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Oshkosh Corporation
Lifting Systems
JLG 20MVL
Oshkosh Corporation JLG 20MVL User Manual
180 pages
Manual
Specs
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Ser
vic
e and Ma
intenance
Manu
al
Mo
dels
20MVL
20MSP
31215825
January
23
, 2019 -
Rev A
PVC 2002
Go to
Discount-Equipment.com
to
order your
parts
2
Table of Contents
Hydraulic System Safety
3
Maintenance
3
Table of Contents
5
General Specifications
17
Machine Specifications
17
Machine Wheel Loads and PSI - Per Wheel
18
Electrical Specifications
18
Platform Data
18
Machine Component Weights
19
Serial Number Locations
19
Lubrication
19
Hydraulic Oil
19
Lubrication Specifications
19
Cylinder Specifications
19
Torque Requirements
19
Threadlocking Compound
21
Torque Charts
22
SAE Fastener Torque Chart
22
Metric Fastener Torque Chart
28
General
33
Machine Preparation, Inspection, and Maintenance
33
Preparation, Inspection, and Maintenance
33
Pre-Start Inspection
33
Pre-Delivery Inspection and Frequent Inspection
33
Annual Machine Inspection
33
Preventative Maintenance
33
Preventive Maintenance and Inspection Schedule
34
Inspection and Maintenance Codes
36
Footnotes
36
Servicing and Maintenance Guidelines
37
General
37
Safety and Workmanship
37
Cleanliness
37
Components Removal and Installation
37
Component Disassembly and Reassembly
37
Pressure-Fit Parts
37
Bearings
37
Gaskets
37
Bolt Usage and Torque Application
37
Hydraulic Lines and Electrical Wiring
38
Hydraulic System
38
Lubrication and Servicing
38
Batteries
38
Mast Chain Inspection Procedure
38
Lubrication Information
40
Hydraulic System
40
Hydraulic Oil
40
Changing Hydraulic Oil
40
Lubrication Specifications
40
Base Components
42
Base Assembly Components
42
Base Frame Covers
43
Drive Motor Cover - Installation
43
Battery Charger Cover - Installation
43
Drive/Elevation Cut-Out Switch Installation
44
Drive and Caster Wheels
44
Tire Wear and Damage
44
Wheel and Tire Replacement
44
Wheel Installation
44
Caster Wheels - Installation
45
Wheel Drive Assembly - Servicing
45
Roll and Leak Testing
45
Oil Type & Capacity
46
Drive Motor Brush Wear - Warning Indication
46
Wheel Drive Assembly - Removal from Machine
47
Wheel Drive Disassembly - Main Components
48
Replacing Drive Motor Brushes
49
Gear Box Main Disassembly
51
Input Carrier Disassembly
52
Hub Disassembly
53
Spindle Disassembly
54
Spindle Sub-Assembly
55
Hub Sub-Assembly
56
Input Carrier Sub-Assembly
57
Main Gear Box Sub-Assembly
58
Motor, Brake and Gear Box Assembly
59
Pot Hole Protection System
60
Battery Charger - Service Procedures
62
Battery Charger General Information
62
Battery Charger Maintenance Information
62
Battery Charge LED Indicator on Platform Control Console
62
Battery Low Voltage Warning Indicators
62
Battery Charging Status Indicators
63
Battery Charger Check/Change Charging Algorithm
64
Battery Charger Removal/Installation
64
Control Components
66
Control Components Overview
66
Controls Cover Installation
67
Battery Cover Doors
67
Center, Left and Right Lower Covers
67
Control Components - Installation
68
Ground Control Module
68
Traction Control Module
68
Platform Control Console Installation
69
Horn Installation
69
Alarm Installation
69
Batteries - Service Procedures
70
Battery Replacement
70
Battery Condition Testing
70
Battery Disconnect (Option)
70
Battery - Installation - (2-12V Batteries)
71
Battery Installation - (4-6V Batteries) (OPTION)
73
Cover Removal/Installation
75
Power Selector/Estop Switch Installation
76
Ground Control Station - Programming
77
General
77
Activating Programming Mode
77
Entering Password
78
Programming Mode Selection
78
Selecting Programmable Item to Adjust
78
Adjusting Programmable Setting
78
Service Programming Mode - (Level-2)
79
Operator Programming Mode - (Level-3)
80
Platform Control Console - Service Procedures
82
General
82
Remove Platform Control Console
82
Display/Controller Module Electrical Connections
83
Mounting Bracket - Install/Remove
83
Rear Cover - Install/Remove
83
Display/Controller Module - Install/Remove
84
Drive/Lift Mode Switch - Install/Remove
84
Horn Button Switch - Install/Remove
84
Key Switch - Install/Remove
84
E-Stop/Shutdown Switch - Install/Remove
85
Joystick Assembly - Install/Remove
85
Pump-Motor Assembly - Service Procedure
86
Hydraulic Pressure Settings and Adjustment
86
Hydraulic Pressure Gauge Connection
86
After Filter Pressure Check
87
Pump/Motor/Tank Installation
87
General Installation and Disassembly
88
Inline Hydraulic Filter Installation
88
FENNER BRAND PUMP - Brush Replacement
88
Motor Cap/Motor Installation
88
Motor Brush Installation
89
Brush Housing Final Assembly Tips
90
MONARCH BRAND PUMP - Brush Replacement
91
Motor Assembly - Remove/Install - Reference Marks
91
Motor/Brush Cover - Remove/Install
91
Brush Carrier Assembly - Remove/Install
92
Brush Assembly - Remove/Install
92
Tank Installation
93
Filter Screen Installation
93
Pump Installation
93
Pressure Adjust Valve Installation
94
Pressure Check Valve Installation
94
Mast Components
96
Mast Components Overview
96
Mast Chains and Sequencing Cables Adjustment
97
Mast Chain/Cable Adjustment
97
Sequencing Cable Adjustment
97
Sequence Cable Replacement Kit
99
Remove Old Cable
99
Replacement Cable Installation
99
Clamp Installation (Drum/Socket Type)
99
Hydraulic Line - Disconnect - Special Tool
102
Tool Use - In-Line Style Fittings
102
Tool Use - Angled Style Fittings
103
Hydraulic Lift Cylinder - Removal, Inspection and Rebuild
104
Lift Cylinder Removal
104
Cylinder Disassembly
107
Lift Cylinder Component Inspection
107
Cylinder Assembly (See Figure 5-11.)
