Jlg 20VP (3120849) Service Manual User Manual

AUSTRALIAN OFFICEJLG INDUSTRIES, INC.P.O. Box 511911 Bolwarra RoadPort Macquarie, AustraliaTelephone: 065 811111Fax: 065 810122EUROPEAN OFFICEJLG INDU

ii – JLG Lift – 3120849TABLE OF CONTENTS (Continued) LIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. Hydraulic Pressure Setting - Adjustment Screw L

3120849 – JLG Lift – iii TABLE OF CONTENTS3-13 PHP Limit Switch Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iv – JLG Lift – 3120849TABLE OF CONTENTS (Continued) This page intentionally left blank.

SECTION 1 - SPECIFICATIONS3120849 – 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 – 3120849Machine Height (In Stowed Position)Euro/UK/Aust. - 2.01m (79 in.) heightBase FootprintVP Series - 0.

SECTION 1 - SPECIFICATIONS3120849 – JLG Lift – 1-31.6 HYDRAULIC PRESSURE ADJUSTMENTAdjust system pressure so that platform will raise withrated capaci

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3120849Figure 1-3. Torque Chart.

SECTION 1 - SPECIFICATIONS3120849 – 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 PROCEDURES3120849 – JLG Lift – 2-1SECTION 2. SERVICE PROCEDURES2.1 GENERALThis section provides general information to assist in

SECTION 2 - SERVICE PROCEDURES2-2 – JLG Lift – 3120849apply pressure to the outer race. If the bearing is to beinstalled on a shaft, apply pressure to

SECTION 2 - SERVICE PROCEDURES3120849 – 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 – 3120849can cause wear or damage to the components and gener-ally results in faulty operation. Every pre

SECTION 2 - SERVICE PROCEDURES3120849 – JLG Lift – 2-52.5 DRIVE MOTOR COMPONENT SERVICE PROCEDURESTorque Limiting Clutch MaintenanceVP Series machines

SECTION 2 - SERVICE PROCEDURES2-6 – JLG Lift – 3120849Torque Limiting Clutch AdjustmentNOTE: The large adjusting nut on the side of the clutchassembly

SECTION 2 - SERVICE PROCEDURES3120849 – 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 – 3120849Brake Assembly Removal1. Lift the machine to gain access to the underside(See Section 2-4., &quo

SECTION 2 - SERVICE PROCEDURES3120849 – 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 – 3120849IF REMOVING THE COMPLETE DRIVE ASSEMBLY, IT WEIGHSAPPROXIMATELY XX LB. AND WILL REQUIRE ASSISTA

SECTION 2 - SERVICE PROCEDURES3120849 – 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 – 3120849Final Gear Box Assembly1. If necessary, install a new drive shaft lip seal into thedrive shaft

SECTION 2 - SERVICE PROCEDURES3120849 – JLG Lift – 2-13Drive Motor Brush ReplacementEach drive motor contains two (2) brushes, the brushesare located

SECTION 2 - SERVICE PROCEDURES2-14 – JLG Lift – 3120849Brush Reassembly (See Figure 2-12.)MAKE CERTAIN THAT THE GROUND WIRE IS SECURELY RECON-NECTED T

SECTION 2 - SERVICE PROCEDURES3120849 – JLG Lift – 2-152.6 PLATFORM CONTROL BOX SERVICE PROCEDURESJoystick Calibration Procedure1. Turn off all power

SECTION 2 - SERVICE PROCEDURES2-16 – JLG Lift – 3120849Platform Control Box DisassemblyDO NOT ATTEMPT TO DISASSEMBLE THE PLATFORM CONTROLBOX IF MACHIN

SECTION 2 - SERVICE PROCEDURES3120849 – 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 – 31208493. Remove the reset button part of the emergency stopswitch by unscrewing the collar on the ins

SECTION 2 - SERVICE PROCEDURES3120849 – 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 – 3120849nector from the touch pad switch through the slot atthe top of the housing. Before pressing the

SECTION 2 - SERVICE PROCEDURES3120849 – 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 – 3120849Interlock Relay Replacement1. Disconnect the wiring connected to the relay.2. Remove the two (2

SECTION 2 - SERVICE PROCEDURES3120849 – JLG Lift – 2-232.8 MAST ASSEMBLY AND DISASSEMBLYPROCEDURESThe VP Series personnel lift mast sections are contr

SECTION 2 - SERVICE PROCEDURES2-24 – JLG Lift – 3120849NOTE: When sliding mast sections apart, be careful not toscratch or score the anodized surface

SECTION 2 - SERVICE PROCEDURES3120849 – JLG Lift – 2-25 Figure 2-17. 10VP Mast Assembly.

