Oshkosh Corporation JLG 20MSP Service And Maintenance Manual Download Page 169

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SECTION 6 - TROUBLESHOOTING

31215825

6-41

6.14 HYDRAULIC LEAK TROUBLESHOOTING

Miscellaneous Hydraulic Leak Troubleshooting

Overview Of Procedure

This series of steps gives remedies for various areas of the machine where leaks could occur.

Table 6-47. Hydraulic Leak Troubleshooting

STEP

ACTION

SPEC

YES

Oil leaking around the lift cylinder rod.

—

Replace the Seal

at the end of the

Piston and Cylin

der Barrel

—

Oil leaking around the cylinder extend or return line fittings.

—

Tighten or

Replace Fittings

—

Oil leaking around the hydraulic lines.

—

Tighten or

Replace

Hydraulic Lines

—

Oil leaking around the lift down valve.

—

Tighten Car

tridge in Pump

Case

—

Oil leaking around the (Red) manual descent valve.

—

Replace Lift Down

Valve

—

Note: Do not overtighten the nut on the solenoid in step 5.

Go to

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order your

parts

Summary of Contents for JLG 20MSP

Page 1: ...Service and Maintenance Manual Models 20MVL 20MSP 31215825 January 23 2019 Rev A PVC 2002 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 2: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 3: ...ATOR B HYDRAULIC SYSTEM SAFETY 1 It should be particularly noted that the machines hydraulic systems operate at extremely high and poten tially dangerous pressures Every effort should be made to relie...

Page 4: ...INTRODUCTION A 2 31215825 REVISON LOG Original Issue A January 23 2019 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 5: ...2 1 Preparation Inspection and Maintenance 2 1 Pre Start Inspection 2 1 Pre Delivery Inspection and Frequent Inspection 2 1 Annual Machine Inspection 2 1 Preventative Maintenance 2 1 2 2 Preventive M...

Page 6: ...on System 3 19 3 7 Battery Charger Service Procedures 3 21 Battery Charger General Information 3 21 Battery Charger Maintenance Information 3 21 Battery Charge LED Indicator on Platform Control Consol...

Page 7: ...Filter Pressure Check 4 22 Pump Motor Tank Installation 4 22 General Installation and Disassembly 4 23 Inline Hydraulic Filter Installation 4 23 FENNER BRAND PUMP Brush Replacement 4 23 Motor Cap Moto...

Page 8: ...See Figure 6 8 6 1 6 4 Electrical Circuit Checks 6 1 General 6 1 6 5 Multimeter Basics 6 2 Grounding 6 2 Back Probing 6 2 Min Max 6 2 Polarity 6 2 Scale 6 2 Continuity Measurement Over Long Distances...

Page 9: ...rol Module 6 30 Code 32 Pump Motor Over Current 6 31 Code 33 Both PHP Bars UP 6 31 Code 34 P2 Auxiliary 1 Inhibit 6 31 Code 35 P2 Auxiliary 1 Tie Down 6 33 Code 38 Battery Voltage Low Warning Level 2...

Page 10: ...vi 31215825 TABLE OF CONTENTS SECTION NO TITLE PAGE NO G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 11: ...ttery Installation Left Side Battery Shown 4 6 4 9 Component Electrical Connections 2 12V Batteries shown 4 7 4 11 Battery Cable to Battery Terminal Connections 4 6V 4 8 4 10 Battery Installation 4 6V...

Page 12: ...nstallation 5 11 5 11 Lift Cylinder Component Cross Section MVL MSP 5 13 5 12 Lift Down Valve and Manual Release Installation 5 14 5 13 Mast Assembly Installation 5 15 5 14 Mast Section Assembly Refer...

Page 13: ...ectrical System Components MVL MSP Sheet 1 of 2 6 46 6 7 Overview of Electrical System Components MVL MSP Sheet 2 of 2 6 47 6 8 Electrical Diagram MVL MSP 6 48 6 9 Electrical Diagram MVL MSP 6 49 6 10...

Page 14: ...Code 12 Right Drive Motor Short Circuit 6 23 6 16 Code 13 Traction Module In Fold Back 6 23 6 17 Code 14 Pump Motor Disconnected 6 24 6 18 Code 15 Lift Down Valve Disconnected 6 24 6 19 Code 16 Lift D...

Page 15: ...Leak Troubleshooting 6 41 6 48 Caster Wheels Not Operating Freely 6 42 6 49 Pot Hole Protection PHP Bars will not Lower 6 42 6 50 Won t Climb Grade 6 43 6 51 Machine Drive in Opposite Direction 6 43 6...

Page 16: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 17: ...owedOnly 5 Max AllowableOperatingSlope Elevated FronttoBack SidetoSide 1 5 1 5 MaximumDriveSpeeds OperatorVariable 0 5 3 4mph 0 8 5 5kph MachineBase Overall WidthxLength 29 25in Wx52in L 74cm x 132cm...

Page 18: ...W withGull Wing Gate SP StockPickerPlatform SPECIFICATION 20MVL 20MSP SystemVoltage 24voltsDC BatterySpecifications BatteryType Voltage DC AmpHour AH Rating AGM VRLA Sealed 12voltsDC 2BatterySystem 6v...