108
Cylinder Installation
108
Mast Assembly Installation
110
Mast Removal
110
Mast Installation
110
Mast Assembly and Disassembly Procedures
111
Mast Disassembly Procedure - MVL/MSP
111
Mast Assembly Procedure - MVL/MSP
114
MSP - Stockpicker Platform - Installation
123
MSP - Stockpicker Platform - MID-Gate Interlock Installation
124
Mast Beacon - Installation
124
Gate Alarm - Installation - Option (for Side Entry W/Folding Material Tray Platform Only)
125
Switches and Wiring
125
Load Sensing System (LSS)
126
Setting Spring Pre-Load
127
Setting Positive Stops
127
Adjusting Switch
127
Troubleshooting
129
General
129
Troubleshooting Information
129
Hydraulic Circuit Checks (See Figure 6-8.)
129
Electrical Circuit Checks
129
Multimeter Basics
130
Grounding
130
Back-Probing
130
Min/Max
130
Polarity
130
Scale
130
Continuity Measurement over Long Distances
133
Requirements
133
Procedure
133
Electrical Switch Testing
134
Basic Check
134
Limit Switches
134
Automatic Switches
135
Switch Wiring - Low Side, High Side
135
Ground Control Module LCD Display
136
Troubleshooting Tables Index
143
Specifications for Various Components
145
Special Pin Extractor Tools for Electrical Connectors
145
Fault Code Troubleshooting Tables
146
Machine in Drive Speed Cut-Back (Turtle) Mode All the Time
146
Battery Voltage Low - Warning Level 3 - Three (3) Led/Lcds Lit
146
Overload Alarm and Overload Indicator
146
Code 02 - Left PHP Bar - up
147
Code 03 - Right PHP Bar - up
147
Code 04 - Tilt Condition
148
Code 05 - Reserved
148
Code 06 - Drive Motor Brush Wear Warning Indicator
149
Code 07 - Left Drive Motor - Disconnected
149
Code 08 - Right Drive Motor - Disconnected
150
Code 09 - Left Brake - Disconnected
150
Code 10 - Right Brake - Disconnected
150
Code 11 - Left Drive Motor - Short Circuit
151
Code 12 - Right Drive Motor - Short Circuit
151
Code 13 - Traction Module - in Fold Back
151
Code 14 - Pump Motor - Disconnected
152
Code 15 - Lift down Valve - Disconnected
152
Code 16 - Lift down Valve - Short Circuit
153
Code 17 - Ground Control Module - in Fold Back
153
Code 18 - Alarm - Short Circuit
153
Code 19 - Alarm - Disconnected
154
Code 20 - Beacon - Short Circuit
154
Code 21 - Beacon - Disconnected
155
Code 22 - Horn - Short Circuit
155
Code 23 - Horn - Disconnected
156
Code 24 - Auxiliary #1 Circuit - Short Circuit
156
Code 25 - Auxiliary #1 Circuit - Disconnected
157
Code 26 - Auxiliary #2 - Short Circuit
157
Code 28 - Reserved
158
Code 29 - Reserved
158
Code 30 - Traction Module - no Communication with Ground Control Module
158
Code 31 - Platform Control Console - no Communication with Ground Control Module
158
Code 32 - Pump Motor - over Current
159
Code 33 - both PHP Bars - up
159
Code 34 - P2-Auxiliary #1 - Inhibit
159
Code 35 - P2-Auxiliary #1 - Tie down
161
Code 38 - Battery Voltage Low - Warning Level 2 - Two (2) Led/Lcds Lit
161
Code 39 - Battery Voltage Low - Warning Level 3 - One (1) Led/Lcds Lit
161
Code 40 - Obstruction Sensor System - no Communication with Ground Control Module
162
Codes 41 Thru 46 - OSS - Sensor 1 through 6 - Fault Condition
162
Codes (100 - 199) Ground Control Module - Fault Condition
163
Codes (200 - 299) Platform Control Console - Fault Condition
164
Codes (300 - 399) Traction Control Module - Fault Condition
164
Main Power Circuit Troubleshooting
165
Machine will Not Power up
165
Mast Troubleshooting
166
Platform will Not Lower Manually
166
Platform Lift up and down - Jerky
166
Mast Noisy When Lifting and Lowering
167
Platform (Mast) Won't Stay Elevated
168
Platform (Mast) Descends too Slowly
168
Hydraulic Leak Troubleshooting
169
Miscellaneous Hydraulic Leak Troubleshooting
169
Base Frame Components Troubleshooting
170
Caster Wheels Not Operating Freely
170
Pot Hole Protection (PHP) Bars will Not Lower
170
Drive System Troubleshooting
171
Won't Climb Grade
171
Machine Drives in Opposite Direction
171
Machine Won't Drive Straight
172
Noise from Drive Assembly
173
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Oshkosh Corporation JLG 20MVL Specifications
General
Fuel Type
Electric
Gradeability
25%
Platform Height
20.5 ft
Platform Capacity
500 lb
Maximum Platform Height
20.5 ft
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