Document Outline

• Model
  • 10VP
  • 15VP
  • 20VP
    • 3120728
      • June 14, 2001
    • SERVICE & MAINTENANCE
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• FOREWORD
  • The purpose of this manual is to provide users with the operating procedures essential for the pr...
  • BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION, PROPER SAF...
  • ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER OPERATING CONDIT...
  • THIS "SAFETY ALERT SYMBOL" IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH MAY LEAD TO SERIO...
  • Safety of personnel and proper use of the machine are of primary concern, DANGER, WARNING, CAUTIO...
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• Introduction - Maintenance safety precautions
  • a. GENERAL
    • This section contains the general safety precautions which must be observed during maintenance of...
    • The specific precautions to be observed during machine maintenance are inserted at the appropriat...
    • Your safety, and that of others, is the first consideration when engaging in the maintenance of e...
  • b. HYDRAULIC SYSTEM SAFETY
    • 1. It should be particularly noted that the machines hydraulic systems operate at extremely high ...
    • 2. Relieve system pressure by activating the lift DOWN control with the platform completely lower...
  • c. MAINTENANCE
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• Effectivity Changes
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• LIST OF FIGURES
• LIST OF TABLES
• 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 – 5 qts. U.S. (4.7 ltr.)
  • 1.2 Component Data
    • Hydraulic Pump/Pump Motor Assembly
      • Pump Motor - 24 Volt DC motor
      • Pump Displacement –
      • 10 & 15VP – .098 cu. in./rev. (1.6cc/rev.)
      • 20VP – .049 cu. in./rev. (0.8cc/rev )
      • Pump Output (Max.) –
      • 10 & 15VP - 1.20 gpm @ 2200 psi
      • 20VP – 0.65 gpm @ 2200 psi
      • Hydraulic System Pressure Setting –
      • 10 & 15VP - 1000 psi (68.95 bar)
      • 20VP - 2500 psi (172.3 bar)
    • Rear Wheel Drive Motors
      • Drive Motors -
      • 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)
    • Batteries/Battery Charger
      • Batteries (2) – 12 Volt / 80 Amp Hour –
      • Deep Cycle Marine - RV
      • Battery Charger –
      • U.S.A./CAN. – 120 Volt A.C. / 60 Hz input
      • Brazil - 220 Volt A.C./ 60 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 – 350 lbs. (160 kg)
      • 15VP – 350 lbs. (160 kg)
      • 20VP – 350 lbs. (160 kg)
    • Extendible Platform Capacity
      • ANSI (U.S.) – 300 lbs. (136 kg)
      • CSA (CAN.) – 250 lbs. (114 kg)
    • Platform Size
      • Standard Platform – 26 in. x 26 in. (66cm) x (66cm)
    • Machine Height (In Stowed Position)
      • VP Series - 79 in. (201cm) height
      • Table 1-1. Machine GVW and Wheel Loads
    • Base Footprint
      • VP Series - 32 in. (81cm) width 56 in. (1.42m) length
    • Max. Platform Height (mast extended)
      • 10VP – 10 ft. 6 in. (3.2m)
      • 15VP – 15 ft. (4.5m)
      • 20VP – 19 ft. 9 in. (5.9m)
    • Platform Working Height (average)
      • 10VP – 16 ft. 6 in. (4.8m)
      • 15VP – 21 ft. (6.4m)
      • 20VP – 25 ft. 9 in. (7.6m)
    • Machine Drive Speed (max.)*
      • Platform Lowered - 2 mph (3.22 kph)
      • Platform Elevated - 0.5 mph (.81 kph)
      • (reduced by limit switch)
      • * Variable to maximum with speed cut back.
    • Amperage Draw (average)
      • Lift - 12 amps. Drive - 20 amps.
    • Interlock Switch Operating Conditions
      • Table 1-4. shown, lists machine response to various interlock switch positions.
  • 1.4 Torque Requirements
    • When maintenance becomes necessary or a fastener has loosened, refer to the Torque Chart, Figure ...
  • 1.5 Lubrication
    • Hydraulic Oil
      • Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and suf...
      • For cold weather applications, i.e. when temperatures remain consistently below +20˚F (–7˚C) JLG ...
      • Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as ...
      • Table 1-2. Hydraulic Oil Operating Range
    • Lubrication Specifications
      • Table 1-3. Lubrication Specifications
      • Table 1-4. Machine Interlock Switch Operating Conditions.
  • 1.6 Hydraulic Pressure Adjustment
    • Adjust system pressure so that platform will raise with rated capacity in platform.
    • The following are recommended factory pressure settings;
    • VP10, VP15 – 1000 psi VP20 – 2500 psi
    • Turning adjustment screw clockwise increases system pressure, turning screw counterclockwise decr...
    • Make pressure adjustment with oil at normal operating temperature. If pressure is set when oil is...
    • Connect pressure gauge as shown in Figure 1-2., Hydraulic Pressure Gauge Installation.
    • Select a T-Fitting to exactly match the thread size of the pump (.562 x 18 THD), pressure line (....
  • 1.7 Cylinder Specifications
    • Table 1-5. Cylinder Specifications
  • 1.8 Serial Number Location
    • For machine identification, a serial number plate is affixed to the machine. The plate is located...
    • Table 1-6. Lubrication Intervals for Various Components
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• Section 2. SERVICE PROCEDURES
  • 2.1 General
    • This section provides general information to assist in the performance of maintenance on the pers...
  • 2.2 Servicing and Maintenance Guidelines
    • General
      • The following information is provided to assist you in the use and application of servicing and m...
    • Safety and Workmanship
      • Your safety, and that of others, is the first consideration when engaging in the maintenance of e...
    • Cleanliness
      • The most important single item in preserving the long service life of a machine is to keep dirt a...
      • At any time when oil lines are disconnected, clear adjacent areas as well as the openings and fit...
      • Clean and inspect all parts during servicing or maintenance, and assure that all passages and ope...
    • Components Removal and Installation
      • Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slin...
      • Should it be necessary to remove a component on an angle, keep in mind that the capacity of an ey...
      • If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., ...
    • Component Disassembly and Reassembly
      • When disassembling or reassembling a component, complete the procedural steps in sequence. Do not...
    • Pressure-Fit Parts
      • When assembling pressure-fit parts, use an “anti-seize” or molybdenum disulfide base compound to ...
    • Bearings
      • When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammabl...
      • Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.
      • If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) pap...
      • Lubricate new or used serviceable bearings before installation. When pressing a bearing into a re...
    • Gaskets
      • Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to h...
    • Bolt Usage and Torque Application
      • Use bolts of proper length. A bolt which is too long will bottom before the head is tight against...
      • Unless specific torque requirements are given within the text, standard torque values should be u...
    • Hydraulic Lines and Electrical Wiring
      • Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when dis...
    • Hydraulic System
      • Keep the system clean. If evidence of metal or rubber particles is found in the hydraulic system,...
      • Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable ...
    • Lubrication and Servicing
      • Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart,...
    • Batteries
      • Clean batteries, using a non-metallic brush and a solution of baking soda and water. Rinse with c...
    • Mast Chain Inspection Procedure
      • Inspect mast chains for the following conditions:
      • Wear: Always inspect that segment of chain that operates over a sheave. As the chain flexes over ...
      • Rust and Corrosion: Rust and corrosion will cause a major reduction in the load carrying capacity...
      • Table 2-1. Chain Stretch Tolerance
  • .50" pitch
  • 12" or 24 pitches
  • .24 in./12 in. span
  • .625 pitch
  • 15" or 24 pitches
  • .30 in./15 in. span
    • Fatigue Cracks: Fatigue is a phenomenon that affects most metals, and is the most common cause of...
    • Tight Joints: All joints in the leaf chain should flex freely. On leaf chain, tight joints are us...
      • 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.
    • Protruding or Turned Pins: Chains operating with inadequate lube generate tremendous friction bet...
    • Chain Anchors and Sheaves: An inspection of the chain must include a close examination of chain a...
    • Inspect the sheaves, sheave bearings, sheave grooves and pins for extreme wear, replace as necess...
      • a. Chains too tight.
      • b. Sheave bearings/pin bad.
      • c. Bent/misaligned chains.
    • Mast Cable Inspection Procedure
      • The periodic inspection shall cover the entire length of the cable. The inspection frequency shal...
      • Only the surface wires of the cable require inspection, do not attempt to open the cable. Any det...
      • Mast cables must be replaced after machine has been in service for five (5) years, regardless of ...
      • Conditions such as the following shall be sufficient reason for questioning continual use of the ...
      • 1. In running ropes, six randomly distributed broken wires in one lay or three broken wires in on...
      • 2. One outer wire broken at the point of contact with the core of the rope which has worked its w...
      • 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. (8mm);
      • 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 contamination. Contaminants enter the system by variou...
        • The design and manufacturing tolerances of the component working parts are very close, therefore,...
        • Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation...
        • It is not advisable to mix oils of different brands or types, as they may not contain the same re...
      • Hydraulic Oil
        • For best performance, JLG recommends the use of ISO- Vg grade 32, 46 oil with a viscosity range b...
      • Changing Hydraulic Oil
        • Use of any of the recommended hydraulic oils eliminates the need for changing the oil on a regula...
        • Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original...
        • While the unit is shut down, a good preventive maintenance measure is to make a thorough inspecti...
      • Lubrication Specifications
        • Specified lubricants, as recommended by the component manufacturers, are always the best choice, ...
    • 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 tr...
      • 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.
      • 3. When lifting with a fork truck, lift only using the fork lift-truck pockets running the length...
      • 4. After lifting machine to desired work height, place support stands under the machine. The supp...
    • 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 cl...
      • Visual Inspection and Limiting Torque Checking Procedure
        • 1. Locate the machine on a firm level surface.
        • 2. Carefully raise the lift to gain access to the underside of the base frame. Refer to Section 2...
        • 3. Locate the clutch assembly on each rear drive axle and check for the following;
          • a. Check the coupling chains for any loose or missing parts, i.e. pins, links, etc., replace if n...
          • b. Check that the allen-head set screws on the (large) clutch adjusting nut are in place and secu...
          • c. Check for any debris wedged in or wrapped around the clutch coupling chains and axle shafts. R...
      • Checking Clutch - Torque Setting (ft. lb.)
        • 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...
        • 3. Slide the tool onto the end of the drive axle aligning the key on the axle shaft (install key ...
        • 4. Turn the torque wrench and note the torque setting when the torque limiting clutch releases. T...
        • 5. If torque setting is OK, re-install the wheels and lower machine, IF NOT, see the following note.
      • Torque Limiting Clutch Adjustment
        • 1. Loosen the two (2) adjusting nut setscrews located on the large adjusting nut on the clutch as...
        • 2. Hold the drive axle steady using service tool (P/N- 0080229) and the torque wrench used to che...
        • 3. Depending on how far off the original torque setting was (see note at beginning of this proced...
        • 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.
      • Drive Motor Brake Adjustment/Removal
        • (See Figure 2-4. & Figure 2-5.)
        • Mounted onto the front of each drive motor housing is a brake assembly. The brakes are normally E...
        • Operation (See Figure 2-4. & Figure 2-5.)
        • When the magnetic coil is not energized (brake on), the armature plate is pushed away from the ma...
        • A correctly adjusted brake will ideally have a measurment of approximately .006" (but will operat...
        • Never allow any type of lubricant (oil, grease, hydraulic fluid, etc.) to come in contact with th...
        • 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...
        • 3. With the brakes ENGAGED measure the air gap between the armature plate and the magnetic coil h...
        • 4. If the air gap falls outside the maximum allowable setting of .010" the friction disk has worn...
        • 5. It the air gap is below the minimum allowable setting of .004", recheck the areas between 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...
        • 2. With the brakes electrically RELEASED (brakes off) the air gap under the screw head increases ...
        • Brake Assembly Removal
        • 1. Lift the machine to gain access to the underside (See Section 2-4., "Positioning Lift For Acce...
        • 2. Disconnect the brake magnetic coil wiring connector and the brake limit (micro) switch wiring ...
        • 3. Disconnect the manual brake release cable from the manual brake release arm attached to the br...
        • 4. Lower machine back down to ground level.
        • 5. Using the Ground Control Switch, raise the platform to gain access to the brake assemblies mou...
        • 6. Remove the four (4) hex cap screws securing the brake assembly to the end of the drive motor a...
        • Brake Assembly Installation
        • 1. Guide the manual release lever, brake coil and brake limit switch wiring connectors through th...
        • 2. If necessary, manually release the brake disk using the manual release lever to allow the brak...
        • 3. Secure the brake assembly to the drive motor using four (4) hex cap screws with washers. Torqu...
        • 4. Lift the machine to gain access to the underside (See Section 2-4., "Positioning Lift For Acce...
        • 5. Reconnect the brake coil and brake limit switch wiring connectors to their respective wiring h...
        • 6. Reconnect the manual release brake cable to the manual release lever (Y shaped lever) and adju...
      • Drive Motor Removal
        • (See Figure 2-7.)
        • The VP drive motors consist of three sections, the gear box atttached to the rear of the drive mo...
        • 1. Disconnect the positive battery terminal from the left side battery.
        • 2. Remove the rear plate weldment from the machine, (plate with the tie down lug) and set aside. ...
        • 3. Carefully raise the lift to gain access to the underside of the base frame. Refer to Section 2...
        • 4. Remove the remaining two (2) bolts attaching the motor cover to the base frame and set it aside.
        • 5. Disconnect the wiring connectors to the drive motor and the brake assembly on either or both s...
        • 6. Disconnect the manual release brake cable from the brake assembly arm on either or both drive ...
        • 7. Remove the one (1) bolt, nut, and two (2) washers from the front of the drive motor mounting p...
        • 8. While holding the drive motor in place, remove the remaining two (2) bolts with washers holdin...
        • 9. Slide the drive motor and torque limiting clutch assembly towards the center of the machine, s...
        • 10. Move drive motor assembly and torque limiting clutch to a suitable work bench for disassembly.
        • 11. Carefully remove the four (4) nuts and washers (outer most holes on the drive assembly weldme...
        • 12. Lower the drive assembly and place on a suitable work surface.
      • Gear Box Disassembly/Assembly
        • (See Figure 2-8.)
        • The drive motor gear box is mounted on the rear of each drive motor transferring power from the e...
        • Gear Box Disassembly (See Figure 2-8.)
        • 1. Remove the drive motor/gear box/brake assembly from the machine using the procedure outlined p...
        • 2. Remove the four (4) hex cap screws securing the side cover to the gear box housing, and remove...
        • 3. Remove the wave washers from atop the large and small bearings and lay inside their respective...
        • 4. Using a suitable catch container, drain the gear oil from the gear box housing.
        • 5. Remove the drive shaft assembly from the housing. Place the drive motor/gear box assembly on a...
        • 6. With the open surface of the housing properly supported, carefully press the drive shaft down ...
        • 7. To remove the large (47mm) (cover side) bearing and (housing side) bearing from the drive shaf...
        • 8. To remove the small (32mm) bearing(s) from the gear (brass) and pinion assembly, use a suitabl...
        • 9. To remove the (brass) worm gear from the pinion assembly, use a suitable hydraulic press and p...
        • 10. Inspect the drive shaft seal for cuts, cracks and wear, or if showing signs of leakage. Repla...
        • Gear/Pinion Shaft Assembly (See Figure 2-9.)
        • 1. Locate the pinion gear/shaft, place the key for the (brass) worm gear into the slot on the gea...
        • 2. Press the (brass) worm gear onto the pinion shaft and align the keyway in the (brass) worm gea...
        • 3. Press the small (32mm) bearings onto the ends of the pinion shaft. The inner race of the beari...
        • Drive Shaft Assembly (See Figure 2-10.)
        • 1. Slide the (housing side), 42mm x 25mm x 12mm (thinner) bearing onto the long end of the drive ...
        • 2. Slide the narrow spacer onto the drive gear end of the shaft and press the (cover side) 42mm x...
        • Final Gear Box Assembly
        • 1. If necessary, install a new drive shaft lip seal into the drive shaft hole in the gear box hou...
        • 2. Lube the drive shaft seal with a thin film of oil before sliding the drive shaft over the seal.
        • 3. Position the gear box with open cover side up, allow space under the gear box for the drive sh...
        • 4. Hold the gear and pinion, and drive shaft assembies together with the pinion gear and the ring...
        • 5. Continue to drop the gear assemblies into the gear box, align the bearings with the bearing se...
        • 6. With the gear box still positoned with the open cover side up, fill the gear box with six (6) ...
        • 7. Wet with gear oil and place the large wave washer on the end of the drive shaft bearing and th...
        • 8. Clean the mating surfaces of the side cover and the gear box and check that the cover dow guid...
        • 9. On older model gear boxes apply sealant to the cover mating surface on the gear box. On newer ...
        • 10. Using the cover dow guide pins, place the cover onto the gear box housing.
        • 11. Secure using the four (4) hex cap screws, torque screws evenly to 90 in. lbs.
        • 12. Install the drive motor back onto the machine.
      • Drive Motor Brush Replacement
        • Each drive motor contains two (2) brushes, the brushes are located under the two (2) large round ...
        • Brush Cleaning and Inspection
        • Brush wear rate varies depending on the individual application’s duty cycle, and should be inspec...
        • Brush Removal (See Figure 2-12.)
        • Removal of the brushes also requires the removal of the drive motor(s) from the machine, see proc...
        • 1. Unscrew the large round brush caps from each side of the drive motor, use as large a screw dri...
        • 2. The brushes are retained by constant-force, roll-type springs. To remove the springs, press in...
        • 3. Now pull the brush out of the brush box by it’s wire (pig-tail).
        • 4. Loosen the the screw securing the pig-tail terminal end to the brush box and slide the termina...
        • Brush Reassembly (See Figure 2-12.)
        • 1. Install the brush (pig-tail) terminal end under the screw on the brush box in the same manner ...
        • 2. Slide the body of the brush into the brush box, be certain that the wire (pig-tail) is aligned...
        • 3. Now install the brush retaining spring bracket. Grasp the tip of the spring bracket such that ...
        • 4. Push the spring bracket slowly into it’s slot while letting it’s two attaching hooks slide on ...
        • 5. Stop, but do not release the spring bracket when it’s hooks slip around the edge of the brush ...
        • 6. While still grasping the spring bracket with the pliers, slowly bring the spring back out of t...
        • 7. Now release the spring bracket and check that it is lying flat against the brush box wall. If ...
        • 8. Also apply slight pressure by pulling up on the spring bracket to be certain it is hooked secu...
        • 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.
    • 2.6 Platform Control Box Service Procedures
      • Joystick Calibration Procedure
        • 1. Turn off all power to the platform control.
        • 2. Move the joystick to the maximum forward position and hold it there.
        • 3. Turn on power to the platform control, nine (9) LED’s will flash rapidly on the platform contr...
        • 4. Depress the horn switch pad, the alarm will sound for about one (1) second, then release the h...
        • 5. Now release the joystick to the neutral position.
        • 6. Turn off system power.
        • The joystick calibration is now complete.
      • Platform Control Box Disassembly
        • The VP Series platform control box allows for replacement of five (5) components internal to the ...
        • Except for the touch pad switch assembly, which plugs into the circuit board, replacement of each...
        • Removing Control Box From Platform
        • 1. Turn off all power to the platfom control box.
        • 2. Unhook the wiring harness cable at the quick-disconnect coupling. (Early VP models were not eq...
        • 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...
        • 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.
        • Lower Half Of Housing Removal
        • 1. Position the control box upside down and remove the six (6) screws attaching the lower half of...
        • 2. Lay screws and lower housing aside.
        • Joystick Assembly Removal
        • 1. Remove the four (4) screws from the top of the bezel around the base of the joystick and slide...
        • 2. Unplug the touchpad switch ribbon connector from the circuit board connector socket.
        • 3. Remove the four (4) screws attaching the circuit board to the upper housing.
        • 4. Position the circuit board and unsolder the wires from the joystick assembly at the J2, J3 and...
        • 5. With all the joystick wiring unsoldered remove joystick assembly from the control box.
        • Emergency Stop Switch Removal
        • 1. Remove the switch part of the emergency stop switch by carefully prying upward at the corner o...
        • 2. Position the circuit board and locate the emergency stop switch wires connected at locations J...
        • 3. Remove the reset button part of the emergency stop switch by unscrewing the collar on the insi...
        • 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...
        • 3. Position the circuit board and locate the speed control switch wires connected at location J5....
        • Touch Pad Switch Removal
        • 1. Unplug the touch pad ribbon cable connector from the circuit board connector socket. (See Figu...
        • 2. Using a thin tool, start by lifting an edge of the touch pad switch and slowly peel away it fr...
      • Platform Control Box Assembly
        • To assemble the components back into the control box follow the previously outlined disassembly p...
        • Joystick Installation
        • 1. Use the following illustrations to reattach the wires from the joystick to the circuit board.
        • 2. If damaged replace the gasket between upper housing surface and the joystick mounting surface ...
        • Emergency Stop Switch Installation
        • 1. Use the following illustration to reattach the wires from the emergency stop switch to the cir...
        • 2. If damaged replace the gasket between the stop switch base plate and the upper housing mountin...
        • Speed Control Switch Installation
        • 1. Use the following illustrations to reattach the wires from the speed control switch to the cir...
        • Touch Pad Switch Installation
        • 1. Thoroughly clean the surface of the upper housing where the touch pad switch adheres to the up...
        • 2. Remove all traces of silicone sealant from around the slot where the ribbon cable connector pa...
        • 3. Remove the adhesive backing off the new touch pad switch, keep this surface clean and free of ...
        • 4. Assemble the new touch pad switch to the upper housing surface by first sliding the ribbon cab...
        • 5. Once the touch pad is installed, on the underside of the housing apply just enough silicone se...
        • 6. Re-install the circuit board and plug the ribbon cable connector into the circuit board cable ...
        • Lower Half Housing Installation
        • 1. Before installing the lower half housing apply a non- conductive grease to the square holes of...
        • 2. Carefully slide the lower housing onto the upper half of the platform control box assembly unt...
        • 3. Secure lower half housing to the upper half housing using the six (6) screws removed during di...
    • 2.7 Battery Charger Assembly and Disassembly
      • General Information
        • The VP Series battery charger allows for replacement of the following internal components. Consul...
        • Replacement and troubleshooting of these components requires removal of the battery charger from ...
        • 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 ...
        • 5. Remove the charger from the machine.
      • 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. Disconnect the wiring connecting the the transformer to other components within the charger as...
        • 2. Remove the four nuts from the cap screws securing the transfromer brackets to the base of the ...
        • 3. Remove transformer.
        • Printed Circuit Board Replacement
        • 1. Disconnect the wide wiring connector from the end of the circuit board.
        • 2. Remove the four (4) screw attaching the card to the front face of the charger chassis.
        • 3. Remove the circuit board.
        • Shunt Assembly Replacement
        • 1. Carefully remove the screw from each end of the shunt assembly. The white insulator may need t...
        • Interlock Relay Replacement
        • 1. Disconnect the wiring connected to the relay.
        • 2. Remove the two (2) nuts securing the interlock relay to the chassis base.
        • 3. Remove the relay.
        • SCR Rectifier Replacement (Either Side)
        • 1. Remove the wiring from the SCR Rectifier.
        • 2. Remove the nut securing the rectifier to the insulated aluminum chassis bracket.
        • 3. Remove the SCR Rectifier.
        • AC Circuit Breaker Replacement
        • 1. Disconnect wiring connected to the breaker poles.
        • 2. Remove the two (2) nuts securing the AC breaker to the chassis screws.
        • 3. Remove the breaker from the chassis.
        • DC Circuit Breaker Replacement
        • 1. Remove the wiring from the DC breaker terminals.
        • 2. To remove the breaker from the front face of the charger, on the inside of the charger front f...
    • 2.8 Hydraulic Lift Cylinder - Removal, Inspection and rebuild
      • Lift Cylinder Removal
        • Removal of the hydraulic lift cylinder without removing the mast from the machine requires laying...
        • 1. Remove the hood from the rear of the machine.
        • 2. Disconnect and remove the batteries from the machine, to prevent acid leakage.
        • 3. Seal the vented cap on the hydraulic fluid reservoir by removing the cap, covering the hole wi...
        • 4. Use a forklift truck or overhead crane and carefully lay the machine on it’s back, place a sup...
        • 5. Manually extend the mast assembly approximately two (2) feet, to allow access to the sheave wh...
        • 6. Remove the set screw securing the lift cylinder rod to the sheave wheel anchor block at the to...
        • 7. Under the base assembly remove the four (4) bolts attaching the PHP bar actuator assembly to t...
        • 8. Carefully disconnect and cap the extend and return lines and fittings from the lift cylinder, ...
        • 9. Remove the bolt securing the lift cylinder to the cylinder mount.
        • 10. Remove the four (4) bolts, washers and nuts attaching the cylinder mount to the base frame. R...
        • 11. At the bottom of mast section 2, slide the lift cylinder assembly out and place on a suitable...
      • Cylinder Disassembly
        • 1. Before disassembling the cylinder, clean away all dirt and foreign substances from openings, p...
        • 2. Extend the rod until the piston bottoms out against the cylinder head.
        • 3. Compress the head retraining ring enough to allow the the cylinder head to be removed.
        • 4. Carefully slide the head/rod/piston assembly out of the cylinder tube. A gentle tap on the hea...
        • 5. Place the head/rod/piston assembly on a surface that will not damage the chrome.
        • 6. Remove the piston locknut and separate the piston from the rod.
        • 7. Slide the head off the rod from the piston end.
        • 8. Remove and discard all old seals.
      • Lift Cylinder Component Inspection
        • Cylinder Rod
        • There should be no scratches or pits deep enough to catch the fingernail. Pits that go to the bas...
        • Cylinder Head
        • Visually inspect the inside bore for scratches or polishing. Deep scratches are unacceptable. Pol...
        • Piston
        • Visually inspect the outside surface for scratches or polishing. Deep scratches are unacceptable....
        • Tube Assembly
        • Visually inspect the inside bore for scratches and pits. There should be no scratches or pits dee...
      • Cylinder Assembly
        • (See Figure 2-17.)
        • 1. Rinse the inside of the tube with hydraulic fluid and allow to drain. A high-pressure rinse fo...
        • 2. Lubricate the head and all seals with hydraulic fluid prior to installation. Install the seal,...
        • 3. Lubricate the piston and all components with hydraulic fluid. Install the seal and wear ring t...
        • 4. Place the rod on a clean table. Install the static o- ring seal into the groove on the piston ...
        • 5. Install the head followed by the piston onto the rod noting the proper orientation of each com...
        • 6. When the rod assembly is ready to be installed into the tube, liberally apply an anti-seize lu...
        • 7. Next dip the entire rod assembly into hydraulic fluid and stuff this assembly into the tube. W...
        • 8. Install the head until the retaining ring seats in it’s groove.
      • Cylinder Installation
        • To install the lift cylinder reverse the Lift Cylinder Removal instructions at the start of this ...
        • 1. Apply Loctite #222 (purple) to the setscrew securing the lift cylinder rod to the sheave wheel...
        • 2. Torque the four (4) cylinder lift mounting bolts to 34 ft. lb.
    • 2.9 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES
      • The VP Series personnel lift mast sections are contructed of extruded aluminum, protected with an...
      • Each VP model mast assembly contains a different number of mast sections as shown following;
      • Table 2-2. VP Series Mast Component Features
  • 10VP
  • 3
  • Cable
  • 15VP
  • 4
  • Cable
  • 20VP
  • 5
  • Chain & Cable
    • Assembly procedures for all mast sections is basically the same, carefully slide the mast section...
    • Mast Disassembly Procedure
      • 1. After the mast assembly has been removed from the machine, lay the mast assembly down on a sui...
      • 2. Remove the sequencing cables and hardware from the sides of the mast assembly. Also remove the...
      • 3. Remove cable adjust nuts from threaded ends of cable attached to the cable anchor plate on BOT...
      • 4. At the TOP of mast section—3/-4/-5, pull cables out and allow to hang loose.
      • 5. Carefully slide mast section-3/-4/-5 out BOTTOM of mast section-2/-3/-4 rails. Disassemble sli...
      • 6. Remove cable adjust nuts from threaded ends of cables attached to the cable anchor plate on bo...
      • 7. At top of mast section-4, pull cables out and allow to hang loose.
      • 8. Slide mast section-4 out the TOP of mast section-3 far enough to allow access to the cable she...
      • 9. Remove countersunk-flathead screws securing cable sheave wheel assembly attach bars on both si...
      • 10. Carefully slide mast section-4 out BOTTOM of section-3. Remove slide pads, shims and cable an...
      • 11. Remove cable/chain adjust nuts from threaded ends of cable/chain attached to the cable/chain ...
      • 12. At TOP of mast section-3, pull cables/chains out and allow to hang loose, (be certain floor s...
      • 13. Slide mast section-3 out TOP of mast section-2 far enough to allow access to the cable/chain ...
      • 14. Remove countersunk-flathead screws securing cable/chain sheave wheel assembly attach bars on ...
      • 15. While mast section-3 is still extended from section-2 remove the bolts attaching the two (2) ...
      • 16. Carefully slide mast section-3 out BOTTOM of section-2. Remove slide pads, shims and chain an...
      • 17. Slide mast section-2 out TOP of mast section-1 far enough to allow access to the cable/chain ...
      • 18. Remove countersunk-flathead screws securing cable/chain anchor block/sheave wheel assembly at...
      • 19. Slide the cable/chain anchor block/sheave wheel assembly and hydraulic cylinder out the TOP o...
      • 20. Remove the setscrew holding the hydraulic cylinder rod into the chain assembly #444 anchor bl...
      • 21. Remove the hydraulic cylinder through BOTTOM of mast section-2, be careful not to nick or sco...
      • 22. Carefully slide mast section-2 out BOTTOM of section-1. Remove slide pads and shims, if neces...
      • 23. Slide the TOP of remaining mast section-1 out over edge of work surface and remove the bolts ...
      • 24. Remove slide pads and shims from mast section-1.
      • Mast disassembly should now be complete.
    • Mast Assembly
      • (See Figure 2-18., 2-19., 2-20. & 2-21.)
      • 1. Place mast section-1, rail (open) side up on a clean, flat surface (preferably a table or work...
      • 2. Locate the two (2) single cable/chain assemblies. Lay out each cable/chain assembly with ancho...
      • 3. Insert the block anchor end into the top of mast section-1 and secure using two (2) 3/8"-16UNC...
      • 4. Locate mast section-2, carefully slide mast section-2 closed rail into section-1 open rail. Sl...
      • 5. Insert slide pads into the slide pad channels at bottom end of mast between section-1 and -2, ...
      • 6. Thread slide pad attaching bolts, (two (2) 1/4"- 20UNC x 3/8" long hex head bolts, place a fla...
      • 7. Shim slide pads using the following steps:
        • 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.Slide ...
        • c. All mast sections are to be shimmed to provide a measurable gap between the slide pad (beveled...
        • d. When mast slide pads are shimmed properly, the mast sections should be able to slide in channe...
      • 8. Insert slide pads into the slide pad channels (top of mast) between section-1 and -2, (one on ...
      • 9. Thread slide pad attaching bolts, (two (2) 1/4"- 20UNC x 3/8" long hex head bolts, place a fla...
      • 10. Shim per instructions in step 7.
      • 11. Locate the hydraulic lift cylinder, slide the lift cylinder into the closed rail side of mast...
      • 12. Locate chain assembly #444 (single anchor block with two narrow chains). Lay out chain assemb...
      • 13. Insert hydraulic cylinder rod end into chain assembly #444, anchor block. Secure cylinder rod...
        • a. Locate mast section-3, carefully slide section-3 closed rail into section-2 open rail. Slide s...
      • 14. Slide mast section-3, approximately two feet out of the top of mast section-2.
      • 15. Insert threaded ends of cable/chain-assembly #466 (attached to top of mast section-1), throug...
      • 16. Slide mast section-2 out of mast section-1 approximately one foot.
      • 10VP Top of Cylinder Assembly
      • 19. Assemble cable sheave wheels to cylinder rod end and attach to mast section-2 using following...
        • a. Attach cable mounting tube to top of hydraulic cylinder using one (1) 1/4"-28NF x 5/8" capscrew.
        • b. Insert sheave pin through cylinder cable mounting 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 hol...
        • 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/ 8"-16UNC x 1/2" long socket head-countersunk-...
      • 15VP Top of Cylinder Assembly
      • 19. Assemble cable sheave wheels to cylinder rod end and attach to mast section-2 using following...
        • a. Attach cable mounting tube to top of hydraulic cylinder using one (1) 1/4"-28NF x 5/8" capscrew.
        • b. Insert sheave pin through cylinder cable mounting 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 hol...
        • g. Before sliding this assembly into the top of mast section two, locate two (2) mast extension c...
        • 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-...
      • 20VP Top of Cylinder Assembly
      • 19. Assemble chain sheaves on chain assembly #444 anchor block (attached to cylinder rod end) and...
        • a. Insert sheave pin through anchor block on cylinder 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 thread...
        • d. Slide the whole anchor block assembly with sheave pin, wheels and pin attach bars into top of ...
        • e. Attach to top of mast section-2 using two (2) 3/ 8"-16UNC x 1/2" long socket head-countersunk-...
      • 20. Slide mast section-2 back into section-1 until end are even.
      • 21. Locate two mast extension cable assemblies. Attach the eyelet anchor end of each cable to the...
      • 22. Carefully slide mast section-3 into section-2 until ends are even. Check to make sure chain a...
      • 23. Insert slide pads into the top end mast rails between section-2 and -3, (one on each side of ...
      • 24. Thread slide pad attaching bolts, (two (2) 1/4"- 20UNC x 3/8" long hex head bolts, place a fl...
      • 25. Shim per instructions in step 7.
      • 26. Insert slide pads into the bottom end mast rails between section-2 and -3, (one on each side ...
      • 27. Thread slide pad attaching bolts, (two (2) 1/4"- 20UNC x 3/8" long hex head bolts, place a fl...
      • 28. Shim per instructions in step 7.
      • 29. Locate mast section-4, carefully slide section-4 closed rail into section-3 open rail. Slide ...
      • 30. Locate one (1) of the chain/cable anchor plates (one with two threaded holes vertically align...
      • 31. Slide mast section-4 out the top of mast section-3 so the chain/cable anchor plate on bottom ...
      • 32. Insert threaded ends of cable/chain assembly (attached to anchor block on top mast section-2)...
      • 33. Slide mast section-4 back into mast section-3 except for about a foot or more. Allow enough s...
      • 34. Extend mast section-3 out far enough from section-2 mast to gain access to top of section-3.
      • 35. Assemble cable/chain sheaves to top of mast section-3 as follows;
        • a. Locate the two cable/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 she...
        • 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 th...
        • e. Attach to top of mast section-3 using two (2) 3/ 8"-16UNC x 1/2" long socket head-countersunk-...
      • 36. Slide mast section-3 back into section-2 until ends are even. (Mast section-2 may need to be ...
      • 37. While mast section-4 is still extended from section-3; locate two cable assemblies. Attach th...
      • 38. While mast section-4 is still extended from section-3, assemble cable sheaves to top of mast ...
        • a. Locate the wide tube spacer and slide onto sheave pin.
        • b. Slide two (2) cable sheave wheels onto sheave pin, one each end of sheave pin to outside of tu...
        • c. Place two (2) large flat washers, one each end of sheave pin to outside of cable sheave wheels.
        • d. Place two (2) sheave pin attach bars, one each end of sheave pin to outside of large flatwashers.
        • e. Holding complete cable sheave wheel assembly, slide assembly into top of mast section-4 and al...
        • f. Attach to top of mast section-4 using two (2) 3/ 8"-16UNC x 1/2" long socket head-countersunk-...
      • 39. Carefully slide mast section-4 back into section-3 until ends are even. Check to make sure ca...
      • 40. Insert slide pads into the top end mast rails between section-3 and -4, (one on each side of ...
      • 41. Thread slide pad attaching bolts, (two (2) 1/4"- 20UNC x 3/8" long hex head bolts, place a fl...
      • 42. Shim per instructions in step 7.
      • 43. Insert slide pads into the bottom end mast rails between section-3 and -4, (one on each side ...
      • 44. Thread slide pad attaching bolts, (two (2) 1/4"- 20UNC x 3/8" long hex head bolts, place a fl...
      • 45. Shim per instructions in step 7.
      • 46. Locate the remaining mast section-4/-5 (platform mounting- mast section). Lay mast section on...
      • 47. Attach the remaining chain/cable anchor plate (one with threaded holes vertically aligned in ...
      • 48. Complete the following steps to determine shim stock thickness required for section-4/-5;
        • 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.
        • c. Attach shim stock and slide pads to both sides of mast section-4/-5 using five (5) 1/4"-20UNC ...
        • d. Carefully thread the slide pad mounting bolts with flatwashers through slide pads and shim sto...
        • e. Begin sliding top of mast section-4/-5 with closed rail down engaging the slide pads into slid...
        • f. Check mast section for side play. If play exists use thicker shims dividing thickness equally ...
        • g. When mast slide pads are shimmed properly, there should be no side to side movement of slide p...
      • 49. Slide mast section-4/-5 to top of section-3/-4.
      • 50. Insert threaded ends of cable assembly (attached to top of mast section—2/3) through the chai...
      • 51. Slide mast section-4/-5 back into mast section-3/-4 until bottom ends of masts are even. Chec...
      • 52. At bottom of mast assembly, thread all chain/ cable adjusting nuts on threaded ends until the...
      • Mast assembly should now be complete.
    • 2.10 Mast To Base Frame Installation
      • 1. Using an overhead crane or suitable lifting device capable of supporting the weight of the bas...
      • 2. Using a sling and suitable lifting equipment (i.e. overhead crane) lift the mast assembly (bal...
      • 3. Extend hydraulic cylinder out from bottom of mast assembly approximately one (1) foot. (Caps o...
      • 4. Carefully position the mast into base frame assembly, (base frame and mast assembly must be he...
      • 5. Slide port end of hydraulic cylinder through hole in base frame cylinder mounting channel. (Re...
      • 6. Align threaded hole in side of hydraulic cylinder head with hole in tab on bottom side of cyli...
      • 7. Carefully push mast assembly and base assembly together until the four (4) holes on bottom rea...
      • 8. Attach mast to base using four (4) 3/8"-16UNC x 1" long hex head bolts, locknuts and flatwashe...
      • 9. Locate the two (2) mast support braces, attach to sides of base frame using a 3/8"-16UNC x 1" ...
      • 10. Before setting machine upright on base, install a short 90˚ elbow fitting, flow control valve...
      • 11. Carefully set machine in an upright position on its base frame wheels.
      • 12. Locate the mast support bracket. Attach mast support bracket to mounting holes halfway up bac...
      • 13. Using a 4 ft. level, ensure the mast is set to vertical (plumb) on the base frame.
      • 14. When mast is vertical (plumb), attach support braces, (bolted to base), to the mast support b...
      • 15. After securing mast to base frame, using 4 ft. level again check that mast is vertical (plumb...
      • 16. Continue installing remaining components to mast assembly, (i.e. hydraulic pump/motor/reservo...
    • 2.11 MAST CHAINS/CABLES AND SEQUENCING CABLES ADJUSTMENT
      • Mast Chain/Cable Adjustment
        • The intention of this procedure is to assure equal load distribution between the individual chain...
        • Adjust using the following procedure;
        • 1. With mast retracted, step into the platform and bounce your weight up and down a few times to ...
        • 2. Then with no load in the platform check the side profile of the top of the mast for the amount...
        • 3. Adjust one mast section at a time starting from the back (section-3, section-4, etc.) of the m...
        • 4. Elevate the platform until the chain/cable anchor adjust nuts are accessible at the front and ...
        • 5. Start with the mast section which needs adjustment and loosen the bottom (jam) nut on each cha...
        • 6. Tighten (to raise mast section), or loosen (to lower mast section) the adjusting nut against t...
        • 7. Retract the mast all the way and check if the top of the mast sections appear as shown in Figu...
        • 8. Repeat steps (1) through (7) for remaining mast sections. ENSURE THAT ALL CHAIN/CABLE PAIRS HA...
        • 9. Once mast section adjustment is completed, apply loctite #242 to the threads under the (jam) n...
      • Sequencing Cable Adjustment
        • 1. Retract mast completely, and check each sequencing cable on outside of masts for excessive sla...
        • 2. Tighten nylock-nut just enough to remove excessive slack from sequencing cable. The springs sh...
        • 3. Run mast through several cycles to verify cable/ chain adjustments and ensure no interference ...
    • 2.12 Sequence Cable replacement kit
      • A sequence cable replacement kit is available from the JLG Parts Department to service broken or ...
      • Remove Old Cable
        • 1. Remove the locking nut from the threaded end of the cable at the top of the mast and then remo...
        • 2. Slide the threaded top end out of the upper anchor bracket, then at the bottom end pull the ca...
      • Replacement Cable Installation
        • 1. Be certain the mast is completely retacted and at the bottom of travel. Check the mast "Side P...
        • 2. To determine where the clamp will be installed at the bottom of the replacement cable, tempora...
        • 3. At the bottom of the mast, thread the loose end of the replacement cable through the proper sh...
        • 4. Grasp the cable and pull on the cable until the spring at the top of the cable is slightly com...
      • Clamp Installation (Drum/Socket Type)
        • 1. Using the recommended vise jaws, clamp the wire rope into a vise with the bottom edge of the b...
        • 2. Twist the sleeve from the clamp kit onto the rope until it is flat against the vise jaws at th...
        • 3. Use a suitable tool and cut the cable as shown in the illustration following. For 1/8 in. cabl...
        • 4. Unlay the cable strands by gently forcing a screwdriver between the outer strands to unlay the...
        • 5. Install the plug supplied with the kit by placing the plug in the center of the strands starti...
        • 6. Reclamp the assembly in the vise on the flats of the sleeve. Using the plug driver, a metal tu...
        • 7. Coat the threads of the socket and sleeve with lubricant and install the socket by twisting it...
        • 8. Inspect for proper assembly prior to loading the cable. Strands visible through the inspection...
        • 9. Install cable on machine and adjust per instructions shown previously in Section 2.11, MAST CH...
    • 2.13 Preventive Maintenance and Inspection Schedule
      • (See Table 2-2.)
      • The preventive maintenance and inspection checks are listed and defined in the following table (S...
      • The checks and services listed in this schedule are not intended to replace any local or regional...
      • JLG Industries requires that a complete annual inspection be performed in accordance with the “An...
      • Table 2-3. Preventive Maintenance & Inspection Schedule.
  • 1,11
  • 1,2
  • 1,2
  • 1,8
  • 1,4
  • MAST
  • 1,4,7,9
  • 12
  • 1,4,7
  • 1,4,7,9
  • 1,7,9
  • BASE FRAME
  • 1,3
  • 5
  • 1
  • 1,8
  • 1
  • 5
  • 1
  • 5
  • 3
  • 5
  • 4
  • 6,14
  • 1,7
  • 1
  • 5,6,13
  • 4
  • 1,2
  • 1
  • 8,9
  • 12
  • 8
  • 12
  • 1,7
  • 1,6,9
  • 1,11
  • 1,2
  • 1,8
  • 1,2
    • * Inspection and Maintenance Code 10 to be performed every two years. ** Maintenance Code 10 to b...
    • Inspection and Maintenance Codes:
    • 1. Check for proper and secure installation.
    • 2. Check for visible damage and legibility.
    • 3. Check for proper fluid level.
    • 4. Check for any structural damage; cracked or broken welds; bent/warped surfaces; broken cable s...
    • 5. Check for leakage.
    • 6. Check for presence of excessive dirt or foreign material.
    • 7. Check for proper operation and freedom of movement.
    • 8. Check for excessive wear or damage.
    • 9. Check for proper tightness and adjustment.
    • 10. Drain, clean and refill.
    • 11. Check for proper operation while pump/motor is running.
    • 12. Check for proper lubrication.
    • 13. Check for evidence of scratches, nicks or rust and for straightness of rod.
    • 14. Check for condition of element; replace as necessary.
• Section 3. troubleshooting
  • 3.1 General
    • This section contains troubleshooting information to be used for locating and correcting most ope...
  • 3.2 Troubleshooting Information
    • Troubleshooting procedures applicable to the VP machine are listed and defined starting with Sect...
    • Each malfunction within an individual group or system is followed by a listing of probable causes...
    • It should be noted that there is no substitute for a thorough knowledge of the equipment and rela...
    • It should be recognized that the majority of the problems arising in the machine will be centered...
    • The first rule for troubleshooting any circuit that is hydraulically operated and electrically co...
  • 3.3 Hydraulic Circuit Checks
    • (See Figure 3-6.)
    • The first reference for improper function of a hydraulic system, where the cause is not immediate...
  • 3.4 ELECTRICAL CIRCUIT CHECKS
    • General
      • The drive system on the VP series machine requires a microprocessor controlled electrical circuit...
      • To help diagnose any problems with the components associated with the microprocessor, the MC-1 is...
    • LED Indicator Strip
      • When the machine is powered up, all function inputs should be open. If any function is active on ...
      • This strip has ten (10) green LEDs and is located on the platform controller box between the func...
    • Fault Code Reference Tables
      • Their are two types of fault codes which can occur to indicate a problem with the machine, these ...
      • 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 is n...
    • ERROR Codes
      • (See Table 3-2.)
      • An ERROR is indicated by an audible beep and continuously fast flashing LED bar. The number of fa...
      • Table 3-1. MC-1 WARNING CODES (Indicated by 3 beeps, then slow flashing LED’s)
      • Table 3-2. MC-1 ERROR CODES (Indicated by rapid LED flashing and periodic beep)
  • Figure 3-2. Overview of Standard Electrical System. (Sheet 2 of 2)
  • Figure 3-3. VP Electrical Diagram. (VP Series - Standard)
  • Figure 3-4. Overview of VP UL-EE Approved Optional Electrical System. (Sheet 2 of 2)
  • Figure 3-5 VP Electrical Diagram. (with UL-EE Approved Option)
    • 3.5 TROUBLESHOOTING SECTION - TABLE OF CONTENTS
      • OHM RATINGS FOR VARIOUS COMPONENTS PAGE
        • Ohm Ratings for Various Components 3-16
      • MAIN POWER CIRCUIT TROUBLESHOOTING
        • Unit Will Not Power Up From Ground Control 3-17
        • No Power At Platform Control 3-18
      • DRIVE TRAIN TROUBLESHOOTING
        • Won’t Drive (Platform Lowered Or Elevated) 3-20
        • Won’t Drive (Platform Elevated Only) 3-22
        • Won’t Climb Grade 3-24
        • Drives In Opposite Direction 3-25
        • Will Only Drive A Short Distance 3-26
        • Won’t Drive Straight 3-28
        • Noise From Drive Assembly 3-29
      • MAST TROUBLESHOOTING
        • Platform Will Not Lift Up Using Platform Control 3-30
        • Platform Will Not Lower Using Platform Control 3-33
        • Platform Will Not Lift Up From Ground Control Toggle Switch 3-34
        • Platform Will Not Lower From Ground Control Toggle Switch 3-35
        • Platform Will Not Lower Manually 3-36
        • Platform Lift Up And Down Jerky 3-37
        • Mast Noisy When Lifting And Lowering 3-38
        • Platform (Mast) Won’t Stay Elevated 3-39
        • Platform (Mast) Descends Too Slowly 3-40
      • HYDRAULIC LEAK TROUBLESHOOTING
        • Miscellaneous Hydraulic Leak Troubleshooting 3-41
      • BASE FRAME COMPONENTS TROUBLESHOOTING
        • Caster Wheels Not Operating Freely 3-42
        • Pot Hole Protection (PHP) Bars Will Not Set 3-42
    • 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
    • 3.7 MAIN POWER CIRCUIT TROUBLESHOOTING
      • Unit Will Not Power Up From Ground Control
        • Overview Of Procedure
        • The following procedure tests the circuits from the Battery (+) terminal through the Ground Contr...
        • 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)
        • Table 3-4. Unit will not Power Up From Ground Control.
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
        • 7.
        • 8.
        • 9.
        • 10.
      • No Power At Platform Control
        • Overview Of Procedure
        • The following procedure checks voltage and ground starting from the power source (batteries) thro...
        • 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)
        • • Connection of X102 Cable from MC-1 box to Platform Control, secure on both ends.
        • Table 3-5. No Power At Platform Control.
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
        • 7.
        • 8.
        • 9.
        • 10.
        • 11.
        • 12.
        • 13.
        • 14.
        • 15.
        • 16.
    • 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 ...
        • Check For These Obvious Conditions First:
        • • Joystick Powered On
        • • Unit will Lift & 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)
        • 1.
        • 2.
        • 3.
        • 4.
          • Table 3-7. Elevation Switch Circuit Check
        • 1.
        • 2.
        • 3.
          • Table 3-8. Brake Limit Switch Circuit Check
        • 1.
        • 2.
        • 3.
        • 4.
          • Table 3-9. Drive Motor/Circuit Check
        • 1.
        • 2.
          • Table 3-10. Brake Switch/Circuit Check
        • 1.
        • 2.
      • 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 ...
        • Check For These Obvious Conditions First:
        • • Joystick Powered On
        • • Unit will Lift & 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
        • 1.
        • 2.
          • Table 3-12. Tilt Sensor Circuit Check
        • 1.
        • 2.
        • 3.
        • 4.
          • Table 3-13. PHP Limit Switch Circuit
        • 1.
        • 2.
        • 3.
      • Won’t Climb Grade
        • Overview Of Procedure
        • The following procedure checks the drive motor and attached components for component failure, mis...
        • Check For These Obvious Conditions First:
        • • Batteries are Fully Charged (24 Volts)
        • • Speed Control is Set to Maximum
        • • Is Grade within the Maximum Allowable Specification of 15% Grade (8.5 degrees)
        • • Does the Travel Surface allow for Proper Drive Wheel Traction
        • • Is Platform Load within the Maximum Rated Capacity
        • Table 3-14. Won’t Climb Grade
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
      • Drives In Opposite Direction
        • Overview Of Procedure
        • The following procedure checks that both the drive motor power wire connections correctly install...
        • Check For These Obvious Conditions First:
        • • If the Left Drive Motor (X103) connector is switched with the Right Drive Motor (X104) connecto...
        • • Check Joystick Calibration (See Procedure in Service Manual, Section-2).
        • Table 3-15. Drives In Opposite Direction
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
        • 7.
          • * Note: If the Orange, 55-3 or 55-6 wires to the right drive motor in the X104 connector or the O...
          • ** Note: If platform controller is not under warranty, the internal components of the platform co...
      • 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 contro...
        • Check For These Obvious Conditions First:
        • • Is Battery Voltage 24 Volts? (Fully Charge Batteries)
        • Table 3-16. Only Drives A Short Distance
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
        • 7.
        • 8.
          • Table 3-17. E-Stop and Key Switch Circuit Check
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
      • Won’t Drive Straight
        • Overview Of Procedure
        • The following procedure examines the drive motor assembly weldments attaching the drive motors to...
        • 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.
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
        • 7.
        • 8.
        • 9.
        • 10.
      • Noise From Drive Assembly
        • Overview Of Procedure
        • The following procedure examines the drive motor assembly weldments attaching the drive motors to...
        • 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.
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
        • 7.
    • 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 oil is within it’s specified operating temperature range.
        • Table 3-20. Platform Will Not Lift Up Using Platform Control.
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
          • Table 3-21. Pump Circuit
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
        • 7.
        • 8.
        • 9.
        • 10.
        • 11.
        • 12.
        • 13.
        • 14.
        • 15.
        • 16.
        • 17.
        • 18.
          • Table 3-22. Pump Valves Circuit
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
      • Platform Will Not Lower Using Platform Control
        • Overview Of Procedure
        • This procedure tests for ground coming out of the MC-1 box to the dump valve circuit and through ...
        • 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.
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
      • 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...
        • 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)
        • • Ground 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.
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
        • 7.
        • 8.
        • 9.
        • 10.
      • 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...
        • 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.
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
        • 7.
        • 8.
      • Platform Will Not Lower Manually
        • Overview Of Procedure
        • The following procedure suggests components on the machine which might attribute to problems with...
        • Table 3-26. Platform Will Not Lower Manually.
        • 1.
        • 2.
        • 3.
      • Platform Lift Up And Down Jerky
        • Overview Of Procedure
        • The following procedure suggests areas on the machine which might attribute to erratic movement o...
        • Check For These Obvious Conditions First:
        • • If 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.
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
        • 7.
      • 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 ...
        • Table 3-28. Mast Noisy when Lifting and Lowering.
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
        • 7.
        • 8.
        • 9.
      • 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...
        • Check For These Obvious Conditions First:
        • • Manual descent valve is closed tight.
        • Table 3-29. Platform (Mast) Won’t Stay Elevated.
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
      • 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.
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
    • 3.10 HYDRAULIC LEAK TROUBLESHOOTING
      • Miscellaneous Hydraulic Leak Troubleshooting
        • Overview Of Procedure
        • This series of steps gives remedies for various areas of the machine where leaks could occur.
        • Table 3-31. Hydraulic Leak Troubleshooting
        • 1.
        • 2.
        • 3.
        • 4.
        • 5.
        • 6.
          • Note: Do not overtighten the nut on the solenoid in steps 4, 5, and 6.
    • 3.11 BASE FRAME COMPONENTS TROUBLESHOOTING
      • Caster Wheels Not Operating Freely
        • Check For These Obvious Conditions First:
        • • Is machine operating on a smooth, level surface?
        • Table 3-32. Caster Wheels Not Operating Freely.
        • 1.
        • 2.
        • 3.
      • 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.
        • 1.
        • 2.