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SERVICE & MAINTENANCE

1. SECTION 2 SERVICE PROCEDURES Printed Circuit Board Replacement 1 Disconnect the wide wiring connector from the end of the circuit board Remove the four 4 screw attaching the card to the front face of the charger chassis Remove the circuit board Shunt Assembly Replacement T JLG Lift Carefully remove the screw from each end of the shunt assembly The white insulator may need to be restrained to keep it from turning while removing the shunt assembly fasteners Also make note of the position of each washer nut and wire connector when removing for later assembly 2 21 SECTION 2 SERVICE PROCEDURES Interlock Relay Replacement AC Circuit Breaker Replacement 1 Disconnect the wiring connected to the relay 1 Disconnect wiring connected to the breaker poles 2 Remove the two 2 nuts securing the interlock relay 2 Remove the two 2 nuts securing the AC breaker to to the chassis base the chassis screws 3 Remove the relay 3 Remove the breaker from the chassis 5222 D r r 7 d SCR Recitifier Replacement Either Side A 1 Remove the wiring from the SCR Rectifier 2 Remove the nut securing the rectifier to the insulated DC Circuit Breaker Replacement aluminum chassis bracket 1
2. 69911 9988 109 OOCCVIL SLLE 0 94 FCCC 9 8165 CELO 00L9 e Z L 669 057 005 V8CV 086 9 9716 6 55 0361 0896 1898 9 8088 87969 8907 6 99 c 8896 01959 ELEC lt 706 8011 8166 ELLEES LOVE S Cl z L GVLE 6996 98GC LECCE 8902 COLL 086 9 1062 1 6 9 L 198 86c veoc 6126 09 7 919 89 95015 bbs 6 66 79657 LC 0161 9 7998 691 89 L 6191 ELOY 7 1281 8 886 999 v9vi 2961 10676 vSCL 1801 G68 COLL OSL 8 2 cl g L L L89L 8681 9651 COEL 987 COLLE 896 9801 28161 0886 7 7100 620 COOL 9951 0804 4 166 898 612 576 CVLOL 07897 Cl 887 LEG CCO 09 c 916 981 99 898 60911 COEG 8 198 8809 586 YZZ 819 G68 0c GOL 929 GLY 269 16971 OCOC v 77 267 06602 968 869 9 01881 8G 94 6 CVS 61691 LEQ OGL 049 SVL 29 86 107 96 01 vVLv6 0 0S06 1 9 LIC G6F 09191 049 907 08 GLG 99 286 GCL Llc 996 7378 0 OL 864 CLOLL 696 gev0l 206 911 LEC V6EL 0990 SL 901 LEC 86c LECO YCC Esl 671 Voc 99 07 40 LL 8026 89 60c 911 8 28 Esl col 9 7 89 991890
3. Inspection and Maintenance Code 10 to performed every two years Maintenance Code 10 to be performed only when serviced requires 171 cc s to fill Inspection and Maintenance Codes E Gee tae 3120849 Check for proper and secure installation Check for visible damage and legibility Check for proper fluid level Check for any structural damage cracked or broken welds bent warped surfaces broken cable strands Check for leakage Check for presence of excessive dirt or foreign material Check for proper operation and freedom of move ment 10 11 12 13 14 JLG Lift Check for excessive wear or damage Check for proper tightness and adjustment Drain clean and refill Check for proper operation while pump motor is running Check for proper lubrication Check for evidence of scratches nicks or rust and for straightness of rod Check for condition of element replace as neces sary 2 37 SECTION 2 SERVICE PROCEDURES This page intentionally left blank 2 38 JLG Lift 3120849 SECTION 3 TROUBLESHOOTING SECTION 3 TROUBLESHOOTING 3 1 GENERAL This section contains troubleshooting information to be used for locating and correcting most operating problems on a VP Series Personnel Lift If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions technically qualified guidance sho
4. 3 34 3 25 Unit Will Not Lower From Ground Control Toggle 3 35 3 26 Platform Will Not Lower Manually 3 36 3 27 Platform Lift Up and Down 3 37 3 28 Mast Noisy when Lifting and Lowering 3 38 3 29 Platform Mast Won t Stay 3 39 3 30 Platform Mast Descends 5 3 40 3 31 Hydraulic Leak 3 41 3 32 Caster Wheels Not Operating 3 42 3 33 Pot Hole Protection PHP Bars Will Not 3 42 3120849 JLG Lift lii TABLE OF CONTENTS Continued This page intentionally left blank iv JLG Lift 3120849 SECTION 1 SPECIFICATIONS SECTION 1 SPECIFICATIONS 1 1 CAPACITIES System Voltage All VP Models 24 Volt DC 2 12 volt DC batteries Hydraulic Oil Reservoir All VP Models 4 7 Itr 5 qts U S 1 2 COMPONENT DATA Hydraulic Pump Pump Motor Assembly Pump Motor 24 Volt DC motor Pump Displacement 10 amp 15VP 098 cu in rev 1 6cc rev 20VP 049 cu in rev 0 8cc rev Pump Output Max
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6. N B M PIN 1 ON PLASTIC BOX RX 00 RECEIVE DATA 1 B CONTROL 3 COMMUNICATION j TRANSMITDATA 8 MAIN POWER DISCONNECT 5 wea ane ck ON LAPTOP GROUND 13 ELEVATION SWITCH 1 LIFT UP 4 TILT CUTOUT LIFT DOWN CHARGER INTERLOCK 4 I PUMP CONTACTOR 5 B 17 eem DRIVE CUTOUT 12 BOX BRAKE STATUS 11 Ti n n T HORN li HAH ALARMS 14 EMERGENCY STOP 14 JHH HOURMETER 3 CAN LO 13 CAN HI 5 CENTER DETECT xz B 1 E EMERGENCY STOP _ X103 LEFT MOTOR PIN 104 RIGNTMOTOR PIN SEL MOTOR 1 M MOTOR 1 M MOTOR 2 MOTOR eg BRAKE 1 5 BRAKE 1 5 BRAKE 3 BRAKE 2 87135 6141 X102 ORN RED 49 1 BLU ORN 52 1 ORN RED 49 3 TAN 4 1 MOTOR TAN 3 1 RIGHT BLU ORN 52 2 BLU ORN 52 3 YEL RED 2 5 10 YEL RED 2 2 YEL RED 2 3 ORN RED 49 5 gt ORN RED 49 6 ORN RED 49 7 BLACK 10 END VIEW OF MC 1 BOX 4932960 A SHOWING X CONNECTOR LOCATION Figure 3 3 VP Electrical Diagram VP Series Standard 3 8 JLG Lift 3120849 SECTION 3 TROUBLESHOOTING ORN RED 49 1 ORN RED 49 1 BLU ORN 52 1 BLU ORN 52 1 LEFT PHP LIMIT SWITCH BLACK ORN RED 49 3 TAN 4 1 TAN 3 1 TAN 55 1 HOURMETER 2 0 BLU ORN 52 2 010700 BLACK EXTERNAL HORN BLU ORN 52 3 D BLACK A _ BLU ORN 880 87 52 4 OPTION YEL RED 2 5 YEL RED 2 5 10 YEL RED 2 2 YEL RED 2 3 ORN RED 49 5 ORN RED 49 6 OR
7. 2 Carefully raise the lift to gain access to the under side of the base frame Refer to Section 2 4 Posi tioning Lift For Access to Components Located Under the Base Frame 3 Locate the clutch assembly on each rear drive axle and check for the following a Check the coupling chains for any loose or miss ing parts i e pins links etc replace if neces sary b Check that the allen head set screws on the large clutch adjusting nut are in place and secure Tighten or replace if necessary c Check for any debris wedged in or wrapped around the clutch coupling chains and axle shafts Remove debris and clean area if neces sary 3120849 SECTION 2 SERVICE PROCEDURES Checking Clutch Torque Setting ft Ib NOTE Check that the machines brakes are engaged before applying torque to the rear drive wheels 1 Remove the drive wheels from the drive axles 2 Select a torque wrench capable of setting a torque of at least 185 ft lb Insert special tool P N 0080229 into a 3 4 socket on the torque wrench 3 Slide the tool onto the end of the drive axle aligning the key on the axle shaft install key on axle if nec essary with key slot in the tool See Figure 2 2 4 Turn the torque wrench and note the torque setting when the torque limiting clutch releases The torque slip setting should be set at 185 ft Ib Check both rear drive axles NOTE The allowable breaking torque for the torque limiti
8. Key switch positioned to Ground GRND control Emergency stop switch pulled out Reset Position Table 3 4 Unit will not Power Up From Ground Control w Checkthe 5 amp inline fuse on the Red 1 1 wire from the battery terminal to the ground control box key switch Under pump motor cover Ground Control Box Assembly Disassembled Is there 24 volts or more reading atthe key switch terminal B Check for 24 volts or more on the Yel Red 2 7 wire from the key switch to the E stop switch Check for 24 volts or more on the Yel Red 2 8 wire from the E stop to the Ground Control Relay terminal 86 Checkfor 24 volts or more on the Yel Red 2 4 wire from the E stop to the Main Contactor Relay terminal 87 Main Contactor Circuit Check for 24 volts or more on the Yel Red 2 4 wire from the Main Contactor Relay terminal 87 to the Main Contactor Did Main Contactor close Is the Black ground wire connection from the Main Contactor to ground OK Atthis point 24 volts should be present atthe following terminal points Terminal 86 on the Ground Control Relay Main Contactor Yel Red 2 4 wire With Main Contactor engaged 24 volts or more should be present at the following terminal points Pump Motor 21 cable 1 Yel Red 2 6 wire on the Pump Contactor Yel Red 2 6 wires on the Lift Up Down Relay 3120849 JLG Lift 24 volts go to Step2 Repla
9. 2 If damaged replace the gasket between the stop switch base plate and the upper housing mounting surface 3120849 SECTION 2 SERVICE PROCEDURES Speed Control Switch Installation 1 Use the following illustrations to reattach the wires from the speed control switch to the circuit board J8 E EH 7 Jio E H CIRCUIT BOARD COMPONENT SIDE a a ORANGE WHITE W ORG 5 GREEN O WIRES FROM SPEED CONTROL SWITCH Touch Pad Switch Installation 1 Thoroughly clean the surface of the upper housing where the touch pad switch adheres to the upper housing 2 Remove all traces of silicone sealant from around the slot where the ribbon cable connector passes through the housing 53 APPLY SILICONE SEALANT HERE IN THIS SLOT 3 Remove the adhesive backing off the new touch pad switch keep this surface clean and free of debris during assembly 4 Assemble the new touch pad switch to the upper housing surface by first sliding the ribbon cable con JLG Lift 2 19 SECTION 2 SERVICE PROCEDURES nector from the touch pad switch through the slot at the top of the housing Before pressing the touch pad adhesive side to the upper housing mounting surface visually align the touch pad edges with the edges of the recess in the housing mounting sur face Once the touch pad is installed on the underside of the housing apply just enough silicone sealant to
10. SERVICE amp MAINTENANCE Model 10VP 15VP 20VP 3120849 November 15 2000 dL AUSTRALIAN OFFICE EUROPEAN OFFICE WORLD HEADQUARTERS JLG INDUSTRIES INC JLG INDUSTRIES EUROPE JLG INDUSTRIES INC 5119 Kilmartin Place 1 JLG Drive 11 Bolwarra Road Tannochside Park McConnellsburg PA Port Macquarie Australia Uddingston Scotland G71 5PH 17233 9533 Telephone 065 811111 Telephone 01698 811005 USA Fax 065 810122 Main Fax 01698 811055 Telephone 717 485 5161 Parts Fax 01698 811455 Fax 717 485 6417 FOREWORD The purpose of this manual is to provide users with the operating procedures essential for the promotion of proper machine operation for its intended purpose It is important to over stress proper machine usage All information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the machine YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL Keep it with the machine REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPER ATING PERSONNEL ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER OPERATING CONDITIONS WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN ALTERATION AND OR MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN WITHOUT WRITTEN APPROVAL FROM JLG INDUSTRIE
11. 10 amp 15VP 1 20 gpm 9 2200 psi 20VP 0 65 2200 psi Hydraulic System Pressure Setting 10 amp 15VP 68 95 bar 1000 psi 20VP 172 3 bar 2500 psi Rear Wheel Drive Motors DriveMotors 24 Volt DC w perm magnet Right angle gear Maintenance free sealed gear Brake shaft and drive shaft Integral to Motor Parking Brake must be released for pushing 10VP CE 615 kg Euro UK Aust 1355 Ib CE 940 kg Euro UK Aust 2072 b 15VP 20VP 158 kg 52 kg 350 Ib 115 Ib 135 psi 70 psi 240 kg 68 kg 13 kg cm 530 Ib 150 Ib 185 psi 91 psi 2 336 kg 9225 kg 741 Ib 496 Ib 265psi 265 psi Batteries Battery Charger Batteries 2 12 Volt 100 Amp Hour Deep CycleMarine RV Battery Charger Euro 240 VAC 50 Hz input U K 115 230 VAC 50 60 Hz input switchable AUST 250 VAC 50 Hz input 24 volt 10 amp output with 2 amp finish Reset Circuit Breaker Automatic Charge Circuit Plug Interlock Circuit 1 3 PERFORMANCE DATA Platform Capacity All Platforms except Extendible 10VP 160 kg 350 Ibs 15VP 160 kg 350 Ibs 20VP 160 kg 350 Ibs Extendible Platform Capacity Extendible Platform 120 kg 265 Ib The extendible platform is rated to carry a maximum weight of 160 kg 350 Ibs however a maximum of 120 kg 265 Ib is allowed out on the platform extension Platform Size Standard Platform 66cm x 66cm 26 in x 26 i
12. 36 6 Watch Dog Replace Controller 30 6 EEPROM Replace Controller 39 6 software Error Replace Controller 3120849 JLG Lift 3 5 SECTION 3 TROUBLESHOOTING BATTERY BATTERY LEFT SIDE RIGHT SIDE Em ur m 6122 PUMP MOTOR ASSEMBLY 7 Figure 3 2 Overview of Standard Electrical System Sheet 1 of 2 3 6 JLG Lift 3120849 SECTION 3 TROUBLESHOOTING LAPTOP COMPUTER remove existing connector at X105 port on the 1 controller box and plug in the 52 26 corrputer Requires F N 2900868 Configuration Kit USE WIRING DIAGRAM FIGURE 3 3 THIS SECTION OF THE MANUAL WITH THIS PICTORIAL WIRING DIAGRAM ARGE x ON md o e m cycle MC CONTROLLER BOX DRIVE MOTOR POWER LEADS LIFT UP LIFT DOWN GROUND CONTROLS lt gt RELAY EXTERNAL gt DRIVE HORN 5 E RELAY CONTACTOR lt gt RELAY 45 BRAKE lt RELEASE WIRING lt A MEME MOTOR BRAKE DRIVE MOTOR POWER LEADS MOTOR BRAKE RIGHT SIDE LEFT SIDE Figure 3 2 Overview of Standard Electrical System Sheet 2 of 2 3120849 JLG Lift 3 7 SECTION 3 TROUBLESHOOTING
13. 8 NOTE A good indicator of a stretched extend retract cable is if the adjusting nuts are bottomed out If no ment remains the cables have stretched and need replacement Also check for cracked bent worn severely corroded or improperly installed cable ends Inspect sheaves sheave grooves and sheave pins for excessive wear replace as necessary 2 3 LUBRICATION INFORMATION Hydraulic System The primary enemy of a hydraulic system is contamina tion Contaminants enter the system by various means e g using inadequate hydraulic oil allowing moisture grease filings sealing components sand etc to enter when performing maintenance or by permitting the pump to cavitate due to insufficient system warm up or leaks in the pump supply The design and manufacturing tolerances of the compo nent working parts are very close therefore even the smallest amount of dirt or foreign matter entering a system 3120849 JLG Lift 2 3 SECTION 2 SERVICE PROCEDURES can cause wear or damage to the components and gener ally results in faulty operation Every precaution must be taken to keep hydraulic oil clean including reserve oil in storage Cloudy oils indicate a high moisture content which per mits organic growth resulting in oxidation or corrosion If this condition occurs the system must be drained flushed and refilled with clean oil It is not advisable to mix oils of different brand
14. Check voltage to the Yel Red 2 3 wire atthe MC 1 box X101 con Replace MC 1 Check voltage to the Yel Red 2 5 wire atthe MC 1 box X101 con nector pin A1 24 volts Goto Step 13 Goto Step 6 Check voltage to the Yel Red 2 2 wire atthe MC 1 box X101 con Checkthe wire in 3 f he P Relay pin 30 nector pin 3 from the Power Relay pin 30 24 volts Go to Step7 betweenthe Power Relay and Connection Check for Ground to the Power Relay on the Black wire pin 85 to Check wiring to Ground Ground Replace Relay Ground Connection Check voltage to the Yel Red 2 4 wire at the Main Contactor from Check the Yel the Power Relay pin 87 24volts Goto Step 10 Red 2 4 Wiring Check for Ground on the Black wire to the Main Contactor Check wiring to Ground Goto Step 11 Ground Connection Check voltage atthe Battery Cable from Battery to Main Contactor DANS Goto Step 12 Check voltage to the Yel Red 2 5 wire atthe Main Contactor Check Yel Red2 Replace Main 24 volts 5 Wire Contactor 3 14 JLG Lift 3120849 If OK goto Step 21 Replace Fuse SECTION 3 TROUBLESHOOTING Table 3 5 No Power At Platform Control Check voltage on the Red BIk wire atthe MC 1 box X102 connec Replace MC 1 tor pin 15 to the Platform Control 24 volts Goto Step 14 Checkfor Ground onthe BRN wire atthe MC 1 box X102 connector Ground Go to Sten 15 Replace MC 1 pin 1 to the Platform Control T Ka voltage on the Red BIk wire pin 9
15. HYDRAULIC LEAK TROUBLESHOOTING Miscellaneous Hydraulic Leak Troubleshooting 3 37 BASE FRAME COMPONENTS TROUBLESHOOTING Caster Wheels Not Operating 3 38 Pot Hole Protection PHP Bars Will 3 38 3120849 JLG Lift 3 11 SECTION 3 TROUBLESHOOTING 3 6 OHM RATINGS FOR VARIOUS COMPONENTS The following table contains ohm ratings for various VP Series machine components Table 3 3 Ohm Ratings for Various Components Main Contactor 46 8o0hm 57 2o0hm 68deg F 3o ohm 67 3ohm Pump Motor 0 0 4ohm 77deg F 0 120hm 0 4900 Pump Relay 16 0ohm 17 6ohm 77deg 9 9ohm 21 80hm Brake Coil 44 7 ohm 52 68deg F 31 40hm 65 Drive Motor Bodine 110 3ohm Can change depending on the rotation of the N A armature and temperature 3 12 JLG Lift 3120849 3 7 MAIN POWER CIRCUIT TROUBLESHOOTING Unit Will Not Power Up From Ground Control Overview Of Procedure SECTION 3 TROUBLESHOOTING The following procedure tests the circuits from the Battery terminal through the Ground Control Box and to the Contactor Relay and Main Contactor for 24 volts or more Also the Lift Up Down Relay circuit is tested Check For These Obvious Conditions First Battery voltage 24 volts Fully charge batteries Battery connections clean and tight
16. Is there an obstruction in the mast Hemove Coto Sten 3 Obstruction The lift cylinder packing could be too tight in the bore of the cylinder Rebuild or Gom ena barrel Replace Cylinder Checkthe flow valve on the extend hydraulic line for a restriction i e Clean or Replace Clean or Replace Replace Hydrau lic Line Is there a restricted hydraulic line smashed Check if the lift down valve is opening completely 3 36 JLG Lift 3120849 3 10 HYDRAULIC LEAK TROUBLESHOOTING Miscellaneous Hydraulic Leak Troubleshooting Overview Of Procedure SECTION 3 TROUBLESHOOTING This series of steps gives remedies for various areas of the machine where leaks could occur Note Do not overtighten the nut on the solenoid in steps 4 5 and 6 3120849 Table 3 31 Hydraulic Leak Troubleshooting JLG Lift Replace the Seal atthe end ofthe Piston and Cylinder Barrel Tighten or Replace Hydraulic Lines Tight Cartridge in Pump Case Tighten Cartridge in Pump Case Replace Lift Down Valve 3 37 SECTION 3 TROUBLESHOOTING 3 11 BASE FRAME COMPONENTS TROUBLESHOOTING Caster Wheels Not Operating Freely Check For These Obvious Conditions First s machine operating on a smooth level surface Table 3 32 Caster Wheels Not Operating Freely Is the caster rotating freely Lubricate or Goto Step 2 Replace Caster Housing Is the wheel spinning freely Lubricate or Is debris stuckinthe plastic
17. JLG Industries recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity of 10W 30 and a viscosity index of 152 For cold weather applications i e when temperatures remain consistently below 7 C 20 F JLG recom mends using Mobil DTE 13 hydraulic oil Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not con tain the same required additives or be of comparable vis cosities If use of hydraulic oil other than Mobilfluid 424 is desired contact JLG Industries for proper recommenda tions Table 1 2 Hydraulic Oil Operating Range HYDRAULIC SYSTEM OPERATING SAE VISCOSITY TEMPERATURE RANGE GRADE 18 C to 5 C 10W 0 F to 23 F 18 C to 99 C 0 F to 210 F 10 C to 210 C 50 F to 210 F 10W 20 10W 30 20W 20 Lubrication Specifications Table 1 3 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 F Excellent water resistance and adhesive qual ities and being of extreme pressure type Timken OK 40 pounds minimum Extreme Pressure Gear Lube oil meeting API service classification GL 5 or MIL Spec MIL L 2105 HO Hydraulic Oil SO Vg grade 32 46 Table 1 4 Machine Interlock Switch Operating Conditions Drive Cutout Mast Elevation PHP System Tilt Status Brake Status not tilted bars raised not tilted
18. REAR PLATE WELDMENT Figure 2 7 Drive Motor Assembly Removal 3120849 JLG Lift 2 9 SECTION 2 SERVICE PROCEDURES REMOVING THE COMP DRIVE VIBLY IT WEIGF APPROXIMATELY XX LB AND WILL REQUIRE ASSISTANCE TO LOWER PREFERABLY USE A MOVABLE TRANSMISSSION OR OTHER HYDRAULIC JACK TO CAREFULLY LOWER ASSEMBLY FROM UNDER MACHINE 11 Carefully remove the four 4 nuts and washers outer most holes on the drive assembly weldment from the carriage bolts attaching the drive motor assembly to the base frame Be aware of the weight of the assembly before completely removing the fas teners see the CAUTION above 12 Lower the drive assembly and place on a suitable work surface BEARING 32mm x 12mm x 10mm N WAVE WASHER 22 P io O RING EARLY MODEL MACHINES USED SEALANT HERE WAVE WASHER T Gear Disassembly Assembly See Figure 2 8 The drive motor gear box is mounted on the rear of each drive motor transferring power from the electric drive motor to the rear drive wheels It is a right angle worm gear type box with a 50 1 reduction drive ratio The inter nal gears and bearings of the gear box are lubricated by 175cc s of gear oil in an unvented aluminum alloy hous ing Early VP machines included a oil drain plug on the rear surface of the gear box housing later model machines do not The following procedures disassemble and assemble the gear b
