JLG 15MSP, 15MVL, 20MSP, 20MVL Vertical Mast Service Manual
174 pages · Publication 3121231
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What's inside
From the manual's own table of contents: 268 sections, 325 entries. See sample pages (PDF, 608 KB)
MAINTENANCE SAFETY PRECAUTIONS
GENERAL
HYDRAULIC SYSTEM SAFETY
MAINTENANCE
REVISION LOG1 topic
- CAPACITIES
System Voltage
Hydraulic System
Drive Motor GearBox (gear oil)1 topic
- COMPONENT DATA
Hydraulic Pump/Pump Motor Assembly
Rear Wheel Drive Motors
Batteries/Battery Charger1 topic
- PERFORMANCE DATA
Platform Capacities
Platform Size
Machine Height (platform stowed)
Machine Ground Clearance
Base Footprint1 topic
- LUBRICATION
Hydraulic Oil
Lubrication Specifications4 topics
- CYLINDER SPECIFICATIONS
- SERIAL NUMBER LOCATIONS
- TORQUE REQUIREMENTS
- MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance1 topic
- PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE
Inspection and Maintenance Codes
Show all 268 sections
Footnotes1 topic
- SERVICING AND MAINTENANCE GUIDELINES
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring1 topic
- TABLE OF CONTENTS Hydraulic System
Lubrication and Servicing
Batteries
Mast Chain Inspection Procedure1 topic
- LUBRICATION INFORMATION
Changing Hydraulic Oil2 topics
- BASE ASSEMBLY COMPONENTS
- BASE FRAME COVERS
Drive Motor Cover - Installation
Battery Charger Cover - Installation2 topics
- DRIVE/ELEVATION CUT-OUT SWITCH INSTALLATION
- DRIVE AND CASTER WHEELS
Tire Wear and Damage
Wheel and Tire Replacement
Wheel Installation
Caster Wheels - Installation1 topic
- WHEEL DRIVE ASSEMBLY - SERVICING
Roll And Leak Testing
Oil Type & Capacity
Drive Motor Brush Wear - Warning Indication
Wheel Drive Assembly - Removal From Machine
Wheel Drive Disassembly - Main Components
Replacing Drive Motor Brushes
Gear Box Main Disassembly
Input Carrier Disassembly
Hub - Disassembly
Spindle Disassembly
Spindle Sub-Assembly
Hub Sub-Assembly
Input Carrier Sub-Assembly
Main Gear Box Sub-Assembly
Motor, Brake and Gear Box Assembly2 topics
- POT HOLE PROTECTION SYSTEM
- BATTERY CHARGER - SERVICE PROCEDURES
Battery Charger General Information
Battery Charger Maintenance Information
Battery Charge LED Indicator on Platform Control Console
Battery Low Voltage Warning Indicators
Battery Charging Status Indicators
Battery Charger Check/Change Charging Algorithm
Battery Charger Removal/Installation2 topics
- CONTROL COMPONENTS OVERVIEW
- CONTROLS COVER INSTALLATION
Battery Cover Doors (Optional Hinged)
Center, Left and Right Lower Covers1 topic
- CONTROL COMPONENTS - INSTALLATION
Ground Control Module1 topic
- TABLE OF CONTENTS Traction Control Module
Platform Control Console Installation
Horn Installation
Alarm Installation1 topic
- BATTERIES - SERVICE PROCEDURES
Battery Condition Testing
Battery Replacement
Battery Disconnect (Option)
Battery - Installation - (2-12V Batteries)
Battery Installation - (4-6V Batteries) (OPTION)1 topic
- GROUND CONTROL MODULE - SERVICE PROCEDURE
Cover Removal/Installation
Power Selector/EStop Switch Installation1 topic
- GROUND CONTROL MODULE - PROGRAMMING
Programming Levels
Activating Programming Mode
Entering Password
Programming Mode Selection
Selecting Programmable Item to Adjust
Adjusting Programmable Setting
Service Programming Mode - (Level-2)
Operator Programming Mode - (Level-3)1 topic
- PLATFORM CONTROL CONSOLE - SERVICE PROCEDURES
Remove Platform Control Console
Display/Controller Module Electrical Connections
Mounting Bracket - Install/Remove
Rear Cover - Install/Remove
Display/Controller Module - Install/Remove
Drive/Lift Mode Switch - Install/Remove
Horn Button Switch - Install/Remove
Key Switch - Install/Remove
E-Stop/ShutDown Switch - Install/Remove
Joystick Assembly - Install/Remove1 topic
- PUMP-MOTOR ASSEMBLY - SERVICE PROCEDURE
Hydraulic Pressure settings and Adjustment
Hydraulic Pressure Gauge Connection
After Filter Pressure Check
Pump/Motor/Tank Installation
General Installation and Disassembly
Inline Hydraulic Filter Installation
FENNER BRAND PUMP - Brush Replacement
Motor Cap/Motor Installation
Motor Brush Installation
Brush Housing Final Assembly Tips
MONARCH BRAND PUMP - Brush Replacement
Motor Assembly - Remove/Install - Reference Marks
Motor/Brush Cover - Remove/Install
Brush Carrier Assembly - Remove/Install
Brush Assembly - Remove/Install
Tank Installation
Filter Screen Installation
Pump Installation
Pressure Adjust Valve Installation
Pressure Check Valve Installation1 topic
- TABLE OF CONTENTS OBSTRUCTION SENSOR SYSTEM - SERVICE PROCEDURE (MSP - OPTION)
Transducer Sensor Check
OSS Component Installation2 topics
- MAST COMPONENTS OVERVIEW
- MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT
Mast Chain/Cable Adjustment
Sequencing Cable Adjustment1 topic
- SEQUENCE CABLE REPLACEMENT KIT
Remove Old Cable
Replacement Cable Installation
Clamp Installation (Drum/Socket Type)1 topic
- HYDRAULIC LINE - DISCONNECT - SPECIAL TOOL
Tool Use - In-Line Style Fittings
Tool Use - Angled Style Fittings1 topic
- HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILD
Lift Cylinder Removal
Cylinder Disassembly
Lift Cylinder Component Inspection
Cylinder Assembly (See Figure 5-4.)
