Jlg 20VP (3120728) Service Manual User Manual

Service and Maintenance ManualANSIModel10VP15VP20VP3120728June 14 2001

ii – JLG Lift – 3120728TABLE OF CONTENTS LIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. Hydraulic Pressure Setting - Adjustment

SECTION 3 - TROUBLESHOOTING3-40 – JLG Lift – 3120728Platform (Mast) Descends Too SlowlyOverview Of ProcedureThe following procedure examines the mast

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-413.10 HYDRAULIC LEAK TROUBLESHOOTINGMiscellaneous Hydraulic Leak TroubleshootingOverview Of Procedu

SECTION 3 - TROUBLESHOOTING3-42 – JLG Lift – 31207283.11 BASE FRAME COMPONENTS TROUBLESHOOTINGCaster Wheels Not Operating FreelyCheck For These Obviou

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Fax: (717) 485-6417JLG Ind

3120728 – JLG Lift – iii TABLE OF CONTENTS3-9 Drive Motor/Circuit Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SECTION 1 - SPECIFICATIONS3120728 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESSystem VoltageAll VP Models –24 Volt DC (2 - 12 volt DC bat

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 3120728Base FootprintVP Series - 32 in. (81cm) width 56 in. (1.42m) lengthMax. Platform Height (mast extend

SECTION 1 - SPECIFICATIONS3120728 – JLG Lift – 1-31.6 HYDRAULIC PRESSURE ADJUSTMENTAdjust system pressure so that platform will raise withrated capaci

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3120728Figure 1-3. Torque Chart.

SECTION 1 - SPECIFICATIONS3120728 – JLG Lift – 1-5Figure 1-4. Lubrication Chart.2134, 56Table 1-6.Lubrication Intervals for Various ComponentsITEM CO

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SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-1SECTION 2. SERVICE PROCEDURES2.1 GENERALThis section provides general information to assist in

SECTION 2 - SERVICE PROCEDURES2-2 – JLG Lift – 3120728apply pressure to the outer race. If the bearing is to beinstalled on a shaft, apply pressure to

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-3Tight Joints: All joints in the leaf chain should flex freely.On leaf chain, tight joints are us

SECTION 2 - SERVICE PROCEDURES2-4 – JLG Lift – 3120728can cause wear or damage to the components and gener-ally results in faulty operation. Every pre

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-52.5 DRIVE MOTOR COMPONENT SERVICE PROCEDURESTorque Limiting Clutch MaintenanceVP Series machines

SECTION 2 - SERVICE PROCEDURES2-6 – JLG Lift – 3120728Torque Limiting Clutch AdjustmentNOTE: The large adjusting nut on the side of the clutchassembly

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-7Operation (See Figure 2-4. & Figure 2-5.)When the magnetic coil is not energized (brake on),

SECTION 2 - SERVICE PROCEDURES2-8 – JLG Lift – 3120728Brake Assembly Removal1. Lift the machine to gain access to the underside(See Section 2-4., &quo

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-9Drive Motor Removal(See Figure 2-7.)The VP drive motors consist of three sections, the gearbox a

SECTION 2 - SERVICE PROCEDURES2-10 – JLG Lift – 3120728IF REMOVING THE COMPLETE DRIVE ASSEMBLY, IT WEIGHSAPPROXIMATELY XX LB. AND WILL REQUIRE ASSISTA

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-11NOTE: The gear oil can be drained out when the side coveris removed in the next step. Remove th

FOREWORDThe purpose of this manual is to provide users with the operating procedures essential for the promotion ofproper machine operation for its in

SECTION 2 - SERVICE PROCEDURES2-12 – JLG Lift – 3120728Final Gear Box Assembly1. If necessary, install a new drive shaft lip seal into thedrive shaft

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-13Drive Motor Brush ReplacementEach drive motor contains two (2) brushes, the brushesare located

SECTION 2 - SERVICE PROCEDURES2-14 – JLG Lift – 3120728Brush Reassembly (See Figure 2-12.)MAKE CERTAIN THAT THE GROUND WIRE IS SECURELY RECON-NECTED T

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-152.6 PLATFORM CONTROL BOX SERVICE PROCEDURESJoystick Calibration Procedure1. Turn off all power

SECTION 2 - SERVICE PROCEDURES2-16 – JLG Lift – 3120728Platform Control Box DisassemblyDO NOT ATTEMPT TO DISASSEMBLE THE PLATFORM CONTROLBOX IF MACHIN

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-173. Remove the four (4) screws attaching the circuitboard to the upper housing. NOTE: If reusing

SECTION 2 - SERVICE PROCEDURES2-18 – JLG Lift – 31207283. Remove the reset button part of the emergency stopswitch by unscrewing the collar on the ins

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-192. If damaged replace the gasket between upper hous-ing surface and the joystick mounting surfa

SECTION 2 - SERVICE PROCEDURES2-20 – JLG Lift – 3120728nector from the touch pad switch through the slot atthe top of the housing. Before pressing the

