JLG Vertical Lift E18MML E18MCL E18MSP Service & Maintenance Manual 3122326800

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JLG Vertical Lift E18MML E18MCL E18MSP Service & Maintenance Manual 3122326800
Size: 25.93 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Vertical Lift
Type of Manual: Service & Maintenance Manual, Electrical and Hydraulic Diagrams
Model: JLG E18MML E18MCL E18MSP Vertical Lift
Part Number: 3122326800
Publication Date: 2024
Number of Pages: 382 Pages

Contents:
Coverpage
Effectivity Page
Safety

General​

1.1.1 Disclaimer​

1.1.2 Operation & Safety Manual​

Safety Information​

1.2.1 Safety Alert System and Signal Words​

Safety Hazards​

1.3.1 Personal Hazards​

1.3.2 Equipment Hazards​

1.3.3 General Hazards​

1.3.4 Operational Hazards​

Safety Decals​

Machine Verification​

General Machine Information and Specifications

Specifications​

2.1.1 Machine Specifications​

2.1.2 Battery Specifications​

2.1.3 Battery Charger​

2.1.4 Cylinder Specifications​

2.1.5 Platform Data​

2.1.6 Machine Wheel Loads and PSI - Per Wheel​

2.1.7 Machine Component Weights​

2.1.8 Specifications For Various Components​

2.1.9 Torque Requirements​

Serial Number Location​

Fluids and Lubrication​

2.3.1 Hydraulic System​

2.3.2 Hydraulic Oil​

2.3.3 Changing Hydraulic Oil​

2.3.4 Lubrication Specifications​

2.3.5 Fluids​

Machine Characteristics​

2.4.1 Primary Regulatory Standards​

2.4.2 Languages of Markings​

2.4.3 Outdoor Rating​

2.4.4 Tilt System​

2.4.5 Platform Height Monitoring System​

2.4.6 Platform Joystick Trigger​

2.4.7 Platform Footswitch​

2.4.8 Battery Charger System​

2.4.9 Platform Load Sensing System (LSS)​

2.4.10 Universal Telematics​

2.4.11 Battery Charge Indication​

2.4.12 Control System​

2.4.13 Beacon​

2.4.14 Lithium-Ion Batteries (If Equipped)​

2.4.15 FLA or AGM Batteries (If Equipped)​

2.4.16 Ground Control Key Switch​

2.4.17 JLG Mobile Control System​

2.4.18 Drive System​

2.4.19 Brake System​

2.4.20 Gate Alarm (Accessory on Material Tray Platform)​

2.4.21 Lift System​

2.4.22 Steer System​

2.4.23 Pothole Protection System​

2.4.24 Manual Descent System​

2.4.25 Wheels/Tires​

2.4.26 Platform Rail System​

2.4.27 Tow System​

2.4.28 Pothole Protection Alarm​

2.4.29 Low Temperature Cutout​

2.4.30 Indoor/Outdoor Mode​

2.4.31 Slope Descent System​

2.4.32 Driving Above Elevated Position​

Clearsky Smart Fleet (If Equipped)​

2.5.1 General​

2.5.2 ClearSky Smart Fleet™ — Access Control​

Maintenance and Inspection Schedules

Machine Preparation, Inspection, and Maintenance​

3.1.1 General​

3.1.2 Preparation, Inspection, and Maintenance​

3.1.3 Pre-Start Inspection​

3.1.4 Pre-Delivery Inspection and Frequent Inspection​

3.1.5 Annual Machine Inspection​

3.1.6 Preventative Maintenance​

Service and Guidelines​

3.2.1 General​

3.2.2 Safety and Workmanship​

3.2.3 Cleanliness​

3.2.4 Components Removal and Installation​

3.2.5 Component Disassembly and Reassembly​

3.2.6 Pressure-Fit Parts​

3.2.7 Bearings​

3.2.8 Gaskets​

3.2.9 Bolt Usage and Torque Application​

3.2.10 Hydraulic Lines and Electrical Wiring​

3.2.11 Hydraulic System​

3.2.12 Lubrication and Servicing​

3.2.13 Batteries​

3.2.14 Mast Chain Inspection Procedure​

3.2.15 Lift Cylinder Component Inspection​

Preventive Maintenance and Inspection Schedule​

Tires and Wheels​

3.4.1 Tire Wear and Damage​

3.4.2 Wheel and Tire Replacement​

Battery System Maintenance/Troubleshooting​

3.5.1 Battery Management System (BMS)​

3.5.2 State of Charge (SOC)​