19. Remove the wiring from the DC breaker terminals 3 Remove the SCR Rectifier 2 To remove the breaker from the front face of the charger on the inside of the charger front face push in on the tabs located on the sides of the breaker assembly and remove the breaker out the front of the charger LOCKING TABS 2 22 JLG Lift 3120849 3120849 2 8 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES The VP Series personnel lift mast sections are contructed of extruded aluminum protected with an anodized surface finish The mast sections are interlocked into each other when assembled by internally mounted slide pads at the top and bottom of each mast section These slide pads run up and down in slide pad channels on each side of the mast Each VP model mast assembly contains a different num ber of mast sections as shown following Table 2 2 VP Series Mast Component Features No of Mast Extend Retract Model Sections Device 10VP 3 Chain 15VP 4 Chain 20VP 5 Chain Assembly procedures for all mast sections is basically the same carefully slide the mast sections together from bot tom until mast ends are even When sliding the mast sec tions together be careful not to scratch the anodized surface Assemble the hardware to the bottom of mast section first slide this section out the top of previous sec tion and assemble hardware to the top of mast See Fig
20. mastretracted bars raised mastretracted Controller Response engaged Full Drive and Lift disengaged Drive and Lift Disabled mast extended bars lowered not tilted engaged Drive 25 maximum mast extended bars raised blocked not tilted engaged Drive Disabled mast extended bars lowered tilt engaged Drive and Lift disabled mastretracted bars raised engaged Lift Disabled mastretracted barsr re charger not tilted engaged Drive Disabled 1 2 JLG Lift 3120849 1 6 HYDRAULIC PRESSURE ADJUSTMENT Adjust system pressure so that platform will raise with rated capacity in platform The following are recommended factory pressure set tings VP10 VP15 1000 psi VP20 2500 psi Turning adjustment screw clockwise increases system REPLACE ELBOW WITH A T FITTING TO CONNECT PRESSURE GAUGE SECTION 1 SPECIFICATIONS PRESSURE pressure turning screw counterclockwise decreases GAUGE system pressure Make pressure adjustment with oil at normal operating temperature If pressure is set when oil is cold platform may not raise rated load after oil has warmed PRESSURE ADJUSTMENT SCREW Figure 1 2 Hydraulic Pressure Gauge Installation 1 7 CYLINDER SPECIFICATIONS NOTE All dimensions are given in centimeters cm with the inches in U S equivalent given in parentheses ADJUSTMENT SCREW CAP Table 1 5 Cylinder Specifications BORE STROKE ROD DI
21. switch by carefully prying upward at the corner of the switch using a straight blade screwdriver This will seperate the switch from the reset button part of the emergency stop button assembly J10 J11 Position the circuit board and locate the emergency stop switch wires connected at locations J8 J9 J10 and J11 Unsolder the four 4 wires to the switch to remove the switch from the board See Figure 2 15 EMERGENCY STOP SWITCH 4 WIRES JOYSTICK WIRING 5 WIRES ee SPEED CONTROL SWITCH 3 WIRES j Figure 2 15 Platform Control Circuit Board Component Wiring Connections JLG Lift SECTION 2 SERVICE PROCEDURES 3 Remove the reset button part of the emergency stop Touch Pad Switch Removal switch by unscrewing the collar on the inside end of 1 the reset button assembly Unplug the touch pad ribbon cable connector from the circuit board connector socket See Figure 2 15 2 Usinga thin tool start by lifting an edge of the touch pad switch and slowly peel away it from the face of the upper housing until completely free Speed Control Switch Removal 1 Remove the speed control knob by pulling up on the knob until it is free of the switch shaft 2 Loosen and remove the retaining nut and lock washer from the switch collar and pull the switch out Platform Control Box Assembly of the housing 9 To
22. them from the unit This will assure that they are correctly reinstalled Hydraulic System Keep the system clean If evidence of metal or rubber par ticles is found in the hydraulic system drain and flush the entire system Disassemble and reassemble parts on clean work sur face Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assem bly Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart See Figure 1 2 Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants are not available consult your local supplier for an equiva lent that meets or exceeds the specifications listed Batteries Clean batteries using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroughly dry batteries and coat terminals with an anti corrosion compound Mast Chain Inspection Procedure A WARNING MAST CHAINS TO BE INSPECTED AND LUBRICATED EVERY THREE MONTHS Inspect mast chains for the following conditions Wear Always inspect that segment of chain that operates over a sheave As the chain flexes over the sheaves joints and plate edges very gradually wear Chain stretch can be measured using a manufacturers wear scale or steel tape When chains have elon
23. 6 through the lift 24 volts Goto Step 10 Tighten Repair Connection Checkthe battery cable from the B 4 left side battery for 24 volts 24 volts Goto Step 11 Tighten Repair Connection Checkthe battery cable going outto the pump case left side stud Tighten Repair for 24 volts 24 volts Goto Step 12 Connection Check the Yel Red 2 5 10 ga wire to the MC 1 box X101 connec Tighten Repair tor pin 1 for 24 volts al Goto Step 13 Connection 3120849 down valve Without any lift functions it should show 24 volts with aliftfunction it should show ground MAIN CONTACTOR CIRCUIT Check the Yel Red 2 4 wire to the Power Relay pin 87 for 24 24 volts Goto Step 14 Tighten Repair volts Connection JLG Lift 3 27 SECTION 3 TROUBLESHOOTING Table 3 21 Pump Circuit Checkthe Blackto ground on the pump contactor Grad Goto Step 15 Tighten Repair Connection POWER RELAY CIRCUIT Checkthe Yel Red 2 4 wire 87 onthe Power Relay to the main contactor and to diode at E Stop for 24 volts Tighten Repair Note Power will stop at diode silverline should be away from the E 24 volts noL DUE Connection Stop Checkthe Yel Red 2 2 wire 30 on the Power Relay to the E stop Tighten Repair and to the MC 1 box X101 connector pin 3 for 24 volts 24 volts Goto 17 Black 85 pin onthe Power Relay for connection to Tighten Repair at pump contactor 5010 Eu Check the Yel Red 2 3 wire 86 on
24. DN Hydraulic oil could be cavatating inside the pump 3 34 JLG Lift 3120849 SECTION 3 TROUBLESHOOTING Platform Mast Won t Stay Elevated Overview Of Procedure The following procedure requests that the lift down dump and pump internal valves be checked to see if any are stuck open it also examines the lift down and dump valve circuits Also suggests that the lift cylinder packing could be leaking internally Check For These Obvious Conditions First Manual descent valve is closed tight Table 3 29 Platform Mast Won t Stay Elevated STEP ACTION Is the lift down valve stuck open Repair or Clean Valve Checkthe valve inside the pump it could be stuck open Replace Pump Goto Step 3 Lift down valves could be open due to incorrect electrical signal Check Pump Valve Electrical Circuit Go to Step 4 Table 3 22 Go to Step 2 Dump valve could be open due to incorrect electrical signal Check Pump Valve Electrical Circuit Goto Step 5 Table 3 22 Oil could be passing around the lift cylinder bore packing Replace or Rebuild the Lift Cylinder 3120849 JLG Lift 3 35 SECTION 3 TROUBLESHOOTING Platform Mast Descends Too Slowly Overview Of Procedure The following procedure examines the mast some hydraulic components for obstructions and defects Table 3 30 Platform Mast Descends Too Slowly ws w Check mast slide pads shimmed to tight Reshim Mast Goto Step 2
25. INSPECTING OR REPLACING BRUSHES Brush Cleaning and Inspection SECTION 2 SERVICE PROCEDURES Brush Removal See Figure 2 12 Removal of the brushes also requires the removal of the drive motor s from the machine see procedure described earlier in this section for instructions to remove the drive motors If not already done disconnect the posi tive battery cable from the left side battery before pro ceding 1 Unscrew the large round brush caps from each side of the drive motor use as large a screw driver as possible 2 The brushes are retained by constant force roll type springs To remove the springs press inward on the end of the spring retaining bracket using the tip of a pair of long nose pliers or other appropriate tool The brushes should pop out if not they can be removed by pulling outward on the spring brackets with a pair of long nose pliers after the inside ends are unhooked 3 Now pull the brush out of the brush box by it s wire pig tail NOTE If only inspecting the brushes it is not necessary to remove the pig tail terminal from it s connection to the brush box 4 Loosen the the screw securing the pig tail terminal end to the brush box and slide the terminal end out from under the screw completely removing the brush from the drive motor wee BOX i i mme Ce BRUSH BOX Brush wear rate varies depending on the individual appli ioo t LA cation s duty cycle and should be inspected at freque
26. a flatwasher under bolt head and nut and mount with nuts on inside of bracket After securing mast to base frame using 4 ft level again check that mast is vertical plumb on base frame 3120849 SECTION 2 SERVICE PROCEDURES 16 Continue installing remaining components to mast 1 assembly i e hydraulic pump motor reservoir bat tery charger etc 2 10 MAST CHAINS CABLES AND 2 SEQUENCING CABLES ADJUSTMENT Mast Chain Cable Adjustment The intention of this procedure is to assure equal load dis tribution between the individual chains cables of a mast section chain cable set Adjust using the following procedure NRI MAST SIDE PROFILE o ADJUST UNTIL TOPS OF MAST MAST COVER HN SECTIONS ARE EVEN SHOWN REMOVED SEQUENCE CABLE ADJUST NUT Li PN SECTION 1 FIXED TO BASE SECTION 2 EXTENDED BY CYLINDER SECTION 3 See BY CHAIN SECTION 4 EXTENDED BY CHAIN CABLE 3120849 NOTE SECTION 5 PLATFORM HEADER SECTION Ay CHAIN CABLE ANCHOR PLATE ADJUST NUT Note
27. assemble the components back into control box follow the previously outlined disassembly procedure and reverse the steps for the component being installed The following are additional guidelines for assembling each component NOTE Be careful when soldering component wires to the circuit board DO NOT OVERHEAT BOARD Joystick Installation 1 Use the following illustrations to reattach the wires from the joystick to the circuit board J O O O 3 Position the circuit board and locate the speed con J trol switch wires connected at location J5 See Fig 3 ure 2 15 Unsolder the three 3 wires to the switch NEU J3 to remove the switch from the platform box e CIRCUIT BOARD BLUE COMPONENT SIDE RED WHITE WIRES FROM JOYSTICK CONTROL 2 18 JLG Lift 3120849 WIRES oJ WHITE light gauge FROM JOYSTICK CONTROL Later Model i Joystick 90 YELLOW light guage Dri CIRCUIT BOARD on Knob COMPONENT SIDE 2 If damaged replace the gasket between upper hous ing surface and the joystick mounting surface before assembling Emergency Stop Switch Installation 1 Use the following illustration to reattach the wires from the emergency stop switch to the circuit board TIT GO EH HG CIRCUIT TP BSO BOARD RED PIN 21 COMPONENT E BLACK PIN 13 SIDE BLACK PIN 14 E av RED PIN 22 WIRES FROM EMERGENCY O STOP SWITCH
28. chain cable Tighten to raise mast section or loosen to lower mast section the adjusting nut against the anchor plate on each chain cable Adjust the nut the amount required to raise or lower the top of the mast section so it is even with the previous mast section when the mast is retracted It is more important that the threaded ends studs protruding on the adjustments are equal side to side on a mast section than it is that the tension in the chains is equal The chain equalizers will always assure equal tension but if the adjustment isn t equal as described the chains may tend to pull to one side or the other The threaded end of the chain cable may need to be restrained while tightening the adjust nut to keep the chain cable from twisting Retract the mast all the way and check if the top of the mast sections appear as shown in Figure 2 20 Repeat steps 1 through 7 for remaining mast sec tions Once mast section adjustment is completed apply loctite 242 to the threads under the jam nuts that were loosened Then re tighten the loosened jam nuts until tight against the top adjust nut Chain cable should have slight tension but should not be taut Sequencing Cable Adjustment 1 2 34 Retract mast completely and check each sequenc ing cable on outside of masts for excessive slack Adjust only to remove slack from cable Tighten nylock nut just enough to remove excessive slack from sequencing ca
29. fill the small slot around the ribbon cable to help seal the slot and also strengthen the ribbon cable con nection at the touch pad surface Re install the circuit board and plug the ribbon cable connector into the circuit board cable socket Lower Half Housing Installation 1 2 20 Before installing the lower half housing apply a non conductive grease to the square holes of the wiring harness connector socket on the inside of the hous ing socket This will help keep out dirt and moisture WIRING HARNESS CONNECTOR SOCKET Carefully slide the lower housing onto the upper half of the platform control box assembly until seated completely against the upper housing edges Secure lower half housing to the upper half housing using the six 6 screws removed during dissassem bly JLG Lift 2 7 BATTERY CHARGER ASSEMBLY AND DISASSEMBLY General Information A IMPORTANT DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGER IF MACHINE IS STILL UNDER WARRANTY OPENING THE BAT TERY CHARGER WHILE THE MACHINE IS UNDER WARRANTY WILL VOID THE CHARGER WARRANTY IF UNDER WARRANTY REQUEST A REPLACEMENT CHARGER FROM THE FACTORY ALSO BEFORE REPLACING ANY COMPONENT USE THE CHARGER MANUFACTURERS TROUBLESHOOTING GUIDE INCLUDED WITH THE MACHINE FOR CHECKING THE INTERNAL AC AND DC CIRCUITS TO DETERMINE WHICH COMPONENT HAS FAILED COMPLETE WIRING DIAGRAMS PERTAINING TO YOUR MODEL CHARGER ARE ALSO INCLUDED IN THE MANUFACTUR ERS CHAR
30. front crossmem ber of the base frame Carefully tilt the base frame back until the front is pointing up and the back is resting on the counterweight battery trays Be sure base is very stable and at a 90 angle to work sur face before proceeding Using a sling and suitable lifting equipment i e overhead crane lift the mast assembly balanced in middle into position in front of the base frame Extend hydraulic cylinder out from bottom of mast assembly approximately one 1 foot Caps on extend and return ports will need to be removed to extend cylinder Catch any hydraulic fluid expelled from return port in a container to prevent spillage onto work area 10 11 12 13 14 15 JLG Lift Carefully position the mast into base frame assem bly base frame and mast assembly must be held at 90 angle to each other Slide port end of hydraulic cylinder through hole in base frame cylinder mounting channel Return port tube side of cylinder must be on right side facing bottom of base and mast Align threaded hole in side of hydraulic cylinder head with hole in tab on bottom side of cylinder mounting channel Secure hydraulic cylinder to cyl inder mounting channel tab using a 5 16 18UNC x 5 8 long hex head bolt and flat washer Carefully push mast assembly and base assembly together until the four 4 holes on bottom rear of mast align with holes in the base frame mast support crossmember Attac
31. on how far off the original torque setting was see note at beginning of this procedure tighten or loosen the adjusting nut accordingly then recheck the slip torque setting 4 When proper torque setting is achieved re tighten the two 2 adjusting nut setscrews 5 Re install the drive wheels remove the jack stand and lower the machine to ground TORQUE LIMIT CLUTCH ADJUSTING NUT Figure 2 3 Torque Limit Clutch Adjustment Components 2 6 JLG Lift Drive Motor Brake Adjustment Removal See Figure 2 4 amp Figure 2 5 Mounted onto the front of each drive motor housing is a brake assembly The brakes are normally ENGAGED brakes on when the machine is parked and are RELEASED electrically brakes off under normal driving conditions when the joystick is enabled and pushed in any direction The brakes can also be RELEASED manu ally using the manual brake release lever mounted on the side of the mast NOTE The brakes are intended only as parking brakes to keep the machine from moving while at rest The brakes are not used to stop the machine during driv ing operations this braking is controlled by the drive motors themselves Under normal driving conditions once released the brakes are not engaged again until the machine comes to a complete stop MANUAL MAGNETIC BRAKE COIL Ua HOUSING x 25 78 b 2 Y WITCH S FRICTION E ARM
32. on the Platform Control m Go to Step 16 Replace Cable Check for Ground on the BRN wire pin 8 on the Platform Control C Replace Platform Dax round Control Replace Cable 3120849 JLG Lift SECTION 3 TROUBLESHOOTING 3 8 DRIVE TRAIN TROUBLESHOOTING Won t Drive Platform Lowered Or Elevated IF MACHINE WON T DRIVE ONLY WHEN PLATFORM IS ELEVATED SEE SECTION 4 4 Overview Of Procedure The following procedures check the components and circuits that feed data to the MC 1 Controller box assuring it is receiv ing the proper signals and conditions before engaging the machines drive motors Check For These Obvious Conditions First Joystick Powered On Unit will Lift amp Lower Platform Machine is not Tilted 3 LEDs flashing at joystick control PHP Device is not Obstructed 4 LEDs flashing at joystick control Brakes are not Released 2 LEDs flashing at joystick control Charger is not Plugged In 8 LEDs flashing at joystick control Table 3 6 Won t Drive Platform Lowered or Elevated Checkfor ground from elevation limit switch inthe X101 connector Check Elevation pin 1 49 5 at MC 1 box Goto Step 2 Limit Switch Circuit Table 3 7 Check for ground from charger circuit wire inthe X101 connector pin 4 49 7 at MC 1 box Perform this check with the charger Faulty Charger Goto Step 3 unplugged Check for ground from brake limit switches in the X105 connector Check Brake pin 11 at MC 1 box Got
33. platform contol box to MC 1 box Repair or Replace damaged check wiring harness visually and individual wires with Harness as Goto Step 9 ohm meter Required Repair Replace Platform control Tighten Connec tions or Replace MC 1 box 3 24 JLG Lift 3120849 Is joystick control defective If possible swap out with another platform control Is MC 1 control box defective or connections tight If possible swap out with another MC 1 control box Inside the drive motor gear box check if the drive shaft is exces sively loose amp conditon of drive shaft bearings Are any gears broken or gearteeth excessively worn SECTION 3 TROUBLESHOOTING Noise From Drive Assembly Overview Of Procedure The following procedure examines the drive motor assembly weldments attaching the drive motors to the base frame Also internal components of the the drive motors gear box and a check of the components between the gear box and the drive wheels Check For These Obvious Conditions First Battery voltage 24 volts Fully charge batteries Nothing is lodged between one of the wheels and the base frame A caster wheel on the front of the machine is seized up creating resistance Table 3 19 Noise from Drive Assembly STEP ACTION Check for the following on the drive assembly drive attachment Repair Replace weldment is bent has broken welds or loose hardware Tighten weldment Checkforthefollowing onthe drive asse
34. sections together be careful not to scratch or score the anodized finish in the slide pad channels Slide mast section 3 back into section 2 until ends are even Mast section 2 may need to be restrained to keep its slide pads from pushing out the bottom of mast section 1 While mast section 4 is still extended from section 3 locate two chain assemblies Attach the eyelet anchor end of each chain to the inside set of holes near top of mast section 4 using 3 8 16UNC x 1 1 4 long hex head bolts nuts and flatwashers Place a flatwasher under bolt head and nut While mast section 4 is still extended from section 3 assemble chain sheaves to top of mast section 4 as follows a Locate the wide tube spacer and slide onto sheave pin b Slide two 2 chain sheave wheels onto sheave pin one each end of sheave pin to outside of tube spacer c Place two 2 large flat washers one each end of sheave pin to outside of chain sheave wheels d Place two 2 sheave pin attach bars one each end of sheave pin to outside of large flatwash ers 3120849 NOTE 39 NOTE 40 41 42 43 44 45 NOTE 3120849 e Holding complete chain sheave wheel assem bly slide assembly into top of mast section 4 and align threaded holes in sheave pin attach bars with holes in mast rails f Attach to top of mast section 4 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat t
