Document Outline

• Model
  • 10VP
  • 15VP
  • 20VP
    • 3120728
      • June 14, 2001
    • SERVICE & MAINTENANCE
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• FOREWORD
  • The purpose of this manual is to provide users with the operating procedures essential for the pr...
  • BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION, PROPER SAF...
  • ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER OPERATING CONDIT...
  • THIS "SAFETY ALERT SYMBOL" IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH MAY LEAD TO SERIO...
  • Safety of personnel and proper use of the machine are of primary concern, DANGER, WARNING, CAUTIO...
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• Introduction - Maintenance safety precautions
  • a. GENERAL
    • This section contains the general safety precautions which must be observed during maintenance of...
    • The specific precautions to be observed during machine maintenance are inserted at the appropriat...
    • Your safety, and that of others, is the first consideration when engaging in the maintenance of e...
  • b. HYDRAULIC SYSTEM SAFETY
    • 1. It should be particularly noted that the machines hydraulic systems operate at extremely high ...
    • 2. Relieve system pressure by activating the lift DOWN control with the platform completely lower...
  • c. MAINTENANCE
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• Effectivity Changes
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• LIST OF FIGURES
• LIST OF TABLES
• Section 1. specifications
  • 1.1 Capacities
    • System Voltage
      • All VP Models – 24 Volt DC (2 - 12 volt DC batteries)
    • Hydraulic Oil Reservoir
      • All VP Models – 5 qts. U.S. (4.7 ltr.)
  • 1.2 Component Data
    • Hydraulic Pump/Pump Motor Assembly
      • Pump Motor - 24 Volt DC motor
      • Pump Displacement –
      • 10 & 15VP – .098 cu. in./rev. (1.6cc/rev.)
      • 20VP – .049 cu. in./rev. (0.8cc/rev )
      • Pump Output (Max.) –
      • 10 & 15VP - 1.20 gpm @ 2200 psi
      • 20VP – 0.65 gpm @ 2200 psi
      • Hydraulic System Pressure Setting –
      • 10 & 15VP - 1000 psi (68.95 bar)
      • 20VP - 2500 psi (172.3 bar)
    • Rear Wheel Drive Motors
      • Drive Motors -
      • 24 Volt DC w/perm. magnet
      • Right angle gear
      • Maintenance free sealed gear
      • Brake shaft and drive shaft, Integral to Motor
      • Parking Brake (must be released for pushing)
    • Batteries/Battery Charger
      • Batteries (2) – 12 Volt / 80 Amp Hour –
      • Deep Cycle Marine - RV
      • Battery Charger –
      • U.S.A./CAN. – 120 Volt A.C. / 60 Hz input
      • Brazil - 220 Volt A.C./ 60 Hz input
      • 24 volt, 10 amp output -
      • with 2 amp finish
      • Reset Circuit Breaker
      • Automatic Charge Circuit
      • Plug Interlock Circuit
  • 1.3 Performance Data
    • Platform Capacity(All Platforms except Extendible)
      • 10VP – 350 lbs. (160 kg)
      • 15VP – 350 lbs. (160 kg)
      • 20VP – 350 lbs. (160 kg)
    • Extendible Platform Capacity
      • ANSI (U.S.) – 300 lbs. (136 kg)
      • CSA (CAN.) – 250 lbs. (114 kg)
    • Platform Size
      • Standard Platform – 26 in. x 26 in. (66cm) x (66cm)
    • Machine Height (In Stowed Position)
      • VP Series - 79 in. (201cm) height
      • Table 1-1. Machine GVW and Wheel Loads
    • Base Footprint
      • VP Series - 32 in. (81cm) width 56 in. (1.42m) length
    • Max. Platform Height (mast extended)
      • 10VP – 10 ft. 6 in. (3.2m)
      • 15VP – 15 ft. (4.5m)
      • 20VP – 19 ft. 9 in. (5.9m)
    • Platform Working Height (average)
      • 10VP – 16 ft. 6 in. (4.8m)
      • 15VP – 21 ft. (6.4m)
      • 20VP – 25 ft. 9 in. (7.6m)
    • Machine Drive Speed (max.)*
      • Platform Lowered - 2 mph (3.22 kph)
      • Platform Elevated - 0.5 mph (.81 kph)
      • (reduced by limit switch)
      • * Variable to maximum with speed cut back.
    • Amperage Draw (average)
      • Lift - 12 amps. Drive - 20 amps.
    • Interlock Switch Operating Conditions
      • Table 1-4. shown, lists machine response to various interlock switch positions.
  • 1.4 Torque Requirements
    • When maintenance becomes necessary or a fastener has loosened, refer to the Torque Chart, Figure ...
  • 1.5 Lubrication
    • Hydraulic Oil
      • Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and suf...
      • For cold weather applications, i.e. when temperatures remain consistently below +20˚F (–7˚C) JLG ...
      • Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as ...
      • Table 1-2. Hydraulic Oil Operating Range
    • Lubrication Specifications
      • Table 1-3. Lubrication Specifications
      • Table 1-4. Machine Interlock Switch Operating Conditions.
  • 1.6 Hydraulic Pressure Adjustment
    • Adjust system pressure so that platform will raise with rated capacity in platform.
    • The following are recommended factory pressure settings;
    • VP10, VP15 – 1000 psi VP20 – 2500 psi
    • Turning adjustment screw clockwise increases system pressure, turning screw counterclockwise decr...
    • Make pressure adjustment with oil at normal operating temperature. If pressure is set when oil is...
    • Connect pressure gauge as shown in Figure 1-2., Hydraulic Pressure Gauge Installation.
    • Select a T-Fitting to exactly match the thread size of the pump (.562 x 18 THD), pressure line (....
  • 1.7 Cylinder Specifications
    • Table 1-5. Cylinder Specifications
  • 1.8 Serial Number Location
    • For machine identification, a serial number plate is affixed to the machine. The plate is located...
    • Table 1-6. Lubrication Intervals for Various Components
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• Section 2. SERVICE PROCEDURES
  • 2.1 General
    • This section provides general information to assist in the performance of maintenance on the pers...
  • 2.2 Servicing and Maintenance Guidelines
    • General
      • The following information is provided to assist you in the use and application of servicing and m...
    • Safety and Workmanship
      • Your safety, and that of others, is the first consideration when engaging in the maintenance of e...
    • Cleanliness
      • The most important single item in preserving the long service life of a machine is to keep dirt a...
      • At any time when oil lines are disconnected, clear adjacent areas as well as the openings and fit...
      • Clean and inspect all parts during servicing or maintenance, and assure that all passages and ope...
    • Components Removal and Installation
      • Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slin...
      • Should it be necessary to remove a component on an angle, keep in mind that the capacity of an ey...
      • If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., ...
    • Component Disassembly and Reassembly
      • When disassembling or reassembling a component, complete the procedural steps in sequence. Do not...
    • Pressure-Fit Parts
      • When assembling pressure-fit parts, use an “anti-seize” or molybdenum disulfide base compound to ...
    • Bearings
      • When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammabl...
      • Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.
      • If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) pap...
      • Lubricate new or used serviceable bearings before installation. When pressing a bearing into a re...
    • Gaskets
      • Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to h...
    • Bolt Usage and Torque Application
      • Use bolts of proper length. A bolt which is too long will bottom before the head is tight against...
      • Unless specific torque requirements are given within the text, standard torque values should be u...
    • Hydraulic Lines and Electrical Wiring
      • Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when dis...
    • Hydraulic System
      • Keep the system clean. If evidence of metal or rubber particles is found in the hydraulic system,...
      • Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable ...
    • Lubrication and Servicing
      • Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart,...
    • Batteries
      • Clean batteries, using a non-metallic brush and a solution of baking soda and water. Rinse with c...
    • Mast Chain Inspection Procedure
      • Inspect mast chains for the following conditions:
      • Wear: Always inspect that segment of chain that operates over a sheave. As the chain flexes over ...
      • Rust and Corrosion: Rust and corrosion will cause a major reduction in the load carrying capacity...
      • Table 2-1. Chain Stretch Tolerance
  • .50" pitch
  • 12" or 24 pitches
  • .24 in./12 in. span
  • .625 pitch
  • 15" or 24 pitches
  • .30 in./15 in. span
    • Fatigue Cracks: Fatigue is a phenomenon that affects most metals, and is the most common cause of...
    • Tight Joints: All joints in the leaf chain should flex freely. On leaf chain, tight joints are us...
      • a. Bent pins or plates.
      • b. Rusty joints.
      • c. Peened plate edges.
    • Oil rusty chains, and replace chains with bent or peened chain components. Keep chains lubricated.
    • Protruding or Turned Pins: Chains operating with inadequate lube generate tremendous friction bet...
    • Chain Anchors and Sheaves: An inspection of the chain must include a close examination of chain a...
    • Inspect the sheaves, sheave bearings, sheave grooves and pins for extreme wear, replace as necess...
      • a. Chains too tight.
      • b. Sheave bearings/pin bad.
      • c. Bent/misaligned chains.
    • Mast Cable Inspection Procedure
      • The periodic inspection shall cover the entire length of the cable. The inspection frequency shal...
      • Only the surface wires of the cable require inspection, do not attempt to open the cable. Any det...
      • Mast cables must be replaced after machine has been in service for five (5) years, regardless of ...
      • Conditions such as the following shall be sufficient reason for questioning continual use of the ...
      • 1. In running ropes, six randomly distributed broken wires in one lay or three broken wires in on...
      • 2. One outer wire broken at the point of contact with the core of the rope which has worked its w...
      • 3. Wear of one-third the original diameter of outside individual wires.
      • 4. Kinking, crushing, birdcaging or any other damage resulting in distortion of the rope structure.
      • 5. Evidence of any heat damage from any cause.
      • 6. Reductions from nominal diameter of more than;
        • a. 1/64th in. (0.4mm) for diameters up to and including 5/16th in. (8mm);
      • Also check for cracked, bent, worn, severely corroded, or improperly installed cable ends.
      • Inspect sheaves, sheave grooves, and sheave pins for excessive wear, replace as necessary.
    • 2.3 Lubrication Information
      • Hydraulic System
        • The primary enemy of a hydraulic system is contamination. Contaminants enter the system by variou...
        • The design and manufacturing tolerances of the component working parts are very close, therefore,...
        • Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation...
        • It is not advisable to mix oils of different brands or types, as they may not contain the same re...
      • Hydraulic Oil
        • For best performance, JLG recommends the use of ISO- Vg grade 32, 46 oil with a viscosity range b...
      • Changing Hydraulic Oil
        • Use of any of the recommended hydraulic oils eliminates the need for changing the oil on a regula...
        • Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original...
        • While the unit is shut down, a good preventive maintenance measure is to make a thorough inspecti...
      • Lubrication Specifications
        • Specified lubricants, as recommended by the component manufacturers, are always the best choice, ...
    • 2.4 Positioning Lift for Access to Components Located Under The Base Frame
      • Access to the underside of the VP lift can be obtained by lifting the machine with a fork lift tr...
      • Lifting with a Fork Truck (See Figure 2-1.)
      • 1. Choose a fork lift truck capable of safely handling the full weight of the machine.
      • 2. Locate work area on a firm, level surface.
      • 3. When lifting with a fork truck, lift only using the fork lift-truck pockets running the length...
      • 4. After lifting machine to desired work height, place support stands under the machine. The supp...
    • 2.5 Drive motor component Service procedures
      • Torque Limiting Clutch Maintenance
        • VP Series machines are equipped with a torque limiting clutch coupling on each drive axle. The cl...
      • Visual Inspection and Limiting Torque Checking Procedure
        • 1. Locate the machine on a firm level surface.
        • 2. Carefully raise the lift to gain access to the underside of the base frame. Refer to Section 2...
        • 3. Locate the clutch assembly on each rear drive axle and check for the following;
          • a. Check the coupling chains for any loose or missing parts, i.e. pins, links, etc., replace if n...
          • b. Check that the allen-head set screws on the (large) clutch adjusting nut are in place and secu...
          • c. Check for any debris wedged in or wrapped around the clutch coupling chains and axle shafts. R...
      • Checking Clutch - Torque Setting (ft. lb.)
        • 1. Remove the drive wheels from the drive axles.
        • 2. Select a torque wrench capable of setting a torque of at least 185 ft. lb. Insert special tool...
        • 3. Slide the tool onto the end of the drive axle aligning the key on the axle shaft (install key ...
        • 4. Turn the torque wrench and note the torque setting when the torque limiting clutch releases. T...
        • 5. If torque setting is OK, re-install the wheels and lower machine, IF NOT, see the following note.
      • Torque Limiting Clutch Adjustment
        • 1. Loosen the two (2) adjusting nut setscrews located on the large adjusting nut on the clutch as...
        • 2. Hold the drive axle steady using service tool (P/N- 0080229) and the torque wrench used to che...
        • 3. Depending on how far off the original torque setting was (see note at beginning of this proced...
        • 4. When proper torque setting is achieved, re-tighten the two (2) adjusting nut, setscrews.
        • 5. Re-install the drive wheels, remove the jack stand and lower the machine to ground.
      • Drive Motor Brake Adjustment/Removal
        • (See Figure 2-4. & Figure 2-5.)
        • Mounted onto the front of each drive motor housing is a brake assembly. The brakes are normally E...
        • Operation (See Figure 2-4. & Figure 2-5.)
        • When the magnetic coil is not energized (brake on), the armature plate is pushed away from the ma...
        • A correctly adjusted brake will ideally have a measurment of approximately .006" (but will operat...
