JLG 10VP 15VP 20VP Service & Maintenance Manual 3120728 – PDF DOWNLOAD
FILE DETAILS:
JLG 10VP 15VP 20VP Service & Maintenance Manual 3120728 – PDF DOWNLOAD
Language : English
Pages :104
Downloadable : Yes
File Type : PDF
DESCRIPTION:
JLG 10VP 15VP 20VP Service & Maintenance Manual 3120728 – PDF DOWNLOAD
GENERAL
This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
- The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.
- Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device.
- Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.
B HYDRAULIC SYSTEM SAFETY
It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system. Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss.
MAINTENANCE
- NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES.
- REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE.
- DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT.
- OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICEMANUAL.
- KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS.
- USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.
- NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED.
- BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS.
- BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS
- KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.
- USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
JLG 10VP 15VP 20VP Service & Maintenance Manual 3120728 – PDF DOWNLOAD
Model 0
10VP 0
15VP 0
20VP 0
3120728 0
June 14, 2001 0
SERVICE & MAINTENANCE 0
This page left intentionally blank 4
FOREWORD 3
The purpose of this manual is to provide users with the operating procedures essential for the pr 3
BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION, PROPER SAF 3
ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER OPERATING CONDIT 3
THIS “SAFETY ALERT SYMBOL” IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH MAY LEAD TO SERIO 3
Safety of personnel and proper use of the machine are of primary concern, DANGER, WARNING, CAUTIO 3
This page intentionally left blank 6
Introduction – Maintenance safety precautions 5
a GENERAL 5
This section contains the general safety precautions which must be observed during maintenance of 5
The specific precautions to be observed during machine maintenance are inserted at the appropriat 5
Your safety, and that of others, is the first consideration when engaging in the maintenance of e 5
b HYDRAULIC SYSTEM SAFETY 5
1 It should be particularly noted that the machines hydraulic systems operate at extremely high 5
2 Relieve system pressure by activating the lift DOWN control with the platform completely lower 5
c MAINTENANCE 5
This page intentionally left blank 8
Effectivity Changes 7
This page intentionally left blank 12
LIST OF FIGURES 10
LIST OF TABLES 10
Section 1 specifications 13
1 1 Capacities 13
System Voltage 13
All VP Models – 24 Volt DC (2 – 12 volt DC batteries) 13
Hydraulic Oil Reservoir 13
All VP Models – 5 qts U S (4 7 ltr ) 13
1 2 Component Data 13
Hydraulic Pump/Pump Motor Assembly 13
Pump Motor – 24 Volt DC motor 13
Pump Displacement – 13
10 & 15VP – 098 cu in /rev (1 6cc/rev ) 13
20VP – 049 cu in /rev (0 8cc/rev ) 13
Pump Output (Max ) – 13
10 & 15VP – 1 20 gpm @ 2200 psi 13
20VP – 0 65 gpm @ 2200 psi 13
Hydraulic System Pressure Setting – 13
10 & 15VP – 1000 psi (68 95 bar) 13
20VP – 2500 psi (172 3 bar) 13
Rear Wheel Drive Motors 13
Drive Motors – 13
24 Volt DC w/perm magnet 13
Right angle gear 13
Maintenance free sealed gear 13
Brake shaft and drive shaft, Integral to Motor 13
Parking Brake (must be released for pushing) 13
Batteries/Battery Charger 13
Batteries (2) – 12 Volt / 80 Amp Hour – 13
Deep Cycle Marine – RV 13
Battery Charger – 13
U S A /CAN – 120 Volt A C / 60 Hz input 13
Brazil – 220 Volt A C / 60 Hz input 13
24 volt, 10 amp output – 13
with 2 amp finish 13
Reset Circuit Breaker 13
Automatic Charge Circuit 13
Plug Interlock Circuit 13
1 3 Performance Data 13
Platform Capacity(All Platforms except Extendible) 13
10VP – 350 lbs (160 kg) 13
15VP – 350 lbs (160 kg) 13
20VP – 350 lbs (160 kg) 13
Extendible Platform Capacity 13
ANSI (U S ) – 300 lbs (136 kg) 13
CSA (CAN ) – 250 lbs (114 kg) 13
Platform Size 13
Standard Platform – 26 in x 26 in (66cm) x (66cm) 13
Machine Height (In Stowed Position) 13
VP Series – 79 in (201cm) height 13
Table 1-1 Machine GVW and Wheel Loads 13
Base Footprint 14
VP Series – 32 in (81cm) width 56 in (1 42m) length 14
Max Platform Height (mast extended) 14
10VP – 10 ft 6 in (3 2m) 14
15VP – 15 ft (4 5m) 14
20VP – 19 ft 9 in (5 9m) 14
Platform Working Height (average) 14
10VP – 16 ft 6 in (4 8m) 14
15VP – 21 ft (6 4m) 14
20VP – 25 ft 9 in (7 6m) 14
Machine Drive Speed (max )* 14
Platform Lowered – 2 mph (3 22 kph) 14
Platform Elevated – 0 5 mph ( 81 kph) 14
(reduced by limit switch) 14
* Variable to maximum with speed cut back 14
Amperage Draw (average) 14
Lift – 12 amps Drive – 20 amps 14
Interlock Switch Operating Conditions 14
Table 1-4 shown, lists machine response to various interlock switch positions 14
1 4 Torque Requirements 14
When maintenance becomes necessary or a fastener has loosened, refer to the Torque Chart, Figure 14
1 5 Lubrication 14
Hydraulic Oil 14
Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and suf 14
For cold weather applications, i e when temperatures remain consistently below +20F (–7C) JLG 14
Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as 14
Table 1-2 Hydraulic Oil Operating Range 14
Lubrication Specifications 14
Table 1-3 Lubrication Specifications 14
Table 1-4 Machine Interlock Switch Operating Conditions 14
1 6 Hydraulic Pressure Adjustment 15
Adjust system pressure so that platform will raise with rated capacity in platform 15
The following are recommended factory pressure settings; 15
VP10, VP15 – 1000 psi VP20 – 2500 psi 15
Turning adjustment screw clockwise increases system pressure, turning screw counterclockwise decr 15
Make pressure adjustment with oil at normal operating temperature If pressure is set when oil is 15
Connect pressure gauge as shown in Figure 1-2 , Hydraulic Pressure Gauge Installation 15
Select a T-Fitting to exactly match the thread size of the pump ( 562 x 18 THD), pressure line ( 15
1 7 Cylinder Specifications 15
Table 1-5 Cylinder Specifications 15
1 8 Serial Number Location 15
For machine identification, a serial number plate is affixed to the machine The plate is located 15
Table 1-6 Lubrication Intervals for Various Components 17
This page intentionally left blank 18
This page intentionally left blank 60
Section 2 SERVICE PROCEDURES 19
2 1 General 19
This section provides general information to assist in the performance of maintenance on the pers 19
2 2 Servicing and Maintenance Guidelines 19
General 19
The following information is provided to assist you in the use and application of servicing and m 19
Safety and Workmanship 19
Your safety, and that of others, is the first consideration when engaging in the maintenance of e 19
Cleanliness 19
The most important single item in preserving the long service life of a machine is to keep dirt a 19
At any time when oil lines are disconnected, clear adjacent areas as well as the openings and fit 19
Clean and inspect all parts during servicing or maintenance, and assure that all passages and ope 19
Components Removal and Installation 19
Use adjustable lifting devices, whenever possible, if mechanical assistance is required All slin 19
Should it be necessary to remove a component on an angle, keep in mind that the capacity of an ey 19
If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc , 19
Component Disassembly and Reassembly 19
When disassembling or reassembling a component, complete the procedural steps in sequence Do not 19
Pressure-Fit Parts 19
When assembling pressure-fit parts, use an “anti-seize” or molybdenum disulfide base compound to 19
Bearings 19
When a bearing is removed, cover it to keep out dirt and abrasives Clean bearings in nonflammabl 19
Discard bearings if the races and balls (or rollers) are pitted, scored, or burned 19