35. shims shim and mast or shim and slide pad when tightened d All mast sections are to be shimmed to provide a measurable gap between the slide pad beveled side and mast channel of 0 012 to 0 025 per side e When mast slide pads are shimmed properly the mast sections should be able to slide in channel by hand Insert slide pads into the slide pad channels top of mast between section 1 and 2 one on each side of the mast with beveled surface facing in towards section 2 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in mast section 1 outside rail top of mast and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 If hydraulic cylinder needs to be extended the pro tective caps on the extend and return ports will need to be removed Be careful not to nick or scour rod surface when extending also catch any oil draining out of cylinder to avoid spillage onto work area Locate the hydraulic lift cylinder slide the lift cylinder into the closed rail side of mast section 2 with rod end to top and port end to bottom of mast Cylinder should extend out of mast on both ends Return tube should be on right side when facing bottom of mast assembly Top of cylinder assembly steps 12 and 13 applies to 20VP only For 10VP amp 15VP continue to step 14 Locate chain assembly 444
36. strands are spaced somewhat equally around the plug Drive the plug until it is firmly seated and no more than 1 3 of the plug is visible from above the sleeve DRIVER li INSERT PLUG T IN THIS npe PLUG 2 POSITION 2 35 SECTION 2 SERVICE PROCEDURES 6 NOTE NOTE 2 36 Reclamp the assembly in the vise on the flats of the sleeve Using the plug driver a metal tube or pliers bend the outer strands toward the center strands enough that the socket can be slipped over all the strands 22 SHAPE PLUG DRIVER STRANDS METAL TUBE AROUND OR PLIERS Ag PLUG When assembling stainless steel parts all threads must be coated with a dry lubricant or an anti sieze lubricant to prevent seizing Coat the threads of the socket and sleeve with lubri cant and install the socket by twisting it over the strands of the cable and engage the threads of the sleeve with the socket Tighten until four threads or fewer are visible If more than four threads are visi ble proof load the cable and retighten the socket fit ting There is no specific requirement for torque INSPECTION INSTALL HOLE SOCKET AND TIGHTEN FOUR THREADS OR LESS SHOWING Inspect for proper assembly prior to loading the cable Strands visible through the inspection hole are your assurance of a proper assembly The end of the rope may not be visible in the inspec tion hole after loading Install
37. the floor to the bottom of the machine and be capable of safely handling the weight of the machine LIFT USING ONLY THE FORK LIFT POCKETS x 2 RUNNING THE LENGTH OF THE BASE FRAME PLACE SUPPORT 4 STAND BETWEEN MACHINE AND FLOOR gt KO Figure 2 1 Accessing Machine Underside Components by Lifting with a Fork Truck 3120849 2 5 DRIVE MOTOR COMPONENT SERVICE PROCEDURES Torque Limiting Clutch Maintenance VP Series machines are equipped with a torque limiting clutch coupling on each drive axle The clutch is mounted inline on the drive axle between the drive wheel and the drive motor gear box The clutch is designed to slip at a pre set torque if the machines rear wheels are over driven while the machine is being towed pushed or forklifted thus preventing damage to the drive gear box Although factory pre set the clutch assembly and torque should be checked at the following interval Every 3 months Visual Inspection and Limiting Torque Checking Procedure 1 Locate the machine on a firm level surface KEEP MACHINE LEVEL OR SLIGHTLY TILTED TOWARD FORKLIFT TRUCK WHEN LIFTING TO PREVENT MACHINE FROM SLIDING OFF LIFTING TINES
38. the six 6 screws attaching the lower half of the housing to the upper half of the control box housing 2 Lay screws and lower housing aside Joystick Assembly Removal NOTE To completely remove the joystick assembly its wir ing will need to be unsoldered from the intregrated circuit board 1 Remove the four 4 screws from the top of the bezel around the base of the joystick and slide the joystick assembly out of the upper housing 2 Unplug the touchpad switch ribbon connector from the circuit board connector socket 3120849 3 Remove the four 4 screws attaching the circuit board to the upper housing NOTE NOTE Later Models With Enable Button On 3120849 If reusing the circuit board be careful when unsolder ing component wires DO OVERHEAT BOARD Position the circuit board and unsolder the wires from the joystick assembly at the J2 J3 and J7 loca tions on the circuit board See Figure 2 15 Early VP model joystick assemblies did not have the drive enable button on the joystick knob Wires from this design were attached in the J3 location on the circuit board only With all the joystick wiring unsoldered remove joy stick assembly from the control box j2 37 JOYSTICK TOUCHPAD WIRING SWITCH 2 WIRES CONNECTOR Knob Only f SECTION 2 SERVICE PROCEDURES Emergency Stop Switch Removal 1 Remove the switch part of the emergency stop
39. 1 connector 5 to the power Repair or Replace relay pin 86 Check continuity at pin 85 24 Volts GotoStep3 Wires orProblem with MC 1 Box Check the voltage from pin 87 onthe power relay to the main con Repair or Replace tactor Main contactor should be closed at this point 24 Volts Goto step 4 Wires or Relay Check the voltage on the Yel Red 2 5 wire on the X101 connector Repair or Replace pin A1 from the main contactor 24 Volts Goto Step 5 Wires or Main Contactor Whattype of surface is machine being operated on Is surface soft Machine will not unstable or up a steep grade soft or unstable Surface if motor draw is over 70 Goto Step 6 amps controller will shutthe machine down 7 LED Code perform wellona Are brakes releasing when trying to drive Repair Replace or Adjust Drive Go to Step 7 Brakes See Procedure in service Manual Is drive system running free No noise or dragging Repair Replace or Adjust Drive Goto Step 8 oystem See Procedure in service Manual Is machine being operated in an environment with high static Machine may be charge building static charge in the MC 1 controller which will make the drive system shut down 3 22 JLG Lift 3120849 SECTION 3 TROUBLESHOOTING Table 3 17 E Stop and Key Switch Circuit Check Batteries Fully Charged 24 Volts Ground Control Key Switch set to the Platform or on Ground position and the Emergency Stop Switch Reset
40. 9 Od s 3q 75 53995 d31V idNn MNO 511089 d31V ld INIZ 804 S30 1VA Figure 1 3 Torque Chart 3120849 JLG Lift 1 4 SECTION 1 SPECIFICATIONS Figure 1 4 Lubrication Chart Table 1 6 Lubrication Intervals for Various Components INTERVAL ANTERVALHOURS 0 00 NO TYPE ITEM COMPONTENT LUBE METHOD COMMENTS LUBE POINTS NORIS MONS T VERS 150 Hrs 300 Hrs 600 Hrs 1200 Hrs Fill To Line on FillToLineon HO CheckHyd Oil Check Hyd Oil Check Hydraulic every 10 hrs Hydraulic Oil every 10 hrs Hydraulic Oil Reservoir Level owe Hydraulic Oil every 1200 5 Qt Reservoir Change Hyd Oil Drive Wheel 2 Bearings 4 Grease Fittings MPG Pressure Gun Tij Drive Wheel Change only when serviced 3 Gear Box 2 Gear Box Gear Dil requires oz 175 5 to fill 4 Caster Axles 2 Grease Fitting MPG Pressure Gun v 5 Swivel Raceways 2 FrontCasters MPG Pressure Gun v 6 MastChains 2 Per Section E 0 Inspect lubricate if dry or rusting Applies Only to MastSections with Chains Key to Lubricants MPG Multipurpose Grease HO Hydraulic Oil See Section 1 5 Lubrication in Service Manual GEAR OIL Good Quality Worm Gear Oil SAE 90 AGMA 5 EP Compounded Notes 1 Be certain to lubricate like items on each side of the machine 2 Recommended lubricating in
41. A cm in cm in cm in Lift Cylinder 3 81 138 43 2 06 Figure 1 1 Hydraulic Pressure Setting Adjustment 10VP 1 50 54 50 1 125 Screw Located at Base of Pump Motor Lift Cylinder 3 81 138 43 2 86 Remove Hex Head Cap as Shown 15VP 1 50 54 50 1 125 Lift Cylinder 3 81 138 43 2 06 HERE 20VP 1 50 54 50 1 125 ONLY OPEN HYDRAULIC SYSTEM LINES WITH THE MAST LOW ERED TO RELIEVE PRESSURE IN THE SYSTEM CAREFULLY LOOSEN REQUIRED FITTINGS WEAR SAFETY PROTECTION EQUIPMENT WHEN WORKING WITH HYDRAULIC SYSTEMS 1 8 SERIAL NUMBER LOCATIONS For machine identification a serial number plate is affixed to the machine The plate is located on the back of the mast just above the mast support bracket In addition should the serial number plate be damaged or missing the machine serial is stamped on the mast and on the base frame Connect pressure gauge as shown in Figure 1 2 Hydrau lic Pressure Gauge Installation Select a T Fitting to exactly match the thread size of the pump 562 x 18 THD pressure line 562 x 18 THD and gauge fitting as required 3120849 JLG Lift 1 3 SECTION 1 SPECIFICATIONS 8 3avso avs avs poejejd uinipeo oj Ajdde jou op
42. ATURE PLATE BRAKE DISK SPRINGS SHIM WASHERS AS REQUIRED SPACER Figure 2 4 Brake Assembly Components 3120849 3120849 FRICTION BRAKE DISK ARMATURE PLATE MAGNETIC COIL Not Energized 0 006 GAP BETWEEN ARMATURE R L PLATE AND ADJUSTMENT MAGNETIC COIL SCREW 0 020 GAP UNDER SCREW HEAD BETWEEN ARMATURE PLATE GAP SETTINGS BRAKE ON Magnet Not Energized MOUNTING PLATE SECTION 2 SERVICE PROCEDURES FRICTION BRAKE DISK ARMATURE PLATE MOUNTING PLATE MAGNETIC COIL 0 006 GAP Energized BETWEEN MANUAL FRICTION RELEASE ARM DISK AND ADJUSTMENT ARMATURE SCREW PLATE 0 026 GAP UNDER SCREW HEAD BETWEEN ARMATURE PLATE GAP SETTINGS BRAKE RELEASED Magnet Energized Figure 2 5 Brake Armature Plate amp Brake Disk Adjustment Operation See Figure 2 4 amp Figure 2 5 When the magnetic coil is not energized brake on the armature plate is pushed away from the magnetic coil sur face by heavy springs internally mounted in the magnetic coil housing This pressure forces the armature plate against the friction brake disk holding it tight between the armature plate and the mounting plate The brake is not released until either the magnetic coil is energized pulling the armature plate away from the friction brake disk or the brake is manually released using the manual brake release handle A correctly adjusted brake will ideally have a measurment o
43. ELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVER HEAD SLING BEFORE MAKING ADJUSTMENTS LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPO NENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACH MENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS This page intentionally left blank JLG Lift 3120849 EFFECTIVITY PAGE EFFECTIVITY CHANGES September 15 1997 Original Issue of Manual January 10 1998 Change 1 Pages Affected Revision Log c Table of Contents Page ii Section 3 Pages 3 8 amp 3 9 February 7 2000 Revised Pages Affected Section 1 Page 1 5 Table 1 5 Section 2 Page 2 18 Table 2 3 removed lube check requirement for drive wheel gear box October 19 2000 Revised Complete Manual November 15 2000 Revised Pages Affected Section 1 Page 1 2 Section 2 Page 2 33 amp 2 34 31207849 JLG Lift C EFFECTIVITY PAGE This Page Left Intentionally Blank JLG Lift 3120849 TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO SECTION INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS a GENERAL eer a b HYDRAUEIC SYSTEM SAFETY za yal eqq i ione a C MAINTENANCE can h e ares Ae et tede va e hend E a EFFEGTIIVITY GHABNGES oi
44. G Lift TABLE OF CONTENTS Continued FIGURE NO TITLE PAGE NO 1 1 Hydraulic Pressure Setting Adjustment Screw Located At Base Of Pump Motor 1 3 1 2 Hydraulic Pressure Gauge 5 1 3 1 3 FOUE Prev 1 4 1 4 Bele Net n 1 5 2 1 Accessing Machine Underside Components By Lifting With A Fork Truck 2 4 2 2 Check Torque Limit Clutch Torque 2 5 2 3 Torque Limit Clutch Adjustment Components 2 6 2 4 Brake Assembly Components 2 6 2 5 Brake Armature Plate amp Brake Disk 2 7 2 6 Manual Release Brake Cable 2 8 2 7 Drive Motor Assembly 2 9 2 8 Drive Motor Gear Box Assembly 2 10 2 9 Geat pimiohn ShalbASsemblys 5252 2 11 2510 Drive REC ub 2 12 Dive Molor Brush xin qe eite hn 2 13 2 12 Drive Motor Brush Ins
45. GER MANUAL The VP Series battery charger allows for replacement of the following internal components Consult your Illustrated Parts Manual for part numbers of these components which are available from the JLG Parts Department Transformer Printed Circuit Board Shunt Assembly Interlock Relay SCR Rectifier AC Circuit Breaker DC Circuit Breaker Replacement and troubleshooting of these components requires removal of the battery charger from it s mounting position on the machine Battery Charger Removal 1 Remove the rear cover from the machine 2 Unbolt and lower the MC 1 Controller Box 3 Remove the four 4 capscrews securing the charger to it s mounting plate 4 Disconnect the DC wiring from the positive negative battery terminals and interlock connector from the wiring harness 5 Remove the charger from the machine 3120849 Battery Charger Part Replacement Cover Removal 1 Remove the eight 8 screws on the sides of the charger cover and remove cover Transformer Replacement 1 3120849 Disconnect the wiring connecting the the trans former to other components within the charger assembly Remove the four nuts from the cap screws securing the transfromer brackets to the base of the charger chassis Remove transformer
46. ION 2 SERVICE PROCEDURES NOTE NOTE NOTE 10 NOTE 11 12 13 14 2 24 When sliding mast sections apart be careful not to scratch or score the anodized surface in the slide pad channels Carefully slide mast section 3 4 5 out BOTTOM of mast section 2 3 4 rails Disassemble slide pads shims and chain anchor plate from mast section 3 4 5 if necessary Steps 6 through 10 apply to removal of mast section 4 on model 20VP lifts which have five 5 mast sec tions If servicing a 15VP mast go to step 11 or a 10VP go to step 17 Remove chain adjust nuts from threaded ends of chains attached to the chain anchor plate on bottom end of mast section 4 Push threaded ends of chains through anchor plate At top of mast section 4 pull chains out and allow to hang loose Slide mast section 4 out the TOP of mast section 3 far enough to allow access to the chain sheave wheel assembly Remove countersunk flathead screws securing chain sheave wheel assembly attach bars on both side rails at top of mast 4 and remove sheave wheel assembly When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 4 out BOTTOM of sec tion 3 Remove slide pads shims and chain anchor plate if necessary Steps 11 through 16 apply to removal of mast sec tion 3 on 15VP chain actuated amp 20VP chain actu ated
47. JLG Industries A IMPORTANT JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN ACCORDANCE WITH THE ANNUAL MACHINE INSPECTION REPORT FORM 3120849 Platform Controller all functions SECTION 2 SERVICE PROCEDURES Table 2 3 Preventive Maintenance amp Inspection Schedule AREA ON MACHINE INTERVAL PLATFORM 10 HRS 50 HRS 200 HRS 500 HRS 1000 HRS DAILY WEEKLY MONTHLY 3MONTHS 6MONTHS ma qo 144 TT 2000 HRS 1 YEAR Placards and Decals LM Control Tags Electrical Cables 48 d Handrail and Bar Gate Mast Chains and all component parts 1 4 7 9 Lou Mast Sections Mast Sequencing Cables Speed PHP Limit Switches 1 4 7 BASE FRAME Batteries Battery Charge Power Cables To Platform Electric Motor Hydraulic Pump Unit Hydraulic Hoses and Fittings Hydraulic Oil Reservoir Hydraulic Oil Reservoir Breather Manual Descent Valve Lift Cylinder Placards and Decals Wheels and Casters Wheel Bearings Electric Drive Wheel Motors Electric Drive Wheel Gear Box Torque Limiting Clutch Power Switch Ground Control Box Control Tags Hoses and Cables Bubble Level Indicator 1 1 1 3 1 1 1 NENNEN WE ERE QU NM NN 1L de 22 NENNEN NE 3 8 i 2 d 11 2 8 2 5 5 6 13 O1 QI I b eo
48. KE ASSEMBLIES MACHINE MAY ROLL AWAY IF NOT SETTING ON A LEVEL SURFACE 5 Using the Ground Control Switch raise the platform to gain access to the brake assemblies mounted on the end of the drive motors located at the base of the mast FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING 6 Remove the four 4 hex cap screws securing the brake assembly to the end of the drive motor and remove the brake assembly from the end of the drive motor Brake Assembly Installation 1 Guide the manual release lever brake coil and brake limit switch wiring connectors through the opening in the drive motor cover and base frame while slid ing the brake assembly onto the front of the drive motor Engage the teeth of the disk brake with the teeth on the drive motor brake gear 2 f necessary manually release the brake disk using the manual release lever to allow the brake assem bly to turn and align the four holes in the brake mounting plate with the mating holes in the drive motor end plate 3 Secure the brake assembly to the drive motor using four 4 hex cap screws with washers Torque evenly to 44 in 16 4 Lift the machine to gain access to the underside See Section 2 4 Positioning Lift For Access To Components Located Under The Base Frame 5 Reconnect the brake coil and brake limit switch wir ing connectors to their respective wiring harness connectors 2 8 JLG Lift 6 Recon
49. LG Lift SECTION 2 SERVICE PROCEDURES f On outside of spacer tubes place a sheave pin attach bar rectangular plate with threaded holes on each side of pin bore hole g Before sliding this assembly into the top of mast section two locate two 2 mast extension chain assemblies and lay their anchor ends into the slots of the chain mounting tube h Slide the assembly with sheave pin wheels and pin attach bars into top of mast section 2 i Attach to top of mast section 2 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten 20VP Top of Cylinder Assembly Assemble chain sheaves on chain assembly 444 anchor block attached to cylinder rod end and attach to mast section 2 using following steps a Insert sheave pin through anchor block on cylin der rod end b Place sheave wheels for wide chain on sheave pin one each side of anchor block c On outside of each sheave wheel place a sheave pin attach bar rectangular plate with threaded holes on each side of pin bore hole d Slide the whole anchor block assembly with sheave pin wheels and pin attach bars into top of mast section 2 Position anchor block with narrow chains facing mast section 3 e Attach to top of mast section 2 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten Sli
50. N RED 49 7 BLACK 10 BLACK 3120849 PTION GREEN A ELEVATION SPEED CUTBACK SWITCH YEL RED 2 5 TILT SENSOR 2 ORN RED 49 2 RIGHT PHP LIMIT SWITCH TRAVEL DESCENT MOTION ALARM OPTION BLACK YEL RED 2 2 BLACK RIGHT BRAKE LEFT BRAKE LIMIT SWITCH LIMIT SWITCH ORN RED 49 4 BLACK N O H C N O H C A e TAN 55 2 2 e 55 1 S U Q o do e YEL RED 2 6 LIFT DOWN EX X YEL RED 2 6 PUMP CONTACTOR YEL RED 2 8 YEL RED 2 4 12V 12V BLACK 10 l 2 LA X 4932960 Figure 3 3 VP Electrical Diagram VP Series Standard JLG Lift 3 9 SECTION 3 TROUBLESHOOTING 3 10 CYLINDER EN N PRES COMPENSATED RETURN TUBE FLOW VALVE by SOLENOID WITH EXTEND TUBE tine SOLENOID TWO POSITION TWO WAY DUMP VALVE FILTER E SCREEN lt ADJ RELIEF i ee TANK FILTER SCREEN 1282953 Figure 3 4 Hydraulic Diagram VP Series JLG Lift 3120849 SECTION 3 TROUBLESHOOTING 3 5 TROUBLESHOOTING SECTION TABLE OF CONTENTS OHM RATINGS FOR VARIOUS COMPONENTS PAGE Ohm Ratings for Various Components 3 12 MAIN POWER CIRCUIT TROUBLESHOOTING Unit Will Not Power Up From Ground 3 13 No Power At Platform Control o cue b dot
51. OPEN RAIL REFERS TO OPEN RAIL FRONT OF MAST SECTION CLOSED RAIL REFERS TO CLOSED RAIL BACK OF MAST SECTION SECTION 2 SERVICE PROCEDURES ure 2 1 Always install slide pad shims with slide pads inserted into the slide pad channels ends of mast sec tions even Applying silicone spray onto the slide pads and slide pad channels before assembly will help mast sections slide easier after slide pads have been properly shimmed Mast Disassembly Procedure NOTE Heference to mast sections 3 4 5 platform mount ing section depends on which VP model lift you are working on 1 After the mast assembly has been removed from the machine lay the mast assembly down on a suitable work table with the platform mounting section on top facing up 2 the sequencing cables and hardware from the sides of the mast assembly Also remove the cover from the top of the mast assembly 3 HRemove chain adjust nuts from threaded ends of chain attached to the chain anchor plate on BOT TOM end of mast section 3 4 5 platform mounting section Push threaded ends of chain through anchor plate 4 Atthe TOP of mast section 3 4 5 pull chains out and allow to hang loose REFERS TO TOP END OF MAST SECTION WHERE COVER AND SHEAVE WHEELS ARE ATTACHED REFERS TO BOTTOM END OF MAST SECTION WHICH SETS IN MACHINE S BASE FRAME Figure 2 16 Mast Section Assembly Reference JLG Lift 2 23 SECT
52. OliSa n b disa b COS dia a 1 2 1 4 Machine Interlock Switch Operating 1 2 1 5 Cylinder peclliCallOPiS za acus dira es d Edu rw awa 1 3 1 6 Lubrication Intervals for Various 5 1 5 2 1 Chain Stretch Tolerance acted sl 2 Par kane do REG C do races Qe ous den y dg d aed 2 2 2 2 VP Series Mast Component 2 23 2 3 Preventive Maintenance amp Inspection 2 37 3 1 MC 1 WARNING CODES Indicated by beeps then slow flashing LED s 3 3 3 2 MC 1 ERROR CODES Indicated by rapid LED flashing and periodic 3 4 3 3 Ohm Ratings for Various 5 3 16 3 4 Unit will not Power Up From Ground Control 3 17 3 5 No Power At Platform Control 5 acu a cd sed qoae Eg e 3 18 3 6 Won t Drive Platform Lowered or 3 20 3 7 Elevation Switch Circuit 3 20 3 8 Brake Limit Switch Circuit Check 3 21 3 9 Drive Mot
