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SECTION 1 - MACHINE SPECIFICATIONS

3121228

 

JLG

 

Lift

 

1-5

1.8 TORQUE SPECIFICATIONS

Figure 1-1.  Torque Chart (SAE Fasteners - Sheet 1 of 7)

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

JLG  P/N

Loctite®  P/N

ND  Industries  P/N

Description

0100011

242

TM

Vibra-TITE

TM

121

Medium  Strength (Blue)

0100019

271

TM

Vibra-TITE

TM

140

High Strength (Red)

0100071

262

TM

Vibra-TITE

TM

131

Medium - High Strength (Red)

Size

TPI

Bolt  Dia

Tensile

Stress Area

Clamp Load

In

Sq  In

LB

IN-LB  

[N.m]

IN-LB  

[N.m]

IN-LB  

[N.m]

IN-LB  

[N.m]

4

40

0.1120

0.00604

380

8

0.9

6

0.7

48

0.1120

0.00661

420

9

1.0

7

0.8

6

32

0.1380

0.00909

580

16

1.8

12

1.4

40

0.1380

0.01015

610

18

2.0

13

1.5

8

32

0.1640

0.01400

900

30

3.4

22

2.5

36

0.1640

0.01474

940

31

3.5

23

2.6

10

24

0.1900

0.01750

1120

43

4.8

32

3.5

32

0.1900

0.02000

1285

49

5.5

36

4

1/4

20

0.2500

0.0318

2020

96

10.8

75

9

105

12

28

0.2500

0.0364

2320

120

13.5

86

10

135

15

In

Sq  In

LB

FT-LB  

[N.m]

FT-LB  

[N.m]

FT-LB  

[N.m]

FT-LB  

[N.m]

5/16

18

0.3125

0.0524

3340

17

23

13

18

19

26

16

22

24

0.3125

0.0580

3700

19

26

14

19

21

29

17

23

3/8

16

0.3750

0.0775

4940

30

41

23

31

35

48

28

38

24

0.3750

0.0878

5600

35

47

25

34

40

54

32

43

7/16

14

0.4375

0.1063

6800

50

68

35

47

55

75

45

61

20

0.4375

0.1187

7550

55

75

40

54

60

82

50

68

1/2

13

0.5000

0.1419

9050

75

102

55

75

85

116

68

92

20

0.5000

0.1599

10700

90

122

65

88

100

136

80

108

9/16

12

0.5625

0.1820

11600

110

149

80

108

120

163

98

133

18

0.5625

0.2030

12950

120

163

90

122

135

184

109

148

5/8

11

0.6250

0.2260

14400

150

203

110

149

165

224

135

183

18

0.6250

0.2560

16300

170

230

130

176

190

258

153

207

3/4

10

0.7500

0.3340

21300

260

353

200

271

285

388

240

325

16

0.7500

0.3730

23800

300

407

220

298

330

449

268

363

7/8

9

0.8750

0.4620

29400

430

583

320

434

475

646

386

523

14

0.8750

0.5090

32400

470

637

350

475

520

707

425

576

1

8

1.0000

0.6060

38600

640

868

480

651

675

918

579

785

12

1.0000

0.6630

42200

700

949

530

719

735

1000

633

858

1  

1/8

7

1.1250

0.7630

42300

800

1085

600

813

840

1142

714

968

12

1.1250

0.8560

47500

880

1193

660

895

925

1258

802

1087

1  

1/4

7

1.2500

0.9690

53800

1120

1518

840

1139

1175

1598

1009

1368

12

1.2500

1.0730

59600

1240

1681

920

1247

1300

1768

1118

1516

1  

3/8

6

1.3750

1.1550

64100

1460

1979

1100

1491

1525

2074

1322

1792

12

1.3750

1.3150

73000

1680

2278

1260

1708

1750

2380

1506

2042

1  

1/2

6

1.5000

1.4050

78000

1940

2630

1460

1979

2025

2754

1755

2379

12

1.5000

1.5800

87700

2200

2983

1640

2224

2300

3128

1974

2676

NO. 50000 59 

REV. J

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Torque

(Dry)

Torque

(Loctite® 262

TM

or Vibra-

TITE

TM

 131)

Torque

Lubricated

Torque

(Loctite® 242

TM

 or 271

TM

OR Vibra-TITE

TM

111 or

140)

3. * ASSEMBLY USES HARDENED WASHER

  NOTES:  1.  THESE  TORQUE VALUES  DO NOT APPLY TO  CADMIUM  PLATED  FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

Summary of Contents for 10msp

Page 1: ...Ser Service and Maintenance Ma vice and Maintenance Manual nual ANSI ANSI Model Model 10MSP 10MSP V Vertical Lift ertical Lift P N 3121228 P N 3121228 April 29 2 April 29 2013 013...