        • Never allow any type of lubricant (oil, grease, hydraulic fluid, etc.) to come in contact with th...
        • Checking/Adjusting Armature Plate Gap Setting
        • 1. First inspect that all parts of the brake assembly are tight and secure. Tighten as necessary.
        • 2. Inspect the brake for any debris which may be lodged in the air gap between the armature plate...
        • 3. With the brakes ENGAGED measure the air gap between the armature plate and the magnetic coil h...
        • 4. If the air gap falls outside the maximum allowable setting of .010" the friction disk has worn...
        • 5. It the air gap is below the minimum allowable setting of .004", recheck the areas between the ...
        • Manual Release Arm - Screw Adjustment
        • 1. With the brakes ENGAGED (brakes on) the air gap under the head of the manual release arm screw...
        • 2. With the brakes electrically RELEASED (brakes off) the air gap under the screw head increases ...
        • Brake Assembly Removal
        • 1. Lift the machine to gain access to the underside (See Section 2-4., "Positioning Lift For Acce...
        • 2. Disconnect the brake magnetic coil wiring connector and the brake limit (micro) switch wiring ...
        • 3. Disconnect the manual brake release cable from the manual brake release arm attached to the br...
        • 4. Lower machine back down to ground level.
        • 5. Using the Ground Control Switch, raise the platform to gain access to the brake assemblies mou...
        • 6. Remove the four (4) hex cap screws securing the brake assembly to the end of the drive motor a...
        • Brake Assembly Installation
        • 1. Guide the manual release lever, brake coil and brake limit switch wiring connectors through th...
        • 2. If necessary, manually release the brake disk using the manual release lever to allow the brak...
        • 3. Secure the brake assembly to the drive motor using four (4) hex cap screws with washers. Torqu...
        • 4. Lift the machine to gain access to the underside (See Section 2-4., "Positioning Lift For Acce...
        • 5. Reconnect the brake coil and brake limit switch wiring connectors to their respective wiring h...
        • 6. Reconnect the manual release brake cable to the manual release lever (Y shaped lever) and adju...
      • Drive Motor Removal
        • (See Figure 2-7.)
        • The VP drive motors consist of three sections, the gear box atttached to the rear of the drive mo...
        • 1. Disconnect the positive battery terminal from the left side battery.
        • 2. Remove the rear plate weldment from the machine, (plate with the tie down lug) and set aside. ...
        • 3. Carefully raise the lift to gain access to the underside of the base frame. Refer to Section 2...
        • 4. Remove the remaining two (2) bolts attaching the motor cover to the base frame and set it aside.
        • 5. Disconnect the wiring connectors to the drive motor and the brake assembly on either or both s...
        • 6. Disconnect the manual release brake cable from the brake assembly arm on either or both drive ...
        • 7. Remove the one (1) bolt, nut, and two (2) washers from the front of the drive motor mounting p...
        • 8. While holding the drive motor in place, remove the remaining two (2) bolts with washers holdin...
        • 9. Slide the drive motor and torque limiting clutch assembly towards the center of the machine, s...
        • 10. Move drive motor assembly and torque limiting clutch to a suitable work bench for disassembly.
        • 11. Carefully remove the four (4) nuts and washers (outer most holes on the drive assembly weldme...
        • 12. Lower the drive assembly and place on a suitable work surface.
      • Gear Box Disassembly/Assembly
        • (See Figure 2-8.)
        • The drive motor gear box is mounted on the rear of each drive motor transferring power from the e...
        • Gear Box Disassembly (See Figure 2-8.)
        • 1. Remove the drive motor/gear box/brake assembly from the machine using the procedure outlined p...
        • 2. Remove the four (4) hex cap screws securing the side cover to the gear box housing, and remove...
        • 3. Remove the wave washers from atop the large and small bearings and lay inside their respective...
        • 4. Using a suitable catch container, drain the gear oil from the gear box housing.
        • 5. Remove the drive shaft assembly from the housing. Place the drive motor/gear box assembly on a...
        • 6. With the open surface of the housing properly supported, carefully press the drive shaft down ...
        • 7. To remove the large (47mm) (cover side) bearing and (housing side) bearing from the drive shaf...
        • 8. To remove the small (32mm) bearing(s) from the gear (brass) and pinion assembly, use a suitabl...
        • 9. To remove the (brass) worm gear from the pinion assembly, use a suitable hydraulic press and p...
        • 10. Inspect the drive shaft seal for cuts, cracks and wear, or if showing signs of leakage. Repla...
        • Gear/Pinion Shaft Assembly (See Figure 2-9.)
        • 1. L