53. PER HALF N SECTION 1 HYDRAULIC LIFT CYLINDER s GNE S SEQUENCE 2 ES 9 CABLE ASSY LOWER HALF BACK UP CABLE ASSY LOWER HALF SECTION 1 Figure 2 17 10VP Mast Assembly 3120849 JLG Lift 2 25 SECTION 2 SERVICE PROCEDURES NOILOAS 31V ld HOHONV Z NOIL23S ASSV a T 5 BS e j gt zm L NOILO3S X H3QNITAO 1 11 31VH ASSV 318VO2 dn Xov8 41VH ASSV J18V2 3oNanoas 3AV3HS 8 3916 83401 NOILOAS v NOILO3S NO aasn ASSV vd 301165 L NOILOAS LISV JO dOL H i H sonate etu t the M HH H 1 41 1 ui s sib rdg toQe t ASSV LSV LSVI 41VH ASSV Figure 2 18 15VP Mast Assembly 3120849 JLG Lift 2 26 SECTION 2 SERVICE PROCEDURES NOILOAS i gt Ld v NOILO3S 1SVW JO 401 Dorp ASSV HOLIMS XTNO LSVIN NOILO3S aasn ASSV 30115 ASSV RY J18VO a 3oNanoas e 4 H3QONI1AO 1317 41VH H3ddn L NOILO3S AS
54. S PER OSHA REGULATIONS THIS SAFETY ALERT SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED Safety of personnel and proper use of the machine are of primary concern DANGER WARNING CAUTION IMPORTANT INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these areas They are defined as follows A DANGER DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUA TION WHICH IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR DEATH CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUA TION WHICH IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES Also in this Manual Notes are used to provide infor mation of special interest A WARNING WARNING INDICATES A POTENTIALLY HAZARDOUS SITU ATION WHICH IF NOT AVOIDED COULD RESULT IN SERI OUS INJURY OR DEATH A IMPORTANT IMPORTANT OR INSTRUCTIONS PROCEDURES ESSENTIAL FOR SAFE OPERATION AND WHICH IF NOT FOLLOWED MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE MACHINE A IMPORTANT JLG INDUSTRIES INC MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT CONTACT JLG INDUS TRIES INC OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLE TINS WHICH MAY HAVE BEEN ISSUED FOR YOUR JLG PRODUCT ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COMPLETED ON THE AFFECTED JLG PRODUCT Due to the continuous produc
55. SHES MAY BE SEATED BY RUNNING THE DRIVE MOTOR AT NO LOAD PROPER SEATING IS REQUIRED FOR LOWEST BRUSH NOISE LEVEL 3120849 SECTION 2 SERVICE PROCEDURES 3 Turn on power to the platform control nine 9 LED s will flash rapidly the platform control touch pad 4 Depress the horn switch pad the alarm will sound Joystick Calibration Procedure for about one 1 second then release the horn pad 5 Now release the joystick to the neutral position 1 Turn off all power to the platform control 6 Turn off system power 2 Move the joystick to the maximum forward position The joystick calibration is now complete and hold it there i NOTE Joystick will be held in the maximum forward position until asked to release it in Step 5 JOYSTICK SET ASSY UPPER HOUSING EMERGENCY STOP SWITCH INTREGRATED BUTTON CIRCUIT SPEED CONTROL a KNOB N LOWER HOUSING 2 Ni ne saei STOP SWITCH LN Figure 2 14 Platform Control Box Assembly Exploded View 3120849 JLG Lift SECTION 2 SERVICE PROCEDURES Platform Control Box Disassembly BOX IF MACHINE IS STILL UNDER WARRANTY OPENING THE PLATFORM CONTROL BOX WHILE THE MACHINE IS UNDER WARRANTY WILL VOID THE WARRANTY IF UNDER WARRANTY REQUEST A REPLACEMENT BOX FROM THE FACTORY The VP Series platform control box allows for replacement of five 5 components internal to the box Controller Integrated Circui
56. SV ISVW dO 3416 ASSV 319 S 3oNanoas 371972 dn M2v8 H3M01 ASSV f 7 TT SASSV 1341M 3AV3HS NIVHO NIVHO Figure 2 19 20VP Mast Assembly 2 27 JLG Lift 3120849 SECTION 2 SERVICE PROCEDURES Mast Assembly See Figure 2 1 2 2 2 3 amp 2 4 1 NOTE NOTE NOTE 2 28 Place mast section 1 rail open side up on a clean flat surface preferably a table or work bench capa ble of supporting the weight of the entire mast assembly Slide mast out over end of work surface far enough to allow access to the chain anchor attach holes at top of mast Locate the two 2 single chain assemblies Lay out each chain assembly with anchor block end towards mast and threaded end away from mast be certain floor surface is clean and free of any metal chips or debris which may stick to lubricated chains Insert the block anchor end into the top of mast sec tion 1 and secure using two 2 3 8 16UNC x 2 1 2 chain long hex head bolts flatwashers and nuts for each attach block Place a flatwasher under bolt head and nut When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Locate mast section 2 care
57. When chain adjustment is complete before JAM NUT tightening the jam nut against the adjust nut SANE et ji apply Loctite 242 to the END Q threads under the jam nut With mast retracted step into the platform and bounce your weight up and down a few times to be certain platform is at the bottom of travel Be certain all chain cable sets are seated in their sheaves prop erly at the top of each mast section Then with no load in the platform check the side pro file of the top of the mast for the amount of adjust ment necessary to make the mast sections even for mast sections 3 and up See Figure 2 20 Mast section 1 is fixed to the base and mast section 2 is attached to the lift cylinder these sections require no adjustment MAST CHAIN CABLE ADJUSTERS Figure 2 20 Mast Chain Cable Sequence Cable Adjustment Components JLG Lift 2 33 SECTION 2 SERVICE PROCEDURES Adjust one mast section at a time starting from the back section 3 section 4 etc of the mast and work forward i e if three is OK then jump to four etc Elevate the platform until the chain cable anchor adjust nuts are accessible at the front and bottom of each mast section See Figure 2 20 FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING 5 NOTE Start with the mast section which needs adjustment and loosen the bottom jam nut on each
58. and brake wires 5 2 Brake Left Open Circuit Check brake wires or plug at Properly attach wires or pins drive motor 6 9 Brake Right Open Circuit Check pins 2 amp 5 of X104 Properly attach wires or pins and brake wires 6 9 Brake Right Open Circuit Check brake wires or plug Properly attach wires or pins at drive motor 7 2 Brake Open Circuit on one or both brakes oee above 8 9 switch Short Circuit Joystick Replace Joystick Box 9 6 Power Circuit Defect Replace Controller 10 1 Battery Low lt 16 5 v Charge Battery 11 9 Check pins amp wire connections atX102 amp joystick Properly attach wires or pins box connector 11 9 Joystick defective Replace Joystick Box 42 8 Check pins amp wire connections at X102 amp joystick Properly attach wires or pins box connector 12 8 Joystick Box Replace Joystick Box 16 7 Current Limiting Motor Short Circuit Gearmotor Replace Gearmotor defective 21 6 36v supply Replace controller 24 5 Configuration Lost Reprogram using MC 1 software if error reoccours then replace controller 25 6 RAM ROM Replace controller 3 4 JLG Lift 3120849 SECTION 3 TROUBLESHOOTING Table 3 2 MC 1 ERROR CODES Indicated by rapid LED flashing and periodic beep ERROR LED S CODE FLASHING PROBABLE CAUSE REMEDY If voltage pin 5 RED2 of X101 is 20v w 24v Battery or if ground controls and operating lift up clears error 26 D
59. approximately a 1 4 radius c Attach shim stock and slide pads to both sides of mast section 4 5 using five 5 1 4 20UNC x 1 1 4 long hex head cap screws per side with flatwasher under each bolt head Assemble shim stock and slide pad to mast section rail with shim stock against rail and slide pad with beveled side out d Carefully thread the slide pad mounting bolts with flatwashers through slide pads and shim stock into threads in mast section 4 5 Be cer tain there are no air gaps between shims shim and mast or shim and slide pad when tightened When sliding mast section 4 5 into section 3 4 note amount of force required to push sections together Fit should be very snug but still be able to be pushed together by hand If too tight remove section 4 5 disassemble slide pad from section 4 5 and reduce thickness of shim stock Open rails of section 3 4 may be sprayed with silicone spray to help section 4 5 slide easier e Begin sliding top of mast section 4 5 with closed rail down engaging the slide pads into slide pad channels at bottom of mast section 3 4 s open rail Continue to push section 4 5 into section 3 4 until BOTTOM ends of mast sec tions are even f Check mast section for side play If play exists use thicker shims dividing thickness equally between both sides of mast 2 31 SECTION 2 SERVICE PROCEDURES 49 50 51 52 g When mast slide pads are shimmed properly there sh
60. armature plate friction disk and mounting plate for debris Clean as neccessary Also check that the manual release arm screws are not tightened to tight Manual Release Arm Screw Adjustment NOTE Always check the armature plate gap setting is within spec before attempting to adjust the manual release arm screw adjustment 1 With the brakes ENGAGED brakes on the air gap under the head of the manual release arm screw to the surface of the armature plate should be set at 020 Adjust using the locknut on the release arm end of the screw 2 With the brakes electrically RELEASED brakes off the air gap under the screw head increases to approximately 026 due to the armature plate move ment towards the magnetic coil releasing the fric tion brake disk When the brakes are RELEASED brakes off manually the screw head pulls in against the armature plate releasing the friction brake disk JLG Lift 2 7 SECTION 2 SERVICE PROCEDURES Brake Assembly Removal 1 Lift the machine to gain access to the underside See Section 2 4 Positioning Lift For Access To Components Located Under The Base Frame 2 Disconnect the brake magnetic coil wiring connector and the brake limit micro switch wiring connector from their wiring harness connectors 3 Disconnect the manual brake release cable from the manual brake release arm attached to the brake assembly 4 Lower machine back down to ground level REMOVING THE BRA
61. at gear set align the drive shaft bearing and wiggle it into it s seat When both are seated continue to next step With the gear box still positoned with the open cover side up fill the gear box with six 6 ounces U S 175cc s of good quality worm gear oil Specifica tion SAE 90 weight AGMA 5 EP Compounded When pouring the gear oil wet the gears and bear ings with the oil Wet with gear oil and place the large wave washer on the end of the drive shaft bearing and the small wave washer on the end of the gear and pinion bear ing Clean the mating surfaces of the side cover and the gear box and check that the cover dow guide pins are properly installed in the cover On older model gear boxes apply sealant to the cover mating surface on the gear box On newer model gear boxes insert the rubber seal into the groove in the cover Using the cover dow guide pins place the cover onto the gear box housing Secure using the four 4 hex cap screws torque screws evenly to 90 in 16 Install the drive motor back onto the machine DRIVE SHAFT SIDE PROFILE Figure 2 10 Drive Shaft Assembly JLG Lift 3120849 Drive Motor Brush Replacement Each drive motor contains two 2 brushes the brushes are located under the two 2 large round slotted brush caps on the front end of each drive motor Figure 2 11 Drive Motor Brush Location DISCONNECT THE POWER LEADS FROM THE POWER SOURCE SPRING in BEFORE
62. ble The springs should not be compressed more than 25 after adjusting Run mast through several cycles to verify cable chain adjustments and ensure no interference exists between chain anchor brackets and mast 2 11 SEQUENCE CABLE REPLACEMENT KIT A sequence cable replacement kit is available from the JLG Parts Department to service broken or worn sequence cables This kit consists of a replacement sequence cable with the threaded top end attached same as the top end of the factory cable Also included is a clamp drum socket type to secure the bottom end of the cable Use the following procedure to install the replacement cable and clamp kit Remove Old Cable 1 Remove the locking nut from the threaded end of the cable at the top of the mast and then remove the spring cap spring and spacer washers if installed Slide the threaded top end out of the upper anchor bracket then at the bottom end pull the cable out though the sheave pulley anchor bracket until it is completely clear of the machine Replacement Cable Installation 1 Be certain the mast is completely retacted and at the bottom of travel Check the mast Side Profile at the top of the mast as shown in Figure 2 20 adjust mast sections to proper height if necessary To determine where the clamp will be installed at the bottom of the replacement cable temporarily assemble the new replacement cable to the top cable anchor bracket on the mast using the was
63. cable on machine and adjust per instructions shown previously in Section 2 10 MAST CHAINS CABLES AND SEQUENCING CABLES ADJUST MENT JLG Lift 2 12 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE See Table 2 2 The preventive maintenance and inspection checks are listed and defined in the following table See Table 2 2 this chapter This table is divided into two basic parts the to be inspected and the INTERVAL at which the inspection is to take place Under the AREA portion of the table the various systems along with the components that make up that system are listed The INTERVAL por tion of the table is divided into five columns representing the various inspection time periods The numbers listed within the interval column represent the applicable inspec tion code for which that component is to be checked The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive Variances in interval times may occur due to climate and or conditions and depend ing on the location and use of the machine JLG Industries requires that a complete annual inspection be performed in accordance with the Annual Machine Inspection Report form Forms are supplied with each new machine and are also available from JLG Customer Service Form must be completed and returned to
64. ce Fuse Check Wiring 24 volts Goto Step 3 irom Battery B Terminal B Repair or Replace Repair wiring 24 volts Goto Step 4 Replace Key switch Repair wiring or Goto Step 5 Replace E Stop switch Repair wiring or Go to Step Replace E Stop switch Repair wiring or Go to Step 7 Replace Main Contactor Relay Go to Step 9 Go to Step 8 Replace Main Repair Ground Contactor Wiring 3 13 SECTION 3 TROUBLESHOOTING No Power At Platform Control Overview Of Procedure The following procedure checks voltage and ground starting from the power source batteries through the ground control station key switch E stop to the MC 1 box and finally to the platform control Check For These Obvious Conditions First Battery voltage 24 volts Fully charge batteries Keyswitch is turned to PLAT Platform Both Emergency Stop Switches Reset Ground Platform Out e Connection of X102 Cable from MC 1 box to Platform Control secure on both ends Table 3 5 No Power At Platform Control Check ifthe inline 5 amp fuse is blown on the Red 1 1 wire atthe ground control station Ground control cover must be removed Check voltage to the Yel Red 2 2 wire atthe MC 1 box X101 con Perform the E nector pin 3 Stop Key Switch 24 volts Goto Step 3 Circuit Check Table 3 17 Checkfor Groundto the Black wire atthe MC 1 box X101 connec Check connec tor pin A2 tion wiring Ground Goto Step 4 between Battery and X101 Pin A2
65. cei nee b oie i tecta C SECTION 1 SPECIFICATIONS 1 1 a 1 1 1 2 ComporehbDald ebbe d HH EO RR dea 1 1 1 3 POFOIianee Dal ud at on Xd e Un do 1 1 1 4 Hedqulremoebls ax 5 3 deco wena a he Rares 1 2 1 5 5 1 2 1 6 Hydraulic Pressure Adjustment ic dan gut kk KK KK KK KK KK Re KI KK a KK kk kk kk tas 1 3 1 7 Cylinder SPSCHIGAIONS 34 35 45 tas Reg obe ban dua it iei Bb a 1 3 1 8 Serial Number 1 3 SECTION 2 SERVICE PROCEDURES 2 1 d UR EE Duo dob 2 1 2 2 Servicing And Maintenance Guidelines 2 1 2 3 Etbricatioh InTOF Ra w 0OBAaerererrr eel aud aate 2 3 2 4 Positioning Lift For Access To Components Located Under The Base Frame 2 4 2 5 Drive Motor Component Service 5 2 5 2 6 Platform Control Box Service Procedures 2 15 2 7 Battery Charger Assembly And 2 20 2 8 Mast Assembly And Disassembly 2 23 2 9 Mast To Base Frame Installdl
66. cket Grasp the tip of the spring bracket such that the roll type spring will be on the brush side of the brush box and resting on top of the brush when the brush spring is completely installed 4 Push the spring bracket slowly into it s slot while let ting it s two attaching hooks slide on the wall of the brush box 5 Stop but do not release the spring bracket when it s hooks slip around the edge of the brush box 6 While still grasping the spring bracket with the pliers slowly bring the spring back out of the brush box until the hooks latch around the edge of the brush box 7 Now release the spring bracket and check that it is lying flat against the brush box wall If it is cocked it is improperly seated and will have to be reinstalled 2 14 JLG Lift CORRECT MI INCORRECT Figure 2 13 Correct Incorrect Brush Spring Bracket Positions A IMPORTANT THE SPRING BRACKET MUST BE ALSO LIE COMPLETELY INSIDE THE BRUSH BOX AND NOT OUT OVER THE EDGE THE ROLL END OF THE SPRING MUST BE CENTERED ON THE TOP OF THE BRUSH SEE FIGURE 2 13 8 Also apply slight pressure by pulling up on the spring bracket to be certain it is hooked securely around the brush box wall at the bottom of the brush box 9 Screw the brush caps back into the end shield using the largest possible screwdriver 10 Reinstall the drive motor s to the machine and reconnect the power source A IMPORTANT NEW BRU
67. cure and tight Also that the joystick control assembly for proper installation at the platform control box Check For These Obvious Conditions First f the Left Drive Motor X103 connector is switched with the Right Drive Motor X104 connector at the MC 1 box you will immediately get an 2 LED flashing Error Code at the Platform Control when the machine is powered up Check Joystick Calibration See Procedure in Service Manual Section 2 Table 3 15 Drives In Opposite Direction Check the connection of the Orange 55 3 wire to the right drive motor at both ends Atthe X104 connector on the MC 1 box pin A1 Goto Step 2 Andthe Black wire at the Drive Motor end onnection Check the connection of the Orange 55 6 wire to the right drive Repair or motor at both ends Coto Sten 3 Bonis Atthe X104 connector on the MC 1 box pin A2 KA e And the White wire at the Drive Motor end Connection Checkthe connection ofthe Orange 55 7 wire to the left drive motor Repair or atoom anos Goto Step 4 Replace e Atthe X103 connector on the MC 1 box pin A1 We And the Black wire at the Drive Motor end Connection Repair or Check the connection of the Orange 55 10 wire to the left drive Repair or motor at both ends Go to Sten 5 Banate e Atthe X103 connector on the MC 1 box pin A2 e e And the White wire at the Drive Motor end Connection Is platform control box under warranty Order New One Goto Step 6 I
68. de mast section 2 back into section 1 until end are even Step 23 and 24 applies to 20VP mast assembly only 10VP and 15VP mast assembly continue at step 25 Locate two mast extension chain assemblies Attach the eyelet anchor end of each chain to the outside holes near top of mast section 3 using 3 8 16UNC x 1 1 4 long hex head bolts nuts and flatwashers Place a flatwasher under bolt head and nut When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 3 into section 2 until ends are even Check to make sure chain assembly 466 wide chains are seating properly in chain 444 anchor block chain sheave wheels attached to mast section 2 Do not attach mast slide pads and shims to mast sections before assembling sections If assembled in 2 29 SECTION 2 SERVICE PROCEDURES 23 24 25 26 27 28 29 30 31 32 2 30 this manner due to the tight fit of the slide pads in the slide pad channels the anodized finish could be removed from the receiving mast s slide pad chan nels Insert slide pads into the top end mast rails between section 2 and 3 one on each side of the mast with beveled surface facing inward towards section 3 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in o
69. e MC 1 box to the dump valve circuit and through to the ground control tog gle switch Check For These Obvious Conditions First Battery voltage 24 volts Fully charge batteries Hydraulic oil is within it s specified operating temperature range Table 3 23 Platform Will Not Lower Using Platform Control GE 3S 3 1 Willmachinelowermanually using the manualdescentknob GotoStep2 See Table 3 26 Will machine lower from ground control switch Note Key switch mustbe setto GRND to check this GotoStep3 See Table 3 23 Check for ground onthe Tan 4 1 wire atthe MC 1 box X105 con Repair Replace nector pin 6 Go to Step 4 Joystick MC 1 Box Check for ground on the Tan 4 1 wire atthe lift down coil Replace Repair Goto Step 5 Wire or Connection BET Check complete pump motor circuit See Table 3 21 EEE EEE EN 3120849 JLG Lift 3 29 SECTION 3 TROUBLESHOOTING Platform Will Not Lift Up From Ground Control Toggle Switch Overview Of Procedure The following procedure examines the complete ground control circuit from the battery all the way to the pump motor for wiring or components which could be causing a failure of that circuit Check For These Obvious Conditions First Battery voltage 24 volts Fully charge batteries Battery connections clean and tight Key switch positioned to Ground GRND control Emergency stop switch pulled out Reset Position Gr