If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) pap 19
Lubricate new or used serviceable bearings before installation When pressing a bearing into a re 19
Gaskets 20
Check that holes in gaskets align with openings in the mating parts If it becomes necessary to h 20
Bolt Usage and Torque Application 20
Use bolts of proper length A bolt which is too long will bottom before the head is tight against 20
Unless specific torque requirements are given within the text, standard torque values should be u 20
Hydraulic Lines and Electrical Wiring 20
Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when dis 20
Hydraulic System 20
Keep the system clean If evidence of metal or rubber particles is found in the hydraulic system, 20
Disassemble and reassemble parts on clean work surface Clean all metal parts with non-flammable 20
Lubrication and Servicing 20
Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart, 20
Batteries 20
Clean batteries, using a non-metallic brush and a solution of baking soda and water Rinse with c 20
Mast Chain Inspection Procedure 20
Inspect mast chains for the following conditions: 20
Wear: Always inspect that segment of chain that operates over a sheave As the chain flexes over 20
Rust and Corrosion: Rust and corrosion will cause a major reduction in the load carrying capacity 20
Table 2-1 Chain Stretch Tolerance 20
50″ pitch 20
12″ or 24 pitches 20
24 in /12 in span 20
625 pitch 20
15″ or 24 pitches 20
30 in /15 in span 20
Fatigue Cracks: Fatigue is a phenomenon that affects most metals, and is the most common cause of 20
Tight Joints: All joints in the leaf chain should flex freely On leaf chain, tight joints are us 21
a Bent pins or plates 21
b Rusty joints 21
c Peened plate edges 21
Oil rusty chains, and replace chains with bent or peened chain components Keep chains lubricated 21
Protruding or Turned Pins: Chains operating with inadequate lube generate tremendous friction bet 21
Chain Anchors and Sheaves: An inspection of the chain must include a close examination of chain a 21
Inspect the sheaves, sheave bearings, sheave grooves and pins for extreme wear, replace as necess 21
a Chains too tight 21
b Sheave bearings/pin bad 21
c Bent/misaligned chains 21
Mast Cable Inspection Procedure 21
The periodic inspection shall cover the entire length of the cable The inspection frequency shal 21
Only the surface wires of the cable require inspection, do not attempt to open the cable Any det 21
Mast cables must be replaced after machine has been in service for five (5) years, regardless of 21
Conditions such as the following shall be sufficient reason for questioning continual use of the 21
1 In running ropes, six randomly distributed broken wires in one lay or three broken wires in on 21
2 One outer wire broken at the point of contact with the core of the rope which has worked its w 21
3 Wear of one-third the original diameter of outside individual wires 21
4 Kinking, crushing, birdcaging or any other damage resulting in distortion of the rope structure 21
5 Evidence of any heat damage from any cause 21
6 Reductions from nominal diameter of more than; 21
a 1/64th in (0 4mm) for diameters up to and including 5/16th in (8mm); 21
Also check for cracked, bent, worn, severely corroded, or improperly installed cable ends 21
Inspect sheaves, sheave grooves, and sheave pins for excessive wear, replace as necessary 21
2 3 Lubrication Information 21
Hydraulic System 21
The primary enemy of a hydraulic system is contamination Contaminants enter the system by variou 21
The design and manufacturing tolerances of the component working parts are very close, therefore, 21
Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation 22
It is not advisable to mix oils of different brands or types, as they may not contain the same re 22
Hydraulic Oil 22
For best performance, JLG recommends the use of ISO- Vg grade 32, 46 oil with a viscosity range b 22
Changing Hydraulic Oil 22
Use of any of the recommended hydraulic oils eliminates the need for changing the oil on a regula 22
Use every precaution to keep the hydraulic oil clean If the oil must be poured from the original 22
While the unit is shut down, a good preventive maintenance measure is to make a thorough inspecti 22
Lubrication Specifications 22
Specified lubricants, as recommended by the component manufacturers, are always the best choice, 22
2 4 Positioning Lift for Access to Components Located Under The Base Frame 22
Access to the underside of the VP lift can be obtained by lifting the machine with a fork lift tr 22
Lifting with a Fork Truck (See Figure 2-1 ) 22
1 Choose a fork lift truck capable of safely handling the full weight of the machine 22
2 Locate work area on a firm, level surface 22
3 When lifting with a fork truck, lift only using the fork lift-truck pockets running the length 22
4 After lifting machine to desired work height, place support stands under the machine The supp 22
2 5 Drive motor component Service procedures 23
Torque Limiting Clutch Maintenance 23
VP Series machines are equipped with a torque limiting clutch coupling on each drive axle The cl 23
Visual Inspection and Limiting Torque Checking Procedure 23
1 Locate the machine on a firm level surface 23
2 Carefully raise the lift to gain access to the underside of the base frame Refer to Section 2 23
3 Locate the clutch assembly on each rear drive axle and check for the following; 23
a Check the coupling chains for any loose or missing parts, i e pins, links, etc , replace if n 23
b Check that the allen-head set screws on the (large) clutch adjusting nut are in place and secu 23
c Check for any debris wedged in or wrapped around the clutch coupling chains and axle shafts R 23
Checking Clutch – Torque Setting (ft lb ) 23
1 Remove the drive wheels from the drive axles 23
2 Select a torque wrench capable of setting a torque of at least 185 ft lb Insert special tool 23
3 Slide the tool onto the end of the drive axle aligning the key on the axle shaft (install key 23
4 Turn the torque wrench and note the torque setting when the torque limiting clutch releases T 23
5 If torque setting is OK, re-install the wheels and lower machine, IF NOT, see the following note 23
Torque Limiting Clutch Adjustment 24
1 Loosen the two (2) adjusting nut setscrews located on the large adjusting nut on the clutch as 24
2 Hold the drive axle steady using service tool (P/N- 0080229) and the torque wrench used to che 24
3 Depending on how far off the original torque setting was (see note at beginning of this proced 24
4 When proper torque setting is achieved, re-tighten the two (2) adjusting nut, setscrews 24
5 Re-install the drive wheels, remove the jack stand and lower the machine to ground 24
Drive Motor Brake Adjustment/Removal 24
(See Figure 2-4 & Figure 2-5 ) 24
Mounted onto the front of each drive motor housing is a brake assembly The brakes are normally E 24
Operation (See Figure 2-4 & Figure 2-5 ) 25
When the magnetic coil is not energized (brake on), the armature plate is pushed away from the ma 25
A correctly adjusted brake will ideally have a measurment of approximately 006″ (but will operat 25
Never allow any type of lubricant (oil, grease, hydraulic fluid, etc ) to come in contact with th 25
Checking/Adjusting Armature Plate Gap Setting 25
1 First inspect that all parts of the brake assembly are tight and secure Tighten as necessary 25
2 Inspect the brake for any debris which may be lodged in the air gap between the armature plate 25
3 With the brakes ENGAGED measure the air gap between the armature plate and the magnetic coil h 25
4 If the air gap falls outside the maximum allowable setting of 010″ the friction disk has worn 25
5 It the air gap is below the minimum allowable setting of 004″, recheck the areas between the 25
Manual Release Arm – Screw Adjustment 25
1 With the brakes ENGAGED (brakes on) the air gap under the head of the manual release arm screw 25