Page 2: ...NOTES NOTES...

Page 3: ...THE OWNER SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER OPERATOR OPERATOR B B HYD HYDRA RAULI ULIC S C SYST YSTEM EM SAF SAFETY ETY 1 1 It sh It should ould be p be particu articularly larly...

Page 4: ...ue of Manual December 23 2005 Manual Revised January 2 2005 Manual Revised January 6 2005 Manual Revised May 23 2006 Manual Revised October 4 2006 Manual Revised December 5 2007 Manual Revised Septemb...

Page 5: ...chine Overall 1 3 Platform Entry Height Floor to Platform Floor 1 3 Machine Ground Clearance 1 3 Machine Turning Radius Outside 1 3 1 4 TORQUE REQUIREMENTS 1 3 1 5 CYLINDER SPECIFICATIONS 1 3 1 6 SERI...

Page 6: ...ation 3 4 3 4 DRIVE ELEVATION CUT OUT SWITCH INSTALLATION 3 5 3 5 WHEEL DRIVE ASSEMBLY SERVICING 3 5 Roll and Leak Testing 3 5 Oil Type and Capacity 3 5 Drive Motor Brush Wear Warning Indication 3 6 W...

Page 7: ...3 Platform Control Console Installation 4 3 Platform Junction Box Install Remove 4 4 Junction Box to Ground Control Harness Remove Install 4 4 Platform Interlock Switch Circuit 4 5 4 3 GROUND CONTROL...

Page 8: ...ALGORITHM PROGRAMMING OF THE DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES THE USE OF NON APPROVED BATTER IES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFORMANCE ISSUES OR BATTE...

Page 9: ...ice 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 viscosi...

Page 10: ...er Section CL BrushorSpray Inspect lubricateifdryorrusting KeytoLubricants MPG MultipurposeGrease HO HydraulicOil ISO Vggrade32 46 GEAROIL GoodQualityWormGearOil SAE90 AGMA 5 EPCompounded CL ChainLube...

Page 11: ...0 136 80 108 9 16 12 0 5625 0 1820 11600 110 149 80 108 120 163 98 133 18 0 5625 0 2030 12950 120 163 90 122 135 184 109 148 5 8 11 0 6250 0 2260 14400 150 203 110 149 165 224 135 183 18 0 6250 0 2560...

Page 12: ...imate and or conditions and depend ing on the location and use of the machine ing on the location and use of the machine T Table 2 1 Ma able 2 1 Maintenance and Inspection intenance and Inspection Req...

Page 13: ...eA As ss se em mb blly y 2 2 2 2 G Ge ea ar rB Bo ox xA As ss se em mb blly y D Dr ri iv ve eM Mo ot to or r B Br ru us sh he es s FUNCTIONS CONTROLS FUNCTIONS CONTROLS 7 7 P Plla at tf fo or rm mC Co...

Page 14: ...d Purchased used used d d Annually Annually no later than 13 months from the d no later than 13 months from the date of the ate of the prior prior inspection inspection GENERAL GENERAL O Op pe er ra a...

Page 15: ...nobstructed 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...

Page 16: ...ays 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 s...

Page 17: ...r protruding pins Keep chains lubricated Stress Corrosion Cracking The outside link plates which are heavily press fitted to the pins are particularly susceptible to stress corrosion cracking Like fat...

Page 18: ...25 hour DRIVE count down the machine will only drive in creep turtle drive mode and platform lift up will be disabled At this point cycling power on off will only repeat the final 10 second mode cycl...

Page 19: ...on Right Side Shown 1 Wheel Drive Assembly 2 Frame Mounting Surface 3 Mounting Bolts Washers a 4 Drive Wheel 5 Wheel Mounting Lugs b NOTE Installation same for left and right drive motor a Apply Locti...

Page 20: ...the brake containment holes This will keep the brake housing in one piece 4 Cut the black wire tie not shown from the frame of the motor 5 Remove the 3 Brake Bolts 7 6 Remove the Brake Housing B1 and...

Page 21: ...CH 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...

Page 22: ...iously with motor cover disassembly shown for reference only 1 3 4 Brush Assembly Remove Install 1 Brush Assembly a 2 Brush Carrier Socket 3 Brush Tab Slot 4 Brush Terminal Screw 5 Brush Attach Termin...

Page 23: ...ubes shown shortened for illustrative purposes only Pump Remove Install Requires removal of tank assembly and pump pick up tube 1 Pump Assembly 3 Motor to Pump Coupler 2 Pump Assembly Screws 4 Pump Sh...

Page 24: ...T MODIFY UNIT IN ANY WAY TO AFFECT STABIL ITY JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FAC TORY APPROVED BATTERIES APPROVED JLG REPLACEMENT BA...

Page 25: ...to keep button from turning 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 Reatt...

Page 26: ...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...

Page 27: ...e then move on to Selecting Programmable Item to Adjust Selecting Programmable Item to Adjust 1 Use the Platform UP DOWN buttons 1 to scroll through the list of programmable items available to your pr...

Page 28: ...um mR Re ev ve er rs se eS Sp pe ee ed d P Plla at tf fo or rm mL Lo ow we er re ed d 2 20 0 1 1 1 10 00 0 2 2 M Ma ax xi im mu um mT Tu ur rn n S Sp pe ee ed d P Plla at tf fo or rm mL Lo ow we er r...

Page 29: ...odule Module Drive Lift Mo Drive Lift Mode Selector de Selector Switch Switch Horn But Horn Button Swit ton Switch ch Rear Rear Cover Cover Wiring Harness Wiring Harness Connector So Connector Socket...

Page 30: ...atformConsole CircuitBoardConnections PlatformConsole CircuitBoardConnections 1 1 Horn Switch C5 Horn Switch C5 2 2 Communications Cable to Communications Cable to Platform Junction Box Platform Junct...

Page 31: ...oving from console PlatformConsole Drive LiftModeSelectSwitch 1 Switch Assembly a 2 Locking Tabs Note a Remove rear cover unplug switch wire press tabs to remove 1 2 1 2 PlatformConsole HornSwitchInst...

Page 32: ...Switch Retainer Slots Note a Use a small straight blade screwdriver to extend the spring loaded retainer hooks 6 out and release the switch from the body 1 2 4 5 3 7 6 PlatformConsole JoystickInstalla...

Page 33: ...N 5 MAST COMPONENTS 3121228 JLG Lift 5 1 SECTION 5 MAST COMPONENTS 5 1 MAST COMPONENTS OVERVIEW Figure 5 1 Mast Components 1 Material Handling Tray 2 Platform Assembly 3 Mast Assembly 4 Platform Mast...

Page 34: ...ay 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 p...

Page 35: ...will need to temporarily uncap the extend and return hydraulic lines to allow mast section 2 to and return hydraulic lines to allow mast section 2 to be extended in the next step Capture any hydraulic...

Page 36: ...oms o oms out ag ut against ainst the cylinder head the cylinder head 3 3 Comp Compress t ress the he he head ret ad retraini raining ri ng ring en ng enough ough to al to allow low the cylinder head...

Page 37: ...aces is unacceptable In the event that an unacceptable condition occurs the piston should be unacceptable condition occurs the piston should be replaced replaced Tube Assembly Tube Assembly Visually i...

Page 38: ...lation 1 Lift Down Valve a 2 Valve Solenoid b 3 Manual Release Assembly 4 O Ring with Backing Rings a 5 Valve O Ring a 6 Solenoid O Ring a Notes a Coat all o rings with clean hydraulic fluid before as...

Page 39: ...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 a...

Page 40: ...e sections together until ends are even 2 Insert slide pads into the slide pad channels at bot tom end of mast between section 1 and 2 one on each side of the mast with beveled surface facing out towa...

Page 41: ...astening and shimming the slide pad on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher 11 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 lo...

Page 42: ...the lower chain anchor bracket Loosely thread two 2 3 8 16UNC nuts onto the stud threads on each chain 7 Slide the anchor plate into the closed rail at the bot tom of mast section 4 and attach the an...