70. echani cally or electrically so that oil is available to the function valve then overriding the function valve mechanically If the function performs satisfactorily the problem exists with the control circuit 3 3 HYDRAULIC CIRCUIT CHECKS See Figure 3 4 The first reference for improper function of a hydraulic system where the cause is not immediately apparent should be the Hydraulic Diagram Circuit The best place to begin the problem analysis is at the power source pump Once it is deter mined that the pump is serviceable then a systematic check of the circuit components would follow NOTE For aid in troubleshooting refer to Figure 3 4 for HYDRAULIC DIAGRAM circuit 3 4 ELECTRICAL CIRCUIT CHECKS General The drive system on the VP series machine requires a microprocessor controlled electrical circuit to operate smoothly and accurately All platform control functions are relayed to various machine components i e platform up down drive functions etc through the MC 1 microprocessor box mounted under the battery charger support bracket To help diagnose any problems with the components associated with the microprocessor the MC 1 is designed with an internal fault messaging system which is displayed by LED flash sequences on the platform controller When operating nor mally the LED panel on the platform controller center LED strip indicates the battery voltage status using ten 10 green LEDs If a malfunction occurs
71. ective Replace switch 14 3 switch 14 3 Tilt Switch open Slope greater than 2 degrees Lower Platform and move to level ground 14 3 No Tilt Switch open circuit at Pin 2 ofX101 WHT Properly attach pin or wire connections wire 14 3 No Tilt Switch open circuit to ground Check ground wire connections BLK1 wire 25 Joystick E Stop Counter Controller Log Only 26 Configuration Access Counter Controller Log Only 3120849 JLG Lift 3 3 SECTION 3 TROUBLESHOOTING Table 3 2 MC 1 ERROR CODES Indicated by rapid LED flashing and periodic beep ERROR LED S CODE FLASHING PROBABLE CAUSE REMEDY 0 8 oystem Overvoltage Charger Unplug Charger 0 8 system Overvoltage Driving down long steep grade Operate ground controls to reduce voltage 1 7 Controller Overtemperature Turn unit off and allow to cool 9 8 Drive Motor Plug Open Circuit check connectors Properly attach wires or pins A1 amp A2 X103 amp X104 2 8 Drive Motor Plug Open Circuit check motor con Properly attach wires or pins WHT amp BLK wires nections at motor 3 6 Brake Safety Relay Replace Controller 4 2 Brake Short Circuit Replace Brake 5 9 Brake Left Open Circuit D connectors 103 amp Switch D connectors Left Motor to X103 Right X104 switched Motorto X104 5 9 Brake Left Open Circuit Check pins 3 amp 5 0f X103 Properly attach wires or pins
72. efective main contactor Replace main contactor Battery cables loose or corroded Clean amp tighten battery cables 26 6 If Ov pind of X101 check connection 7 amp Properly attach wires or pins 14 of X102 26 6 Connection pin 5 of X101 bad Properly attach wires or pins 26 6 Defective Power Relay Replace Relay 26 6 Defective Power Relay ground wire Properly attach wire Safety Circuit Joystick check pin 6 o X102 Red Properly attach wire or pin 27 6 Wi ire 57 6 safety Circuit Joystick check pin 3 joystick Properly attach wire or pin connector Red Wire Defective Joystick Normal voltage pin 6 of X102 Replace Joystick 27 6 Red Wire Joystick centered 5v Joystick not cen tered Ov 27 6 Safety Circuit Defective Controller Replace Controller 28 6 Current Measurement Replace Controller 29 6 Drive Circuit Left Defective Controller Replace Controller 31 6 Drive Circuit Right Defective Controller Replace Controller 32 1 Output driver defect check for short in Hourmeter Replace defective component Horn Alarm or Power Relay 32 1 Output Driver Defective Defective Controller Replace Controller 35 8 Communication Error Check Pins amp 13 0f X102 Properly attach wires or pins Orange amp Blue Wires 35 8 Communication Error Check Pins 4 amp 5 at Joystick Properly attach wires or pins Orange amp Blue Wires 35 8 Defective Joystick Replace Joystick 35 8 Defective Controller Replace Controller
73. els Check For These Obvious Conditions First Battery voltage 24 volts Fully charge batteries Nothing is lodged between one of the wheels and the base frame A caster wheel on the front of the machine is seized up creating resistance Joystick properly calibrated per procedure in Section 2 of Service Manual Table 3 18 Won t Drive Straight STEP ACTION SPEC YES O Check for the following on the drive assembly drive attachment Goto Step 2 weldment is bent has broken welds or loose hardware Tighten weldment Repair Replace o Tighten weldment Check for the following the drive assembly drive motor hard Repair Replace ware is hardware loose flange bearing bad loose slip clutch Tighten compo Goto Step 4 checktorque settings or adjustment nent Checkforthefollowing onthe drive assembly drive motor mounting plates are bent are square with drive weldments or is hardware loose releasing properly Checkthe left and right drive motor brakes forloose hardware amp not Tighten or Adjust per procedure inthis Goto Step 5 service Manual Repair Replace components per procedure in this service Manual Is the electrical signal and amperage draw to the drive motors 24 volts Recheck Steps Go to Sten 7 equal 15amps 1thru5 Checkthe drive motor brushes do they need replaced Replace per procedureinthis Goto Step 8 service Manual Is the X102 wiring harness from
74. f approximately 006 but will operate normally at 004 to 010 between the armature plate and magnetic coil housing surface when the brakes are ENGAGED brakes on Never allow any type of lubricant oil grease hydraulic fluid etc to come in contact with the brake friction disk or it s contacting surfaces Also if the brake becomes clogged with debris or dirt the brake may not release properly Checking Adjusting Armature Plate Gap Setting 1 First inspect that all parts of the brake assembly are tight and secure Tighten as necessary 2 Inspect the brake for any debris which may be lodged in the air gap between the armature plate and magnetic coil when the brakes are ENGAGED brakes on on either side of the friction disk when the brake is RELEASED brakes off or any dirt or debris lodged between the manual release arm and the magnetic coil housing Clean and remove debris as necessary 3 With the brakes ENGAGED measure the air gap between the armature plate and the magnetic coil housing The correct setting should be 006 how ever the brakes will operate properly if the measure ment is a minimum of 004 and a maximum of 010 See Figure 2 5 4 lf the air gap falls outside the maximum allowable setting of 010 the friction disk has worn To correct this replace the disk with a new one 5 air gap is below the minimum allowable setting of 004 recheck the areas between the magnetic coil housing
75. for y right motor and the 55 7 wire atthe X103 connector pin A1 for left 24 volts Ric ae 2 i motor connections ox or Joystic Table 3 10 Brake Switch Circuit Check Perform these checks with the joystick enabled and pushed to the full forward position Check for 24 volts at the wiring connectors on the 55 4 wire on the Clean Gap or right drive motor brake unit and the 55 8 wire on the left drive motor 24 volts Replace Brake Goto Step 2 brake unit Check for 24 volts at the 55 4 wire at the X104 connector 5 for 7 bA RW right motor and the 55 8 wire atthe X103 connector pin 5 for left 24 volts motor y Unit 3120849 JLG Lift 3 17 SECTION 3 TROUBLESHOOTING Won t Drive Platform Elevated Only Overview Of Procedure The following procedures check the components and circuits that feed data to the MC 1 Controller box assuring it is receiv ing the proper signals and conditions before engaging the machines drive motors Check For These Obvious Conditions First Joystick Powered On Unit will Lift amp Lower Platform Machine is not Tilted 3 LEDs flashing at joystick control PHP Device is not Obstructed 4 LEDs flashing at joystick control Brakes are not Released 2 LEDs flashing at joystick control Charger is not Plugged In 8 LEDs flashing at joystick control Table 3 11 Won t Drive with Platform Elevated Check for ground ontilt circuit at MC 1 bo
76. fully slide mast section 2 closed rail into section 1 open rail Slide sections together until ends are even Do not attach mast slide pads and shims to mast sections before assembling sections If assembled in this manner due to the tight fit of the slide pads in the slide pad channels the anodized finish could be removed from the receiving mast s slide pad chan nels Insert slide pads into the slide pad channels at bot tom end of mast between section 1 and 2 one on each side of the mast with beveled surface facing out towards section 1 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in mast section 2 inside rail into the slide pad inserts Thread in enough to hold pad in place Shim slide pads using the following steps Always use the an even amount of shim material behind slide pads on both sides of the mast rails This will keep mast sections centered in rail chan nels and prevent any distortion of the mast section a Use two shim pieces per slide pad a thick one and a thin one b Start with a total thickness of approximately a 025 thick shim and a 055 thick shim c Slide shims into place between slide pad and mast rail Tighten the slide pad mounting bolts be sure there are no air gaps on flat side of slide 8 10 NOTE 11 NOTE 12 13 NOTE 14 15 JLG Lift pad between
77. g or Turned Pins Chains operating with inade quate lube generate tremendous friction between the pin and plates pin and bushing on leaf chain In extreme cases this frictional torque can actually turn the pins in the outside press fit plates Inspect for turned pins which can be easily spotted as the V flats on the pin heads are no longer in line Replace all chains showing evidence of turned or protruding pins Keep chains lubricated Chain Anchors and Sheaves An inspection of the chain must include a close examination of chain anchors and sheaves Check chain anchors for wear breakage and misalignment Anchors with worn or broken fingers should be replaced They should also be adjusted to eliminate twisting the chain for an even load distribution Inspect the sheaves sheave bearings sheave grooves and pins for extreme wear replace as necessary worn sheave can mean several problems as follows a Chains too tight b Sheave bearings pin bad c Bent misaligned chains Mast Cable Inspection Procedure MAST CABLES ARE TO BE INSPECTED EVERY THREE MONTHS OR MORE FREQUENTLY AS DESCRIBED FOLLOWING WEAR PROTECTIVE GLOVES TO PROTECT HANDS WHEN HAN DLING CABLE The periodic inspection shall cover the entire length of the cable The inspection frequency shall be based on such factors as expected cable life as determined by experi ence on the particular application or similar installations severity of environment percen
78. gated 3 they must be removed and replaced Refer to Table 2 1 for proper chain specifications and allowable stretch tolerances Peening and wear of chain plate edges are caused by sliding over a chain worn contact face of a sheave or unusually heavy loads All of the above require replacement of the chain and correction of the cause Chain side wear noticeable when pin heads and outside plates show a definite wear pattern is caused by misalignment of the sheave chain anchors and must be corrected promptly Do not repair chains if a section of chain is damaged replace the entire chain set Rust and Corrosion Rust and corrosion will cause a major reduction in the load carrying capacity of the chain because these are primary reasons for side plate crack ing The initial lubrication at the factory is applied in a hot dip tank to assure full penetration into the joint Do not steam clean or degrease chains At time of chain installa tion factory lube must be supplemented by a mainte nance program to provide a film of oil on the chains at all times If chains are corroded they must be inspected especially the outside plates for cracks in line with the pins If cracks are found replace the chain if no cracks are discovered lubricate the chains by dipping in heated oil and reinstall on the machine Keep chains lubricated Table 2 1 Chain Stretch Tolerance Chain Size Allowable Stretch Measurement 50 pitch 12 or 24
79. h ers spring spring cap and lock nut previously dis assembled Thread the lock nut on until approximately 1 8 in 3mm of threads are exposed At the bottom of the mast thread the loose end of the replacement cable through the proper sheave pulley and through the hole in the sheave pully anchor bracket on the mast section ahead of the sheave pulley Grasp the cable and pull on the cable until the spring at the top of the cable is slightly compressed Use a black marker to mark the cable on the top side of the sheave pully anchor bracket This will determine where the clamp drum socket sleeve will be positioned on the cable A IMPORTANT DO NOT CUT THE CABLE AT THE MARKED POINT ON THE CABLE THIS IS ONLY USED AS A REFERENCE FOR POSITIONING THE CABLE SLEEVE WHICH WILL REST AGAINST THE ANCHOR BRACKET ONCE INSTALLED JLG Lift 3120849 Clamp Installation Drum Socket Type THE MANUFACTURER OF THE DRUM SOCKET CLAMP RECOM MENDS THE USE OF THEIR CABLE CLAMP ASSEMBLY KIT JLG P N 7023275 TO ASSEMBLE THE CLAMP TO THE WIRE ROPE THE KIT CONSISTS OF VISE JAWS TO HOLD THE WIRE ROPE IN A VISE PROPERLY WITHOUT DAMAGING ANY ROPE STRANDS AND A PLUG DRIVER TO DRIVE THE PLUG INTO THE CENTER OF THE WIRE ROPE AND IS ALSO USED TO FORM THE STRANDS OF THE ROPE DURING ASSEMBLY NOTE The tools in the clamp assembly kit may be frabri cated if necessary The vise clamp consists of vise jaws with a hole drilled 1 32 in smaller tha
80. h mast to base using four 4 3 8 16UNC x 1 long hex head bolts locknuts and flatwashers place a flatwasher under bolt head and nut and mount with nuts on inside of frame Locate the two 2 mast support braces attach to sides of base frame using a 3 8 16UNC x 1 long hex head bolt nut and flatwashers each brace place a flatwasher under bolt head and nut and mount with nuts on inside of frame Use access hole in bottom of frame to attach nut inside frame Before setting machine upright on base install a short 90 elbow fitting flow control valve and another short 90 elbow fitting on the end of the flow control valve in the extend left port on bottom of hydraulic cylinder Install a long 90 elbow fitting on return right port Use sealant tape on fitting threads Cap ports until hydraulic lines are installed Carefully set machine in an upright position on its base frame wheels Locate the mast support bracket Attach mast sup port bracket to mounting holes halfway up back of mast using four 4 3 8 16UNC x 2 3 4 long hex head bolts locknuts and flatwashers Place a flat washer under bolt head and nut and mount with nuts on inside of frame Using a 4 ft level ensure mast is set to vertical plumb on the base frame When mast is vertical plumb attach support braces bolted to base to the mast support bracket bolted to mast using 3 8 16UNC x 2 3 4 long hex head bolts nuts and flatwashers Place
81. has been activated and Enter Code or deactivate using MC 1 configuration must be entered before operation software 1 8 Charger Connected Unplug Charger Brake Status Switch Open Parking brake manually Reset Parking Brake 3 2 released 3 9 Brake manual release lever obstructed located at Clear obstruction and reset lever drive motor brake 3 2 Defective parking brake status switch located at Replace Switch drive motor brake 3 2 Defective pin 11 at X105 wire connection or Properly attach wires or pin improper wiring 3 2 Improper wiring at parking brake status switch Properly attach wires Improper wiring from parking brake status switchto Properly attach wires 3 2 ground Configuration Lost Drive Characteristic has Reprogram using MC 1 software 4 5 changed 5 6 Current Measurement faulty Drive characteristic Cycle on off and reprogram if necessary may have changed 6 7 High Temperature in controller Reduce power 7 7 Motor Stalled Check drive wheels and motors 9 1 Battery Low 18v and power reduced Charge Batteries 12 9 opeed Control Potentiometer defective Replace Joystick 13 4 Drive Cutout Input Open PHP bar must be downto Lower PHP drive while elevated 13 4 PHP baris down but drive is disabled Defective wir Properly attach wire RED BLU or pin 12 of X105 ing at D connector connector 13 4 PHP baris down but drive is disabled Defective Properly attach wires ground wiring PHP baris down but drive is disabled Def
82. hreads with Loctite 171 and tighten When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 4 back into section 3 until ends are even Check to make sure chain assemblies are seating properly in chain sheave wheels attached to top of mast section 3 Do not attach mast slide pads and shims to mast sections before assembling sections If assembled in this manner due to the tight fit of the slide pads in the slide pad rails the anodized finish could be removed from the receiving mast s slide pad chan nels Insert slide pads into the top end mast rails between section 3 and 4 one on each side of the mast with beveled surface facing inward towards section 4 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in outside rail on top of mast section 3 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Insert slide pads into the bottom end mast rails between section 3 and 4 one on each side of the mast with beveled surface facing out towards sec tion 3 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes on inside rail on bottom end of mast section 4 and into the slide pad inserts Thread in eno
83. il is within it s specified operating temperature range Table 3 20 Platform Will Not Lift Up Using Platform Control STEP ACTION YES Will platform liftfrom ground control switch Note Key switch must be setto GRND to test this Gotostep2 See Figure 3 24 Does pump motor run see Pump Circuit Goto Step 3 Check Table 3 21 Arethe down and dump valves opening closing properly oee Pump Valves Note If machine will not lift and hydraulic oil is visible flowing in the Goto Step 4 Circuit Check hydraulic tank the dump valve is stuck in the open position Table 3 22 pressure specifi cation per this service Manual Is the lift cylinder OK Rebuild or Check Mast Rebuild if Necessary Goto Step 5 Are the mast sections operating freely Consult Factory Is the pressure set properly onthe pump Set to correct 3 26 JLG Lift 3120849 SECTION 3 TROUBLESHOOTING Table 3 21 Pump Circuit Battery voltage 24 volts Fully charge batteries e Key switch setto Platform Atthe pump motor check for 24 volts at both ends of the battery Tighten cable running from the main con rtoth lef unning the main contactorto the pump case stud left 24 volts Goto Step2 Connection or side Replace Cable if Necessary PUMP CONTACTOR RELAY CIRCUIT Checkthe connection of the ground cable attached to 5 16 stud Tighten leftside tothe pump contactor is tightand connected on other end Connectio
84. ilure misadjustment due to wear Check For These Obvious Conditions First Batteries are Fully Charged 24 Volts Speed Control is Set to Maximum s Grade within the Maximum Allowable Specification of 1596 Grade 8 5 degrees Does the Travel Surface allow for Proper Drive Wheel Traction s Platform Load within the Maximum Rated Capacity Table 3 14 Won t Climb Grade ACTION Does machine drive straight on a level surface Referto Machine Won t Drive Goto Step 2 Straight Table 3 18 Are both the left and right drive motor slip clutches located Repair Replace between the drive motor and the drive wheels working properly Go to Step 3 or Adjust Slip Clutch Dothe left and right drive motor brakes release properly and allow Dragging the drive wheels to rotate freely Goto Step 4 Repair Replace or Adjust Brakes Check the amperage output of the on the drive motor leads They Controller will should not exceed 70 amps while pulling a grade Shut Drive Down and will flash a 7 LED Code Checkthe condition of the drive motor brushes Worn down goto Step6 replace brushes or drive motor If all above is OK Drive motors are working properly Consult Fac tory Goto Step 5 3 20 JLG Lift 3120849 SECTION 3 TROUBLESHOOTING Drives In Opposite Direction Overview Of Procedure The following procedure checks that both the drive motor power wire connections correctly installed and are se