Page 19: ...CYLINDER SPECIFICATIONS NOTE All dimensionsare givenin inches in with the metric equivalent centimeters cm given inparentheses 1 4 TORQUE REQUIREMENTS When maintenance becomes necessary or a fastener...

Page 20: ...seGrease HO HydraulicOil ISO Vggrade32 46 CL ChainLube Useagoodqualitychainlubricant NOTE a Becertaintolubricatelikeitemsoneachsideofthemachine b Recommended lubricating intervalsare based on normalus...

Page 21: ...be substituted in place of Vibra TITE 121 JLGPN Loctite NDIndustries Description 0100011 242 Vibra TITE 121 MediumStrength Blue 1001095650 243 Vibra TITE 122 MediumStrength Blue 0100019 271 Vibra TITE...

Page 22: ...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...

Page 23: ...110 150 90 120 9 16 12 0 5625 0 1820 16400 155 210 140 190 115 155 18 0 5625 0 2030 18250 170 230 155 210 130 175 5 8 11 0 6250 0 2260 20350 210 285 190 260 160 220 18 0 6250 0 2560 23000 240 325 215...

Page 24: ...0 0 5000 0 1599 10700 75 100 71 97 65 88 9 16 12 0 5625 0 1820 11600 90 120 87 118 80 109 18 0 5625 0 2030 12950 105 145 97 132 90 122 5 8 11 0 6250 0 2260 14400 130 175 120 163 115 156 18 0 6250 0 25...

Page 25: ...130 90 120 9 16 12 0 5625 0 1820 16400 130 175 125 170 115 155 18 0 5625 0 2030 18250 145 195 135 185 130 175 5 8 11 0 6250 0 2260 20350 180 245 170 230 160 220 18 0 6250 0 2560 23000 205 280 190 260...

Page 26: ...130 175 5 8 11 0 6250 0 2260 20350 180 245 170 230 160 220 18 0 6250 0 2560 23000 205 280 190 260 180 245 3 4 10 0 7500 0 3340 30100 320 435 300 415 280 380 16 0 7500 0 3730 33600 355 485 335 455 315...

Page 27: ...85 130 175 5 8 11 0 6250 0 2260 20350 180 245 170 230 160 220 18 0 6250 0 2560 23000 205 280 190 260 180 245 3 4 10 0 7500 0 3340 30100 320 435 300 415 280 380 16 0 7500 0 3730 33600 355 485 335 455 3...

Page 28: ...4 30 36 7 88 66 79 97 14 2 115 50 0 140 105 126 154 16 2 157 68 3 219 164 197 241 18 2 5 192 83 5 301 226 271 331 20 2 5 245 106 5 426 320 383 469 22 2 5 303 132 0 581 436 523 639 24 3 353 153 5 737 5...

Page 29: ...1 75 84 30 52 5 125 115 95 14 2 115 71 6 200 180 150 16 2 157 97 8 315 280 235 18 2 5 192 119 5 430 385 325 20 2 5 245 152 5 610 550 460 22 2 5 303 189 0 830 750 625 24 3 353 222 0 1065 960 800 27 3 4...

Page 30: ...43 40 38 12 1 75 84 30 36 7 75 70 66 14 2 115 50 0 119 110 105 16 2 157 68 3 186 175 165 18 2 5 192 83 5 256 240 225 20 2 5 245 106 5 362 340 320 22 2 5 303 132 0 494 465 435 24 3 353 153 5 627 590 55...

Page 31: ...55 12 1 75 84 30 52 5 105 100 95 14 2 115 71 6 170 160 150 16 2 157 97 8 265 250 235 18 2 5 192 119 5 365 345 325 20 2 5 245 152 5 520 490 460 22 2 5 303 189 0 705 665 625 24 3 353 222 0 905 850 800 2...

Page 32: ...SECTION 1 GENERAL SPECIFICATIONS 1 16 31215825 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 33: ...he Frequent Inspection shall be accomplished for each machine in service 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...

Page 34: ...ur due to climate and or conditions and depending on the loca tion and use of the machine Table 2 1 Inspection and Maintenance Type Frequency Primary Responsibility Service Qualification Reference Pre...

Page 35: ...7 1 7 StaticStrap 1 1 CasterWheels 1 2 1 2 DriveWheels 2 2 GearBoxAssembly 1 2 9 1 2 9 DriveMotorBrushes 1 2 1 2 BrakeRelease 5 5 FUNCTIONS CONTROLS PlatformControls 5 6 7 5 6 7 GroundControls 5 6 5...

Page 36: ...3 months or more or Purchased used d Annually no later than 13 months from the date of the prior annual inspection HydraulicFluid 11 11 ElectricalConnections 20 20 Instruments Gauges Switches Lights H...

Page 37: ...nt 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 Disassem...

Page 38: ...ed using a manufacturers wear scale or steel tape When chains have elongated 3 they must be removed and replaced Refer to Table 2 3 following for proper chain specifi cations and allowable stretch tol...