Cylinder Installation1 topic
- MAST ASSEMBLY INSTALLATION
Mast Removal
Mast Installation1 topic
- MAST ASSEMBLY AND DISASSEMBLY PROCEDURES
Mast Disassembly Procedure
Mast Assembly - MVL/MSP3 topics
- MSP - STOCKPICKER PLATFORM - INSTALLATION
- MSP - STOCKPICKER PLATFORM - MID-GATE INTERLOCK INSTALLATION
- MAST BEACON - INSTALLATION
MATERIAL TRAY PLATFORM ONLY)
Switches and Wiring6 topics
- MAST - 14 FT. HEIGHT LIMITING SWITCH -15MSP OPTION
- GENERAL
- TROUBLESHOOTING INFORMATION
- HYDRAULIC CIRCUIT CHECKS
- ELECTRICAL CIRCUIT CHECKS
- MULTIMETER BASICS
Grounding
Backprobing
Min/Max
Polarity
Scale
Continuity Measurement Over Long Distances
Requirements
Procedure1 topic
- TABLE OF CONTENTS ELECTRICAL SWITCH TESTING
Basic Check
Limit Switches
Automatic Switches
Switch Wiring - Low Side, High Side2 topics
- GROUND CONTROL MODULE LCD DISPLAY
- TROUBLESHOOTING TABLES INDEX
Specifications For Various Components
Special Pin Extractor Tools For Electrical Connectors
Fault Code Troubleshooting Tables
Main Power Circuit Troubleshooting
Mast Troubleshooting
Hydraulic Leak Troubleshooting
Base Frame Components Troubleshooting
Drive System Troubleshooting3 topics
- SPECIFICATIONS FOR VARIOUS COMPONENTS
- SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS
- FAULT CODE TROUBLESHOOTING TABLES
Machine in Drive Speed Cut-Back (Turtle) Mode All The Time
Obstruction Sensor System - Detection
Battery Voltage Low - Warning Level 3 - Three (3) LED/LCDs lit
Code 02 - Left PHP Bar - UP
Code 03 - Right PHP Bar - UP
Code 04 - Tilt Condition
Code 05 - Reserved
Code 06 - Drive Motor Brush Wear Warning Indicator
Code 07 - Left Drive Motor - Disconnected
Code 08 - Right Drive Motor - Disconnected
Code 09 - Left Brake - Disconnected
Code 10 - Right Brake - Disconnected
Code 11 - Left Drive Motor - Short Circuit
Code 12 - Right Drive Motor - Short Circuit
Code 13 - Traction Module - In Fold Back
Code 14 - Pump Motor - Disconnected
Code 15 - Lift Down Valve - Disconnected
Code 16 - Lift Down Valve - Short Circuit
Code 17 - Ground Control Module - In Fold Back
Code 18 - Alarm - Short Circuit
Code 19 - Alarm - Disconnected
Code 20 - Beacon - Short Circuit
Code 21 - Beacon - Disconnected
Code 22 - Horn - Short Circuit
Code 23 - Horn - Disconnected
Code 24 - Auxiliary #1 Circuit - Short Circuit
Code 25 - Auxiliary #1 Circuit - Disconnected
Code 26 - Auxiliary #2 - Short Circuit
Code 27 - Auxiliary #2 - Disconnected
Code 28 - Reserved
Code 29 - Reserved
Code 30 - Traction Module - No Communication with Ground Control Module
Code 32 - Pump Motor - Over Current
Code 33 - Both PHP Bars - UP
Code 34 - P2-Auxiliary #1 - Inhibit
Code 35 - P2-Auxiliary #1 - Tie Down
Code 38 - Battery Voltage Low - Warning Level 2 - Two (2) LED/LCDs lit1 topic
- TABLE OF CONTENTS Code 39 - Battery Voltage Low - Warning Level 3 - One (1) LED/LCDs lit
Codes
Codes (100 - 199) Ground Control Module - Fault Condition
Codes (200 - 299) Platform Control Console - Fault Condition
Codes (300 - 399) Traction Control Module - Fault Condition1 topic
- MAIN POWER CIRCUIT TROUBLESHOOTING
Machine Will Not Power Up1 topic
- MAST TROUBLESHOOTING
Platform Will Not Lower Manually
Platform Lift Up And Down - Jerky
Mast Noisy When Lifting And Lowering
Platform (Mast) Won’t Stay Elevated
Platform (Mast) Descends Too Slowly1 topic