2 With the brakes electrically RELEASED (brakes off) the air gap under the screw head increases 25
Brake Assembly Removal 26
1 Lift the machine to gain access to the underside (See Section 2-4 , “Positioning Lift For Acce 26
2 Disconnect the brake magnetic coil wiring connector and the brake limit (micro) switch wiring 26
3 Disconnect the manual brake release cable from the manual brake release arm attached to the br 26
4 Lower machine back down to ground level 26
5 Using the Ground Control Switch, raise the platform to gain access to the brake assemblies mou 26
6 Remove the four (4) hex cap screws securing the brake assembly to the end of the drive motor a 26
Brake Assembly Installation 26
1 Guide the manual release lever, brake coil and brake limit switch wiring connectors through th 26
2 If necessary, manually release the brake disk using the manual release lever to allow the brak 26
3 Secure the brake assembly to the drive motor using four (4) hex cap screws with washers Torqu 26
4 Lift the machine to gain access to the underside (See Section 2-4 , “Positioning Lift For Acce 26
5 Reconnect the brake coil and brake limit switch wiring connectors to their respective wiring h 26
6 Reconnect the manual release brake cable to the manual release lever (Y shaped lever) and adju 26
Drive Motor Removal 27
(See Figure 2-7 ) 27
The VP drive motors consist of three sections, the gear box atttached to the rear of the drive mo 27
1 Disconnect the positive battery terminal from the left side battery 27
2 Remove the rear plate weldment from the machine, (plate with the tie down lug) and set aside 27
3 Carefully raise the lift to gain access to the underside of the base frame Refer to Section 2 27
4 Remove the remaining two (2) bolts attaching the motor cover to the base frame and set it aside 27
5 Disconnect the wiring connectors to the drive motor and the brake assembly on either or both s 27
6 Disconnect the manual release brake cable from the brake assembly arm on either or both drive 27
7 Remove the one (1) bolt, nut, and two (2) washers from the front of the drive motor mounting p 27
8 While holding the drive motor in place, remove the remaining two (2) bolts with washers holdin 27
9 Slide the drive motor and torque limiting clutch assembly towards the center of the machine, s 27
10 Move drive motor assembly and torque limiting clutch to a suitable work bench for disassembly 27
11 Carefully remove the four (4) nuts and washers (outer most holes on the drive assembly weldme 28
12 Lower the drive assembly and place on a suitable work surface 28
Gear Box Disassembly/Assembly 28
(See Figure 2-8 ) 28
The drive motor gear box is mounted on the rear of each drive motor transferring power from the e 28
Gear Box Disassembly (See Figure 2-8 ) 28
1 Remove the drive motor/gear box/brake assembly from the machine using the procedure outlined p 28
2 Remove the four (4) hex cap screws securing the side cover to the gear box housing, and remove 29
3 Remove the wave washers from atop the large and small bearings and lay inside their respective 29
4 Using a suitable catch container, drain the gear oil from the gear box housing 29
5 Remove the drive shaft assembly from the housing Place the drive motor/gear box assembly on a 29
6 With the open surface of the housing properly supported, carefully press the drive shaft down 29
7 To remove the large (47mm) (cover side) bearing and (housing side) bearing from the drive shaf 29
8 To remove the small (32mm) bearing(s) from the gear (brass) and pinion assembly, use a suitabl 29
9 To remove the (brass) worm gear from the pinion assembly, use a suitable hydraulic press and p 29
10 Inspect the drive shaft seal for cuts, cracks and wear, or if showing signs of leakage Repla 29
Gear/Pinion Shaft Assembly (See Figure 2-9 ) 29
1 Locate the pinion gear/shaft, place the key for the (brass) worm gear into the slot on the gea 29
2 Press the (brass) worm gear onto the pinion shaft and align the keyway in the (brass) worm gea 29
3 Press the small (32mm) bearings onto the ends of the pinion shaft The inner race of the beari 29
Drive Shaft Assembly (See Figure 2-10 ) 29
1 Slide the (housing side), 42mm x 25mm x 12mm (thinner) bearing onto the long end of the drive 29
2 Slide the narrow spacer onto the drive gear end of the shaft and press the (cover side) 42mm x 29
Final Gear Box Assembly 30
1 If necessary, install a new drive shaft lip seal into the drive shaft hole in the gear box hou 30
2 Lube the drive shaft seal with a thin film of oil before sliding the drive shaft over the seal 30
3 Position the gear box with open cover side up, allow space under the gear box for the drive sh 30
4 Hold the gear and pinion, and drive shaft assembies together with the pinion gear and the ring 30
5 Continue to drop the gear assemblies into the gear box, align the bearings with the bearing se 30
6 With the gear box still positoned with the open cover side up, fill the gear box with six (6) 30
7 Wet with gear oil and place the large wave washer on the end of the drive shaft bearing and th 30
8 Clean the mating surfaces of the side cover and the gear box and check that the cover dow guid 30
9 On older model gear boxes apply sealant to the cover mating surface on the gear box On newer 30
10 Using the cover dow guide pins, place the cover onto the gear box housing 30
11 Secure using the four (4) hex cap screws, torque screws evenly to 90 in lbs 30
12 Install the drive motor back onto the machine 30
Drive Motor Brush Replacement 31
Each drive motor contains two (2) brushes, the brushes are located under the two (2) large round 31
Brush Cleaning and Inspection 31
Brush wear rate varies depending on the individual application’s duty cycle, and should be inspec 31
Brush Removal (See Figure 2-12 ) 31
Removal of the brushes also requires the removal of the drive motor(s) from the machine, see proc 31
1 Unscrew the large round brush caps from each side of the drive motor, use as large a screw dri 31
2 The brushes are retained by constant-force, roll-type springs To remove the springs, press in 31
3 Now pull the brush out of the brush box by it’s wire (pig-tail) 31
4 Loosen the the screw securing the pig-tail terminal end to the brush box and slide the termina 31
Brush Reassembly (See Figure 2-12 ) 32
1 Install the brush (pig-tail) terminal end under the screw on the brush box in the same manner 32
2 Slide the body of the brush into the brush box, be certain that the wire (pig-tail) is aligned 32
3 Now install the brush retaining spring bracket Grasp the tip of the spring bracket such that 32
4 Push the spring bracket slowly into it’s slot while letting it’s two attaching hooks slide on 32
5 Stop, but do not release the spring bracket when it’s hooks slip around the edge of the brush 32
6 While still grasping the spring bracket with the pliers, slowly bring the spring back out of t 32
7 Now release the spring bracket and check that it is lying flat against the brush box wall If 32
8 Also apply slight pressure by pulling up on the spring bracket to be certain it is hooked secu 32
9 Screw the brush caps back into the end shield using the largest possible screwdriver 32
10 Reinstall the drive motor(s) to the machine and reconnect the power source 32
2 6 Platform Control Box Service Procedures 33
Joystick Calibration Procedure 33
1 Turn off all power to the platform control 33
2 Move the joystick to the maximum forward position and hold it there 33
3 Turn on power to the platform control, nine (9) LED’s will flash rapidly on the platform contr 33
4 Depress the horn switch pad, the alarm will sound for about one (1) second, then release the h 33
5 Now release the joystick to the neutral position 33
6 Turn off system power 33
The joystick calibration is now complete 33
Platform Control Box Disassembly 34
The VP Series platform control box allows for replacement of five (5) components internal to the 34
Except for the touch pad switch assembly, which plugs into the circuit board, replacement of each 34
Removing Control Box From Platform 34