85. is not corrected An audible three beeps indication is given at the beginning of each warning displayed WHEN A WARNING CODE IS INDICATED THE MACHINE WILL USUALLY FUNCTION however some machine functions may be disabled See Table 3 1 for explanation of WARNING codes ERROR Codes See Table 3 2 An ERROR is indicated by an audible beep and continuously fast flashing LED bar The number of fast rapidly flashing LEDs indicate the particular error message AN ERROR CONDITION WILL DISABLE THE MACHINE until the problem is cor rected The ERROR message is only reset by turning off the system however if the problem has not been corrected the ERROR will be indicated again at machine power up See Table 3 2 for explanation of ERROR codes NOTE As shown in the following WARNING and ERROR code tables a specific number of LEDs flashing can indicate more than one WARNING or ERROR code These tables suggest specific areas to check as the probable cause for the fault code which has occured The fault code number is shown in the first column of the table and the number of LEDs flash ing on the platform controller LED strip is shown in the second column of the table 3 2 JLG Lift 3120849 Table 3 1 MC 1 WARNING CODES SECTION 3 TROUBLESHOOTING Indicated by 3 beeps then slow flashing LED s WARNING LED S CODE FLASHING PROBABLE CAUSE REMEDY 0 10 Enter Code Security Code
86. is the first consideration when engaging in the maintenance of equipment Always be conscious of component 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 ade quate support is provided NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING Cleanliness The most important single item in preserving the long ser vice life of a machine is to keep dirt and foreign materials out of the vital components Precautions have been taken to safeguard against this Shields covers seals and fil ters are provided to keep the wheel bearings mast sec tions and oil supply clean however these items must be maintained on a scheduled basis in order to function properly At any time when oil lines are disconnected clear adja cent areas as well as the openings and fittings them selves As soon as a line or component is disconnected cap or cover all openings to prevent entry of foreign mat ter Clean and inspect all parts during servicing or mainte nance and assure that all passages and openings are unobstructed Cover all parts to keep them clean Be sure all parts are clean before they are installed New parts should remain in their containers until they are ready to be used Components Removal and Installation Use ad
87. justable lifting devices whenever possible if mechanical assistance is required slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted Should it be necessary to remove a component on an angle keep in mind that the capacity of an eyebolt or sim ilar bracket lessens as the angle between the supporting structure and the component becomes less than 90 degrees If a part resists removal check to see whether all nuts bolts cables brackets wiring etc have been removed and that no adjacent parts are interfering Component Disassembly and Reassembly When disassembling or reassembling a component com plete the procedural steps in sequence Do not partially disassemble or assemble one part then start on another Always recheck your work to assure that nothing has been overlooked Do not make any adjustments other than those recommended without obtaining proper approval Pressure Fit Parts When assembling pressure fit parts use an anti seize or molybdenum disulfide base compound to lubricate the mating surface Bearings When a bearing is removed cover it to keep out dirt and abrasives Clean bearings in nonflammable cleaning sol vent and allow to drip dry Compressed air can be used but do not spin the bearing Discard bearings if the races and balls or rollers are pit ted scored or burned If bearing is found to be serviceab
88. lace the drive motor gear box assembly on a hydraulic press with the open side of the gear box housing facing down Support the gear box housing surface but do not block the free travel of the drive gear and bearings on the drive shaft or the pinion gear assembly With the open surface of the housing properly sup ported carefully press the drive shaft down through until it is free of the housing When the drive shaft assembly is free slide it completely out of the hous ing To remove the large 47mm cover side bearing and housing side bearing from the drive shaft use a suitable hydraulic press and press the bearing s off the shaft Keep the spacer from between the cover side bearing and the drive shaft gear for reuse during assembly To remove the small 32mm bearing s from the gear brass and pinion assembly use a suitable hydrauic press and press the bearing s off the gear and pinion shaft To remove the brass worm gear from the pinion assembly use a suitable hydraulic press and press the gear off the pinion shaft Keep the brass gear key for reuse during assembly Inspect the drive shaft seal for cuts cracks and wear or if showing signs of leakage Replace if nec essary SECTION 2 SERVICE PROCEDURES Gear Pinion Shaft Assembly See Figure 2 9 1 NOTE Locate the pinion gear shaft place the key for the brass worm gear into the slot on the gear shaft Press the brass worm gear onto the pi
89. latform Does it Lower 3 32 JLG Lift 3120849 SECTION 3 TROUBLESHOOTING Platform Lift Up And Down Jerky Overview Of Procedure The following procedure suggests areas on the machine which might attribute to erratic movement of the platform during lift up and down Check For These Obvious Conditions First f mast is not running smooth or has tight and rough spots refer to the Mast Section Rebuild Hydraulic oil level in reservoir tank at full level Hydraulic oil no milky presence of water or not foamy full of air Table 3 27 Platform Lift Up and Down Jerky CONTROLS ELECTRICAL Is platform control enable up or down pad defective or worn out EEE Replace pad Goto Step 2 Loose connections ground and power DA Goto Step 3 connection Valve coils or solenoids keep opening and closing Repair Connec tion or Replace Goto Step 4 Valve Za Problem internal to the MC 1 control box Replace box Goto Step 5 HYDRAULIC 5 Arethe hydraulic valves working properly ReplaceValve Goto Step 6 6 Pump drive cavitates ReplacePump GotoStep7 Lift cylinder Rebuild or Replace Cylinder 3120849 JLG Lift 3 33 SECTION 3 TROUBLESHOOTING Mast Noisy When Lifting And Lowering Overview Of Procedure This procedure examines components of the mast itself and as well as it s lifting components for dirt debris proper lubrica tion and operation Table 3 28 Ma
90. le apply a light coat of oil and wrap it in clean waxed paper Do not unwrap reusable or new bearings until they are ready to install Lubricate new or used serviceable bearings before instal lation When pressing a bearing into a retainer or bore 3120849 JLG Lift 2 1 SECTION 2 SERVICE PROCEDURES apply pressure to the outer race If the bearing is to be installed on a shaft apply pressure to the inner race Gaskets Check that holes in gaskets align with openings in the mating parts If it becomes necessary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usage and Torque Application Use bolts of proper length A bolt which is too long will bottom before the head is tight against its related part If a bolt is too short there will not be enough thread area to engage and hold the part properly When replacing bolts use only those having the same specifications of the origi nal or one which is equivalent Unless specific torque requirements are given within the text standard torque values should be used on heat treated bolts studs and steel nuts in accordance with recommended shop practices See Figure 1 1 Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacles when disconnecting or removing
91. lifts If servicing a 10VP mast go to step 17 Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate on BOT TOM end of mast section 3 Push threaded ends of chain through anchor plate At TOP of mast section 3 pull chains out and allow to hang loose be certain floor surface is clean and free of any metal chips or debris which may stick to lubricated chains Slide mast section 3 out TOP of mast section 2 far enough to allow access to the chain sheave wheel assembly Remove countersunk flathead screws securing chain sheave wheel assembly attach bars on both side rails at TOP of mast section 3 and remove the sheave wheel assembly NOTE 15 NOTE 16 NOTE 17 18 19 20 21 NOTE 22 23 24 Step 15 applies only to 20VP lift models which have five 5 mast sections If servicing a 15VP mast go to step 16 While mast section 3 is still extended from section 2 remove the bolts attaching the two 2 chain assem bly anchor eyelets to the TOP of mast section 3 Remove chains When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 3 out BOTTOM of sec tion 2 Remove slide pads shims and chain anchor plate if necessary Removal of mast section 2 cylinder attach section is basically the same for all VP model lifts except where noted Slide mast section 2 ou
92. linder rod end and attach to mast section 2 using following steps 19 a Attach chain mounting tube to top of hydraulic cylinder using one 1 1 4 28NF x 5 8 cap screw b Insert sheave pin through cylinder chain mount ing tube on cylinder rod end c Place a spacer tube on each side of mounting tube d Next slide sheave wheels on onto sheave pin against spacer on each side of mounting tube e On outside of each sheave wheel place another spacer tube f On outside of spacer tubes place a sheave pin attach bar rectangular plate with threaded holes on each side of pin bore hole g Slide the assembly with sheave pin wheels and pin attach bars into top of mast section 2 h Attach to top of mast section 2 using two 2 3 20 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten NOTE 15VP Top of Cylinder Assembly 19 Assemble chain sheave wheels to cylinder rod end 21 and attach to mast section 2 using following steps a Attach chain mounting tube to top of hydraulic cylinder using one 1 1 4 28NF x 5 8 screw b Insert sheave pin through cylinder chain mount NOTE ing tube on cylinder rod end c Place a spacer tube on each side of mounting tube 22 d Next slide sheave wheels on onto sheave pin against spacer on each side of mounting tube e On outside of each sheave wheel place another spacer tube NOTE 3120849 J
93. mbly SECTION 2 SERVICE PROCEDURES Final Gear Box Assembly 1 NOTE 2 12 If necessary install a new drive shaft lip seal into the drive shaft hole in the gear box housing before assembling the drive shaft gear set into the gear box Install the seal so it is even with the bottom of the chamfer in the drive shaft hole on the outside of the housing and flush with the bearing seat on the inside of the housing Lube the drive shaft seal with a thin film of oil before sliding the drive shaft over the seal Position the gear box with open cover side up allow space under the gear box for the drive shaft to extend through without obstruction Hold the gear and pinion and drive shaft assembies together with the pinion gear and the ring gear on the drive shaft meshing Now carefully slide these assemblies into the gear box housing sliding the drive shaft through the drive shaft lip seal While assembling the gear assemblies into the gear box housing be careful with the drive shaft seal and the softer brass worm gear and brass drive worm gear from the drive motor Continue to drop the gear assemblies into the gear box align the bearings with the bearing seats in the housing on both assemblies Drop the gear and pin ion smaller bearing into it s seat first while wiggling 10 11 12 PINION GEAR PINION GEAR KEY SPACER 42mm x 25mm x 12mm BEARING 42mm x 20mm x 14mm BEARING th
94. mbly drive motor mounting plates are bent are square with drive weldments or is hardware Goto Step 3 Go to Step 2 loose Tighten weldment Check for the following on the drive assembly drive motor hard Repair Replace ware is hardware loose flange bearing bad loose slip clutch Tighten Go to Step 4 check torque settings or adjustment Component Service Manual Is the electrical signal and amperage draw to the drive motors 24 volts Recheck Steps Go to Sten 7 equal 15 amps 1thru5 7 Checkthe drive motor brushes do they need replaced Replace per procedure in this service Manual Inside the drive motor gear box check if the drive shaftis exces Repair Replace sively loose amp conditon of drive shaft bearings components per Coto Sten 6 Are any gears broken or gear teeth excessively worn procedure in this 0 to step Checkthe left and right drive motor brakes for loose hardware amp not Tighten or Adjust releasing properly per procedure Go to Step 5 inthis service Manual 3120849 JLG Lift 3 25 SECTION 3 TROUBLESHOOTING 3 9 MAST TROUBLESHOOTING Platform Will Not Lift Up Using Platform Control Overview Of Procedure This procedure examines the complete pump motor ground control and pump valves electrical circuits Check For These Obvious Conditions First Battery voltage 24 volts Fully charge batteries Platform loaded within maximum allowable capacity Hydraulic o
95. n Table 1 1 Machine GVW and Wheel Loads VP MODEL GVW DRIVE WHEEL CASTER Kg cm Kg cm no load ea w rated load ea w rated load Drive Caster 420 kg 930 Ib 9 5 kg cm 4 5kg cm 6 4 kg cm 18 6kg cm 18 6 kg cm Note 1 Maximum wheel load in any configuration with rated load 2 Standard platform or with extended platform retracted 3 Maximum with extended platform extended 3120849 JLG Lift 1 1 SECTION 1 SPECIFICATIONS Machine Height In Stowed Position Euro UK Aust 2 01m 79 in height Base Footprint VP Series 0 81m 32 in width 1 42m 56 in length Max Platform Height mast extended 10VP 3 1m 10 ft 2 in 15VP 4 36m 14 ft 4 in 20VP 5 82m 19 ft 1 in Platform Working Height average 10VP 4 92m 16 ft 2 in 15VP 6 2m 20 ft 4 in 20VP 7 64m 25 ft 1 in Machine Drive Speed max Platform Lowered 3 22 kph 2 mph Platform Elevated 81 kph 0 5 mph reduced by limit switch Variable to maximum with speed cut back Amperage Draw average Lift 12 amps Drive 20 amps When maintenance becomes necessary or a fastener has loosened refer to the Torque Chart Figure 1 2 to deter mine proper torque value 1 5 LUBRICATION Hydraulic Oil Hydraulic oils must have anti wear qualities at least to Service Classification GL 3 and sufficient chemical stabil ity for mobile hydraulic system service
96. n or to B atthe right side battery Ground Goto Step 3 Replace Cable if Necessary Checkthe connection of the ground cable other side is tight and Tighten conn h onnected to the pump case stud center Goto Step4 Connection or Replace Cable if Necessary Checkthe Yel Red 2 6 wire connected to the positive post on the Tighten Repair pump case fortightness and 24 volt reading 24 volts Goto steps Check the Tan 55 1 wire connected to both the Ground control switch and the MC 1 box X105 connector pin 5 through the pump rod Go to Sten 6 Tighten Repair contactor relay Without any lift functions activated it should show Connection 24 volts with a lift function activated it should show ground DUMP VALVE CIRCUIT Check the Yel Red 2 6 wire connected to the positive post on Tighten Repair the pump case for 24 volts 24 volts Goto Step 7 Connection 7 Checkthe Tan 3 1 wire connected to both the Ground control switch and the MC 1 box X105 connector pin 4 through the lift up 24 volts Go to Sten 8 Tighten Repair valve Without any liftfunction activated it should show 24 volts Connection with a lift function activated it should show ground DOWN VALVE CIRCUIT Check the Yel Red 2 6 wire connected to the positive post on Tighten Repair the pump case for 24 volts Goto Step 9 Connection Checkthe Tan 4 1 wire connected to both the Ground control switch and the MC 1 box X105 connector pin
97. n the diameter of the wire rope you are working with i e 1 8 in rope 3 32 in hole The plug driver is a metal tube with a hole in the bot tom to allow the strands of the wire rope to be shaped after the plug has been tapped into the cen ter of the wire rope 1 Using the recommended vise jaws clamp the wire rope into a vise with the bottom edge of the black mark made on the wire rope resting just above the vise jaws CABLE RECOMMENDED VISE JAWS MARK ON CABLE 2 Twist the sleeve from the clamp kit onto the rope until it is flat against the vise jaws at the mark made made on the wire rope SLEEVE INSTALLED 3120849 JLG Lift SECTION 2 SERVICE PROCEDURES 3 Use a suitable tool and cut the cable as shown in the illustration following For 1 8 in cable the recom mended length is 5 8 in past the end of the sleeve 4 Unlay the cable strands by gently forcing a screw driver between the outer strands to unlay the cable When done properly the outer strands will form a symmetrical basket Do not straighten out the spiral lay of the strands unlay any wires that make up the strand or allow the strands to cross each other inside the sleeve STRANDS UNLAYED Install the plug supplied with the kit by placing the plug in the center of the strands starting with the small tapered end of the plug Use a metal tube plug driver and hammer to drive the plug into the sleeve while assuring that the
98. nect the manual release brake cable to the manual release lever Y shaped lever and adjust cable so brakes are released when manual release lever is in the down position See Figure 2 6 MANUAL TO MANUAL RELEASE RELEASE BRAKE CABLE HANDLE MOUNTED ONSIDE OF MAST SET MANUAL BRAKES BRAKE RELEASE ARE RELEASED HANDLE TO WHEN CABLE PULLS LEVER IN THIS DIRECTION FREE WHEELING AND ADJUST HERE UNTIL BRAKE DISK IS COMPLETELY RELEASED Figure 2 6 Manual Release Brake Cable Adjustment 3120849 Drive Motor Removal 5 See Figure 2 7 The VP drive motors consist of three sections the gear box atttached to the rear of the drive motor the electric 6 drive motor itself and the brake assembly mounded at the front of the drive motor Each drive motor is mounted inde pendently of the other on a completely removable drive assembly weldment at the back of the machine NOTE 1 Disconnect the positive battery terminal from the left side battery 2 Remove the rear plate weldment from the machine T plate with the tie down lug and set aside Three 3 bolts hold the top of the rear plate weldment to the 8 base frame four 4 bolts attach it to the motor cover weldment located under machine at the back and on the sides 3 Carefully raise the lift to gain access to the under 9 side of the base frame Refer to Section 2 4 Posi tioning Lift For Access to Components Located Unde
99. ng clutch can be set as much as 35 ft Ib less than the factory setting of 185 ft Ib but never more than the 185 ft Ib factory setting 5 f torque setting is OK re install the wheels and lower machine IF NOT see the following note NOTE If torque setting is outside the allowable range of specifications the torque limiting clutch will need adjustment See Torque Limiting Clutch Adjustment following SERVICE TOOL P N 0080229 REQUIRES A 1 3 4 SOCKET CO Oe DU K 2 Wan bbs LIMITING CLUTCH LOC AAT ICON Figure 2 2 Check Torque Limit Clutch Torque Setting JLG Lift 2 5 SECTION 2 SERVICE PROCEDURES Torque Limiting Clutch Adjustment NOTE The large adjusting nut on the side of the clutch assembly is a standard type thread If the torque slip setting of the clutch assembly is under spec by more than 35 ft Ib the large adjust ing nut must be tightened turned clockwise to increase the torque setting If the torque slip setting is over spec over 185 ft lb the large adjusting nut must be loosened turned counter clockwise to decrease the torque set ting 1 Loosen the two 2 adjusting nut setscrews located on the large adjusting nut on the clutch assembly See Figure 2 3 2 Hold the drive axle steady using service tool P N 0080229 and the torque wrench used to check the torque setting 3 Depending
100. nion shaft and align the keyway in the brass worm gear with the key on the pinion shaft Press the brass worm gear onto the shaft until it bottoms out against the pinion gear teeth Press bearings onto the shaft pressing only against the bearing inner race Do not press against the outer race or damage could occur to the bearing Press the small 32mm bearings onto the ends of the pinion shaft The inner race of the bearing on the pinion gear side can be bottomed out against the pinion gear Do not press the bearing on the brass worm gear side of the shaft in tight against the brass worm gear This bearing must be flush with the end of the shaft on the outside yet have clear ance from the brass worm gear on the inside so it can rotate freely Drive Shaft Assembly See Figure 2 10 1 JLG Lift Slide the housing side 42mm x 25mm x 12mm thinner bearing onto the long end of the drive shaft Press the bearing inner race until it bottoms against the shaft shoulder between the drive gear and the bearing Slide the narrow spacer onto the drive gear end of the shaft and press the cover side 42mm x 20mm x 14mm wider bearing onto the drive shaft until it bottoms against the spacer This bearing should be flush with the end of the drive shaft SIDE PROFILE WORM GEAR LEAVE BRASS HERE PINION GEAR 32mm SHAFT 32mm BEARING BEARING N WORM GEAR KEY Figure 2 9 Gear Pinion Shaft Asse