3.5.3 Battery Status Indicator (LED)​

Testing, Calibrations and Special Procedures

Special Tools​

4.1.1 Multimeter Basics​

4.1.2 Threadlocking Compound​

4.1.3 Tools Catalog​

4.1.4 Special Pin Extractor Tools For Electrical Connectors​

4.1.5 Hydraulic Line - Disconnect - Special Tool​

Testing Procedures​

4.2.1 LSS Testing and Evaluation​

4.2.2 Battery Condition Testing​

4.2.3 Electrical Switch Testing​

4.2.4 Verify Elevation​

Calibration Procedures​

4.3.1 Load Sensing System (LSS)​

Special Procedure​

4.4.1 Emergency Procedure​

4.4.2 Base Assembly Components​

4.4.3 Joystick Controller​

4.4.4 Mast Chains And Sequencing Cables Adjustment​

4.4.5 Sequence Cable Replacement Kit​

4.4.6 Traction System​

4.4.7 Factory Reset​

4.4.8 Preventative Maintenance - Brush Wear - Dust Removal Procedure​

4.4.9 Lithium-Ion Battery Troubleshooting Notes​

WHEEL DRIVE ASSEMBLY - SERVICING​

4.5.1 Roll And Leak Testing​

4.5.2 Oil Type & Capacity​

System Software

Control Module​

5.1.1 Ground Control Module​

5.1.2 Machine Software​

Ground Control Station - Programming​

5.2.1 General​

5.2.2 Ground Control Station Functions​

Machine Configuration Programming Information​

Machine Model Adjustment​

ClearSky (CS550) Configuration and Troubleshooting​

5.5.1 ClearSky Smart FleetTM CS550 Configuration​

5.5.2 Troubleshooting​

Fault Codes

Introduction​

6.1.1 General​

6.1.2 Troubleshooting Information​

DTC Check Tables​

6.2.1 ClearSky Smart Fleet DTC Fault Codes​

Main Power Circuit Troubleshooting​

6.3.1 Machine Will Not Power Up​

Mast Troubleshooting​

6.4.1 Platform Will Not Lower Manually​

6.4.2 Platform Lift Up And Down - Jerky​

6.4.3 Mast Noisy When Lifting And Lowering​

6.4.4 Platform (Mast) Will Not Stay Elevated​

6.4.5 Platform (Mast) Descends Too Slowly​

Hydraulic Leak Troubleshooting​

6.5.1 Miscellaneous Hydraulic Leak Troubleshooting​

Base Frame Components Troubleshooting​

6.6.1 Caster Wheels Not Operating Freely​

6.6.2 Pot Hole Protection (PHP) Bars will not Lower​

Drive System Troubleshooting​

6.7.1 Will Not Climb Grade​

6.7.2 Machine Drives in Opposite Direction​

6.7.3 Machine will Not Drive Straight​

6.7.4 Noise From Drive Assembly​

Hydraulics

General Information and Safety​

Theory Of Operation​

7.2.1 Cylinders​

7.2.2 Valves​

7.2.3 Pump/Motor​

7.2.4 Hydraulic Circuit Checks​

Pressure Setting pocedures​

7.3.1 Main/Lift Relief​

7.3.2 Steer Reliefs - 18MCL only​

Torque Values​

7.4.1 Manifold Valve Torque Specifications​

Electricals

General Electrical Information​

8.1.1 Applying Silicone Dielectric Compound to Amp Connectors​

8.1.2 Dielectric Grease Application​

8.1.3 Installation​

8.1.4 AMP Mate-N-Lok​

8.1.5 AMP Faston​

8.1.6 AMP Micro-Fit​

8.1.7 AMP Mini Fit Jr​

8.1.8 Mini Fit Sr​

8.1.9 DIN Connectors​

8.1.10 Exceptions​

8.1.11 Electrical Circuit Checks​

Electrical Connectors​

8.2.1 Deutsch Connectors​

Electrical Component Terminology​

8.3.1 Component Location​

8.3.2 Controls​

Harness Layouts​

Board Layouts​

8.5.1 Logic Control Module​

8.5.2 Drive Control Module​

AMP Connector​

8.6.1 Assembly​

8.6.2 Disassembly​

8.6.3 Wedge Lock​

8.6.4 Service - Voltage Reading​

Switches​

8.7.1 Basic check​

8.7.2 Limit Switches​

8.7.3 Automatic Switches​

8.7.4 Switch Wiring - Low Side, High Side​

Wiring Harness​

Removal and Installation

Pothole Protection System​

9.1.1 Pothole Protection System Components​

Tires and Wheels​

9.2.1 Removal​

9.2.2 Installation​

Steering, Caster and Ackermann​