1 Turn off all power to the platfom control box 34
2 Unhook the wiring harness cable at the quick-disconnect coupling (Early VP models were not eq 34
3 Remove the platform control box and box mount to a suitable work surface 34
4 Remove the control box from the control box mount by removing the four (4) nuts from the studs 34
5 Unplug the wiring harness cable connector on the back of the lower housing half 34
6 Lay control box mount and wiring harness assembly aside 34
Lower Half Of Housing Removal 34
1 Position the control box upside down and remove the six (6) screws attaching the lower half of 34
2 Lay screws and lower housing aside 34
Joystick Assembly Removal 34
1 Remove the four (4) screws from the top of the bezel around the base of the joystick and slide 34
2 Unplug the touchpad switch ribbon connector from the circuit board connector socket 34
3 Remove the four (4) screws attaching the circuit board to the upper housing 35
4 Position the circuit board and unsolder the wires from the joystick assembly at the J2, J3 and 35
5 With all the joystick wiring unsoldered remove joystick assembly from the control box 35
Emergency Stop Switch Removal 35
1 Remove the switch part of the emergency stop switch by carefully prying upward at the corner o 35
2 Position the circuit board and locate the emergency stop switch wires connected at locations J 35
3 Remove the reset button part of the emergency stop switch by unscrewing the collar on the insi 36
Speed Control Switch Removal 36
1 Remove the speed control knob by pulling up on the knob until it is free of the switch shaft 36
2 Loosen and remove the retaining nut and lock washer from the switch collar and pull the switch 36
3 Position the circuit board and locate the speed control switch wires connected at location J5 36
Touch Pad Switch Removal 36
1 Unplug the touch pad ribbon cable connector from the circuit board connector socket (See Figu 36
2 Using a thin tool, start by lifting an edge of the touch pad switch and slowly peel away it fr 36
Platform Control Box Assembly 36
To assemble the components back into the control box follow the previously outlined disassembly p 36
Joystick Installation 36
1 Use the following illustrations to reattach the wires from the joystick to the circuit board 36
2 If damaged replace the gasket between upper housing surface and the joystick mounting surface 37
Emergency Stop Switch Installation 37
1 Use the following illustration to reattach the wires from the emergency stop switch to the cir 37
2 If damaged replace the gasket between the stop switch base plate and the upper housing mountin 37
Speed Control Switch Installation 37
1 Use the following illustrations to reattach the wires from the speed control switch to the cir 37
Touch Pad Switch Installation 37
1 Thoroughly clean the surface of the upper housing where the touch pad switch adheres to the up 37
2 Remove all traces of silicone sealant from around the slot where the ribbon cable connector pa 37
3 Remove the adhesive backing off the new touch pad switch, keep this surface clean and free of 37
4 Assemble the new touch pad switch to the upper housing surface by first sliding the ribbon cab 37
5 Once the touch pad is installed, on the underside of the housing apply just enough silicone se 38
6 Re-install the circuit board and plug the ribbon cable connector into the circuit board cable 38
Lower Half Housing Installation 38
1 Before installing the lower half housing apply a non- conductive grease to the square holes of 38
2 Carefully slide the lower housing onto the upper half of the platform control box assembly unt 38
3 Secure lower half housing to the upper half housing using the six (6) screws removed during di 38
2 7 Battery Charger Assembly and Disassembly 38
General Information 38
The VP Series battery charger allows for replacement of the following internal components Consul 38
Replacement and troubleshooting of these components requires removal of the battery charger from 38
Battery Charger Removal 38
1 Remove the rear cover from the machine 38
2 Unbolt and lower the MC-1 Controller Box 38
3 Remove the four (4) capscrews securing the charger to it’s mounting plate 38
4 Disconnect the DC wiring from the positive/negative battery terminals and interlock connector 38
5 Remove the charger from the machine 38
Battery Charger Part Replacement 39
Cover Removal 39
1 Remove the eight (8) screws on the sides of the charger cover and remove cover 39
Transformer Replacement 39
1 Disconnect the wiring connecting the the transformer to other components within the charger as 39
2 Remove the four nuts from the cap screws securing the transfromer brackets to the base of the 39
3 Remove transformer 39
Printed Circuit Board Replacement 39
1 Disconnect the wide wiring connector from the end of the circuit board 39
2 Remove the four (4) screw attaching the card to the front face of the charger chassis 39
3 Remove the circuit board 39
Shunt Assembly Replacement 39
1 Carefully remove the screw from each end of the shunt assembly The white insulator may need t 39
Interlock Relay Replacement 40
1 Disconnect the wiring connected to the relay 40
2 Remove the two (2) nuts securing the interlock relay to the chassis base 40
3 Remove the relay 40
SCR Rectifier Replacement (Either Side) 40
1 Remove the wiring from the SCR Rectifier 40
2 Remove the nut securing the rectifier to the insulated aluminum chassis bracket 40
3 Remove the SCR Rectifier 40
AC Circuit Breaker Replacement 40
1 Disconnect wiring connected to the breaker poles 40
2 Remove the two (2) nuts securing the AC breaker to the chassis screws 40
3 Remove the breaker from the chassis 40
DC Circuit Breaker Replacement 40
1 Remove the wiring from the DC breaker terminals 40
2 To remove the breaker from the front face of the charger, on the inside of the charger front f 40
2 8 Hydraulic Lift Cylinder – Removal, Inspection and rebuild 41
Lift Cylinder Removal 41
Removal of the hydraulic lift cylinder without removing the mast from the machine requires laying 41
1 Remove the hood from the rear of the machine 41
2 Disconnect and remove the batteries from the machine, to prevent acid leakage 41
3 Seal the vented cap on the hydraulic fluid reservoir by removing the cap, covering the hole wi 41
4 Use a forklift truck or overhead crane and carefully lay the machine on it’s back, place a sup 41
5 Manually extend the mast assembly approximately two (2) feet, to allow access to the sheave wh 41
6 Remove the set screw securing the lift cylinder rod to the sheave wheel anchor block at the to 41
7 Under the base assembly remove the four (4) bolts attaching the PHP bar actuator assembly to t 41
8 Carefully disconnect and cap the extend and return lines and fittings from the lift cylinder, 41
9 Remove the bolt securing the lift cylinder to the cylinder mount 41
10 Remove the four (4) bolts, washers and nuts attaching the cylinder mount to the base frame R 41
11 At the bottom of mast section 2, slide the lift cylinder assembly out and place on a suitable 41
Cylinder Disassembly 41
1 Before disassembling the cylinder, clean away all dirt and foreign substances from openings, p 41
2 Extend the rod until the piston bottoms out against the cylinder head 41
3 Compress the head retraining ring enough to allow the the cylinder head to be removed 41
4 Carefully slide the head/rod/piston assembly out of the cylinder tube A gentle tap on the hea 41
5 Place the head/rod/piston assembly on a surface that will not damage the chrome 41
6 Remove the piston locknut and separate the piston from the rod 41
7 Slide the head off the rod from the piston end 41
8 Remove and discard all old seals 41
Lift Cylinder Component Inspection 42
Cylinder Rod 42
There should be no scratches or pits deep enough to catch the fingernail Pits that go to the bas 42
Cylinder Head 42
Visually inspect the inside bore for scratches or polishing Deep scratches are unacceptable Pol 42
Piston 42
Visually inspect the outside surface for scratches or polishing Deep scratches are unacceptable 42
Tube Assembly 42
Visually inspect the inside bore for scratches and pits There should be no scratches or pits dee 42
Cylinder Assembly 42
(See Figure 2-17 ) 42
1 Rinse the inside of the tube with hydraulic fluid and allow to drain A high-pressure rinse fo 42
2 Lubricate the head and all seals with hydraulic fluid prior to installation Install the seal, 42
3 Lubricate the piston and all components with hydraulic fluid Install the seal and wear ring t 42
4 Place the rod on a clean table Install the static o- ring seal into the groove on the piston 42
5 Install the head followed by the piston onto the rod noting the proper orientation of each com 42
6 When the rod assembly is ready to be installed into the tube, liberally apply an anti-seize lu 42
7 Next dip the entire rod assembly into hydraulic fluid and stuff this assembly into the tube W 42
8 Install the head until the retaining ring seats in it’s groove 42
Cylinder Installation 42
To install the lift cylinder reverse the Lift Cylinder Removal instructions at the start of this 42
1 Apply Loctite #222 (purple) to the setscrew securing the lift cylinder rod to the sheave wheel 42
2 Torque the four (4) cylinder lift mounting bolts to 34 ft lb 42
2 9 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES 44
The VP Series personnel lift mast sections are contructed of extruded aluminum, protected with an 44
Each VP model mast assembly contains a different number of mast sections as shown following; 44
Table 2-2 VP Series Mast Component Features 44
10VP 44
3 44
Cable 44
15VP 44
4 44
Cable 44
20VP 44
5 44
Chain & Cable 44
Assembly procedures for all mast sections is basically the same, carefully slide the mast section 44
Mast Disassembly Procedure 44
1 After the mast assembly has been removed from the machine, lay the mast assembly down on a sui 44
2 Remove the sequencing cables and hardware from the sides of the mast assembly Also remove the 44
3 Remove cable adjust nuts from threaded ends of cable attached to the cable anchor plate on BOT 44
4 At the TOP of mast section—3/-4/-5, pull cables out and allow to hang loose 44
5 Carefully slide mast section-3/-4/-5 out BOTTOM of mast section-2/-3/-4 rails Disassemble sli 45
6 Remove cable adjust nuts from threaded ends of cables attached to the cable anchor plate on bo 45
7 At top of mast section-4, pull cables out and allow to hang loose 45
8 Slide mast section-4 out the TOP of mast section-3 far enough to allow access to the cable she 45
9 Remove countersunk-flathead screws securing cable sheave wheel assembly attach bars on both si 45
10 Carefully slide mast section-4 out BOTTOM of section-3 Remove slide pads, shims and cable an 45
11 Remove cable/chain adjust nuts from threaded ends of cable/chain attached to the cable/chain 45
12 At TOP of mast section-3, pull cables/chains out and allow to hang loose, (be certain floor s 45
13 Slide mast section-3 out TOP of mast section-2 far enough to allow access to the cable/chain 45
14 Remove countersunk-flathead screws securing cable/chain sheave wheel assembly attach bars on 45
15 While mast section-3 is still extended from section-2 remove the bolts attaching the two (2) 45
16 Carefully slide mast section-3 out BOTTOM of section-2 Remove slide pads, shims and chain an 45
17 Slide mast section-2 out TOP of mast section-1 far enough to allow access to the cable/chain 45
18 Remove countersunk-flathead screws securing cable/chain anchor block/sheave wheel assembly at 45
19 Slide the cable/chain anchor block/sheave wheel assembly and hydraulic cylinder out the TOP o 45
20 Remove the setscrew holding the hydraulic cylinder rod into the chain assembly #444 anchor bl 45
21 Remove the hydraulic cylinder through BOTTOM of mast section-2, be careful not to nick or sco 45
22 Carefully slide mast section-2 out BOTTOM of section-1 Remove slide pads and shims, if neces 45
23 Slide the TOP of remaining mast section-1 out over edge of work surface and remove the bolts 45
24 Remove slide pads and shims from mast section-1 45
Mast disassembly should now be complete 45
Mast Assembly 49
(See Figure 2-18 , 2-19 , 2-20 & 2-21 ) 49
1 Place mast section-1, rail (open) side up on a clean, flat surface (preferably a table or work 49
2 Locate the two (2) single cable/chain assemblies Lay out each cable/chain assembly with ancho 49
3 Insert the block anchor end into the top of mast section-1 and secure using two (2) 3/8″-16UNC 49
4 Locate mast section-2, carefully slide mast section-2 closed rail into section-1 open rail Sl 49
5 Insert slide pads into the slide pad channels at bottom end of mast between section-1 and -2, 49
6 Thread slide pad attaching bolts, (two (2) 1/4″- 20UNC x 3/8″ long hex head bolts, place a fla 49
7 Shim slide pads using the following steps: 49
a Use two shim pieces per slide pad, a thick one and a thin one 49
b Start with a total thickness of approximately a 025″ thick shim and a 055″ thick shim Slide 49
c All mast sections are to be shimmed to provide a measurable gap between the slide pad (beveled 49
d When mast slide pads are shimmed properly, the mast sections should be able to slide in channe 49
8 Insert slide pads into the slide pad channels (top of mast) between section-1 and -2, (one on 49
9 Thread slide pad attaching bolts, (two (2) 1/4″- 20UNC x 3/8″ long hex head bolts, place a fla 49
10 Shim per instructions in step 7 49
11 Locate the hydraulic lift cylinder, slide the lift cylinder into the closed rail side of mast 49
12 Locate chain assembly #444 (single anchor block with two narrow chains) Lay out chain assemb 49
13 Insert hydraulic cylinder rod end into chain assembly #444, anchor block Secure cylinder rod 49
a Locate mast section-3, carefully slide section-3 closed rail into section-2 open rail Slide s 49
14 Slide mast section-3, approximately two feet out of the top of mast section-2 50
15 Insert threaded ends of cable/chain-assembly #466 (attached to top of mast section-1), throug 50
16 Slide mast section-2 out of mast section-1 approximately one foot 50
10VP Top of Cylinder Assembly 50
19 Assemble cable sheave wheels to cylinder rod end and attach to mast section-2 using following 50
a Attach cable mounting tube to top of hydraulic cylinder using one (1) 1/4″-28NF x 5/8″ capscrew 50
b Insert sheave pin through cylinder cable mounting tube on cylinder rod end 50
c Place a spacer tube on each side of mounting tube 50
d Next slide sheave wheels on onto sheave pin against spacer, on each side of mounting tube 50
e On outside of each sheave wheel, place another spacer tube 50
f On outside of spacer tubes place a sheave pin attach bar, (rectangular plate with threaded hol 50
g Slide the assembly with sheave pin, wheels and pin attach bars into top of mast section-2 50
h Attach to top of mast section-2 using two (2) 3/ 8″-16UNC x 1/2″ long socket head-countersunk- 50
15VP Top of Cylinder Assembly 50
19 Assemble cable sheave wheels to cylinder rod end and attach to mast section-2 using following 50
a Attach cable mounting tube to top of hydraulic cylinder using one (1) 1/4″-28NF x 5/8″ capscrew 50
b Insert sheave pin through cylinder cable mounting tube on cylinder rod end 50
c Place a spacer tube on each side of mounting tube 50
d Next slide sheave wheels on onto sheave pin against spacer, on each side of mounting tube 50
e On outside of each sheave wheel, place another spacer tube 50
f On outside of spacer tubes place a sheave pin attach bar, (rectangular plate with threaded hol 50
g Before sliding this assembly into the top of mast section two, locate two (2) mast extension c 50
h Slide the assembly with sheave pin, wheels and pin attach bars into top of mast section-2 50
i Attach to top of mast section-2 using two (2) 3/ 8″-16UNC x 1/2″ long socket head-countersunk- 50
20VP Top of Cylinder Assembly 50
19 Assemble chain sheaves on chain assembly #444 anchor block (attached to cylinder rod end) and 50
a Insert sheave pin through anchor block on cylinder rod end 50