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-21Battery Charger Part ReplacementCover Removal1. Remove the eight (8) screws on the sides of the

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SECTION 2 - SERVICE PROCEDURES2-22 – JLG Lift – 3120728Interlock Relay Replacement1. Disconnect the wiring connected to the relay.2. Remove the two (2

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-232.8 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILDHYDRAULIC CYLINDERS ARE DESIGNED T

SECTION 2 - SERVICE PROCEDURES2-24 – JLG Lift – 3120728Lift Cylinder Component InspectionCylinder RodThere should be no scratches or pits deep enough

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-25 Figure 2-17. Lift Cylinder Internal Component Assembly Cross-Section.PISTONLOCKNUT(Torque

SECTION 2 - SERVICE PROCEDURES2-26 – JLG Lift – 31207282.9 MAST ASSEMBLY AND DISASSEMBLYPROCEDURESThe VP Series personnel lift mast sections are contr

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-275. Carefully slide mast section-3/-4/-5 out BOTTOM ofmast section-2/-3/-4 rails. Disassemble sl

SECTION 2 - SERVICE PROCEDURES2-28 – JLG Lift – 3120728Figure 2-19. 10VP Mast Assembly.

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-29Figure 2-20. 15VP Mast Assembly.

SECTION 2 - SERVICE PROCEDURES2-30 – JLG Lift – 3120728Figure 2-21. 20VP Mast Assembly.

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-31Mast Assembly(See Figure 2-18., 2-19., 2-20. & 2-21.)1. Place mast section-1, rail (open) s

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS3120728 – JLG Lift – aINTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA. GENERALThis section contains the ge

SECTION 2 - SERVICE PROCEDURES2-32 – JLG Lift – 3120728bracket). Attach using outer set of holes in bot-tom of mast section-3 with two (2) 1/4"-2

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-33this manner, due to the tight fit of the slide pads inthe slide pad channels, the anodized fini

SECTION 2 - SERVICE PROCEDURES2-34 – JLG Lift – 3120728e. Holding complete cable sheave wheel assem-bly, slide assembly into top of mast section-4and

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-35g. When mast slide pads are shimmed properly,there should be no side to side movement ofslide p

SECTION 2 - SERVICE PROCEDURES2-36 – JLG Lift – 3120728control valve in the extend (left) port on bottom ofhydraulic cylinder. Install a long 90° elbo

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-379. Once mast section adjustment is completed, applyloctite #242 to the threads under the (jam)

SECTION 2 - SERVICE PROCEDURES2-38 – JLG Lift – 31207282.12 SEQUENCE CABLE REPLACEMENT KITA sequence cable replacement kit is available from theJLG Pa

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-393. Use a suitable tool and cut the cable as shown in theillustration following. For 1/8 in. cab

SECTION 2 - SERVICE PROCEDURES2-40 – JLG Lift – 31207282.13 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE(See Table 2-2.)The preventive maintenance a

SECTION 2 - SERVICE PROCEDURES3120728 – JLG Lift – 2-41Inspection and Maintenance Codes:1. Check for proper and secure installation.2. Check for visib

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SECTION 2 - SERVICE PROCEDURES2-42 – JLG Lift – 3120728This page intentionally left blank.

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-1SECTION 3. TROUBLESHOOTING3.1 GENERALThis section contains troubleshooting information to be used

SECTION 3 - TROUBLESHOOTING3-2 – JLG Lift – 3120728LED Indicator StripWhen the machine is powered up, all function inputs should be open. If any funct

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-3Table 3-1. MC-1 WARNING CODES(Indicated by 3 beeps, then slow flashing LED’s)WARNING CODELED’S FLA

SECTION 3 - TROUBLESHOOTING3-4 – JLG Lift – 3120728Table 3-2. MC-1 ERROR CODES(Indicated by rapid LED flashing and periodic beep)ERROR CODELED’S FLAS

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-526 6If voltage @ pin 5 (RED2) of X101 is 20v w/24v @ Battery or if ground controls and operating li

SECTION 3 - TROUBLESHOOTING3-6 – JLG Lift – 3120728Figure 3-2. Overview of Standard Electrical System. (Sheet 1 of 2)BEACONFROM X101CONNECTORFROM X10

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-7Figure 3-2. Overview of Standard Electrical System. (Sheet 2 of 2)TO (+)BATTERYTERMINALTO (—)BAT

SECTION 3 - TROUBLESHOOTING3-8 – JLG Lift – 3120728Figure 3-3. VP Electrical Diagram. (VP Series - Standard)ORN/RED 49-3BLU/ORN 52-1ORN/RED 49-1ORANG

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-9Figure 3-3. VP Electrical Diagram. (VP Series - Standard)ORN/RED 49-3ORN/RED 49-38787A308586BLU/OR

EFFECTIVITY PAGE 3120728 – JLG Lift – cEFFECTIVITY CHANGESSeptember 15, 1997 – Original Issue of ManualJanuary 10, 1998 – Change 1– Pages Affected:

SECTION 3 - TROUBLESHOOTING3-10 – JLG Lift – 3120728Figure 3-4. Overview of VP UL-EE Approved Optional Electrical System. (Sheet 1 of 2)TO B

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-11Figure 3-4. Overview of VP UL-EE Approved Optional Electrical System. (Sheet 2 of 2)+TOBATTERYTER

SECTION 3 - TROUBLESHOOTING3-12 – JLG Lift – 3120728 Figure 3-5. VP Electrical Diagram. (with UL-EE Approved Option)X102 X103X105 X1

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-13Figure 3-5 VP Electrical Diagram. (with UL-EE Approved Option)4933134_ABEACON BRKR.TILT BEAKERPUM

SECTION 3 - TROUBLESHOOTING3-14 – JLG Lift – 3120728Figure 3-6. Hydraulic Diagram. (VP Series)RETURN TUBEEXTEND TUBEPRES.COMPENSATEDFLOW VALVECYLINDE

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-153.5 TROUBLESHOOTING SECTION - TABLE OF CONTENTSOHM RATINGS FOR VARIOUS COMPONENTS PAGEOhm Ratings

SECTION 3 - TROUBLESHOOTING3-16 – JLG Lift – 31207283.6 OHM RATINGS FOR VARIOUS COMPONENTSThe following table contains ohm ratings for various VP Seri

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-173.7 MAIN POWER CIRCUIT TROUBLESHOOTINGUnit Will Not Power Up From Ground ControlOverview Of Proced

SECTION 3 - TROUBLESHOOTING3-18 – JLG Lift – 3120728No Power At Platform ControlOverview Of ProcedureThe following procedure checks voltage and ground

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-1913. Check voltage on the Red/Blk wire at the MC-1 box, X102 connec-tor, pin 15, to the Platform C

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SECTION 3 - TROUBLESHOOTING3-20 – JLG Lift – 31207283.8 DRIVE TRAIN TROUBLESHOOTINGWon’t Drive (Platform Lowered Or Elevated)IF MACHINE WON’T DRIVE ON

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-21 Table 3-8. Brake Limit Switch Circuit CheckSTEP ACTION SPEC YES NO1. Check for ground into the

SECTION 3 - TROUBLESHOOTING3-22 – JLG Lift – 3120728Won’t Drive (Platform Elevated Only)Overview Of ProcedureThe following procedures check the compon

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-23Table 3-13. PHP Limit Switch Circuit• No ground on PHP circuit at MC-1 box, X105 connector, pin 1

SECTION 3 - TROUBLESHOOTING3-24 – JLG Lift – 3120728Won’t Climb GradeOverview Of ProcedureThe following procedure checks the drive motor and attached

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-25Drives In Opposite DirectionOverview Of ProcedureThe following procedure checks that both the driv

SECTION 3 - TROUBLESHOOTING3-26 – JLG Lift – 3120728Will Only Drive A Short DistanceOverview Of ProcedureThe following procedure will eliminate any pr

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-27Table 3-17. E-Stop and Key Switch Circuit Check• Batteries Fully Charged. (24 Volts) • Ground Con

SECTION 3 - TROUBLESHOOTING3-28 – JLG Lift – 3120728Won’t Drive StraightOverview Of ProcedureThe following procedure examines the drive motor assembly

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-29Noise From Drive AssemblyOverview Of ProcedureThe following procedure examines the drive motor ass

3120728 – JLG Lift – i TABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION INTRODUCTION - - MAINTENANCE SAFETY PRECAUTI

SECTION 3 - TROUBLESHOOTING3-30 – JLG Lift – 31207283.9 MAST TROUBLESHOOTINGPlatform Will Not Lift Up Using Platform ControlOverview Of ProcedureThis

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-31Table 3-21. Pump Circuit• Battery voltage 24 volts. (Fully charge batteries)• Key switch set to P

SECTION 3 - TROUBLESHOOTING3-32 – JLG Lift – 312072814. Check the Black to ground on the pump contactor.Ground Go to Step 15Tighten/RepairConnectionPO

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-33Platform Will Not Lower Using Platform ControlOverview Of ProcedureThis procedure tests for ground

SECTION 3 - TROUBLESHOOTING3-34 – JLG Lift – 3120728Platform Will Not Lift Up From Ground Control Toggle SwitchOverview Of ProcedureThe following proc

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-35Platform Will Not Lower From Ground Control Toggle SwitchOverview Of ProcedureThe following proced

SECTION 3 - TROUBLESHOOTING3-36 – JLG Lift – 3120728Platform Will Not Lower ManuallyOverview Of ProcedureThe following procedure suggests components o

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-37Platform Lift Up And Down JerkyOverview Of ProcedureThe following procedure suggests areas on the

SECTION 3 - TROUBLESHOOTING3-38 – JLG Lift – 3120728Mast Noisy When Lifting And LoweringOverview Of ProcedureThis procedure examines components of the

SECTION 3 - TROUBLESHOOTING3120728 – JLG Lift – 3-39Platform (Mast) Won’t Stay ElevatedOverview Of ProcedureThe following procedure requests that the