SECTION 2 - SERVICE PROCEDURES2-26 – JLG Lift – 3120849 Figure 2-18. 15VP Mast Assembly.

SECTION 2 - SERVICE PROCEDURES3120849 – JLG Lift – 2-27Figure 2-19. 20VP Mast Assembly.

SECTION 2 - SERVICE PROCEDURES2-28 – JLG Lift – 3120849Mast Assembly(See Figure 2-1, 2-2, 2-3 & 2-4.)1. Place mast section-1, rail (open) side up

SECTION 2 - SERVICE PROCEDURES3120849 – JLG Lift – 2-29mast section-3 with two (2) 1/4"-20UNC x 3/4" longbolts, place a flatwasher under hea

SECTION 2 - SERVICE PROCEDURES2-30 – JLG Lift – 3120849this manner, due to the tight fit of the slide pads inthe slide pad channels, the anodized fini

SECTION 2 - SERVICE PROCEDURES3120849 – JLG Lift – 2-31e. Holding complete chain sheave wheel assem-bly, slide assembly into top of mast section-4and

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS3120849 – JLG Lift – aINTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA. GENERALThis section contains the ge

SECTION 2 - SERVICE PROCEDURES2-32 – JLG Lift – 3120849g. When mast slide pads are shimmed properly,there should be no side to side movement ofslide p

SECTION 2 - SERVICE PROCEDURES3120849 – JLG Lift – 2-3316. Continue installing remaining components to mastassembly, (i.e. hydraulic pump/motor/reserv

SECTION 2 - SERVICE PROCEDURES2-34 – JLG Lift – 31208493. Adjust one mast section at a time starting from theback (section-3, section-4, etc.) of the

SECTION 2 - SERVICE PROCEDURES3120849 – JLG Lift – 2-35Clamp Installation (Drum/Socket Type)THE MANUFACTURER OF THE DRUM/SOCKET CLAMP RECOM-MENDS THE

SECTION 2 - SERVICE PROCEDURES2-36 – JLG Lift – 31208496. Reclamp the assembly in the vise on the flats of thesleeve. Using the plug driver, a metal t

SECTION 2 - SERVICE PROCEDURES3120849 – JLG Lift – 2-37Inspection and Maintenance Codes:1. Check for proper and secure installation.2. Check for visib

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SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-1SECTION 3. TROUBLESHOOTING3.1 GENERALThis section contains troubleshooting information to be used

SECTION 3 - TROUBLESHOOTING3-2 – JLG Lift – 3120849LED Indicator StripWhen the machine is powered up, all function inputs should be open. If any funct

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-3Table 3-1. MC-1 WARNING CODES(Indicated by 3 beeps, then slow flashing LED’s)WARNING CODELED’S FLA

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSb – JLG Lift – 3120849This page intentionally left blank.

SECTION 3 - TROUBLESHOOTING3-4 – JLG Lift – 3120849Table 3-2. MC-1 ERROR CODES(Indicated by rapid LED flashing and periodic beep)ERROR CODELED’S FLAS

SECTION 3 - TROUBLESHOOTING3120849 – 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 – 3120849Figure 3-2. Overview of Standard Electrical System. (Sheet 1 of 2)TO BATTERY TERMINALB

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-7Figure 3-2. Overview of Standard Electrical System. (Sheet 2 of 2)+TOBATTERYTERMINALTOBATTERYTERMI

SECTION 3 - TROUBLESHOOTING3-8 – JLG Lift – 3120849Figure 3-3. VP Electrical Diagram. (VP Series - Standard)ORN/RED 49-3BLU/ORN 52-1ORN/RED 49-1ORANG

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-9Figure 3-3. VP Electrical Diagram. (VP Series - Standard)

SECTION 3 - TROUBLESHOOTING3-10 – JLG Lift – 3120849Figure 3-4. Hydraulic Diagram. (VP Series)RETURN TUBEEXTEND TUBEPRES.COMPENSATEDFLOW VALVECYLINDE

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-113.5 TROUBLESHOOTING SECTION - TABLE OF CONTENTSOHM RATINGS FOR VARIOUS COMPONENTS PAGEOhm Ratings

SECTION 3 - TROUBLESHOOTING3-12 – JLG Lift – 31208493.6 OHM RATINGS FOR VARIOUS COMPONENTSThe following table contains ohm ratings for various VP Seri