b Place sheave wheels (for wide chain) on sheave pin, one each side of anchor block 50
c On outside of each sheave wheel, place a sheave pin attach bar, (rectangular plate with thread 50
d Slide the whole anchor block assembly with sheave pin, wheels and pin attach bars into top of 50
e Attach to top of mast section-2 using two (2) 3/ 8″-16UNC x 1/2″ long socket head-countersunk- 50
20 Slide mast section-2 back into section-1 until end are even 50
21 Locate two mast extension cable assemblies Attach the eyelet anchor end of each cable to the 50
22 Carefully slide mast section-3 into section-2 until ends are even Check to make sure chain a 50
23 Insert slide pads into the top end mast rails between section-2 and -3, (one on each side of 51
24 Thread slide pad attaching bolts, (two (2) 1/4″- 20UNC x 3/8″ long hex head bolts, place a fl 51
25 Shim per instructions in step 7 51
26 Insert slide pads into the bottom end mast rails between section-2 and -3, (one on each side 51
27 Thread slide pad attaching bolts, (two (2) 1/4″- 20UNC x 3/8″ long hex head bolts, place a fl 51
28 Shim per instructions in step 7 51
29 Locate mast section-4, carefully slide section-4 closed rail into section-3 open rail Slide 51
30 Locate one (1) of the chain/cable anchor plates (one with two threaded holes vertically align 51
31 Slide mast section-4 out the top of mast section-3 so the chain/cable anchor plate on bottom 51
32 Insert threaded ends of cable/chain assembly (attached to anchor block on top mast section-2) 51
33 Slide mast section-4 back into mast section-3 except for about a foot or more Allow enough s 51
34 Extend mast section-3 out far enough from section-2 mast to gain access to top of section-3 51
35 Assemble cable/chain sheaves to top of mast section-3 as follows; 51
a Locate the two cable/chain sheave wheels and slide onto sheave pin 51
b Slide two (2) short spacer tubes onto sheave pin, one each end of sheave pin to outside of she 51
c Place two (2) sheave pin attach bars, one each end of sheave pin to outside of space tubes 51
d Holding complete sheave wheel assembly, slide assembly into top of mast section-3 and align th 51
e Attach to top of mast section-3 using two (2) 3/ 8″-16UNC x 1/2″ long socket head-countersunk- 51
36 Slide mast section-3 back into section-2 until ends are even (Mast section-2 may need to be 51
37 While mast section-4 is still extended from section-3; locate two cable assemblies Attach th 51
38 While mast section-4 is still extended from section-3, assemble cable sheaves to top of mast 51
a Locate the wide tube spacer and slide onto sheave pin 51
b Slide two (2) cable sheave wheels onto sheave pin, one each end of sheave pin to outside of tu 51
c Place two (2) large flat washers, one each end of sheave pin to outside of cable sheave wheels 51
d Place two (2) sheave pin attach bars, one each end of sheave pin to outside of large flatwashers 51
e Holding complete cable sheave wheel assembly, slide assembly into top of mast section-4 and al 52
f Attach to top of mast section-4 using two (2) 3/ 8″-16UNC x 1/2″ long socket head-countersunk- 52
39 Carefully slide mast section-4 back into section-3 until ends are even Check to make sure ca 52
40 Insert slide pads into the top end mast rails between section-3 and -4, (one on each side of 52
41 Thread slide pad attaching bolts, (two (2) 1/4″- 20UNC x 3/8″ long hex head bolts, place a fl 52
42 Shim per instructions in step 7 52
43 Insert slide pads into the bottom end mast rails between section-3 and -4, (one on each side 52
44 Thread slide pad attaching bolts, (two (2) 1/4″- 20UNC x 3/8″ long hex head bolts, place a fl 52
45 Shim per instructions in step 7 52
46 Locate the remaining mast section-4/-5 (platform mounting- mast section) Lay mast section on 52
47 Attach the remaining chain/cable anchor plate (one with threaded holes vertically aligned in 52
48 Complete the following steps to determine shim stock thickness required for section-4/-5; 52
a Use two shim pieces per slide pad, a thick one and a thin one 52
b Start with a total thickness of approximately 035″ and 075″ thick shim stock 52
c Attach shim stock and slide pads to both sides of mast section-4/-5 using five (5) 1/4″-20UNC 52
d Carefully thread the slide pad mounting bolts with flatwashers through slide pads and shim sto 52
e Begin sliding top of mast section-4/-5 with closed rail down engaging the slide pads into slid 52
f Check mast section for side play If play exists use thicker shims dividing thickness equally 52
g When mast slide pads are shimmed properly, there should be no side to side movement of slide p 53
49 Slide mast section-4/-5 to top of section-3/-4 53
50 Insert threaded ends of cable assembly (attached to top of mast section—2/3) through the chai 53
51 Slide mast section-4/-5 back into mast section-3/-4 until bottom ends of masts are even Chec 53
52 At bottom of mast assembly, thread all chain/ cable adjusting nuts on threaded ends until the 53
Mast assembly should now be complete 53
2 10 Mast To Base Frame Installation 53
1 Using an overhead crane or suitable lifting device capable of supporting the weight of the bas 53
2 Using a sling and suitable lifting equipment (i e overhead crane) lift the mast assembly (bal 53
3 Extend hydraulic cylinder out from bottom of mast assembly approximately one (1) foot (Caps o 53
4 Carefully position the mast into base frame assembly, (base frame and mast assembly must be he 53
5 Slide port end of hydraulic cylinder through hole in base frame cylinder mounting channel (Re 53
6 Align threaded hole in side of hydraulic cylinder head with hole in tab on bottom side of cyli 53
7 Carefully push mast assembly and base assembly together until the four (4) holes on bottom rea 53
8 Attach mast to base using four (4) 3/8″-16UNC x 1″ long hex head bolts, locknuts and flatwashe 53
9 Locate the two (2) mast support braces, attach to sides of base frame using a 3/8″-16UNC x 1” 53
10 Before setting machine upright on base, install a short 90 elbow fitting, flow control valve 53
11 Carefully set machine in an upright position on its base frame wheels 54
12 Locate the mast support bracket Attach mast support bracket to mounting holes halfway up bac 54
13 Using a 4 ft level, ensure the mast is set to vertical (plumb) on the base frame 54
14 When mast is vertical (plumb), attach support braces, (bolted to base), to the mast support b 54
15 After securing mast to base frame, using 4 ft level again check that mast is vertical (plumb 54
16 Continue installing remaining components to mast assembly, (i e hydraulic pump/motor/reservo 54
2 11 MAST CHAINS/CABLES AND SEQUENCING CABLES ADJUSTMENT 54
Mast Chain/Cable Adjustment 54
The intention of this procedure is to assure equal load distribution between the individual chain 54
Adjust using the following procedure; 54
1 With mast retracted, step into the platform and bounce your weight up and down a few times to 54
2 Then with no load in the platform check the side profile of the top of the mast for the amount 54
3 Adjust one mast section at a time starting from the back (section-3, section-4, etc ) of the m 54
4 Elevate the platform until the chain/cable anchor adjust nuts are accessible at the front and 54
5 Start with the mast section which needs adjustment and loosen the bottom (jam) nut on each cha 54
6 Tighten (to raise mast section), or loosen (to lower mast section) the adjusting nut against t 54
7 Retract the mast all the way and check if the top of the mast sections appear as shown in Figu 54
8 Repeat steps (1) through (7) for remaining mast sections ENSURE THAT ALL CHAIN/CABLE PAIRS HA 54
9 Once mast section adjustment is completed, apply loctite #242 to the threads under the (jam) n 55
Sequencing Cable Adjustment 55
1 Retract mast completely, and check each sequencing cable on outside of masts for excessive sla 55
2 Tighten nylock-nut just enough to remove excessive slack from sequencing cable The springs sh 55
3 Run mast through several cycles to verify cable/ chain adjustments and ensure no interference 55
2 12 Sequence Cable replacement kit 56
A sequence cable replacement kit is available from the JLG Parts Department to service broken or 56
Remove Old Cable 56
1 Remove the locking nut from the threaded end of the cable at the top of the mast and then remo 56
2 Slide the threaded top end out of the upper anchor bracket, then at the bottom end pull the ca 56
Replacement Cable Installation 56
1 Be certain the mast is completely retacted and at the bottom of travel Check the mast “Side P 56
2 To determine where the clamp will be installed at the bottom of the replacement cable, tempora 56
3 At the bottom of the mast, thread the loose end of the replacement cable through the proper sh 56
4 Grasp the cable and pull on the cable until the spring at the top of the cable is slightly com 56
Clamp Installation (Drum/Socket Type) 56
1 Using the recommended vise jaws, clamp the wire rope into a vise with the bottom edge of the b 56
2 Twist the sleeve from the clamp kit onto the rope until it is flat against the vise jaws at th 56
3 Use a suitable tool and cut the cable as shown in the illustration following For 1/8 in cabl 57
4 Unlay the cable strands by gently forcing a screwdriver between the outer strands to unlay the 57
5 Install the plug supplied with the kit by placing the plug in the center of the strands starti 57
6 Reclamp the assembly in the vise on the flats of the sleeve Using the plug driver, a metal tu 57
7 Coat the threads of the socket and sleeve with lubricant and install the socket by twisting it 57
8 Inspect for proper assembly prior to loading the cable Strands visible through the inspection 57
9 Install cable on machine and adjust per instructions shown previously in Section 2 11, MAST CH 57
2 13 Preventive Maintenance and Inspection Schedule 58
(See Table 2-2 ) 58
The preventive maintenance and inspection checks are listed and defined in the following table (S 58
The checks and services listed in this schedule are not intended to replace any local or regional 58
JLG Industries requires that a complete annual inspection be performed in accordance with the “An 58
Table 2-3 Preventive Maintenance & Inspection Schedule 59
* Inspection and Maintenance Code 10 to be performed every two years ** Maintenance Code 10 to b 59
Inspection and Maintenance Codes: 59
1 Check for proper and secure installation 59
2 Check for visible damage and legibility 59
3 Check for proper fluid level 59
4 Check for any structural damage; cracked or broken welds; bent/warped surfaces; broken cable s 59
5 Check for leakage 59
6 Check for presence of excessive dirt or foreign material 59
7 Check for proper operation and freedom of movement 59
8 Check for excessive wear or damage 59
9 Check for proper tightness and adjustment 59
10 Drain, clean and refill 59
11 Check for proper operation while pump/motor is running 59
12 Check for proper lubrication 59
13 Check for evidence of scratches, nicks or rust and for straightness of rod 59
14 Check for condition of element; replace as necessary 59
Section 3 troubleshooting 61
3 1 General 61
This section contains troubleshooting information to be used for locating and correcting most ope 61
3 2 Troubleshooting Information 61
Troubleshooting procedures applicable to the VP machine are listed and defined starting with Sect 61
Each malfunction within an individual group or system is followed by a listing of probable causes 61
It should be noted that there is no substitute for a thorough knowledge of the equipment and rela 61
It should be recognized that the majority of the problems arising in the machine will be centered 61
The first rule for troubleshooting any circuit that is hydraulically operated and electrically co 61
3 3 Hydraulic Circuit Checks 61
(See Figure 3-6 ) 61
The first reference for improper function of a hydraulic system, where the cause is not immediate 61
3 4 ELECTRICAL CIRCUIT CHECKS 61
General 61
The drive system on the VP series machine requires a microprocessor controlled electrical circuit 61
To help diagnose any problems with the components associated with the microprocessor, the MC-1 is 61
LED Indicator Strip 62
When the machine is powered up, all function inputs should be open If any function is active on 62
This strip has ten (10) green LEDs and is located on the platform controller box between the func 62
Fault Code Reference Tables 62
Their are two types of fault codes which can occur to indicate a problem with the machine, these 62
The fault codes can occur either at machine power up or during operation of the machine 62
WARNING Codes 62
(See Table 3-1 ) 62
The WARNING will be indicated for 4 seconds and will be repeated every minute if the problem is n 62
ERROR Codes 62
(See Table 3-2 ) 62
An ERROR is indicated by an audible beep and continuously fast flashing LED bar The number of fa 62
Table 3-1 MC-1 WARNING CODES (Indicated by 3 beeps, then slow flashing LED’s) 63
Table 3-2 MC-1 ERROR CODES (Indicated by rapid LED flashing and periodic beep) 64
Figure 3-2 Overview of Standard Electrical System (Sheet 2 of 2) 67
Figure 3-3 VP Electrical Diagram (VP Series – Standard) 69
Figure 3-4 Overview of VP UL-EE Approved Optional Electrical System (Sheet 2 of 2) 71
Figure 3-5 VP Electrical Diagram (with UL-EE Approved Option) 73
3 5 TROUBLESHOOTING SECTION – TABLE OF CONTENTS 75
OHM RATINGS FOR VARIOUS COMPONENTS PAGE 75
Ohm Ratings for Various Components 3-16 75
MAIN POWER CIRCUIT TROUBLESHOOTING 75
Unit Will Not Power Up From Ground Control 3-17 75
No Power At Platform Control 3-18 75
DRIVE TRAIN TROUBLESHOOTING 75
Won’t Drive (Platform Lowered Or Elevated) 3-20 75
Won’t Drive (Platform Elevated Only) 3-22 75
Won’t Climb Grade 3-24 75
Drives In Opposite Direction 3-25 75
Will Only Drive A Short Distance 3-26 75
Won’t Drive Straight 3-28 75
Noise From Drive Assembly 3-29 75
MAST TROUBLESHOOTING 75
Platform Will Not Lift Up Using Platform Control 3-30 75
Platform Will Not Lower Using Platform Control 3-33 75
Platform Will Not Lift Up From Ground Control Toggle Switch 3-34 75
Platform Will Not Lower From Ground Control Toggle Switch 3-35 75
Platform Will Not Lower Manually 3-36 75
Platform Lift Up And Down Jerky 3-37 75
Mast Noisy When Lifting And Lowering 3-38 75
Platform (Mast) Won’t Stay Elevated 3-39 75
Platform (Mast) Descends Too Slowly 3-40 75
HYDRAULIC LEAK TROUBLESHOOTING 75
Miscellaneous Hydraulic Leak Troubleshooting 3-41 75
BASE FRAME COMPONENTS TROUBLESHOOTING 75
Caster Wheels Not Operating Freely 3-42 75
Pot Hole Protection (PHP) Bars Will Not Set 3-42 75
3 6 ohm ratings for various components 76
The following table contains ohm ratings for various VP Series machine components 76
Table 3-3 Ohm Ratings for Various Components 76
3 7 MAIN POWER CIRCUIT TROUBLESHOOTING 77
Unit Will Not Power Up From Ground Control 77
Overview Of Procedure 77
The following procedure tests the circuits from the Battery (+) terminal through the Ground Contr 77
Check For These Obvious Conditions First: 77
• Battery voltage 24 volts (Fully charge batteries) 77
• Battery connections clean and tight 77
• Key switch positioned to Ground (GRND) control 77
• Emergency stop switch pulled out (Reset Position) 77
Table 3-4 Unit will not Power Up From Ground Control 77
No Power At Platform Control 78
Overview Of Procedure 78
The following procedure checks voltage and ground starting from the power source (batteries) thro 78
Check For These Obvious Conditions First: 78
• Battery voltage 24 volts (Fully charge batteries) 78
• Keyswitch is turned to PLAT (Platform) 78
• Both Emergency Stop Switches Reset (Ground/Platform) (Out) 78
• Connection of X102 Cable from MC-1 box to Platform Control, secure on both ends 78
3 8 DRIVE TRAIN TROUBLESHOOTING 80
Won’t Drive (Platform Lowered Or Elevated) 80
IF MACHINE WON’T DRIVE ONLY WHEN PLATFORM IS ELEVATED, SEE SECTION 4 4 80
Overview Of Procedure 80
The following procedures check the components and circuits that feed data to the MC-1 Controller 80
