Service and Maintenance Manual Model 15VPSP 3120797 February 26, 2001 ANSI
FOREWORD The purpose of this manual is to provide users with the operating procedures essential for the promotion of proper machine operation for its intended purpose. It is important to over-stress proper machine usage. All information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the machine. YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL - Keep it with the machine. REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR.
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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A. GENERAL C. MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others or damage to the equipment.
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EFFECTIVITY PAGE EFFECTIVITY CHANGES February 28, 2000 – Original Issue of Manual October 19, 2000 – Revised – Complete Manual November 15, 2000 – Revised – Pages Affected: Section 1 - Pages 1-1 & 1-2 Section 2 - Pages 31 & 32. February 26, 2001 – Revised – Pages Affected: 3120797 Section 3 - Pages 3-8 & 3-9.
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TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION INTRODUCTION - - MAINTENANCE SAFETY PRECAUTIONS A B C GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a HYDRAULIC SYSTEM SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (Continued) LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 2-7. 2-8. 2-9. 2-10. 2-11. 2-12. 2-13. 2-14. 2-15. 2-16. 2-17. 2-18. 2-19. 3-1. 3-2. 3-3. 3-4. TITLE PAGE NO. Hydraulic Pressure Setting - Adjustment Screw Located at Base of Pump Motor . . . . . . . . . . . .1-4 Hydraulic Pressure Gauge Installation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 Lubrication Chart. . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS 3-14 3-15 3-16 3-17 3-18 3-19 3-20 3-21 3-22 3-23 3-24 3-25 3-26 3-27 3-28 3-29 3-30 3-31 3-32 3-33 3120797 Won’t Climb Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20 Drives In Opposite Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21 Only Drives A Short Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 15VPSP OPERATING SPECIFICATIONS Maximum Occupants: . . . . . . . . . . . . . . . . . . . . . . . . . . 1 person Maximum Work Load (Capacity): Total platform capacity: . . . . . . . . . . . . . . . . . . . . . . . . 500 lb. (230 kg) Maximum allowed on rear of platform: . . . . . . . . . . . . . 250 lb. (115 kg) Maximum allowed on front of platform: . . . . . . . . . . . . . 250 lb. (115 kg) Maximum Travel Grade (Gradeability): . . . . . . . . . . . . .
SECTION 1 - SPECIFICATIONS 1.1 CAPACITIES 1.3 System Voltage PERFORMANCE DATA Platform Capacity All VP Models –24 Volt DC (2 - 12 volt DC batteries) 15VPSP –500 lbs. (230 kg) (250 lb. Front/250 lb. Rear) Hydraulic Oil Reservoir Platform Size All VP Models – 5 qts. U.S. (4.7 ltr.) 15VPSP – 28 in. width x 48 in. length (71 cm) x (122 cm) Machine Height (In Stowed Position) 1.2 COMPONENT DATA 15VPSP - 82 in. (2.
SECTION 1 - SPECIFICATIONS Table 1-2. Machine Interlock Switch Operating Conditions. Drive Cutout (PHP System) Mast Elevation mast retracted mast retracted mast extended mast extended mast extended mast retracted mast retracted 1.
SECTION 1 - SPECIFICATIONS RETURN LINE PRESSURE ADJUSTMENT SCREW REPLACE ELBOW WITH A T-FITTING TO CONNECT PRESSURE GAUGE HERE EXTEND LINE PRESSURE GAUGE ADJUSTMENT SCREW CAP Figure 1-1. Hydraulic Pressure Setting - Adjustment Screw Located at Base of Pump Motor (Remove Hex Head Cap as Shown) Figure 1-2. Hydraulic Pressure Gauge Installation. 1.7 CYLINDER SPECIFICATIONS NOTE: All dimensions are given in inches (in), with the metric equivalent, centimeters (cm), given in parentheses. Table 1-5.
SECTION 1 - SPECIFICATIONS 6 1 2 5 3 4 Figure 1-3. Lubrication Chart. Table 1-6.Lubrication Intervals for Various Components INTERVAL HOURS ITEM COMPONTENT NO/TYPE LUBE POINTS LUBE/METHOD 3 6 MONTHS MONTHS 150 Hrs. 300 Hrs. 1 Hydraulic Oil Fill To Line on Reservoir 5 Qt.
SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart.
SECTION 2 - SERVICE PROCEDURES SECTION 2. SERVICE PROCEDURES 2.1 GENERAL This section provides general information to assist in the performance of maintenance on the personnel lift. Descriptions, techniques and specific procedures are designed to provide the safest and most efficient maintenance for use by personnel responsible for ensuring the correct installation and operation of machine components and systems. selves.
SECTION 2 - SERVICE PROCEDURES apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race. Gaskets Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious system damage. Bolt Usage and Torque Application Use bolts of proper length.
SECTION 2 - SERVICE PROCEDURES Tight Joints: All joints in the leaf chain should flex freely. On leaf chain, tight joints are usually caused by rust/corrosion, or the inside plates “walking” off the bushing. Limber up rusty/corroded chains (after inspecting care fully) with a heavy application of oil (preferably a hot oil dip). Tap inside “walking” plates inward; if “walking” persists, replace the chain.
SECTION 2 - SERVICE PROCEDURES can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage. 2.4 POSITIONING LIFT FOR ACCESS TO COMPONENTS LOCATED UNDER THE BASE FRAME Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil.
SECTION 2 - SERVICE PROCEDURES 2.5 DRIVE MOTOR COMPONENT SERVICE PROCEDURES Torque Limiting Clutch Maintenance Checking Clutch - Torque Setting (ft. lb.) NOTE: Check that the machines brakes are engaged before applying torque to the rear drive wheels. 1. Remove the drive wheels from the drive axles. VP Series machines are equipped with a torque limiting clutch coupling on each drive axle. The clutch is mounted inline on the drive axle between the drive wheel and the drive motor gear box.
SECTION 2 - SERVICE PROCEDURES Torque Limiting Clutch Adjustment Drive Motor Brake Adjustment/Removal NOTE: The large adjusting nut on the side of the clutch assembly is a standard type thread. If the torque (slip) setting of the clutch assembly is under spec (by more than 35 ft. lb.), the large adjusting nut must be (tightened) turned clockwise to increase the torque setting. If the torque (slip) setting is over spec (over 185 ft. lb.
SECTION 2 - SERVICE PROCEDURES FRICTION BRAKE DISK FRICTION BRAKE DISK MOUNTING PLATE ARMATURE PLATE MAGNETIC COIL (Not Energized) MANUAL RELEASE ARM/ ADJUSTMENT SCREW MOUNTING PLATE ARMATURE PLATE 0.006” GAP BETWEEN ARMATURE PLATE AND MAGNETIC COIL MAGNETIC COIL (Energized) MANUAL RELEASE ARM/ ADJUSTMENT SCREW 0.020” GAP UNDER SCREW HEAD BETWEEN ARMATURE PLATE 0.006” GAP BETWEEN FRICTION DISK AND ARMATURE PLATE 0.
SECTION 2 - SERVICE PROCEDURES Brake Assembly Removal 6. Reconnect the manual release brake cable to the manual release lever (Y shaped lever) and adjust cable so brakes are released when manual release lever is in the down position. (See Figure 2-6.) 1. Lift the machine to gain access to the underside (See Section 2-4., "Positioning Lift For Access To Components Located Under The Base Frame"). 2.
SECTION 2 - SERVICE PROCEDURES Drive Motor Removal 5. Disconnect the wiring connectors to the drive motor and the brake assembly on either or both sides, depending on which drive assembly(ies) is being removed. (See Figure 2-7.) The VP drive motors consist of three sections, the gear box atttached to the rear of the drive motor, the electric drive motor itself, and the brake assembly mounded at the front of the drive motor.
SECTION 2 - SERVICE PROCEDURES Gear Box Disassembly/Assembly IF REMOVING THE COMPLETE DRIVE ASSEMBLY, IT WEIGHS APPROXIMATELY XX LB. AND WILL REQUIRE ASSISTANCE TO LOWER. PREFERABLY USE A MOVABLE TRANSMISSSION OR OTHER HYDRAULIC JACK TO CAREFULLY LOWER ASSEMBLY FROM UNDER MACHINE. 11. Carefully remove the four (4) nuts and washers (outer most holes on the drive assembly weldment) from the carriage bolts attaching the drive motor assembly to the base frame.
SECTION 2 - SERVICE PROCEDURES NOTE: The gear oil can be drained out when the side cover is removed in the next step. Remove the side cover from the gear box with the drive shaft side pointing down, then tilt drive motor/gear box assembly to drain the oil into a suitable container. 2. Remove the four (4) hex cap screws securing the side cover to the gear box housing, and remove the side cover and rubber seal ring.
SECTION 2 - SERVICE PROCEDURES Final Gear Box Assembly that gear set align the drive shaft bearing and wiggle it into it’s seat. When both are seated continue to next step. 1. If necessary, install a new drive shaft lip seal into the drive shaft hole in the gear box housing before assembling the drive shaft gear set into the gear box.
SECTION 2 - SERVICE PROCEDURES Brush Removal (See Figure 2-12.) Drive Motor Brush Replacement Each drive motor contains two (2) brushes, the brushes are located under the two (2) large round slotted brush caps on the front end of each drive motor. BRUSH CAP Removal of the brushes also requires the removal of the drive motor(s) from the machine, see procedure described earlier in this section for instructions to remove the drive motors.
SECTION 2 - SERVICE PROCEDURES Brush Reassembly (See Figure 2-12.) MAKE CERTAIN THAT THE GROUND WIRE IS SECURELY RECONNECTED TO THE GROUND TERMINAL IF REMOVED. LEADS, INTERNAL TO THE SHEILD, MUST BE ROUTED AWAY FROM THE ARMATURE, (E.G.: BE CLOSE TO THE INSIDE WALL OF THE ALUMINUM SHIELD) TO PREVENT A SAFETY HAZARD AND/OR DAMAGE TO THE MOTOR. 1. Install the brush (pig-tail) terminal end under the screw on the brush box in the same manner as the old brush that was removed and tighten the screw. 2.
SECTION 2 - SERVICE PROCEDURES 2.6 3. Turn on power to the platform control, nine (9) LED’s will flash rapidly on the platform control touch pad. PLATFORM CONTROL BOX SERVICE PROCEDURES 4. Depress the horn switch pad, the alarm will sound for about one (1) second, then release the horn pad. Joystick Calibration Procedure 5. Now release the joystick to the neutral position. 1. Turn off all power to the platform control. 6. Turn off system power. 2.
SECTION 2 - SERVICE PROCEDURES Lower Half Of Housing Removal Platform Control Box Disassembly 1. Position the control box upside down and remove the six (6) screws attaching the lower half of the housing to the upper half of the control box housing. IMPORTANT DO NOT ATTEMPT TO DISASSEMBLE THE PLATFORM CONTROL BOX IF MACHINE IS STILL UNDER WARRANTY. OPENING THE PLATFORM CONTROL BOX WHILE THE MACHINE IS UNDER WARRANTY WILL VOID THE WARRANTY. IF UNDER WARRANTY REQUEST A REPLACEMENT BOX FROM THE FACTORY.
SECTION 2 - SERVICE PROCEDURES 3. Remove the four (4) screws attaching the circuit board to the upper housing. Emergency Stop Switch Removal 1. Remove the switch part of the emergency stop switch by carefully prying upward at the corner of the switch using a straight blade screwdriver. This will seperate the switch from the reset button part of the emergency stop button assembly. NOTE: If reusing the circuit board be careful when unsoldering component wires DO NOT OVERHEAT BOARD. 4.
SECTION 2 - SERVICE PROCEDURES 3. Remove the reset button part of the emergency stop switch by unscrewing the collar on the inside end of the reset button assembly. Touch Pad Switch Removal 1. Unplug the touch pad ribbon cable connector from the circuit board connector socket. (See Figure 215.) 2. Using a thin tool, start by lifting an edge of the touch pad switch and slowly peel away it from the face of the upper housing until completely free. Speed Control Switch Removal 1.
SECTION 2 - SERVICE PROCEDURES Speed Control Switch Installation 1. Use the following illustrations to reattach the wires from the speed control switch to the circuit board. WIRES FROM JOYSTICK CONTROL (Later Model Joystick w/Drive Enable on Knob) WHITE (light gauge) YELLOW (light guage) CIRCUIT BOARD COMPONENT SIDE CIRCUIT BOARD COMPONENT SIDE ORANGE WHITE W/ORG GREEN 2. If damaged replace the gasket between upper housing surface and the joystick mounting surface before assembling.
SECTION 2 - SERVICE PROCEDURES nector from the touch pad switch through the slot at the top of the housing. Before pressing the touch pad adhesive side to the upper housing mounting surface, visually align the touch pad edges with the edges of the recess in the housing mounting surface. 5.
SECTION 2 - SERVICE PROCEDURES Printed Circuit Board Replacement Battery Charger Part Replacement 1. Disconnect the wide wiring connector from the end of the circuit board. Cover Removal 1. Remove the eight (8) screws on the sides of the charger cover and remove cover. 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 Transformer Replacement 1.
SECTION 2 - SERVICE PROCEDURES Interlock Relay Replacement AC Circuit Breaker Replacement 1. Disconnect the wiring connected to the relay. 1. Disconnect wiring connected to the breaker poles. 2. Remove the two (2) nuts securing the interlock relay to the chassis base. 2. Remove the two (2) nuts securing the AC breaker to the chassis screws. 3. Remove the relay. 3. Remove the breaker from the chassis. SCR Rectifier Replacement (Either Side) 1. Remove the wiring from the SCR Rectifier. 2.
SECTION 2 - SERVICE PROCEDURES 2.8 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES The VPSP personnel lift mast sections are contructed of extruded aluminum, protected with an anodized surface finish. The mast sections are interlocked into each other when assembled, by internally mounted slide pads at the top and bottom of each mast section. These slide pads run up and down in slide pad channels on each side of the mast. inserted into the slide pad channels, (ends of mast sections even).
SECTION 2 - SERVICE PROCEDURES NOTE: When sliding mast sections apart, be careful not to scratch or score the anodized surface in the slide pad channels. 5. Carefully slide mast section-5 out the BOTTOM of mast section-4 rails. Disassemble slide pads, shims and chain anchor plate from mast section-5, if necessary. MAST SECTION-4 - REMOVAL 6. Remove chain adjust nuts from threaded ends of chains attached to the chain anchor plate (lower) on BOTTOM end of mast section-4.
SECTION 2 - SERVICE PROCEDURES Mast Assembly between both sides of mast. Insert shims until the shims cannot be inserted halfway by hand with the mast pulled to the opposite side. (See Figure 2-2.) d. When mast slide pads are shimmed properly, there should be no side to side movement of slide pad in rail channel. Mast sections should be snug in channels but still be able to slide in channel by hand. MAST SECTION 1 - ASSEMBLY 1. Place mast section-1, rail (open) side up (See Figure 2-1.
SECTION 2 - SERVICE PROCEDURES MAST TOP COVER SECTION-3 SHEAVE WHEEL ASSY. SECTION-4 SHEAVE WHEEL ASSY. CHAIN ANCHOR PLATE (UPPER) SECTION-2 SHEAVE WHEEL ASSY. CHAIN SET CHAIN ANCHOR PLATE (UPPER) ATTACH PIN KEEPER SEQUENCE CABLE ATTACH ASSY. (UPPER) CHAIN SET CHAIN SET ANCHOR PLATE ATTACH PIN MAST SECTION-4 CHAIN ANCHOR BLOCK (TOP OF HYD. CYL.