101. nt intervals to determine an appropriate inspection schedule Brushes should be replaced before they are less than 375 in 9 5mm in length Carbon dust accumulation should be removed periodically If the end shield has been ME removed from the drive a clean dry non linting cloth can be used for cleaning DO NOT use solvents as they my damage non metallic parts and adversely affect subse quent brush commutation i K r PIGTAIL WIRE SPRING BRACKET Figure 2 12 Drive Motor Brush Installation 3120849 JLG Lift 2 13 SECTION 2 SERVICE PROCEDURES Brush Reassembly See Figure 2 12 NECTED TO THE GROUND TERMINAL IF REMOVED LEADS INTERNAL TO THE SHEILD MUST BE ROUTED AWAY FROM THE ARMATURE E G BE CLOSE TO THE INSIDE WALL OF THE ALUMINUM SHIELD TO PREVENT A SAFETY HAZARD AND OR DAMAGE TO THE MOTOR 1 Install the brush pig tail terminal end under the screw on the brush box in the same manner as the old brush that was removed and tighten the screw 2 Slide the body of the brush into the brush box be certain that the wire pig tail is aligned with the slot in the base of the brush box so that it can feed into the brush box slot as the brush wears down NOTE The pig tail wire should be formed to rest against the nonmetallic insulator It must be spaced from any metallic surfaces other than the brush box by a mini mum of 125 in 3mm 3 Now install the brush retaining spring bra
102. nternal to the platform control check that the joystick assembly Re install Coto Sten 7 inside the platform control has not been installed backwards Correctly 7 Internal to the platform control check that the joystick assembly Re install Pansulkeactor wiring to the platform control circuit card is not wired backwards Correctly Note If the Orange 55 3 or 55 6 wires to the right drive motor in the X104 connector or the Orange 55 7 or 55 10 wires to the left drive motor in the X103 connector at the MC 1 controller are crossed up that drive motor will run backwards Note If platform controller is not under warranty the internal components of the platform controller are replaceable and can be ordered and replaced seperately from the complete platform control box See procedures in Section 2 of this Service Manual for Joystick Assembly Disassembly 3120849 JLG Lift 3 21 SECTION 3 TROUBLESHOOTING Will Only Drive A Short Distance Overview Of Procedure The following procedure will eliminate any problems found in the power circuit to the MC 1 controller box and also any objectionable environmental conditions Check For These Obvious Conditions First s Battery Voltage 24 Volts Fully Charge Batteries Table 3 16 Only Drives A Short Distance Is au controller staying powered up when machine stops driv Checkthe E Stop ing amp Key Switch Goto Step 2 Circuit Table 3 17 Check the voltage out of the X10
103. oStep4 LimitSwitch Cir cuit Table 3 8 Check that brakes are releasing 2 LEDs when joystick is enabled Check Drive Check Brake amp moved forward Motor Circuit Switch Circuit Table 3 9 Table 3 10 Perform these checks atthe elevation switch which is located inside the top of mast section 1 Check with mast lowered ACTION Check for ground into the switch from ground connection Goto Step Repair Connection Check for ground out of switch to the 49 5 wire Goto Step 3 Adjust Replace switch Check for ground from switch to X101 Pin 1 Repair Wire or Connection 3 16 JLG Lift 3120849 SECTION 3 TROUBLESHOOTING Table 3 8 Brake Limit Switch Circuit Check Check for ground into the switch from the ground connection on the Coto Step Repair left brake limit switch SOL Connection Check for ground on the 49 4 wire coming out of left brake limit Adjust Replace Check for ground on the 49 4 wire going into the right brake limit Repair Replace Checkfor gound on the 49 3 side ofthe right brake limit switch Replace Repair wire or MC 1 box Connection Table 3 9 Drive Motor Circuit Check e Perform these checks with the joystick enabled and pushed to the full forward position Check for 24 volts at the drive motor on the 55 3 wire on the right 24 volts Problem with Go the Step 2 motor and the 55 7 wire onthe left drive motor Positive Side Motor Check for 24 volts atthe 55 3 wire atthe X104 connector pin A2
104. olLizs a 523 325 8 KK KK KK KK RR KK 2 32 2 10 Mast Chains cables And Sequencing Cables 2 33 2 11 Sequence Cable Replacement 2 34 2 12 Preventive Maintenance And Inspection Schedule 2 36 SECTION 3 TROUBLESHOOTING 3 1 General ttr md asi e x cad aep 3 1 3 2 Troubleshooting InformallODi 4 6 crt Uk t Un rg cuc ah e cR 3 1 3 3 Hydraulic Circuit 5 3 1 3 4 Electrical GIECUIE GIT CK SS s ss s rte EE all 3 1 9 5 Troubleshooting Section Table Of Contents 3 15 3 6 Ohm Ratings For Various Components 3 16 3 7 Main Power Circuit 3 17 3 8 Drive Train Ti OUDl SI 8019 ahs aii d BAR ae Ak Red B Sodio 3 20 3 9 ITOUDIGSMOOUMG 3 diea vetat ie E a zn 3 30 3 10 Hydraulic Leak 3 41 3 11 Base Frame Components Troubleshooting 3 42 3120849 JL
105. or KI KI KIRI KIR KK KK fet KK ka 3 14 DRIVE TRAIN TROUBLESHOOTING Won t Drive Platform Lowered Or 3 16 Won t Drive Platform Elevated 3 18 Wene la ez n B e eaenbbbmyzddgbmpp wv yy 3 20 Drives In Opposite Direction 3 21 Will Only Drive A Short Distance 3 22 ell ala RD 3 24 INOISe EFOITI a bala y Re 3 25 MAST TROUBLESHOOTING Platform Will Not Lift Up Using Platform 3 26 Platform Will Not Lower Using Platform 3 29 Platform Will Not Lift Up From Ground Control Toggle Switch 3 30 Platform Will Not Lower From Ground Control Toggle Switch 3 31 Platform Will Not Lower Manually 3 32 Platform Lift Up And Down 3 33 Mast Noisy When Lifting And 3 34 Platform Mast Won t Stay 3 35 Platform Mast Descends Too 5 3 36
106. or Circull Check 5c na eco 3 21 3 10 Brake Switch Circuit 3 21 3 11 Won t Drive with Platform 3 22 3 12 Tilt Sensor Circuit Check oru kw epo ha foe 3 22 JLG Lift 3120849 LIST OF FIGURES TABLE OF CONTENTS 3 13 s esa GM Ig Sea a ORI d dua au dro cat a 3 23 3 14 ETE ET OE DET TR T OTT 3 24 3 15 Drives In Opposite DIFGCHOEN bala yal wo nda eden E RR Rr wn 3 25 3 16 Only Drives A Short Distance 3 26 3 17 E Stop and Key Switch Circuit 3 27 3 18 Won t DVS MEM n HEME HRH HHHH a m dide AUR c di OU HH N 3 28 3 19 Noise from Drive Assembly 3 29 3 20 Platform Will Not Lift Up Using Platform 3 30 3 21 CICU s ae Jl S 3 31 3 22 Pulp Vaes Geul 553 uus aded EUR d e mm IR qug date eh 3 32 3 23 Platform Will Not Lower Using Platform Control 3 33 3 24 Unit Will Not Lift Up From Ground Control Toggle Switch
107. ould be no side to side movement of slide pad in rail channel Mast sections should be very snug in channels but still be able to slide in channel by hand Slide mast section 4 5 to top of section 3 4 Insert threaded ends of chain assembly attached to top of mast section 2 3 through the chain anchor plate located on bottom of extended mast section 4 5 Loosely thread two 2 3 8 16UNC nuts onto stud threads on each chain Chains will be adjusted later in assembly Slide mast section 4 5 back into mast section 3 4 until bottom ends of masts are even Check to make sure chain set attached to top of section 2 3 is seat ing properly in chain sheave wheels attached to top of mast section 3 4 Mast sections 2 3 and 4 may need to be restrained to keep their slide pads from pushing out the bottom of mast sections 1 2 and 3 At bottom of mast assembly thread all chain adjust ing nuts on threaded ends until they are snug against the anchor plates and all slack is removed from chains Check that chains are seated in their sheave wheels at top of mast assembly Also ends of mast sections should be even with each other Mast assembly should now be complete Bo MAST TO BASE FRAME INSTALLATION THEIR TRAYS BEFORE LAYING THE BASE FRAME IN A HORIZON TAL POSITION 2 32 Using an overhead crane or suitable lifting device capable of supporting the weight of the base frame attach a sling strap or chain to the
108. ound control power supply and wiring OK Table 3 4 Manual descent valve closed 5 amp fuses on power and pump circuits OK Hydraulic oil level OK Weight in platform does not exceed machine maximum capacity Table 3 24 Unit Will Not Lift Up From Ground Control Toggle Switch Does the pump motor run when lift up is selected atthe ground con Check Ground trol switch Power Circuit Goto Steps 5 6 Table 3 4 Note Steps 2 thru 9 areto be performed with LIFT UP selected atthe and 10 Before Continu ground control ingto Step 3 Checkterminal 30 and 85 on the ground control relay for ground Is Repair Wiring or Check continuity across terminals 87 and 30 on the ground control relay Is there continuity Relay must be energized NE Goto step 4 Replace Relay Check the Black wire from terminal 87 on the ground control relay to Go to Sten 5 Repair Wiring or the liftup down ground control switch Is there continuity with B Connection Check the Tan 3 1 wire for continuity from the lift up down ground Repair Wiring switch to the lift up coil Is there continuity Goto Step 7 Check the Tan 55 1 wire from the lift up down ground switch to the Coto Sten 8 Repair Wiring or pump contactor for continuity Is there continuity Connection Checkthe Yel Red 2 6 wire from the pump motorto the pump con Repair Wiring or tactor and lift up coil for voltage Is there voltage 24 Volts Go to Step 9 Connection Checkthe wire f
109. ox housing internal components Gear Box Disassembly See Figure 2 8 1 Remove the drive motor gear box brake assembly from the machine using the procedure outlined pre viously in this section of the manual GEAR amp PINION DRIVE ASSY SHAFT KEY SHAFT DRIVE SHAFT DRAIN PLUG INCLUDED ONLY ON OLDER MACHINES LIP SEAL BEARING amp RETAINING RING BEARING 47mm x 25mm x 12mm GEAR SPACER BEARING 47mm x 20mm x 14mm Figure 2 8 Drive Motor Gear Box Assembly 2 10 JLG Lift 3120849 NOTE The gear oil can be drained out when the side cover 10 3120849 is removed in the next step Remove the side cover from the gear box with the drive shaft side pointing down then tilt drive motor gear box assembly to arain the oil into a suitable container Remove the four 4 hex cap screws securing the side cover to the gear box housing and remove the side cover and rubber seal ring Note Early model machines did not have the rubber seal ring and were sealed with sealant only Be careful not to scratch or gouge the mating surfaces between the cover and the gear box housing This area is sealed by the rub ber ring sealant and may leak oil if damaged Remove the wave washers from atop the large and small bearings and lay inside their respective holes in the side cover Using a suitable catch container drain the gear oil from the gear box housing Remove the drive shaft assembly from the housing P
110. pair Wiring or Ed ground contact OK Continuity with B Goto Step 4 Connection Check continuity across terminals 87 and 30 on the ground control Ed relay Is there continuity Relay must be energized Ground Goto steps Replace Relay Will machine lower manually Check the Black wire from terminal 87 on the ground control relay to Go to Sten 6 Repair Wiring or the lift up down ground control switch Is there continuity with B Connection Check for continuity across the terminals Black to Tan 4 1 wire of Replace Lift Up the liftup down ground control toggle switch Is there continuity Goto Step 7 Down Ground with the switch activated Control Switch 7 Checkthe Tan 4 1 wire for continuity from the lift up down ground Go to Sten 7 Repair Wiring or switch to the lift down coil Is there continuity Connection Checkthe Yel Red 2 6 wire from the pump motor to the lift down 24 volts Repair Wiring or coil for voltage Is there voltage Connection 3120849 JLG Lift 3 31 SECTION 3 TROUBLESHOOTING Platform Will Not Lower Manually Overview Of Procedure The following procedure suggests components on the machine which might attribute to problems with the manual descent circuit Table 3 26 Platform Will Not Lower Manually Check manual override solenoid with manual override knob open oto Step 2 sin NE Consult Factory 2 Check Steps 1 thru 6 of Table 3 30 Place the maximum capacity of weight in the P
111. pitches 24in 12in span 625 pitch 15 or 24 pitches 30in 15in span JLG Lift Fatigue Cracks Fatigue is a phenomenon that affects most metals and is the most common cause of chain plate failures Fatigue cracks are found through the link holes perpendicular 90 degrees from the pin in line position Inspect chains carefully after long time use and heavy loading for this type of crack If any cracks are dis covered replace all chains as seemingly sound plates are on the verge of cracking Fatigue and ultimate strength failures on JLG Lifts are incurred as a result of severe abuse as design specs are well within the rated lift ing capacity of these chains 3120849 Tight Joints All joints in the leaf chain should flex freely On leaf chain tight joints are usually caused by rust corro sion or the inside plates walking off the bushing Limber up rusty corroded chains after inspecting care fully with a heavy application of oil preferably a hot oil dip Tap inside walking plates inward if walking persists replace the chain This type of problem is accelerated by poor lubrication maintenance practice and most tight joint chains have been operated with little or no lubrica tion Tight joints on leaf chain are generally caused by a Bent pins or plates b Rusty joints c Peened plate edges Oil rusty chains and replace chains with bent or peened chain components Keep chains lubricated Protrudin
112. port while performing next step Insert threaded ends of chain assembly attached to anchor block on top mast section 2 through the chain anchor plate located on bottom of extended mast section 4 Loosely thread two 2 3 8 16UNC nuts onto stud threads on each chain Chains will be adjusted later in assembly NOTE 33 34 35 NOTE 36 37 38 JLG Lift When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Slide mast section 4 back into mast section 3 except for about a foot or more Allow enough slack in chains to mount sheave wheels to top of mast sec tion 3 Extend mast section 3 out far enough from section 2 mast to gain access to top of section 3 Assemble chain sheaves to top of mast section 3 as follows a Locate the two chain sheave wheels and slide onto sheave pin b Slide two 2 short spacer tubes onto sheave pin one each end of sheave pin to outside of sheave wheels c Place two 2 sheave pin attach bars one each end of sheave pin to outside of space tubes d Holding complete sheave wheel assembly slide assembly into top of mast section 3 and align threaded holes in sheave pin attach bars with holes in mast rails e Attach to top of mast section 3 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten When sliding mast
113. r the Base Frame 4 Remove the remaining two 2 bolts attaching the motor cover to the base frame and set it aside DRIVE MOTOR DRIVE MOTOR MOUNT MANUAL PLATE FASTENERS RELEASE THREE ON EACH MOUNT E CE BRAKE ALSO SEE INSET p ce CABLE gt D 1 SE b DRIVE MOTOR COVER SECTION 2 SERVICE PROCEDURES Disconnect the wiring connectors to the drive motor and the brake assembly on either or both sides depending on which drive assembly ies is being removed Disconnect the manual release brake cable from the brake assembly arm on either or both drive motors if removing the complete drive assembly If removing each arive motor seperately continue to Step 7 If removing the complete drive assembly with both motors attached go to Step 11 the one 1 bolt nut and two 2 washers from the front of the drive motor mounting plate While holding the drive motor in place remove the remaining two 2 bolts with washers holding the drive motor mounting plate to the drive motor assembly weldment Slide the drive motor and torque limiting clutch assembly towards the center of the machine sliding the torque limiting clutch off the outer drive shaft Move drive motor assembly and torque limiting clutch to a suitable work bench for disassembly DRIVE MOTOR ASSEMBLY CONNECTORS ATTACH BOLTS 2 EACH INSIDE FORK LIFT POCKET
114. romthe lift switch Tan 55 1 pump contactorto the Repair Wiring or battery terminalfor continuity Is there continuity Connection Checkthe pump motor pressure relief setting Is it within specifica tion per Service Manual setas Required Check for continuity across the terminals Black to Tan 3 1 and Tan Replace Lift Up 55 1 ofthe lift up down ground control toggle switch Is there con Goto Step 6 Down Ground tinuity Control Switch EG 3 30 JLG Lift 3120849 SECTION 3 TROUBLESHOOTING Platform Will Not Lower From Ground Control Toggle Switch Overview Of Procedure The following procedure examines the complete ground control circuit from the battery all the way to the pump motor for wiring or components which could be causing a failure of that circuit Check For These Obvious Conditions First Battery voltage 24 volts Fully charge batteries Battery connections clean and tight Key switch positioned to Ground GRND control Emergency stop switch set to the Reset position Ground control power supply and wiring OK Table 3 4 5 amp fuses on power and pump circuits OK Hydraulic oil level OK Table 3 25 Unit Will Not Lower From Ground Control Toggle Switch STEP Goto Step 3 Go to Step 2 Check for obstructions in the mast cylinder hydraulic lines and lift Repair Replace Coto Sten 3 down valve or Adjust Check terminal 30 and 85 on the ground control relay for ground 15 Re
115. s lines fittings etc as well as a functional check of each system before placing the machine back in service Lubrication Specifications Specified lubricants as recommended by the component manufacturers are always the best choice however multi purpose greases usually have the qualities which meet a variety of single purpose grease requirements Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion Refer to Table 1 3 in this Service Manual for an expla nation of the lubricant key designations appearing in the Lubrication Chart 2 4 JLG Lift 2 4 POSITIONING LIFT FOR ACCESS TO COMPONENTS LOCATED UNDER THE BASE FRAME Access to the underside of the VP lift can be obtained by lifting the machine with a fork lift truck using the fork lift pockets in the base frame Lifting with a Fork Truck See Figure 2 1 1 Choose a fork lift truck capable of safely handling the full weight of the machine 2 Locate work area on a firm level surface A WARNING KEEP MACHINE LEVEL OR SLIGHTLY TILTED TOWARD FORKLIFT TRUCK WHEN LIFTING TO PREVENT MACHINE FROM SLIDING OFF LIFTING TINES 3 When lifting with a fork truck lift only using the fork lift truck pockets running the length of the machine s base frame from rear to front 4 After lifting machine to desired work height place support stands under the machine The support stands must reach from
116. s or types as they may not contain the same required additives or be of comparable viscosities Good grade mineral oils with viscosities suited to the ambient temperatures in which the machine is operating are recommended for use NOTE Metal particles may appear in the oil of new machines due to the wear in of meshing compo nents Hydraulic Oil SSS ee gt 1 For best performance JLG recommends the use of ISO Vg grade 32 46 oil with a viscosity range between 15 250 SUS at 100 degrees F 32 54 cST at 40 degrees C Refer to Section 1 5 of this Service Manual for recommended hydraulic oils Changing Hydraulic Oil Use of any of the recommended hydraulic oils eliminates the need for changing the oil on a regular basis If it is nec essary to change the oil use only those oils meeting or exceeding the specifications appearing in this manual If unable to obtain the same type of oil supplied with the machine consult local supplier for assistance in selecting the proper equivalent Avoid mixing petroleum and syn thetic base oils JLG Industries recommends changing the hydraulic oil annually Use every precaution to keep the hydraulic oil clean If the oil must be poured from the original container into another be sure to clean all possible contaminants from the service container While the unit is shut down a good preventive mainte nance measure is to make a thorough inspection of all hydraulic component
117. single anchor block with two narrow chains Lay out chain assembly with anchor block end towards mast be certain floor surface is clean and free of any metal chip or debris which may stick to lubricated chains Insert hydraulic cylinder rod end into chain assem bly 444 anchor block Secure cylinder rod to anchor block with 1 4 28UNF x 50 long C setscrew Coat threads with blue Loctite 242 before assembly When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad rails Locate mast section 3 carefully slide section 3 closed rail into section 2 open rail Slide sections together until ends are even Locate one 1 of the chain anchor plates one with threaded holes horizontally aligned to outside of bracket Attach using outer set of holes in bottom of 3120849 mast section 3 with two 2 1 4 200 x 3 4 long bolts place a flatwasher under head of each bolt 16 Slide mast section 3 approximately two feet out of the top of mast section 2 17 Insert threaded ends of chain assembly 466 attached to top of mast section 1 through holes in anchor plate attached to bottom of mast section 3 Loosely thread two 2 3 8 16UNC nuts onto stud threads on each chain Chains will be adjusted later in assembly 18 Slide mast section 2 out of mast section 1 approxi mately one foot 10VP Top of Cylinder Assembly 19 Assemble chain sheave wheels to cy
118. st Noisy when Lifting and Lowering Do slide pads and slide pad channels need to be cleaned of dust dirt or other debris Do chain cables needto be lubricated per JLG specification in the service Manual Arethe chain cable sheave wheels dry and need lubrication Note Plastic wheels will howl on the sheave pin when they are dry sheave wheels may seize to the sheave pin and the pin may turn in the pin retainer blocks Are the sequence cables located on the side of mast chattering when the springs are compressed Clean Pads and Channels Go to Step 2 Lubricate as Required Goto Step 3 Lubricate or Replace Sheave Go to Step 4 Pins and Wheels Clean Slide Pads Channels or Re Shim Mast per Service Manual Replace Packing or Lift Cylinder Go to Step 6 Step 7 ump Adjustthe Posi tion of the Lines Tighten pump mounting Goto Step 9 fasteners Repair or Replace Pump Note This noise is normal atthe sequence cable sheave wheels when the mastis completely lowered However if the sequence cable chattering is happening no matter what position the mastis in it could be a result of the mast being shimmed to tight or dirt and debris in the slide pad channels causing the mastto be tight Is the bore ofthe lift cylinder dry Are the bearings in the lift pump motor and pump drive worn Are the hydraulic lines vibrating together M Checkifthe pump motoris loose to it s mounting plate
119. t Board Joystick Assembly e Emergency Stop Switch Speed Control Switch Touch Pad Switch Assembly Except for the touch pad switch assembly which plugs into the circuit board replacement of each component requires unsoldering then soldering each replacement components wiring to the controller s integrated circuit board Due to the small contact area when connecting each wire to the circuit board this soldering requires pre cise temperatures and neatness of the soldered point itself so as not to destroy the circuit board or cross any of the circuit paths on the board THE INTEGRATED CIRCUIT BOARD PLACE THE PLATFORM CONTROL BOX ON A NON CONDUCTIVE SURFACE WHEN OPEN ING THE BOX AND WORKING DIRECTLY WITH THE CIRCUIT BOARD Removing Control Box From Platform 1 Turn off all power to the platfom control box 2 Unhook the wiring harness cable at the quick dis connect coupling Early VP models were not equipped with the quick disconnect coupling skip to Step 4 3 Remove the platform control box and box mount to a suitable work surface 4 Remove the control box from the control box mount by removing the four 4 nuts from the studs on the bottom of the control box 5 Unplug the wiring harness cable connector on the back of the lower housing half 6 Lay control box mount and wiring harness assembly aside 2 16 JLG Lift Lower Half Of Housing Removal 1 Position the control box upside down and remove
120. t TOP of mast section 1 far enough to allow access to the chain assembly anchor block sheave wheel assembly Remove _ countersunk flathead screws securing chain anchor block sheave wheel assembly attach bars on both side rails at TOP of mast section 2 Slide the chain anchor block sheave wheel assem bly and hydraulic cylinder out the TOP of mast sec tion 2 far enough to allow removal of the sheave wheel attach bars sheave wheels and sheave pin from chain assembly anchor block Remove the setscrew holding the hydraulic cylinder rod into the chain assembly 444 anchor block Lay chain assembly 444 to side Remove the hydraulic cylinder through BOTTOM of mast section 2 be careful not to nick or score cylin der rod surface while removing When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 2 out BOTTOM of sec tion 1 Remove slide pads and shims if necessary Slide the TOP of remaining mast section 1 out over edge of work surface and remove the bolts attaching the chain anchor blocks to mast section 1 Remove chain assemblies from mast and lay aside Remove slide pads and shims from mast section 1 Mast disassembly should now be complete JLG Lift 3120849 SECTION 2 SERVICE PROCEDURES CHAIN amp CHAIN SHEAVE WHEEL ASSEMBLY BACK UP CABLE ASSY UPPER HALF PA SEQUENCE CABLE ASSY UP
121. t improvements JLG Industries Inc reserves the right to make specification changes without prior notification Contact JLG Industries Inc for updated information This page left intentionally blank INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A GENERAL C MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform It is of utmost importance that maintenance per A WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN sonnel pay strict attention to these warnings and precau THIS SECTION COULD RESULT IN MACHINE DAMAGE PERSON tions to avoid possible injury to themselves or others or damage to the equipment A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe to operate MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA TION The specific precautions to be observed during machine 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 component weight and never at
122. tage of capacity lifts fre quency rates of operation and exposure to shock loads SECTION 2 SERVICE PROCEDURES Inspection should be more frequent as cables approach the end of their useful lives Only the surface wires of the cable require inspection do not attempt to open the cable Any deterioration resulting in any loss of original strength such as described below shall be noted and then a determination made if further use would constitute a hazard Mast cables must be replaced after machine has been in service for five 5 years regardless of cable condition or sooner if conditions dictate Conditions such as the following shall be sufficient reason for questioning continual use of the cable or increasing the frequency of inspection 1 running ropes six randomly distributed broken wires in one lay or three broken wires in one strand in one lay 2 One outer wire broken at the point of contact with the core of the rope which has worked its way out of the rope structure and protrudes or loops out from the rope structure Additional inspection of this sec tion is required 3 Wear of one third the original diameter of outside individual wires 4 Kinking crushing birdcaging or any other damage resulting in distortion of the rope structure 5 Evidence of any heat damage from any cause 6 Reductions from nominal diameter of more than a 1 64th in 0 4mm for diameters up to and including 5 16th in
123. tallation kk kk kk kK KK KI KI KIR KI KIRI K KIRR RII hh 2 13 2 13 Correct incorrect Brush Spring Bracket 5 2 14 2 14 Platform Control Box Assembly Exploded 2 15 2 15 Platform Control Circuit Board Component Wiring 2 17 2 16 Mast Section Assembly Reference 2 23 2 17 TOVE Mast 2 25 2 18 Pes Dvd EU be an dun Dor Maa AK 2 26 2 19 20VP Mast ASSermbly iua a k EG EM EX Ee AW l px dou wu lk a ia d 2 27 2 20 Mast Chain Cable Sequence Cable Adjustment 5 2 33 3 1 Led Battery fault Code Indicator Strip On Platform Controller 3 2 3 2 Overview Of Standard Electrical System Sheet 1 2 3 6 3 3 VP Electrical Diagram VP Series 3 8 3 4 Hydraulic Diagram VP Series 3 10 LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 Machine GVW and Wheel Loads 1 1 1 2 Hydraulic Oil Operating Harige s dun os ita Ge ee 1 2 1 3 Lubrication opecifleatl
124. tempt 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 ade quate support is provided SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON TROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER OPERATOR B HYDRAULIC SYSTEM SAFETY 1 should be particularly noted that the machines hydraulic systems operate at extremely high and potentially dangerous pressures Every effort should be made to relieve any system pressure prior to dis connecting or removing any portion of the system 2 Relieve system pressure by activating the lift DOWN control with the platform completely lowered to direct any line pressure back into the return line to the reservoir Pressure feed lines to system compo nents can then be disconnected with minimal fluid loss 3120849 JLG Lift NEL INJURY OR DEATH AND IS A SAFETY VIOLATION 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 DANGER WARNING CAU TION AND OTHER INSTRUCTIONS ON MACHINE AND IN SERVICE MANUAL KEEP STANDING SURFACES AND HAND HOLDS FREE OF OIL GREASE WATER ETC NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAF
125. tervals are based on normal use If machine is subjected to severe operating conditions such as high number of cycles location corrosive dirty environment etc user must adjust lubricating requirements accordingly 3 Priorto checking hydraulic oil level operate machine through one complete cycle of lift function full up and down Failure to do so will result in incorrect oil level reading on the hydraulic reservoir 3120849 JLG Lift 1 5 SECTION 1 SPECIFICATIONS 1 6 This page left intentionally blank JLG Lift 3120849 SECTION 2 SERVICE PROCEDURES SECTION 2 SERVICE PROCEDURES 2 1 GENERAL This section provides general information to assist in the performance of maintenance on the personnel lift Descriptions techniques and specific procedures are designed to provide the safest and most efficient mainte nance for use by personnel responsible for ensuring the correct installation and operation of machine components and systems WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK IS RESUMED 2 2 SERVICING AND MAINTENANCE GUIDELINES General The following information is provided to assist you in the use and application of servicing and maintenance proce dures contained in this chapter Safety and Workmanship Your safety and that of others
126. the Power Relay to the MC 1 Tighten Repair box X101 connector pin 5 for 24 volts when the platform control is Goto Step powered up Table 3 22 Pump Valves Circuit Battery voltage 24 volts Fully charge batteries Set key switch to Platform and setthe Emergency Stop Button to the RESET position Down Valve should be normal closed Dump Valve up should be normal open f machine will not lift and hydraulic oil is visible flowing in the hydraulic tank the dump valve is stuck open STEP ACTION SPEC YES NO LIFT UP CONDITIONS WHEN PUMP MOTOR IS RUNNING Pump Contactor Coil Yel Red 2 6 wire 24 volts Tan 55 1 wire Ground Lift Up Valve Coil Yel Red 2 6 wire 24 volts Tan 3 1 wire Ground LIFT UP CHECK WHEN PUMP MOTOR IS NOT RUNNING Pump Contactor Coil Yel Red 2 6 wire 24 volts Tan 55 1 wire 24 volts Lift Up Valve Coil Yel Red 2 6 wire 24 volts Tan 3 1 wire 24 volts LIFT DOWN CHECK WHEN DOWN AND ENABLE PADS ARE PUSHED ON THE PLATFORM CONTROL Lift Down Valve Coil Yel Red 2 6 wire 24 volts Tan 4 1 wire Ground LIFT DOWN CHECK WHEN NO FUNCTION ARE ENABLED ON THE PLATFORM CONTROL Lift Down Valve Coil Yel Red 2 6 wire 24 volts Tan 4 1 wire 24 volts 3 28 JLG Lift 3120849 SECTION 3 TROUBLESHOOTING Platform Will Not Lower Using Platform Control Overview Of Procedure This procedure tests for ground coming out of th
127. to ON KEY SET TO PLATFORM Check voltage on the Yel Red 2 2 wire from the emergency stop switch to MC 1 controller box pin in the 24 Volts Circuitis OK Goto Step 2 X101 connector and pin 30 on the Power Relay KEY SETTO GROUND Check voltage onthe Yel Red 2 4 wire com ing out of the ground control box assembly to pin 87 on the power T relay and main contactor Yel Red 2 8 wire to pin 86 on the ground 24 Volts Circuit is OK Goto Step 3 relay Open the Ground Control Box Assembly housing with key switch Repair connec and E stop switch mounted inside and check the voltage on the Yel Red 2 1 wire leading into the emergency stop switch from the Key 24 Volts tion to or replace Goto step 3 Switch E Stop switch Check voltage onthe Red 1 1 wire leading into the Key switch Repair connec 24 Volts tion to or replace Goto Step 4 key switch Check voltage and continuity through the 5 amp fuse mounted inline Replace Fuse or outside of the ground control box assembly onthe Red 1 1 wire 24 Volts Go to Step Fuse Holder if damaged Check connection at battery 24 Volts Circuit OK 3120849 JLG Lift 3 23 SECTION 3 TROUBLESHOOTING Won t Drive Straight Overview Of Procedure The following procedure examines the drive motor assembly weldments attaching the drive motors to the base frame Also internal components of the the drive motors gear box and a check of the components between the gear box and the drive whe
128. to any of the drive components the platform controller or the MC 1 unit itself these LEDs will flash a fault code Warning or Error type to help locate the problem area The possible causes of fault codes are outlined in the following sub sections of this chapter see Table 3 1 and Table 3 2 NOTE For aid in troubleshooting electrical problem refer to Figure 3 3 for an ELECTRICAL DIAGRAM of the various circuits Also a pictorial overview of the Section see Figure 3 2 Pictorial Overview of VP Electrical System 3120849 JLG Lift 3 1 SECTION 3 TROUBLESHOOTING LED lt lt INDICATOR STRIP Figure 3 1 LED Battery Fault Code Indicator Strip on Platform Controller Box LED Indicator Strip When the machine is powered up all function inputs should be open If any function is active on power up all functions will be made inoperative and a fault will be indicated at the platform controller box LED strip This strip has ten 10 green LEDs and is located on the platform controller box between the function touch pad buttons See Figure 3 1 Fault Code Reference Tables Their are two types of fault codes which can occur to indicate a problem with the machine these are WARNING codes and ERROR codes The fault codes can occur either at machine power up or during operation of the machine WARNING Codes See Table 3 1 The WARNING will be indicated for 4 seconds and will be repeated every minute if the problem
129. ugh to hold pad in place Shim per instructions in step 7 The platform mounting section section 4 on 15VP and section 5 20VP machines slide pads are assembled differently than the slide pads for the other mast sections Mast section 4 5 slide pads may need to be assembled disassembled several times in order to determine the correct shim stock required for proper fit 46 47 48 JLG Lift SECTION 2 SERVICE PROCEDURES Locate the remaining mast section 4 5 platform mounting mast section Lay mast section on flat stable surface Attach the remaining chain anchor plate one with threaded holes vertically aligned in center of bracket Attach through inner vertical set of holes in bottom of mast section 4 5 with two 2 1 4 20UNC x 3 4 long bolts place a flatwasher under head of each bolt Complete the following steps to determine shim stock thickness required for section 4 5 Always use the an even amount of shim material behind slide pads on both sides of the mast rails This will keep mast sections centered in rail chan nels and prevent any distortion of the section a Use two shim pieces per slide pad a thick one and a thin one b Start with a total thickness of approximately 035 and 075 thick shim stock To protect the anodized finish when sliding the assembled mast section 4 5 into section 3 4 grind top and bottom edges of slide pads to
130. uld be obtained before proceeding with any maintenance 3 2 TROUBLESHOOTING INFORMATION Troubleshooting procedures applicable to the VP machine are listed and defined starting with Section 3 5 TROUBLE SHOOTING SECTION TABLE OF CONTENTS in this chapter of the manual Each malfunction within an individual group or system is followed by a listing of probable causes which will enable determi nation of the applicable remedial action The probable causes and the remedial action should where possible be checked in the order listed in the tables It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electri cal systems For this reason every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment In the remaining machine groups only those problems which are symptomatic of greater problems which have more than one probable cause and remedy are included This means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if the cir cuit is lacking hydraulic oil and electrical control power This can be ascertained by overriding the bypass valve m
131. upiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 81 23 557 2493 JLG Industries Pty Ltd Unit 1 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone 27 11 453 1334 Fax 27 11 453 1342 JLG Deutschland GmbH Max Planck Strasse 21 D 27721 Ritterhude Ihlpohl Bei Bremen Germany Phone 49 421 693 500 Fax 49 421 693 5035 JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47 6682 2001 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755Castellbisbal Spain Phone 34 93 77 24700 Fax 34 93 77 11762 JLG Industries Italia Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 02 9359 5210 Fax 39 02 9359 5845 JLG Polska Ul Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 200 JLG Industries Sweden Enkopingsvagen 150 Box 704 SE 175 27 Jarfalla Sweden Phone 46 8 506 59500 Fax 46 8 506 59534
132. utside rail on top of mast section 2 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Insert slide pads into the bottom end mast rails between section 2 and 3 one on each side of the mast with beveled surface facing out towards sec tion 2 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes on inside rail on bottom end of mast section 3 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Assembly of 10VP mast should now be complete To continue with 15VP assembly go to step 48 20VP assembly continues following When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Locate mast section 4 carefully slide section 4 closed rail into section 3 open rail Slide sections together until ends are even Locate one 1 of the chain anchor plates one with two threaded holes vertically aligned in center of bracket Attach through inner vertical set of holes at bottom of mast section 4 using two 2 1 4 20UNC x 3 4 long bolts place a flatwashers under head of each bolt Slide mast section 4 out the top of mast section 3 so the chain anchor plate on bottom of mast section 4 is easily accessible at top end of mast section 3 Rest the top end of mast section 4 on a sup
133. wheel Remove Debris or Replace Wheel Pot Hole Protection PHP Bars Will Not Set Check For These Obvious Conditions First Obstruction under pot hole bar on either side of machine Obstruction around the actuator assembly at the base of the mast Table 3 33 Pot Hole Protection PHP Bars Will Not Set Checkthe actuator cables for adjustment or damage AdjustorReplace Goto Step 2 Check the PHP limit switch s at both sides of the machine for dam Replace Adjust age adjustment and for continuity through switch to ground when ens bars are down or Repair Wiring 3 38 JLG Lift 3120849 Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Phone 717 485 5161 Customer Support Toll Free 877 554 5438 Fax 717 485 6417 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 2 65 811111 Fax 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Industries Europe Kilmartin Place Tannochside Park Uddingston G71 5PH Scotland Phone 44 1 698 811005 Fax 44 1 698 811055 JLG Industries UK Unit 12 Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Europe B V J
134. x X101 connector pin 2 CheckTilt Sensor O R 49 6 wire Goto Step 2 Circuit Table 3 12 Check for ground on PHP circuit at MC 1 box X105 connector pin Check PHP 12 O R 49 1 wire Problemin MC 1 sv cn Circuit controller box Table 3 13 Is tilt sensorlighton showing atilt condition eventhough machine is Adjusttilt sensor Goto Sten within tilt limit if necessary Checkfor ground onthe Black wire directto ground running into tilt Coto Sten 3 Repair sensor Continuity to B Connection Check Connec Go to Step 4 tion to Main Con tactor Relay Repair connec tion atthe X101 connector end broken wire O R 49 6 Replace Tilt Sensor 3 18 JLG Lift 3120849 SECTION 3 TROUBLESHOOTING Table 3 13 PHP Limit Switch Circuit No ground on PHP circuit at MC 1 box X105 connector pin 12 O R 49 1 wire e With PHP bars up STEP ACTION Check for ground on Black wire direct to ground on the right side Repair PHP limit switch Continuity to B Connection Check for ground on O R 49 1 wire to MC 1 box X105 connector Repair connec pin 12 tion atthe X105 connector end Adjust Replace Left Switch Check for ground on O R 49 2 wire to left PHP limit switch Adjust Replace Right Switch 3120849 JLG Lift 3 19 SECTION 3 TROUBLESHOOTING Won t Climb Grade Overview Of Procedure The following procedure checks the drive motor and attached components for component fa

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