JLG Boom Lift 10MSP Service & Maintenance Manual 3121228 2025

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JLG Boom Lift 10MSP Service & Maintenance Manual 3121228 2025
Size: 17.43 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Service & Maintenance Manual, Electrical and Hydraulic Diagrams
Model: JLG 10MSP Boom Lift
SN 0130000001-0130037734
Part Number: 3121228
Publication Date: 2025
Number of Pages: 178 Pages

Contents:
Section 1. MACHINE SPECIFICATIONS

1.1 Capacities​

System Voltage​

Hydraulic System​

Drive Motor Torque Hub (Gear Oil)​

1.2 Component Data​

Hydraulic Pump/Pump Motor Assembly​

Rear Wheel Drive Motors​

Batteries/Battery Charger​

1.3 Performance Data​

Platform Capacity​

Maximum Horizontal Manual Side Force​

Platform Size​

Material Tray Size​

Platform Height (Fully Elevated)​

Platform Maximum (Working) Height​

Machine Height​

Machine Overall​

Platform Entry Height​

Machine Ground Clearance​

Machine Turning Radius (Outside)​

1.4 Serial Number Plate Locations​

1.5 Torque Requirements​

1.6 Cylinder Specifications​

1.7 Lubrication​

Hydraulic Oil​

Lubrication Specifications​

1.8 Torque SPEcifications​

Section 2. GENERAL Service Information

2.1 Machine Preparation, Inspection, and Maintenance​

General​

Preparation, Inspection, and Maintenance​

Pre-Start Inspection​

Pre-Delivery Inspection and Frequent Inspection​

Annual Machine Inspection​

Preventative Maintenance​

2.2 Preventive Maintenance and Inspection Schedule​

2.3 Servicing and Maintenance Guidelines​

General​

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 Wiring​

Hydraulic System​

Lubrication and Servicing​

Batteries​

Mast Chain Inspection Procedure​

2.4 Lubrication Information​

Hydraulic System​

Hydraulic Oil​

Changing Hydraulic Oil​

Lubrication Specifications​

Section 3. BASE COMPONENTS

3.1 Base Assembly Components​

3.2 Base Frame Covers​

Hood (Carry Deck)​

Hood (Carry Deck) Frame​

Drive Motor Cover​

Rear Bumper Cover​

3.3 Drive And Caster Wheels​

Tire Wear and Damage​

Wheel and Tire Replacement​

Wheel Installation​

(Front) Caster Wheel Installation​

3.4 Drive/Elevation Cut-Out Switch Installation​

3.5 Wheel Drive Assembly Servicing​

Roll and Leak Testing​

Oil Type and Capacity​

Drive Motor Brush Wear - Warning Indication​

Wheel Drive Assembly Removal​

Wheel Drive Main Components Disassembly​

Replacing Drive Motor Brushes​

Torque Hub Main Disassembly​

Input Carrier Disassembly​

Hub Disassembly​

Spindle Disassembly​

Spindle Sub-Assembly​

Hub Sub-Assembly​

Input Carrier Sub-Assembly​

Main Torque Hub Sub-Assembly​

Motor, Brake, and Torque Hub Assembly​

3.6 Pump Motor Assembly​

General​

Hydraulic Pressure Settings and Adjustment​

Hydraulic Pressure Gauge Connection​

After Filter Pressure Check​

Pump Motor Assembly Removal​

Pump Motor Assembly Installation​

Motor/Brush Cover Removal​

Brush Carrier Assembly Removal​

Brush Assembly Removal​

Tank Removal​

Filter Screen Removal​

Pump Removal​

Pressure Adjust Valve Removal​

Pressure Check Valve Removal​

3.7 Batteries and Battery Charger​

Battery Condition Testing​

Battery Replacement​

Battery Installation (2-12V)​

Battery Installation (4-6V)​

Battery Charge LED Indicator on Platform Control Console​

Battery Low Voltage Warning Indicators​

Battery Charging Status Indicators​

Battery Charger Maintenance​

Battery Charger Check/Change Charging Algorithm​

Battery Charger Removal/Installation​

Section 4. CONTROL COMPONENTS

4.1 CONTROL Components Overview​

4.2 Control Components Installation​

Ground Control Module​

Traction Control Module Installation​

Platform Control Console Installation​

Platform Junction Box Installation​

Junction Box to Ground Control Harness Installation​

Platform Interlock Switch Circuit​

Component Electrical Connections​

4.3 Ground Control Module​

Cover Removal/Installation​

Power Selector/Emergency Stop Switch Installation​

4.4 Ground Control Module Programming​

General​

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​

4.5 Platform Control Console​

General​

Display/Controller Module Electrical Connections​

Mounting Bracket​

Rear Cover​

Display/Controller Module​

Drive/Lift Mode Switch (Prior to SN 0130032507)​

Horn Button Switch​

Key Switch​

E-Stop/ShutDown Switch​

Joystick Assembly​

4.6 Object Detection System (If Equipped)​

Removal​

Installation​

Section 5. MAST COMPONENTS

5.1 Mast Components Overview​

5.2 Mast Cover​

5.3 Platform Assembly​

5.4 7 Foot Height Limit Switch (If Equipped)​

5.5 Manual Material Tray​

5.6 Power Tray Disassembly​

Covers and Tray Removal​

Electrical and Hydraulic Components Removal​

Pulley System Disassembly​

Power Tray Lift Cylinder​

5.7 Power Tray Installation​

Pulley System Assembly​

Electrical and Hydraulic Components Installation​

Covers and Tray Installation​

5.8 Hydraulic Line Disconnect Tool​

In-Line Style Fittings​

Angled-Style Fittings​

5.9 Mast Removal​

Mast Installation​

5.10 MAST Disassembly​

Procedure​

Mast Section 4 (Platform Mount)​

Mast Section 3​

Mast Section 2​

Mast Section 1​

5.11 Cylinder Disassembly​

Lift Cylinder Component Inspection​

Cylinder Assembly​

Manual Descent Valve​

Remote Manual Descent (If Equipped)​

5.12 Mast Assembly​

Mast Section 1​

Mast Section 2​

Mast Section 3​

Mast Section 4​

5.13 Mast Chains and Sequencing Cables Adjustment​

Mast Chain/Cable Adjustment​

Sequencing Cable Adjustment​

SECTION 6. TROUBLESHOOTING

6.1 General​

6.2 Troubleshooting Information​

6.3 Hydraulic Circuit Checks​

6.4 Electrical Circuit Checks​

General​

6.5 Multimeter Basics​

Grounding​

Backprobing​

Min/Max​

Polarity​

Scale​

Voltage Measurement​

Resistance Measurement​

Continuity Measurement​

Current Measurement​

Continuity Measurement Over Long Distances​

Requirements​

Procedure​

6.6 Electrical Switch Testing​

Basic Check​

Limit Switches​

Automatic Switches​

Switch Wiring - Low Side, High Side​

6.7 Ground Control Module LCD Display​

6.8 Specifications for Various Components​

6.9 Special Pin Extractor Tools for Electrical Connectors​

6.10 Fault Code Troubleshooting Tables​

6.11 Main Power Circuit Troubleshooting​

Machine Will Not Power Up​

6.12 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 Slowly​

6.13 Hydraulic Leak Troubleshooting​

Miscellaneous Hydraulic Leak Troubleshooting​

6.14 Base Frame Components Troubleshooting​

Caster Wheels Not Operating Freely​

6.15 Drive System Troubleshooting​

Won’t Climb Grade​

Machine Drives in Opposite Direction​

Machine Won’t Drive Straight​

Noise From Drive Assembly​