Check For These Obvious Conditions First: 80
• Joystick Powered On 80
• Unit will Lift & Lower Platform 80
• Machine is not Tilted – (3 LEDs flashing at joystick control) 80
• PHP Device is not Obstructed – (4 LEDs flashing at joystick control) 80
• Brakes are not Released – (2 LEDs flashing at joystick control) 80
• Charger is not Plugged In – (8 LEDs flashing at joystick control) 80
Table 3-6 Won’t Drive (Platform Lowered or Elevated) 80
Won’t Drive (Platform Elevated Only) 82
Overview Of Procedure 82
The following procedures check the components and circuits that feed data to the MC-1 Controller 82
Check For These Obvious Conditions First: 82
• Joystick Powered On 82
• Unit will Lift & Lower Platform 82
• Machine is not Tilted – (3 LEDs flashing at joystick control) 82
• PHP Device is not Obstructed – (4 LEDs flashing at joystick control) 82
• Brakes are not Released – (2 LEDs flashing at joystick control) 82
• Charger is not Plugged In – (8 LEDs flashing at joystick control) 82
Table 3-11 Won’t Drive with Platform Elevated 82
Won’t Climb Grade 84
Overview Of Procedure 84
The following procedure checks the drive motor and attached components for component failure, mis 84
Check For These Obvious Conditions First: 84
• Batteries are Fully Charged (24 Volts) 84
• Speed Control is Set to Maximum 84
• Is Grade within the Maximum Allowable Specification of 15% Grade (8 5 degrees) 84
• Does the Travel Surface allow for Proper Drive Wheel Traction 84
• Is Platform Load within the Maximum Rated Capacity 84
Table 3-14 Won’t Climb Grade 84
Drives In Opposite Direction 85
Overview Of Procedure 85
The following procedure checks that both the drive motor power wire connections correctly install 85
Check For These Obvious Conditions First: 85
• If the Left Drive Motor (X103) connector is switched with the Right Drive Motor (X104) connecto 85
• Check Joystick Calibration (See Procedure in Service Manual, Section-2) 85
Table 3-15 Drives In Opposite Direction 85
* Note: If the Orange, 55-3 or 55-6 wires to the right drive motor in the X104 connector or the O 85
** Note: If platform controller is not under warranty, the internal components of the platform co 85
Will Only Drive A Short Distance 86
Overview Of Procedure 86
The following procedure will eliminate any problems found in the power circuit to the MC-1 contro 86
Check For These Obvious Conditions First: 86
• Is Battery Voltage 24 Volts? (Fully Charge Batteries) 86
Table 3-16 Only Drives A Short Distance 86
Won’t Drive Straight 88
Overview Of Procedure 88
The following procedure examines the drive motor assembly weldments attaching the drive motors to 88
Check For These Obvious Conditions First: 88
• Battery voltage 24 volts (Fully charge batteries) 88
• Nothing is lodged between one of the wheels and the base frame 88
• A caster wheel on the front of the machine is seized up, creating resistance 88
• Joystick properly calibrated per procedure in Section-2 of Service Manual 88
Table 3-18 Won’t Drive Straight 88
Noise From Drive Assembly 89
Overview Of Procedure 89
The following procedure examines the drive motor assembly weldments attaching the drive motors to 89
Check For These Obvious Conditions First: 89
• Battery voltage 24 volts (Fully charge batteries) 89
• Nothing is lodged between one of the wheels and the base frame 89
• A caster wheel on the front of the machine is seized up, creating resistance 89
Table 3-19 Noise from Drive Assembly 89
3 9 MAST TROUBLESHOOTING 90
Platform Will Not Lift Up Using Platform Control 90
Overview Of Procedure 90
This procedure examines the complete pump motor, ground control and pump valves electrical circuits 90
Check For These Obvious Conditions First: 90
• Battery voltage 24 volts (Fully charge batteries) 90
• Platform loaded within maximum allowable capacity 90
• Hydraulic oil is within it’s specified operating temperature range 90
Table 3-20 Platform Will Not Lift Up Using Platform Control 90
Table 3-22 Pump Valves Circuit 92
Platform Will Not Lower Using Platform Control 93
Overview Of Procedure 93
This procedure tests for ground coming out of the MC-1 box to the dump valve circuit and through 93
Check For These Obvious Conditions First: 93
• Battery voltage 24 volts (Fully charge batteries) 93
• Hydraulic oil is within it’s specified operating temperature range 93
Table 3-23 Platform Will Not Lower Using Platform Control 93
Platform Will Not Lift Up From Ground Control Toggle Switch 94
Overview Of Procedure 94
The following procedure examines the complete ground control circuit from the battery all the way 94
Check For These Obvious Conditions First: 94
• Battery voltage 24 volts (Fully charge batteries) 94
• Battery connections clean and tight 94
• Key switch positioned to Ground (GRND) control 94
• Emergency stop switch pulled out (Reset Position) 94
• Ground control power supply and wiring, OK (Table 3-4) 94
• Manual descent valve closed 94
• 5 amp fuses on power and pump circuits, OK 94
• Hydraulic oil level, OK 94
• Weight in platform does not exceed machine maximum capacity 94
Table 3-24 Unit Will Not Lift Up From Ground Control Toggle Switch 94
Platform Will Not Lower From Ground Control Toggle Switch 95
Overview Of Procedure 95
The following procedure examines the complete ground control circuit from the battery all the way 95
Check For These Obvious Conditions First: 95
• Battery voltage 24 volts (Fully charge batteries) 95
• Battery connections clean and tight 95
• Key switch positioned to Ground (GRND) control 95
• Emergency stop switch set to the Reset position) 95
• Ground control power supply and wiring, OK (Table 3-4) 95
• 5 amp fuses on power and pump circuits, OK 95
• Hydraulic oil level, OK 95
Table 3-25 Unit Will Not Lower From Ground Control Toggle Switch 95
Platform Will Not Lower Manually 96
Overview Of Procedure 96
The following procedure suggests components on the machine which might attribute to problems with 96
Table 3-26 Platform Will Not Lower Manually 96
Platform Lift Up And Down Jerky 97
Overview Of Procedure 97
The following procedure suggests areas on the machine which might attribute to erratic movement o 97
Check For These Obvious Conditions First: 97
• If mast is not running smooth or has tight and rough spots, refer to the Mast Section Rebuild 97
• Hydraulic oil level in reservoir tank at full level 97
• Hydraulic oil no milky (presence of water), or not foamy (full of air) 97
Table 3-27 Platform Lift Up and Down Jerky 97
Mast Noisy When Lifting And Lowering 98
Overview Of Procedure 98
This procedure examines components of the mast itself and as well as it’s lifting components for 98
Table 3-28 Mast Noisy when Lifting and Lowering 98
Platform (Mast) Won’t Stay Elevated 99
Overview Of Procedure 99
The following procedure requests that the lift down, dump, and pump internal valves be checked to 99
Check For These Obvious Conditions First: 99
• Manual descent valve is closed tight 99
Platform (Mast) Descends Too Slowly 100
Overview Of Procedure 100
The following procedure examines the mast some hydraulic components for obstructions and defects 100
Table 3-30 Platform (Mast) Descends Too Slowly 100
3 10 HYDRAULIC LEAK TROUBLESHOOTING 101
Miscellaneous Hydraulic Leak Troubleshooting 101
Overview Of Procedure 101
This series of steps gives remedies for various areas of the machine where leaks could occur 101
Note: Do not overtighten the nut on the solenoid in steps 4, 5, and 6 101
3 11 BASE FRAME COMPONENTS TROUBLESHOOTING 102
Caster Wheels Not Operating Freely 102
Check For These Obvious Conditions First: 102
• Is machine operating on a smooth, level surface? 102
Table 3-32 Caster Wheels Not Operating Freely 102
Pot Hole Protection (PHP) Bars Will Not Set 102
Check For These Obvious Conditions First: 102
• Obstruction under pot hole bar on either side of machine 102
• Obstruction around the actuator assembly at the base of the mast 102
Table 3-33 Pot Hole Protection (PHP) Bars Will Not Set 102
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
S.M