- HYDRAULIC LEAK TROUBLESHOOTING
Miscellaneous Hydraulic Leak Troubleshooting1 topic
- BASE FRAME COMPONENTS TROUBLESHOOTING
Caster Wheels Not Operating Freely
Pot Hole Protection (PHP) Bars will not Lower1 topic
- DRIVE SYSTEM TROUBLESHOOTING
Won’t Climb Grade
Machine Drives in Opposite Direction
Machine Won’t Drive Straight
Noise From Drive Assembly
Torque Chart (SAE Fasteners - Sheet 1 of 7)
Torque Chart (SAE Fasteners - Sheet 2 of 7))
Torque Chart (SAE Fasteners - Sheet 3 of 7)
Torque Chart (SAE Fasteners - Sheet 4 of 7)
Torque Chart (METRIC Fasteners - Sheet 5 of 7))
Torque Chart (METRIC Fasteners - Sheet 6 of 7)
Torque Chart (METRIC Fasteners - Sheet 7 of 7)
Base Components
Wheel Lug Nut Tightening Sequence
Control Components Location - MVL/MSP
Component Electrical Connections. (2-12V Batteries shown)
Battery Cable to Battery Terminal Connections (4-6V)
Ground Control Module Components
Platform Control Console Components
Hydraulic Pressure Adjustment Screw. (Machine Rear Covers Removed)
Typical Hydraulic Pressure Gauge Installation (Hydraulic Filter Removed)
Typical Hydraulic Pressure Gauge Installation (After Hydraulic Filter)
Obstruction Sensor System Components (Platform Cutaway)
Mast Components. (MVL/MSP)
MVL/MSP - Mast Chain and Sequence Cable Adjustment Components
Machine Positioned for Cylinder Removal
Lift Cylinder Component Cross-Section (MVL/MSP)
Mast Section - Assembly Reference
Mast Chain Routing Diagram. - MVL/MSP
Mast Bottom End - Slide Pad Installation
MSP - StockPicker Platform Installation
Voltage Measurement (DC)
Resistance Measurement
Continuity Measurement
Current Measurement (DC)
Component Electrical Connections
Overview of Electrical System Components. (MVL/MSP) (Sheet 1 of 2)
Electrical Diagram. (MVL/MSP) (Sheet 1)
Hydraulic Diagram. (MVL/MSP)
General Machine Specifications
15MVL/MSP - Machine Maximum Wheel Loads (Lb.) and (PSI) - Per Wheel
20MVL/MSP - Machine Maximum Wheel Loads (Lb.) and (PSI) - Per Wheel
Hydraulic Oil Operating Range
Cylinder Specifications
Lubrication Intervals for Various Components
Inspection and Maintenance
MVL/MSP - Preventive Maintenance & Inspection Schedule
Chain Stretch Tolerance
Wheel Torque Chart
Battery Charger Algorithm Settings
MVL/MSP Ground Control Module - Field Programmable Settings and Factory Preset
MVL/MSP Mast Component Features
LCD Display - Service Fault Code Conditions
Ohm Ratings for Various Components
Amperage Draw for Various Components
Code 08 - Right Drive Motor Disconnected
Code 21 - Beacon - Short Disconnected
Code 31 - Platform Control Console - No Communication with Ground Control Module
Code 40 - OSS - No Communication with Ground Control Module
Code (200 - 299) Platform Control Console - Fault Condition
Platform Lift Up and Down Jerky
Machine Drive in Opposite Direction
Inside this manual
Real pages from this service manual (174 pages). Open the sample pages (PDF, 607 KB)
- Specifications, page 15: SECTION 1 - MACHINE SPECIFICATIONS
- Troubleshooting, page 121: SECTION 6. TROUBLESHOOTING
- Diagram, page 143: Code 11 - Left Drive Motor - Short Circuit
- Color page, page 123: SECTION 6 - TROUBLESHOOTING
Other manuals for this machine
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 174 pages
Quantity one is the manual described above.
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