SECTION 2 - SERVICE PROCEDURES Figure 2-18. Mast Chain Routing Diagram.
SECTION 2 - SERVICE PROCEDURES 17. Assemble chain sheaves on chain assembly anchor block (attached to cylinder rod end) and attach to mast section-2 using following steps; a. Insert sheave pin through anchor block and cylinder rod on cylinder rod end. b. Load three 1" flatwashers onto the sheave pin on each side of the anchor block. c. Place sheave wheels (for wide #544 chain) on sheave pin, one each side of anchor block. d.
SECTION 2 - SERVICE PROCEDURES flathead cap screws, each side. Coat threads with Loctite #171 and tighten. 32. Slide mast section-3 back into section-2 until ends are even. Check to make sure chain assembly (wide chains) are seating properly in chain anchor block chain sheave wheels attached to mast section-2. plate attached to bottom of mast section-4. Loosely thread two (2) 3/8"-16UNC nuts onto stud threads on each chain. Chains will be adjusted later in assembly. 43.
SECTION 2 - SERVICE PROCEDURES NOTE: Always use the an even amount of shim material behind slide pads on both sides of the mast rails. This will keep mast sections centered in rail channels and prevent any distortion of the section. 7. Adjust top and bottom ends of mast sections so they are all even with each other. At bottom of mast assembly, thread all chain adjusting nuts on threaded ends until they are snug against the bottom anchor plates and all slack is removed from chains.
SECTION 2 - SERVICE PROCEDURES return (right) port. Use sealant tape on fitting threads. Cap ports until hydraulic lines are installed. 3. Adjust one mast section at a time starting from the back (section-3, section-4, etc.) of the mast and work forward. (i.e.. if three is OK, then jump to four, etc.) 8. Carefully set machine in an upright position on its base frame wheels. 9. Locate the mast support bracket.
SECTION 2 - SERVICE PROCEDURES MAST SIDE PROFILE MAST CHAIN/CABLE ADJUSTERS STEP APPROXIMATELY 7/16 in.
SECTION 2 - SERVICE PROCEDURES 2.11 SEQUENCE CABLE REPLACEMENT KIT A sequence cable replacement kit is available from the JLG Parts Department to service broken or worn sequence cables. This kit consists of a replacement sequence cable with the threaded (top) end attached same as the top end of the factory cable. Also included is a clamp (drum/socket type) to secure the bottom end of the cable. Use the following procedure to install the replacement cable and clamp kit. Remove Old Cable 1.
SECTION 2 - SERVICE PROCEDURES 3. Use a suitable tool and cut the cable as shown in the illustration following. For 1/8 in. cable the recommended length is 5/8 in. past the end of the sleeve. 4. Unlay the cable strands by gently forcing a screwdriver between the outer strands to unlay the cable. When done properly the outer strands will form a symmetrical basket.
SECTION 2 - SERVICE PROCEDURES 2.12 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE (See Figure 2-3) The preventive maintenance and inspection checks are listed and defined in the following table (See Figure 2-3, this chapter). This table is divided into two basic parts, the “AREA” to be inspected and the “INTERVAL” at which the inspection is to take place. Under the “AREA” portion of the table, the various systems along with the components that make up that system are listed.
SECTION 2 - SERVICE PROCEDURES Table 2-3. Preventive Maintenance & Inspection Schedule. AREA ON MACHINE PLATFORM INTERVAL (10 HRS.) DAILY (50 HRS.) WEEKLY (200 HRS.
SECTION 3 - TROUBLESHOOTING SECTION 3. TROUBLESHOOTING 3.1 GENERAL This section contains troubleshooting information to be used for locating and correcting most operating problems. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance. 3.
SECTION 3 - TROUBLESHOOTING LED INDICATOR STRIP Figure 3-1. LED Battery/Fault Code Indicator Strip on Platform Controller Box. LED Indicator Strip When the machine is powered up, all function inputs should be open. If any function is active on power up, all functions will be made inoperative and a fault will be indicated at the platform controller box LED strip. This strip has ten (10) green LEDs and is located on the platform controller box between the function touch pad buttons. See Figure 3-1.
SECTION 3 - TROUBLESHOOTING Table 3-1. MC-1 WARNING CODES (Indicated by 3 beeps, then slow flashing LED’s) WARNING CODE LED’S FLASHING 0 10 Enter Code - Security Code has been activated and must be entered before operation Enter Code or deactivate using MC-1 configuration software.
SECTION 3 - TROUBLESHOOTING Table 3-2.
SECTION 3 - TROUBLESHOOTING Table 3-2.
SECTION 3 - TROUBLESHOOTING BATTERY (RIGHT SIDE) BATTERY (LEFT SIDE) (–) (+) (+) TO PUMP MOTOR SOLENOID (–) HORN BEACON ALARM F COROM NN X10 EC 1 TO R HOURMETER TO BATTERY TERMINAL GROUND CONTROL BOX MAIN CONTACTOR RELAY 05 X1 R M CTO O FR NNE CO CO F N R RE TA OM LACTO Y R PUMP START CONTACTOR MANUAL OVERRIDE/ LIFT DOWN VALVE DUMP VALVE PUMP/MOTOR ASSEMBLY POT-HOLE PROTECTION LIMIT SWITCHES Figure 3-2. Overview of Standard Electrical System Components.
SECTION 3 - TROUBLESHOOTING LAPTOP COMPUTER (remove existing connector at X105 port on the MC-1 controller box and plug-in the laptop computer. Requires P/N-2900868 Configuration Kit.) PLATFORM CONTROL BOX TILT SENSOR SWITCH TO + BATTERY TERMINAL USE WIRING DIAGRAM FIGURE 3-3.
SECTION 3 - TROUBLESHOOTING PINS USED FOR COMMUNICATION TO SERIAL PORT ON LAPTOP OR PC.
SECTION 3 - TROUBLESHOOTING 4933172_A Figure 3-3. VPSP Electrical Diagram.
SECTION 3 - TROUBLESHOOTING CYLINDER PRES. COMPENSATED FLOW VALVE RETURN TUBE SOLENOID WITH MANUAL OVERRIDE EXTEND TUBE FILTER/ SCREEN FILTER/SCREEN CHECK VALVE ADJ. RELIEF VALVE PUMP ENDHEAD SOLENOID TWO POSITION/TWO WAY DUMP VALVE PUMP MOTOR TANK FILTER/SCREEN 1282953 Figure 3-4. Hydraulic Diagram.
SECTION 3 - TROUBLESHOOTING 3.5 TROUBLESHOOTING SECTION - TABLE OF CONTENTS OHM RATINGS FOR VARIOUS COMPONENTS PAGE Ohm Ratings for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 MAIN POWER CIRCUIT TROUBLESHOOTING Unit Will Not Power Up From Ground Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 No Power At Platform Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 - TROUBLESHOOTING 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 COMPONENT NOMINAL RESISTANCE @ TEMPERATURE RESISTANCE RANGE POSSIBLE 46.8ohm - 57.2ohm @ 68deg F 35.7ohm - 67.3ohm Pump Motor 0.2ohm - 0.4ohm @ 77deg F 0.12ohm - 0.49ohm Pump Relay 16.0ohm - 17.6ohm @ 77deg F 9.9ohm - 21.8ohm 44.7ohm - 52ohm @ 68deg F 31.4ohm - 65.3ohm .1 to .
SECTION 3 - TROUBLESHOOTING 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 Control Box and to the Main Contactor Relay and Main Contactor for 24 volts or more. Also the Lift Up/Down Relay circuit is tested. Check For These Obvious Conditions First: • Battery voltage 24 volts. (Fully charge batteries) • Battery connections clean and tight.
SECTION 3 - TROUBLESHOOTING No Power At Platform Control Overview Of Procedure The following procedure checks voltage and ground starting from the power source (batteries) through the ground control station (key switch/E-stop) to the MC-1 box and finally to the platform control. 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).
SECTION 3 - TROUBLESHOOTING Table 3-5. No Power At Platform Control. 13. Check voltage on the Red/Blk wire at the MC-1 box, X102 connector, pin 15, to the Platform Control. 24 volts Go to Step 14 Replace MC-1 Box 14. Check for Ground on the BRN wire at the MC-1 box, X102 connector, pin 1, to the Platform Control. Ground Go to Step 15 Replace MC-1 Box 15. Check voltage on the Red/Blk wire, pin 9 on the Platform Control box. 24 volts Go to Step 16 Replace Cable 16.
SECTION 3 - TROUBLESHOOTING 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 box assuring it is receiving the proper signals and conditions before engaging the machines’ drive motors.
SECTION 3 - TROUBLESHOOTING Table 3-8. Brake Limit Switch Circuit Check STEP ACTION SPEC YES NO — Go to Step 2 Repair Connection Check for ground on the 49-4 wire coming out of left brake limit switch. — Go to Step 3 Adjust/Replace Switch 3. Check for ground on the 49-4 wire going into the right brake limit switch. — Go to Step 4 Repair/Replace 49-4 wire 4. Check for gound on the 49-3 side of the right brake limit switch. — Replace MC-1 box Repair wire or Connection 1.
SECTION 3 - TROUBLESHOOTING 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 box assuring it is receiving the proper signals and conditions before engaging the machines’ drive motors.
SECTION 3 - TROUBLESHOOTING Table 3-13. PHP Limit Switch Circuit • No ground on PHP circuit at MC-1 box, X105 connector, pin 12, (O/R, 49-1 wire). • With PHP bars up. STEP ACTION 1. Check for ground on Black wire (direct to ground) on the right side PHP limit switch. (Continuity to B –) 2. Check for ground on O/R, 49-2 wire to left PHP limit switch. 3. Check for ground on O/R, 49-1 wire to MC-1 box, X105 connector, pin 12.
SECTION 3 - TROUBLESHOOTING Won’t Climb Grade Overview Of Procedure The following procedure checks the drive motor and attached components for component failure, misadjustment due to wear. 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.
SECTION 3 - TROUBLESHOOTING Drives In Opposite Direction Overview Of Procedure The following procedure checks that both the drive motor power wire connections correctly installed and are secure and tight. Also that the joystick control assembly for proper installation at the platform control box.
SECTION 3 - TROUBLESHOOTING 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 controller box and also any objectionable environmental conditions. Check For These Obvious Conditions First: • Is Battery Voltage 24 Volts? (Fully Charge Batteries) Table 3-16. Only Drives A Short Distance STEP 1. 2.
SECTION 3 - TROUBLESHOOTING Table 3-17. E-Stop and Key Switch Circuit Check • Batteries Fully Charged. (24 Volts) • Ground Control Key Switch set to the Platform or on Ground position and the Emergency Stop Switch Reset to ON. STEP 1. 2. 3. 4. 5. 6. 3120728 ACTION SPEC YES NO KEY SET TO PLATFORM: Check voltage on the Yel/Red, 2-2 wire from the emergency stop switch to MC-1 controller box, pin 3 in the X101 connector and pin 30 on the Power Relay.
SECTION 3 - TROUBLESHOOTING Won’t Drive Straight Overview Of Procedure The following procedure examines the drive motor assembly weldments attaching the drive motors to the base frame. Also internal components of the the drive motors, gear box and a check of the components between the gear box and the drive wheels. 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.
SECTION 3 - TROUBLESHOOTING Noise From Drive Assembly Overview Of Procedure The following procedure examines the drive motor assembly weldments attaching the drive motors to the base frame. Also internal components of the the drive motors, gear box and a check of the components between the gear box and the drive wheels. 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.
SECTION 3 - TROUBLESHOOTING 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.
SECTION 3 - TROUBLESHOOTING Table 3-21. Pump Circuit • Battery voltage 24 volts. (Fully charge batteries) • Key switch set to Platform . STEP 1. ACTION SPEC At the pump motor, check for 24 volts at both ends of the battery cable running from the main contactor to the pump case stud.
SECTION 3 - TROUBLESHOOTING Table 3-21. Pump Circuit Ground Go to Step 15 Tighten/Repair Connection Check the Yel/Red, 2-4 wire, #87 on the Power Relay to the main contactor, and to diode at E-Stop for 24 volts. Note: Power will stop at diode, silver line should be away from the EStop. 24 volts Go to Step 16 Tighten/Repair Connection 16. Check the Yel/Red, 2-2 wire, #30 on the Power Relay to the E-stop and to the MC-1 box, X101 connector pin 3, for 24 volts.
SECTION 3 - TROUBLESHOOTING 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 to the ground control toggle switch. 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. STEP ACTION SPEC YES NO 1.
SECTION 3 - TROUBLESHOOTING 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 to the pump motor for wiring or components which could be causing a failure of that circuit. 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.
SECTION 3 - TROUBLESHOOTING 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 to the pump motor for wiring or components which could be causing a failure of that circuit. 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.
SECTION 3 - TROUBLESHOOTING Platform Will Not Lower Manually Overview Of Procedure The following procedure suggests components on the machine which might attribute to problems with the manual descent circuit. Table 3-26. Platform Will Not Lower Manually. STEP ACTION SPEC 1. Check manual override solenoid with manual override (knob open). 2. Check Steps 1 thru 6 of ( Table 3-30) 3. Place the maximum capacity of weight in the Platform.
SECTION 3 - TROUBLESHOOTING Platform Lift Up And Down Jerky Overview Of Procedure The following procedure suggests areas on the machine which might attribute to erratic movement of the platform during lift up and down. 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.
SECTION 3 - TROUBLESHOOTING 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 dirt, debris, proper lubrication and operation. Table 3-28. Mast Noisy when Lifting and Lowering. STEP ACTION SPEC YES NO 1. Do slide pads and slide pad channels need to be cleaned of dust, dirt, or other debris? — Clean Pads and Channels Go to Step 2 2.
SECTION 3 - TROUBLESHOOTING 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 see if any are stuck open, it also examines the lift down and dump valve circuits. Also suggests that the lift cylinder packing could be leaking internally. Check For These Obvious Conditions First: • Manual descent valve is closed tight. Table 3-29. Platform (Mast) Won’t Stay Elevated. STEP ACTION 1.
SECTION 3 - TROUBLESHOOTING 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. STEP ACTION SPEC YES NO — Reshim Mast Go to Step 2 — Remove Obstruction Go to Step 3 1. Check mast slide pads shimmed to tight. 2. Is there an obstruction in the mast? 3. The lift cylinder packing could be too tight in the bore of the cylinder barrel.
SECTION 3 - TROUBLESHOOTING 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 STEP ACTION 1. Oil leaking around the lift cylinder rod. 2. Oil leaking around the cylinder fitting/flow valve. 3. Oil leaking around the hydraulic lines. 4. Oil leaking around the lift up valve. 5.
SECTION 3 - TROUBLESHOOTING 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. STEP 1. ACTION SPEC YES NO — Go to Step 2 Lubricate or Replace Caster Housing — Go toStep 3 Lubricate or Replace Wheel — Remove Debris or Replace Wheel — Is the caster rotating freely? 2. Is the wheel spinning freely? 3.
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Customer Support Toll Free: (877) 554-5438 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.