9.3.1 Caster Wheel​

9.3.2 Hydraulic Steering​

Battery​

9.4.1 Battery Cover Removal​

9.4.2 Battery Cover Installation​

9.4.3 Battery Replacement​

9.4.4 Battery Quick-Disconnect​

9.4.5 Lead Acid Battery​

9.4.6 Lithium Ion Battery​

Battery Charger​

9.5.1 Battery Charger (Delta-Q 650 W (CAN))​

9.5.2 Battery Charger (Delta-Q 1200 W (CAN))​

9.5.3 Battery Charger (Green Power)​

Tilt Sensor​

9.6.1 Removal​

9.6.2 Installation​

Ground Control Module​

9.7.1 Removal​

9.7.2 Installation​

9.7.3 Alarm Removal​

Hood Assembly​

9.8.1 Removal​

9.8.2 Installation​

Drive Motor System​

9.9.1 Drive Cover Removal​

9.9.2 Installation​

9.9.3 Drive Motor Removal​

9.9.4 Drive Motor Installation​

Drive Control Module​

9.10.1 Removal​

9.10.2 Installation​

Logic Control Module​

9.11.1 Module Access​

9.11.2 Removal​

9.11.3 Installation​

Pump Motor Assembly​

9.12.1 Removal​

9.12.2 Installation​

Platform Control Console​

9.13.1 Removal​

9.13.2 Installation​

9.13.3 Joystick Assembly​

Mast​

9.14.1 Removal​

9.14.2 Installation​

Lift Cylinder​

9.15.1 Removal​

9.15.2 Installation​

Platform​

9.16.1 Platform Removal​

9.16.2 Platform Installation​

ClearSky® LED Motion / Amber Beacon (CS550) (if equipped)​

9.17.1 ClearSky® LED Motion / Amber Beacon (CS550) (if equipped)​

Disassembly and Assembly

Drive Assembly​

10.1.1 Torque Hub​

10.1.2 Primary Planet Carrier​

10.1.3 Spindle Carrier​

Platform Control Station​

10.2.1 Control Components Overview​

10.2.2 Disassembly​

Lift Cylinder​

Steer Cylinder​

Pump/Motor​

10.5.1 Hydraulic Pressure Settings and Adjustment​

10.5.2 Hydraulic Pressure Gauge Connection​

10.5.3 After Filter Pressure Check​

10.5.4 Pump/Motor/Tank Installation​

10.5.5 General Assembly and Disassembly​

10.5.6 Inline Hydraulic Filter Installation​

10.5.7 Fenner Brand Pump - Brush Replacement​

10.5.8 Monarch Brand Pump - Brush Replacement​

Mast Assembly and Disassembly​

10.6.1 Mast Components Overview​

10.6.2 Mast Disassembly Procedure - MML/MCL/MSP​

10.6.3 Mast Assembly Procedure - MML/MCL/MSP​

Torque/Connection Information

Hydraulic Fittings​

11.1.1 Tapered Thread Types​

11.1.2 Straight Thread Types, Tube and Hose Connections​

11.1.3 Straight Thread Types, Port Connections​

11.1.4 Flange Connection Types​

11.1.5 Tightening Methods​

11.1.6 Assembly and Torque Specifications​

11.1.7 General Tube Type Fitting Assembly Instructions​

11.1.8 Assembly Instructions for American Standard Pipe Thread Tapered Connections.​

11.1.9 Assembly Instructions for British Standard Pipe Thread Tapered Connections​

11.1.10 Assembly Instructions for 37° (JIC) Flare Fittings​

11.1.11 Assembly Instructions for 45° SAE Flare Fittings​

11.1.12 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings​

11.1.13 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)​

11.1.14 Assembly Instructions for Bulkhead (BH) Fittings​

11.1.15 Assembly Instructions for O-Ring Boss (ORB) Fittings​

11.1.16 Assembly Instructions for Adjustable Port End Metric Fittings​

11.1.17 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends​

11.1.18 Assembly instructions for Adjustable Port End (BSPP) Fittings​

11.1.19 Assembly Instructions for Flange Connections: (FL61 and FL62)​

11.1.20 Double Wrench Method​

11.1.21 FFWR and TFFT Methods​

11.1.22 Adjustable Stud End Assembly​

11.1.23 O-ring Installation (Replacement)​

Torque Charts​

11.2.1 SAE Fastener Torque Chart​

11.2.2 Metric Fastener Torque Chart​

Schematics

Hydraulic Schematic​

Electrical Schematic​