Page 39: ...d 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 Stress Corrosion Cracki...

Page 40: ...range between 15 250 SUS at 100 degrees F 32 54 cST at 40 degrees C Refer to Section 1 of this Service Manual for recommended hydraulic oils Changing HydraulicOil Use of any of the recommended hydrau...

Page 41: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 42: ...ounted Beacon 2 Battery Charger Cover 3 Front Tie Down Lug 4 Battery Charger Assembly 5 Base Frame 6 Front Caster Wheel Assembly 7 Left Drive Motor Assy 8 Pot Hole Protection System 9 Drive Motor Cove...

Page 43: ...before tightening Figure 3 3 Battery Charger Cover Installation 1 Cover 2 Attach Screws and Washers a 3 Set Cover Tab on Lower portion of Cover in Slot on Base Frame Figure 3 2 Drive Motor Cover Insta...

Page 44: ...with a lug wrench then immediately have a service garage or dealer tighten the lug nuts to the proper torque Over tighten ing will result in breaking the lug nuts or permanently deform ing the mounti...

Page 45: ...ur unit seem to roll hard as long as they roll with consistency The Leak Test The purpose of a leak test is to make sure the unit is air tight You can tell if your unit has a leak if the pressure gaug...

Page 46: ...include brush wear sensors that activate a warning indicating the drive motor brushes will require replacement soon This warning protects the drive motors from damage due to extreme brush wear When t...

Page 47: ...Place a block or safety stand under machine 3 Remove the wheel drive cover assembly 4 Remove the drive wheel mounting lugs and remove the drive wheel s 5 Disconnect the power harness terminals and br...

Page 48: ...ake 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 the Spacers B4 NOTE The brake wires will have som...

Page 49: ...in its correct recoil direction NOTE The spring contains a flat area with a coil at each end The spring should be oriented such that the bend from the flat area to the coil is towards the brush 10 In...

Page 50: ...ousing 19 Line up the timing marks between the brush housing and the motor frame 20 Install the motor bolts 21 Install the motor flange so that the tapped holes line up with the motor bolts WHEN TIGHT...

Page 51: ...t Sun Gear G4 4 Remove Input Carrier Sub assembly 5 Remove Cover 11 and O ring G20 6 Remove Input Ring Gear G3 NOTE The Input Ring Gear G3 is held in with a press fit on its out side diameter Insert j...

Page 52: ...5 Press out Bushing G26 from the bore of each Planet Gear G5 Bushings cannot be reused when removed 6 Remove the other Thrust Washer G25 from each Planet Shaft G6 7 Remove Retaining Ring G24 from Outp...

Page 53: ...ter push in the inner race of the bearing Apply force to the push the bearing out This bearing will need to be replaced upon reassembly 2 Remove main Lip Seal G16 NOTE This Lip Seal G16 is also held i...

Page 54: ...of the Spindle G1 NOTE The Output Planet Gears G9 are very similar in size to the Input Planet Gears 5 tag or label the Planet Gears to avoid confusion 4 Press out Bushing G26 from the bore of each Pl...

Page 55: ...t as you can Use grease to hold the Thrust Washer in place 6 Slide the Output Planet Gear G9 into the window with the Tanged Thrust Washer G32 until the bores line up 7 Insert Output Planet Shaft G10...

Page 56: ...it is flush with the edge of the hub NOTE The Seal has a thin outer shell that can be easily damaged if not installed with care It is a good idea to start the Seal into the bore with a rubber mallet b...

Page 57: ...ers install the Retaining Ring G24 into the groove of the Output Sun Gear G8 Make sure that the Retaining Ring G24 is correctly seated in the groove and that the Output Sun Gear G8 cannot be pulled ou...

Page 58: ...ove 6 Using the appropriate pressing tool T 174356 press in the Input Ring Gear G3 into the bore of Hub Subassem bly NOTE Do not use excessive pressing force because it will be reacted by the main whe...

Page 59: ...sing B1 Tighten to 4 5 ft lbs 5 7 Nm 7 Remove and discard the 2 bolts in the Brake Contain ment Holes 8 Pull the Brake Lead through the through the slot in the motor flange Make sure the leads are all...

Page 60: ...ce 4 Left Side Counterbalance 5 PHP Link see detail illustration following 6 Left PHP Bar 7 Right PHP Bar 8 PHP Bar Pivot Pin and Retaining Ring 1 PHP Counterweight Bar Link 2 Flange Bearing 3 PHP Cou...

Page 61: ...er just past click tighten screws to frame b Apply Loctite 222 to screw threads before tightening c Add as required if switch is adjusted to maximum and plunger has not clicked to engage switch 2 1 MA...

Page 62: ...e warning indicators 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 2 following Table...

Page 63: ...arger by interrupting AC power for at least 10 sec onds Others may be simply transient and will automati cally recover when the fault condition is eliminated To indicate which error occurred the RED F...

Page 64: ...nt memory 3 Remove AC power from the charger and reconnect the charger positive connector to the battery pack It is highly recommended to check a newly changed algo rithm by repeating the above steps...

Page 65: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 66: ...ntrol Components Location MVL MSP 1 Pump Motor Tank Assembly 4 Batteries 2 12V standard 7 Platform Control Console 2 Alarm 5 Traction Control Module 8 Obstruction Sensor System MSP Option 3 Horn 6 Gro...

Page 67: ...F31400 1 2 1 Right Side Cover 2 Mast Support Column MAF31410 2 1 LowerLeftCover FrontView CenterCover LowerLeftandRightCovers RearView LowerRightCover FrontView MAF31430 MAF31420 MAF31440 Note Center...

Page 68: ...y optional equipment See Section 4 6 Ground Con trol Station Programming Traction Control Module The Traction Control Module is mounted below the Ground Control Module on the mast support column The t...

Page 69: ...end of this harness is plugged into the plat form junction box mounted to the mast behind the plat form decal board From the console the harness is tie strapped to the platform rail and run inside th...

Page 70: ...d be kept at 12 5V or higher Before testing for battery condition the open circuit voltage should be taken from each battery If the voltage of the batter ies differs by 0 3 volts or more the lower vol...

Page 71: ...batteries set in machine with the posts to the inside Left side battery NEG post at front shown below Right side battery POS post towards machine front Note a Mount with terminal posts inboard b Apply...

Page 72: ...ess a P4 Platform Junction Box Harness a Module Plugs P2 PHP Elevation Speed Charger Limit Switch Harness a P5 Joystick Protocol Harness a P3 Programmable Security Lock Harness Option a Notes a Apply...

Page 73: ...ry 5 Upper Right Side Battery 6 175 Amp Inline Fuse Note a Label battery cables before removing to ensure proper installation The battery cables connecting the batteries are identical only the cable c...

Page 74: ...t of two 2 components internal to the mod ule Emergency Stop Switch Power Selector Switch Key ELECTROSTATIC DISCHARGE CAN DAMAGE COMPONENTS ON THE INTEGR ATED CIRCUIT BOARD PLACE THE GROUND CONTROL MO...

Page 75: ...tor 3 Support for Cover 2 Ribbon Cable 1 1 2 3 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...

Page 76: ...tch 3 Align and insert tab on switch into slot on cover Note Re attach wires to the same terminals on new switch 1 2 4 5 6 1 2 3 1 LCD and Button Circuit Board 2 Emergency Stop Switch Connector 3 Main...

Page 77: ...ca tion 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 Leve...

Page 78: ...Press the Brake Release button 3 to enter selected mode then move on to Selecting Programmable Item to Adjust 1 2 3 00000 4 1 2 3 1 Use the Platform UP DOWN buttons 1 to scroll through the list of pr...

Page 79: ...Y axis 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 t...

Page 80: ...ages and one for Asian Languages 1 1 English 6 Italian 2 German 7 Swedish 3 Dutch 8 BrazilianPortuguese 4 French 9 Finnish 5 Spanish 2 1 English 3 Japanese 2 Chinese 2 SetMaximumLiftUpSpeed 100 0 100...

Page 81: ...eed platformlowered 20 1 100 2 MinimumTurnSpeed platformlowered 15 1 100 2 MinimumForwardSpeed platformelevated 13 1 100 2 MinimumReverseSpeed platformelevated 13 1 100 2 MinimumTurnSpeed platformelev...

Page 82: ...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 cont...

Page 83: ...rcuit Board Connections 1 Horn Switch C5 2 Communications Cable to Platform Junction Box C6 3 ON OFF Key Switch C3 4 E Stop Shut Down Switch C4 5 Drive Lift Mode Select Switch C7 6 Joystick C8 Note Th...

Page 84: ...cover unplug switch wire press tabs to remove 1 2 1 2 1 Horn Button Switch a 2 Lock Washer 3 Nut Note a Remove rear cover unplug wire remove nut and lock washer then slide switch out of console 1 Key...

Page 85: ...aight 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 Figure 4 34 Platform Console Joystick Installation 1 Joystick Assembly 2 Att...

Page 86: ...CAREFULLY LOOSEN REQUIRED FITTINGS WEAR SAFETY PROTEC TION EQUIPMENT W HEN WO RKING W ITH HYDRAULIC SYSTEMS Remove the hydraulic oil filter and install a t fitting between the pump and the extend line...

Page 87: ...ssure Gauge Installation After Hydraulic Filter Pump Motor Tank Installation BE CERTAIN THE MAST IS FULLY LOWERED BEFORE REMOVING ANY HYDRAULIC LINES FROM THE PUMP UNIT WEAR PROTECTIVE GEAR WHEN WORKI...

Page 88: ...nd o rings when disas sembling and reassembling the pump motor unit The motor and motor brushes can be serviced without remov ing the complete pump motor unit However components on the bottom end of t...

Page 89: ...g Washer Note Length of wires to brush assemblies shown exaggerated for illustrative purposes 1 2 3 1 2 3 3 4 Figure 4 44 New Brush Installation 1 Brush Terminal Screw4 Brush Spring 2 Brush 5 See Inst...

Page 90: ...are positioned not to block the holes for the motor mounting bolts inside the motor housing After final assembly of the brush housing check that all brush terminal screws are tight and the brush sprin...

Page 91: ...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 CO...

Page 92: ...ier Position on Motor Housing 4 Brush Carrier Assembly Note a Removed previously with motor cover disassembly shown for reference only 1 2 3 4 Figure 4 48 Brush Assembly Remove Install 5 Brush Assembl...

Page 93: ...r to pry tank away from pump head Figure 4 50 Filter Screen Installation 1 Filter Screen 2 Pump Pick Up Tube 1 2 2 3 4 1 2 Figure 4 51 Pump Installation 1 Pump Assembly 3 Pump Shaft Seal 2 Pump Assemb...

Page 94: ...6 Extend Pressure Port Shown Plugged Note Adjust pressure per specification shown in Section 1 of this service manual 1 2 3 4 6 5 Figure 4 54 Pressure Check Valve Installation 1 Check Valve Assembly 5...

Page 95: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 96: ...ction 1 4 Mast Section 4 7 Lift Cylinder Mount 10 Lanyard Attach 13 Chain Equalizer 2 Mast Section 2 5 Mast Section 5 8 Slide Pads 11 Chain Guard Plate Assemblies 3 Mast Section 3 6 Lift Cylinder 9 Ch...

Page 97: ...plate on each chain cable 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 2 when the mast is retracted NOTE It is more impo...

Page 98: ...ble Adjust Nut 4 Mast Section 3 7 Check Mast Stowed Height 10 Chain Lock Nut 2 Mast Section 1 5 Mast Section 4 8 Chain Anchor Plate 11 Threaded Chain End 3 Mast Section 2 6 Mast Section 5 9 Chain Adju...

Page 99: ...ve pulley and through the hole in the sheave pulley anchor bracket on the mast section ahead of the sheave pulley 4 Grasp the cable and pull on the cable until the spring at the top of the cable is sl...

Page 100: ...ay of the strands unlay any wires that make up the strand or allow the strands to cross each other inside the sleeve 5 Install the plug supplied with the kit by placing the plug in the center of the s...

Page 101: ...ket Tighten until four threads or fewer are visible If more than four threads are visible proof load the cable and retighten the socket fitting There is no specific requirement for torque 8 Inspect fo...

Page 102: ...WHEN WORKING WITH HYDRAULIC SYSTEMS Instructions for tool use on both in line and angled hose fit tings are shown on the pages following Tool Use In Line Style Fittings Push Type Hydraulic Line Remov...

Page 103: ...ate the tool see arrow Step 6 Release the tool and pull on hose assem bly to complete disconnection Step 1 Prior to disconnection ensure that sys tem is not under pressure Step 2 Pull on hose assembly...

Page 104: ...vented cap on the hydraulic fluid reservoir by removing the cap covering the hole with a few layers of plastic wrap or equivalent Then install and tighten the cap over the plastic wrap to prevent lea...

Page 105: ...ns 3 4 and 5 back towards the base assembly allowing the top of mast section 2 to be com pletely exposed Figure 5 4 Hydraulic Extend and Return Lines 1 Cylinder Return Line 3 Manual Descent Valve 2 Cy...

Page 106: ...er and mount assembly out of the bottom of mast section 1 and 2 and place on a suitable work surface Figure 5 8 Snap Ring Installation 1 Back of Mast Section 2 3 Pin and Snap Ring 2 Cyl Chain Anchor B...

Page 107: ...hes 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 unacce...

Page 108: ...y 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 Cylinder Installation T...

Page 109: ...lean hydraulic fluid before assembling b Mount with electrical terminals pointing to right side of machine 1 2 3 4 5 6 1 Lift Down Valve a 2 Valve Solenoid b 3 Manual Release Assembly 4 O Ring with Ba...

Page 110: ...e or suitable lifting device capa ble of supporting the weight of the mast assembly attach a sling strap to the mast If installed use the optional crane lifting lug on the back of the mast 8 Remove th...

Page 111: ...ed Mast DisassemblyProcedure MVL MSP 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...

Page 112: ...on both side rails at TOP of mast section 3 and remove the sheave wheel assembly 15 While mast section 3 is still extended from section 2 remove the pin attaching the chain anchor plate to the TOP of...

Page 113: ...SECTION 5 MAST COMPONENTS 5 18 31215825 Figure 5 15 Mast Chain Routing Diagram MVL MSP G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 114: ...channels at bottom end of mast between section 1 and 2 one on each side of the mast with beveled surface facing out towards section 1 6 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex...

Page 115: ...in 30cm before installation for later attachment of the upper chain anchor block to mast sec tion 2 Remove any protective caps on the extend and return ports temporarily to allow rod extension Catch...

Page 116: ...to the slotin each end of the pin and then place a sheave pin support bar rect angular plate with threaded holes on each side of pin bore hole e Slide the whole anchor block cylinder assembly with she...

Page 117: ...ts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes on inside rail on bottom end of mast section 3 and into the slide pad inserts Thread in enough to...

Page 118: ...n with the cutouts in the pin support bars d Holding complete sheave wheel assembly slide assembly into top of mast section 3 and align threaded holes in sheave pin support bars with holes in mast rai...

Page 119: ...tom of section 3 approxi mately one 1 foot 47 Locate one 1 of the chain bottom anchor plates one with threaded holes horizontally aligned to center of bracket Attach using holes in bottom of mast sect...

Page 120: ...g five 5 1 4 20UNC x 1 1 4 long hex head capscrews per side with flatwasher under each bolt head Assemble shim stock and slide pad to mast section rail with shim stock against rail and slide pad with...

Page 121: ...heels at top of mast assembly 58 Do not assemble the mini covers to the top of mast sec tions until the mast chains have been adjusted properly 59 Attach the lanyard attach assembly to the side of mas...

Page 122: ...MAST COMPONENTS 31215825 5 27 Figure 5 28 Lanyard Attach Installation Figure 5 29 Sequence Cable Bracket Installation Bottom End G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r...

Page 123: ...st Platform Header Section 2 Nut 3 Washers 4 Hex Head Screws 2 inch 5 Hex Head Screws 2 1 2 inch 6 Platform Bumper Rest a NOTE a Once mounted adjust bumper rests on both sides evenly so the platform r...

Page 124: ...Interlock Switch Wiring Harness Routing 1 Interlock Switch 3 Connection at Junction Box 2 Wire Routing 4 Platform Junction Box NOTE Decal billboard removed in above illustration 2 3 4 5 6 1 1 2 2 2 2...

Page 125: ...IT to 5 Switches and Wiring Proximity Switch Wire Harness Routing Proximity Switch Wiring 1 Connector 2 Splice 3 Proximity Switches Proximity Switch Location 1 Platform Vertical Rail 2 Left Platform G...

Page 126: ...MAF30460B 1001230530 B 4 5 1 3 2 6 7 8 1 Coil Spring 2 Capscrew 3 Lock Nut 4 Bolt 5 Nut 6 Capscrew 7 Lock Nut 8 Washer Figure 5 34 Load Sensing System LSS SECTION A A DETAIL A SEE DETAIL A G o t o D i...

Page 127: ...with 120 rated load 4 For Bolt On Platform adjust capscrews 2 with 1 32 to 1 16 air gap between capscrews 6 head and angle on washer 8 5 For Quick Change Platform adjust capscrews 2 with 1 16 to 1 8...

Page 128: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 129: ...e for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if the circuit is lacking hydraulic oil and electrical control power This can be ascertaine...

Page 130: ...or probe tips specifically designed for this technique espe cially on sealed connectors Whenever possible insert probes into the side of the connector such that the test also checks both termi nals o...

Page 131: ...ntact with meter leads First test meter and leads by touching leads together Resistance should read a short circuit very low resis tance Circuit power must be turned OFF before testing resis tance Dis...

Page 132: ...cuit before testing Use firm contact with meter leads First test meter and leads by touching leads together Meter should produce an audible alarm indicating conti nuity Set up the meter for the expect...

Page 133: ...nect all connections associated with the wire under test and the two additional wires If harness is not completely iso lated disconnect battery terminals also as a precaution 2 Measure continuity betw...

Page 134: ...ate position Mechanical limit switches are just like manually operated switches except that the moving object operates the switch These switches can be tested the same way as a standard switch by manu...

Page 135: ...is called a high side switch The switch supplies the power to the load When a switch is wired between the negative side of the power source and the load it is a low side switch The switch provides th...

Page 136: ...y as shown follow ing LCD Display Symbols 1 Battery Charge Indicator BCI 2 Function Display or Function Disable Indicators 3 Hour Meter Display 4 Fault Code Indicator 5 Fault Code Text Message Display...

Page 137: ...Ground Control P1 Horn Alarm Beacons Lift Down Valve Harness a P4 Platform Junction Box Harness a Module Plugs P2 PHP Elevation Speed Charger Limit Switch Harness a P5 Joystick Protocol Harness a P3 P...

Page 138: ...eration 1 LowBatteryVoltage SeePage6 18 9 OverloadAlarmand OverloadIndicator SeePage6 18 02 2 LeftPHPBarUP PlatformElevated DRIVEandLiftUPDis abled SeeTable6 6 Page6 19 03 2 RightPHPBarUP PlatformElev...

Page 139: ...d SeeTable6 16 Page6 23 14 7 PumpMotorDiscon nected LiftUPDisabled SeeTable6 17 Page6 24 15 7 LiftDownValve Disconnected LiftUP DOWNDisabled SeeTable6 18 Page6 24 16 7 DownValveorDown Valve CircuitSho...

Page 140: ...31 PlatformControlConsole NoCommunicationwith GroundControlModule SeeTable6 31 Page6 30 32 7 PumpMotorOverCurrent LIFTUPDisabled SeeTable6 32 Page6 31 33 2 BothPHPBarsUP DRIVEandLiftUPDis abled SeeTab...

Page 141: ...eTable6 36 Page6 34 41 InternalOSSSensor 1 FaultCondition SeeTable6 37 Page6 34 42 InternalOSSSensor 2 FaultCondition SeeTable6 37 Page6 34 43 InternalOSSSensor 3 FaultCondition SeeTable6 37 Page6 34...

Page 142: ...38 Page6 35 200 10 PlatformControlConsole FaultCondition SeeTable6 39 Page6 36 300 10 TractionControlModule FaultCondition SeeTable6 40 Page6 36 400 OSSControlModule LowInternalSupply SeeTable6 36 Pa...

Page 143: ...Code 08 Right Drive Motor Disconnected 6 22 Code 09 Left Brake Disconnected 6 22 Code 10 Right Brake Disconnected 6 22 Code 11 Left Drive Motor Short Circuit 6 23 Code 12 Right Drive Motor Short Circ...

Page 144: ...6 35 Codes 200 299 Platform Control Console Fault Condition 6 36 Codes 300 399 Traction Control Module Fault Condition 6 36 Main Power Circuit Troubleshooting Machine Will Not Power Up 6 37 Mast Troub...

Page 145: ...MPERAGE GroundControlModule 20MVL 95Amps roomtemperaturewithratedload 15MSP 110Amps roomtemperaturewithratedload TractionControlModule LEVEL SURFACE 24V RATED LOAD 15 GRADE 24V RATED LOAD NO LOAD 24V...

Page 146: ...f the alarm will be software controlled and sound a continuous alarm while LSS is active Overload Indicator The overload indicator will be mounted on the platform box and connected internally to the p...

Page 147: ...rolModule GotoStep2 2 Checktheactuatorcablesforadjustmentordamage AdjustorReplace GotoStep3 3 CheckthePHPlimitswitch s atbothsidesofthemachinefordam age adjustmentandforcontinuitythroughswitchtoground...

Page 148: ...heXandtheYdirections Doessurfacecheckwithin machinespecification 1 5 XandYDirection GotoStep2 DriveMachineto LevelSurface 2 AttheGroundControlModule entertheprogrammingmode See GroundControlProgrammin...

Page 149: ...ng then checkthevoltageatthebrushwearindicationrelaywherethewires wht red57 1and57 2 fromthedrivemotorsconnect atterminal 85 Ifthereisvoltageonrelayterminal 85 youhaveaproblemwiththe motor checkforvol...

Page 150: ...on nectorwiringharnessgoingtotherightdrivemotor Isreading withinspec 1to3ohms ReplaceTraction Module GotoStep2 2 Repairorreplacerightdrivemotorwiring brushesormotor Forbrushreplacement seeSection3ofth...

Page 151: ...solated RepairorReplace Componentsas Required GotoStep2 2 Checkforcontinuityofboththepinstoground NoGround Replace Traction ControlModule Table 6 15 Code 12 Right Drive Motor Short Circuit STEP ACTION...

Page 152: ...pumpmotor SeeTable6 2 ReplaceGround ControlModule RepairorReplace PumpMotoror MotorBrushes Table 6 18 Code 15 Lift Down Valve Disconnected STEP ACTION SPEC YES NO 1 CheckvoltageattheP1connectorontheG...

Page 153: ...thecoil Iscoilwithinspecification 6Ohms GotoStep3 ReplaceCoil 3 Withtheterminalsstillremovedfromtheliftdownvalvecoil check continuityofthewiresfrompins10and3ontheP1connectortothe liftdownvalve 00Ohms...

Page 154: ...pin 6 Isreadingwithinspecification 2 4VDC ReplaceGround ControlModule GotoStep2 2 Removethewireterminalsatthealarm checkcontinuityofeachof thewiresfrompins13and6ontheP1connectortothealarmend Replaceth...

Page 155: ...trolModule 3 CheckvoltageattheP1connectorontheGroundControlModule betweenpin 12andpin 5 Isreadingwithinspecification 2 4VDC ReplaceGround ControlModule GotoStep4 4 Removethewireterminalsatthebeacon ch...

Page 156: ...voltageattheP1connectorontheGroundControlModule betweenpin 14andpin 7 Isreadingwithinspecification 2 4VDC ReplaceGround ControlModule GotoStep4 4 Removethewireterminalsatthehorn checkcontinuityofeacho...

Page 157: ...ound ControlModule 3 CheckvoltageattheP1connectorontheGroundControlModule betweenpin 9andpin 2 Isreadingwithinspecification 2 4VDC ReplaceGround ControlModule GotoStep4 4 RemovethewireterminalsattheAu...

Page 158: ...ctorattheTractionControlModule Checkcontinuityofallthree 3 wiresinthecommunicationscable fromendtoend P5 Pins2 3 and4 GotoStep3 RepairorReplace Wire s 3 Withcommunicationscabledisconnectedatbothends c...

Page 159: ...STEP ACTION SPEC YES NO 1 Checkcurrentdrawofpumpmotorbyelevatingtheplatformtofull heightandloadpumpbycontinuingtopresstheUPbutton Isreadingwithinspec Lessthan 145Amps GotoStep2 GotoStep3 2 Didunitgiv...

Page 160: ...Module P2connector checkthevoltage acrosspins 16 orange red49 5 and6 black12 isreadingwithin specification 0 2VDC GotoStep2 ReplaceGround ControlModule 2 RemovetheP2connectorfromtheGroundStationModule...

Page 161: ...e 39 Code 39 BatteryVoltage Low Warning Level 3 One 1 LED LCDslit To maximize battery life it is recommended that the factory supplied batteries be charged continuously for a minimum of 4 hours or unt...

Page 162: ...e frame Table 6 36 Code 40 OSS No Communication with Ground Control Module STEP ACTION SPEC YES NO 1 IsmachineequippedwithanOSSsystem GottoStep4 GotoStep2 2 AttheGroundControlModule enterprogrammingmo...

Page 163: ...bothinstalledbatteriesare12VoltDC 12VDC GotoStep4 Replacewith properBatteries 4 Checkbatteryvoltagewhilechargerisoperating Isvoltagewithin specification Maximumof 31VoltsDC Replace GroundControl Modul...

Page 164: ...9pinPlatformControlModuleconnectorfromthe sideofthePlatformJunctionBoxandtheP4connectoratthe GroundControlModule CheckcontinuityfromtheP4connector pin 5toJunctionBoxpin 3andP4 pin 9toJunctionBoxpin 4...

Page 165: ...sitive andnegative mainpower cableconnectionsontheGroundControlModule 24VDC GotoStep2 Replacethe175 AmpInlineFuse onthePositive powercable 2 CheckcontinuityoftheEmergencyStopwiresrunningtothePlat form...

Page 166: ...m Will Not Lower Manually STEP ACTION SPEC YES NO 1 ChecktoseeoftheplatformwilllowerfromtheGroundControlSta tioninGroundControlMode RepairorReplace theManual DescentControl Valve GotoStep2 2 Checktose...

Page 167: ...ceSheave PinsandWheels GotoStep4 4 Arethesequencecables locatedonthesideofmast chattering whenthespringsarecompressed Note Thisnoiseisnormalatthesequencecablesheavewheels whenthemastiscompletelylowere...

Page 168: ...iftdownvalvestuckopen RepairorClean Valve GotoStep2 2 Liftdownvalvescouldbeopenduetoincorrectelectricalsignal CheckPump ValveElectrical Circuit GotoStep3 3 Oilcouldbepassingaroundtheliftcylinderborepa...

Page 169: ...lleakingaroundtheliftcylinderrod ReplacetheSeal attheendofthe PistonandCylin derBarrel 2 Oilleakingaroundthecylinderextendorreturnlinefittings Tightenor ReplaceFittings 3 Oilleakingaroundthehydraulicl...

Page 170: ...ound the actuator assembly at the base of the mast Table 6 48 Caster Wheels Not Operating Freely STEP ACTION SPEC YES NO 1 Isthecasterrotatingfreely GotoStep2 Lubricateor ReplaceCaster Housing 2 Isthe...

Page 171: ...ndallow thedrivewheelstorotatefreely GotoStep3 Dragging Repair Replaceor AdjustBrakes 3 Checktheamperageoutputoftheonthedrivemotorleads They shouldnotexceed100ampswhilepullingagrade Controllerwill Shu...

Page 172: ...t GotoStep2 2 Checkforthefollowingonthedriveassembly drivemotormount ingplates arebent aresquarewithdriveweldments orishardware loose Repair Replace Tightenweld ment GotoStep3 3 Checkforthefollowingon...

Page 173: ...GotoStep2 2 Checkforthefollowingonthedriveassembly drivemotormount ingplates arebent aresquarewithdriveweldments orishardware loose Repair Replace Tightenweld ment GotoStep3 3 Checkforthefollowingont...

Page 174: ...SECTION 6 TROUBLESHOOTING 6 46 31215825 Figure 6 6 Overview of Electrical System Components MVL MSP Sheet 1 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 175: ...SECTION 6 TROUBLESHOOTING 31215825 6 47 Figure 6 7 Overview of Electrical System Components MVL MSP Sheet 2 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 176: ...4 9 5 6 7 8 1 2 3 4 JUNCTION BOX ES IN YELLOW SHIELD B BLACK RS485B BLUE RS485A ORANGE AUX 1 SIGNAL B RED BLACK AUX 1 RETURN BLUE BLACK SUPPLY 24V DC RED DIGITAL RETURN BROWN LSS LED ORANGE BLACK LSS...

Page 177: ...PWM 4 10 5 VDC 5 AMP MAX LSS SWITCH RETURN INHIBITS LIFT DRIVE 5 AMP MAX 5 AMP MAX 5 AMP MAX 5 AMP MAX 5 AMP MAX 5 AMP MAX 24VDC 24VDC 24VDC PWM 24VDC 24VDC B B B B B SIGNAL IN SIGNAL OUT 2 4 3 2 3 4...

Page 178: ...Valve 6 Extend Line 7 Hydraulic Filter 8 Return Line 9 Check Valve 10 Pressure Compensator Flow Control Valve 11 Manual Decent Valve 12 Lift Cylinder Figure 6 10 Hydraulic Diagram MVL MSP 1 2792504_B...

Page 179: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 180: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

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