Page 43: ...the mast See Section 5 5 Platform 7 FT HEIGHT Limit Switch OPTION 14 The mast assembly is now complete and ready to install onto the base frame TopofMast Section 4 Slide PadInstallation 1 Slide Pads 2...

Page 44: ...Short Circuit 6 21 Code 12 Right Drive Motor Short Circuit 6 21 Code 13 Traction Module In Fold Back 6 21 Code 14 Pump Motor Disconnected 6 22 Code 15 Lift Down Valve Disconnected 6 22 Code 16 Lift Do...

Page 45: ...4 MAIN POWER CIRCUIT TROUBLESHOOTING Machine Will Not Power Up 6 35 MAST TROUBLESHOOTING Platform Will Not Lower Manually 6 36 Platform Lift Up And Down Jerky 6 36 Mast Noisy When Lifting And Lowering...

Page 46: ...Amperage Draw for Various Components COMPONENT AMPERAGE GroundControlModule 95Amps roomtemperaturewithratedload TractionControlModule LEVEL SURFACE 24V RATED LOAD 15 GRADE 24V RATED LOAD NO LOAD 24V 7...

Page 47: ...is in the drive speed cut back 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 mode a turtle is displayed on the...

Page 48: ...edinto anACoutlet anACoutlet G Go oT To oS St te ep p2 2 S Se ee e B Ba at tt te er ry y B Ba at tt te er ry y C Ch ha ar r ger Servicing ger Servicing Section3ofthisManual Section3ofthisManual 2 2 Is...

Page 49: ...allevelofthe machines restingsurfacein machines restingsurfacein boththeXandtheY boththeXandtheY directions Doessurfacecheckwithin directions Doessurfacecheckwithin machinespecifi machinespecifi catio...

Page 50: ...acrosspositive andnegative leadsinM2connec tor wiringharnessgoingtotheright drivemotor Isreadingwithin spec 1 to 3ohms Replace Traction Module GotoStep2 2 Repairorreplacerightdrivemotorwiring brusheso...

Page 51: ...egative lug No Voltage Thiscircuitshould beisolated RepairorReplace Componentsas Required GotoStep2 2 Checkforcontinuityofboththepinstoground NoGround Replace Traction ControlModule Table 6 13 Code 12...

Page 52: ...eacrossthepositive andnegative studsonthe pumpmotor SeeTable6 2 ReplaceGround ControlModule RepairorReplace PumpMotoror Motor Brushes Table 6 16 Code 15 Lift Down Valve Disconnected STEP ACTION SPEC Y...

Page 53: ...7 PlugthecommunicationscableontheTractionControlModuletotheround socketontheoppositeendofthe module Doesthisfixproblem Done Replace GroundControl Module Table 6 35 Code 200 299 Platform Control Consol...

Page 54: ...between eachpowerrecycle Doesfaultclear Done GotoStep2 2 IsacodenumberdisplayingontheGroundControlStation Code 316 GotoStep3 Replace TractionControl Module Code 325 GotoStep5 3 Confirmthatbothinstalle...

Page 55: ...EP ACTION SPEC YES NO 1 Checkfor24VDCatthepositive andnegative mainpowercable connectionsontheGroundControlModule 24VDC GotoStep2 Replacethe175 AmpInlineFuseon the Positivepower cable 2 Checkcontinuit...

Page 56: ...SECTION 6 TROUBLESHOOTING 3121228 JLG Lift 6 45 Figure 6 6 10MSP Overview of Electrical System Components...

Page 57: ...SECTION 6 TROUBLESHOOTING 6 46 JLG Lift 3121228 Figure 6 7 Electrical Diagram 1870201_G Keyed Switch Removed for AustraliaSpec...

Page 58: ...SECTION 6 TROUBLESHOOTING 3121228 JLG Lift 6 47 Figure 6 3 Electrical Diagram 1870201 G...

Page 59: ...Figure 6 8 Hydraulic Diagram 2792684_A 1 Tank 5 Pressure Adjust Valve 9 Check Valve 2 Filter Screen 6 Extend Line 10 PressureCompensator FlowControlValve 3 Pump 7 Hydraulic Filter 11 Manual Decent Va...

Page 60: ......

Page 61: ...ce 33 0 5 53 88 31 70 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany 49 0 421 69 350 20 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark Nor...

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