$7.95
JLG 10VP, 15VP & 20VP Vertical Mast Lifts Service and Maintenance Manual (ANSI)
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This service manual PDF download for the 10VP, 15VP & 20VP JLG Vertical Mast Lifts has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
JLG Lift 10VP
JLG Lift 15VP
JLG Lift 20VP
TABLE OF CONTENTS :
SECTION INTRODUCTION - - MAINTENANCE SAFETY PRECAUTIONS
A General
B Hydraulic System Safety
C Maintenance
Effectivity Changes
SECTION 1 - SPECIFICATIONS
1.1 Capacities
1.2 Component Data
1.3 Performance Data
1.4 Torque Requirements
1.5 Lubrication
1.6 Hydraulic Pressure Adjustment
1.7 Cylinder Specifications
1.8 Serial Number Location
SECTION 2 - SERVICE PROCEDURES
2.1 General
2.2 Servicing And Maintenance Guidelines
2.3 Lubrication Information
2.4 Positioning Lift For Access To Components Located Under The Base Frame
2.5 Drive Motor Component Service Procedures
2.6 Platform Control Box Service Procedures
2.7 Battery Charger Assembly And Disassembly
2.8 Hydraulic Lift Cylinder - Removal, Inspection And Rebuild
2.9 Mast Assembly And Disassembly Procedures
2.10 Mast To Base Frame Installation
2.11 Mast Chains/cables And Sequencing Cables Adjustment
2.12 Sequence Cable Replacement Kit
2.13 Preventive Maintenance And Inspection Schedule
SECTION 3 - TROUBLESHOOTING
3.1 General
3.2 Troubleshooting Information
3.3 Hydraulic Circuit Checks
3.4 Electrical Circuit Checks
3.5 Troubleshooting Section - Table Of Contents
3.6 Ohm Ratings For Various Components
3.7 Main Power Circuit Troubleshooting.
3.8 Drive Train Troubleshooting
3.9 Mast Troubleshooting
3.10 Hydraulic Leak Troubleshooting
3.11 Base Frame Components Troubleshooting
LIST OF FIGURES
LIST OF TABLES
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Pub No. : 3120728
Total Pages : 104
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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.
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