 Remove Platform Control Console 4 15 Display Controller Module Electrical Connections 4 16 Mounting Bracket Install Remove 4 16 Rear Cover Install lRemove 4 16 3121187 JLG Lift iii TABLE OF 5 Display Controller Module 4
175. xtensive knowledge train ing or experience has successfully demonstrated the ability and proficiency to service repair and maintain the subject JLG product model Reference Table 2 2 SSV 10 Preventive Maintenance amp Inspection Schedule and the appropriate areas of this manual for servicing and maintenance procedures The frequency of service and maintenance must be increased as environment severity and frequency of usage requires JLG Lift 2 1 SECTION 2 GENERAL SERVICE INFORMATION Table 2 1 Maintenance and Inspection Requirements Type Frequenc Eu pence Reference 4 y Responsibility Qualification Pre Start Priorto use each day or User or Operator User or Operator Operator and Safety Manual Inspection Ateach Operator change Pre Delivery Priorto each sale lease or 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 fora period of more than 3 months or Pur Mechanic ual and applicable JLG inspec chased used tion form Annual Annually no later than 13 months fromthe Owner Dealer or User Qualified JLG Service and Maintenance Man Machine date of the prior inspection Mechanic ual and applicable JLG inspec Inspection tion form Preventative Atintervals as

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