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-133.7 MAIN POWER CIRCUIT TROUBLESHOOTINGUnit Will Not Power Up From Ground ControlOverview Of Proced

EFFECTIVITY PAGE 31207849 – JLG Lift – cEFFECTIVITY CHANGESSeptember 15, 1997 – Original Issue of ManualJanuary 10, 1998 – Change 1– Pages Affected

SECTION 3 - TROUBLESHOOTING3-14 – JLG Lift – 3120849No Power At Platform ControlOverview Of ProcedureThe following procedure checks voltage and ground

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-1513. Check voltage on the Red/Blk wire at the MC-1 box, X102 connec-tor, pin 15, to the Platform C

SECTION 3 - TROUBLESHOOTING3-16 – JLG Lift – 31208493.8 DRIVE TRAIN TROUBLESHOOTINGWon’t Drive (Platform Lowered Or Elevated)IF MACHINE WON’T DRIVE ON

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-17 Table 3-8. Brake Limit Switch Circuit CheckSTEP ACTION SPEC YES NO1. Check for ground into the

SECTION 3 - TROUBLESHOOTING3-18 – JLG Lift – 3120849Won’t Drive (Platform Elevated Only)Overview Of ProcedureThe following procedures check the compon

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-19Table 3-13. PHP Limit Switch Circuit• No ground on PHP circuit at MC-1 box, X105 connector, pin 1

SECTION 3 - TROUBLESHOOTING3-20 – JLG Lift – 3120849Won’t Climb GradeOverview Of ProcedureThe following procedure checks the drive motor and attached

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-21Drives In Opposite DirectionOverview Of ProcedureThe following procedure checks that both the driv

SECTION 3 - TROUBLESHOOTING3-22 – JLG Lift – 3120849Will Only Drive A Short DistanceOverview Of ProcedureThe following procedure will eliminate any pr

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-23Table 3-17. E-Stop and Key Switch Circuit Check• Batteries Fully Charged. (24 Volts) • Ground Con

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SECTION 3 - TROUBLESHOOTING3-24 – JLG Lift – 3120849Won’t Drive StraightOverview Of ProcedureThe following procedure examines the drive motor assembly

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-25Noise From Drive AssemblyOverview Of ProcedureThe following procedure examines the drive motor ass

SECTION 3 - TROUBLESHOOTING3-26 – JLG Lift – 31208493.9 MAST TROUBLESHOOTINGPlatform Will Not Lift Up Using Platform ControlOverview Of ProcedureThis

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-27Table 3-21. Pump Circuit• Battery voltage 24 volts. (Fully charge batteries)• Key switch set to P

SECTION 3 - TROUBLESHOOTING3-28 – JLG Lift – 312084914. Check the Black to ground on the pump contactor.Ground Go to Step 15Tighten/RepairConnectionPO

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-29Platform Will Not Lower Using Platform ControlOverview Of ProcedureThis procedure tests for ground

SECTION 3 - TROUBLESHOOTING3-30 – JLG Lift – 3120849Platform Will Not Lift Up From Ground Control Toggle SwitchOverview Of ProcedureThe following proc

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-31Platform Will Not Lower From Ground Control Toggle SwitchOverview Of ProcedureThe following proced

SECTION 3 - TROUBLESHOOTING3-32 – JLG Lift – 3120849Platform Will Not Lower ManuallyOverview Of ProcedureThe following procedure suggests components o

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-33Platform Lift Up And Down JerkyOverview Of ProcedureThe following procedure suggests areas on the

3120849 – JLG Lift – i TABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION INTRODUCTION - - MAINTENANCE SAFETY PRECAUTI

SECTION 3 - TROUBLESHOOTING3-34 – JLG Lift – 3120849Mast Noisy When Lifting And LoweringOverview Of ProcedureThis procedure examines components of the

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-35Platform (Mast) Won’t Stay ElevatedOverview Of ProcedureThe following procedure requests that the

SECTION 3 - TROUBLESHOOTING3-36 – JLG Lift – 3120849Platform (Mast) Descends Too SlowlyOverview Of ProcedureThe following procedure examines the mast

SECTION 3 - TROUBLESHOOTING3120849 – JLG Lift – 3-373.10 HYDRAULIC LEAK TROUBLESHOOTINGMiscellaneous Hydraulic Leak TroubleshootingOverview Of Procedu

SECTION 3 - TROUBLESHOOTING3-38 – JLG Lift – 31208493.11 BASE FRAME COMPONENTS TROUBLESHOOTINGCaster Wheels Not Operating FreelyCheck For These Obviou

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Customer Support Toll Free: