JLG 20VP Service Manual

Service and Maintenance Manual

Model

10VP

15VP

20VP

3120728

June 14 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.

BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION, PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPERATING PERSONNEL.

ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER OPERATING CONDITIONS, WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN. ALTERATION AND/ OR MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN, WITHOUT WRITTEN APPROVAL FROM JLG INDUSTRIES, PER OSHA REGULATIONS.

THIS "SAFETY ALERT SYMBOL" IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED.

Safety of personnel and proper use of the machine are of primary concern, DANGER, WARNING, CAUTION, IMPORTANT, INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these areas. They are defined as follows:

DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR DEATH.

CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES.

WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY OR DEATH.

IMPORTANT OR INSTRUCTIONS PROCEDURES ESSENTIAL FOR SAFE OPERATION AND WHICH, IF NOT FOLLOWED MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE MACHINE.

Also in this Manual "Notes:" are used to provide information of special interest.

JLG INDUSTRIES, INC. MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR YOUR JLG PRODUCT. ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COMPLETED ON THE AFFECTED JLG PRODUCT.

Due to the continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.

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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A. GENERAL

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. A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe to operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA-

TION.

The specific precautions to be observed during machine maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of component weight and never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON-

TROL OVER THE FIELD INSPECTION AND MAINTENANCE,

SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER/ OPERATOR.

C. MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN

THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.

•REMOVE ALL RINGS, WATCHES, AND JEWELRY WHEN PERFORMING ANY MAINTENANCE.

•DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT.

•OBSERVE AND OBEY ALL DANGER, WARNING, CAUTION AND OTHER INSTRUCTIONS ON MACHINE AND IN SERVICE MANUAL.

•KEEP STANDING SURFACES AND HAND HOLDS FREE OF OIL, GREASE, WATER, ETC.

•NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING.

•BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS.

•BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPONENTS.

•KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.

•USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

B.HYDRAULIC SYSTEM SAFETY

1.It should be particularly noted that the machines hydraulic systems operate at extremely high and potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system.

2.Relieve system pressure by activating the lift DOWN control with the platform completely lowered to direct any line pressure back into the return line to the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss.

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EFFECTIVITY PAGE

EFFECTIVITY CHANGES

September 15, 1997 – Original Issue of Manual

January 10, 1998 – Change 1– Pages Affected: Revision Log - Page c

Table of Contents - Page ii

Section 3 - Pages 3-8 & 3-9

February 7, 2000 – Revised – Pages Affected: Section-1, Page 1-5, Table 1-5.

Section-2, Page 2-18, Table 2-3.

(removed lube check requirement for drive wheel gear box)

March 22, 2000– Revised – Added 20VP UL-EE Option.

September 8, 2000 – Revised Complete Manual

October 19, 2000 – Revised – Pages Affected:Section-2, Pages 2-20 thru 2-22 also 2-32 and 2-33. Section-3, Page 3-16, added Table 3-3.

November 15, 2000 – Revised – Pages Affected:Section-1, Page 1-1

Section-2, Pages 2-33 & 2-34.

June 14, 2001 – Revised – Pages Affected:Section-2, Pages 2-23 thru 2-25

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EFFECTIVITY PAGE

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TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH

PAGE NO.

SECTION INTRODUCTION - - MAINTENANCE SAFETY PRECAUTIONS

A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a

B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a

C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a

Effectivity Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c

SECTION 1 - SPECIFICATIONS

1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.4 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.5 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.6 Hydraulic Pressure Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.7 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.8 Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

SECTION 2 - SERVICE PROCEDURES

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 2.2 Servicing And Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 2.3 Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 2.4 Positioning Lift For Access To Components Located Under The Base Frame . . . . . . . . . . . . . . .2-4 2.5 Drive Motor Component Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 2.6 Platform Control Box Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 2.7 Battery Charger Assembly And Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 2.8 Hydraulic Lift Cylinder - Removal, Inspection And Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23 2.9 Mast Assembly And Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 2.10 Mast To Base Frame Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35 2.11 Mast Chains/cables And Sequencing Cables Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36 2.12 Sequence Cable Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38 2.13 Preventive Maintenance And Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

SECTION 3 - TROUBLESHOOTING

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 Troubleshooting Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.4 Electrical Circuit Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.5 Troubleshooting Section - Table Of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3.6 Ohm Ratings For Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

3.7 Main Power Circuit Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3.8 Drive Train Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3.9 Mast Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

3.10 Hydraulic Leak Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41

3.11 Base Frame Components Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

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TABLE OF CONTENTS

LIST OF FIGURES

FIGURE NO.

TITLE

PAGE NO.

1-1. Hydraulic Pressure Setting - Adjustment Screw Located at Base of Pump Motor . . . . . . . . . . . .1-3 1-2. Hydraulic Pressure Gauge Installation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 1-3. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 1-4. Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 2-1. Accessing Machine Underside Components by Lifting with a Fork Truck. . . . . . . . . . . . . . . . . . .2-4 2-2. Check Torque Limit Clutch - Torque Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 2-3. Torque Limit Clutch - Adjustment Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 2-4. Brake Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 2-5. Brake Armature Plate & Brake Disk Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 2-6. Manual Release Brake Cable Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 2-7. Drive Motor Assembly Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 2-8. Drive Motor Gear Box Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 2-9. Gear/Pinion Shaft Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 2-10. Drive Shaft Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 2-11. Drive Motor Brush Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 2-12. Drive Motor Brush Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 2-13. Correct/Incorrect Brush Spring Bracket Positions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14 2-14. Platform Control Box Assembly (Exploded View). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15 2-15. Platform Control - Circuit Board Component Wiring Connections. . . . . . . . . . . . . . . . . . . . . . . . .2-17 2-16. Machine Positioned for Cylinder Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23 2-17. Lift Cylinder Internal Component Assembly Cross-Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 2-18. Mast Section - Assembly Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 2-19. 10VP Mast Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 2-20. 15VP Mast Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29 2-21. 20VP Mast Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30 2-22. Mast Chain/Cable/Sequence Cable Adjustment Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37 3-1. LED Battery/Fault Code Indicator Strip on Platform Controller Box. . . . . . . . . . . . . . . . . . . . . . . .3-2 3-2. Overview of Standard Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 3-3. VP Electrical Diagram. (VP Series - Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8 3-4. Overview of VP UL-EE Approved Optional Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 3-5. VP Electrical Diagram. (with UL-EE Approved Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12 3-6. Hydraulic Diagram. (VP Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

LIST OF TABLES

TABLE NO.

TITLE

PAGE NO.

1-1. Machine GVW and Wheel Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1-2. Hydraulic Oil Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 1-3. Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 1-4 Machine Interlock Switch Operating Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 1-5. Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 1-6 Lubrication Intervals for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 2-1 Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 2-2 VP Series Mast Component Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 2-3 Preventive Maintenance & Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41 3-1 MC-1 WARNING CODES (Indicated by 3 beeps, then slow flashing LED’s). . . . . . . . . . . . . . . . .3-3 3-2 MC-1 ERROR CODES (Indicated by rapid LED flashing and periodic beep) . . . . . . . . . . . . . . . .3-4 3-3 Ohm Ratings for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16 3-4 Unit will not Power Up From Ground Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17 3-5 No Power At Platform Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18 3-6 Won’t Drive. (Platform Lowered or Elevated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20 3-7 Elevation Switch Circuit Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20 3-8 Brake Limit Switch Circuit Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

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3-9 Drive Motor/Circuit Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21 3-10 Brake Switch/Circuit Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21 3-11 Won’t Drive with Platform Elevated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22 3-12 Tilt Sensor Circuit Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22 3-13 PHP Limit Switch Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23 3-14 Won’t Climb Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24 3-15 Drives In Opposite Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25 3-16 Only Drives A Short Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 3-17 E-Stop and Key Switch Circuit Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27 3-18 Won’t Drive Straight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28 3-19 Noise from Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 3-20 Platform Will Not Lift Up Using Platform Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 3-21 Pump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31 3-22 Pump Valves Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32 3-23 Platform Will Not Lower Using Platform Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33 3-24 Unit Will Not Lift Up From Ground Control Toggle Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34 3-25 Unit Will Not Lower From Ground Control Toggle Switch.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35 3-26 Platform Will Not Lower Manually. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36 3-27 Platform Lift Up and Down Jerky. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37 3-28 Mast Noisy when Lifting and Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38 3-29 Platform (Mast) Won’t Stay Elevated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39 3-30 Platform (Mast) Descends Too Slowly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40 3-31 Hydraulic Leak Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41 3-32 Caster Wheels Not Operating Freely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42 3-33 Pot Hole Protection (PHP) Bars Will Not Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

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SECTION 1. SPECIFICATIONS

1.1CAPACITIES

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.)

1.2COMPONENT 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

DriveMotors -

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 CycleMarine - 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

1.3PERFORMANCE 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

	VP MODEL	CONFIG.	GVW (no load)	DRIVE WHEEL	CASTER	PSI	PSI
				(ea) w/rated load	(ea) w/rated load	(Drive)	(Caster)
	10VP	ANSI (U.S.)	930 lb. (422 kg)	424 lb.	216 lb.	76 psi	102 psi
		CSA (CAN.)	930 lb. (422 kg)	424 lb.	216 lb.	76 psi	102 psi
	15VP	ANSI (U.S.)	1,355 lb. (615 kg)	604 lb.	249 lb.	108 psi	117 psi
		CSA (CAN.)	1,425 lb. (647 kg)	630 lb.	257 lb.	113 psi	121 psi
	20VP	ANSI (U.S.)	1,910 lb. (867 kg)	750 lb.	400 lb.	134 psi	188 psi
		CSA (CAN.)	2,100 lb. (953 kg)	774 lb.	470 lb.	140 psi	220 psi

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Base Footprint

1.5 LUBRICATION

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.

Hydraulic Oil

Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries, recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152.

For cold weather applications, i.e. when temperatures remain consistently below +20°F (–7°C) JLG recommends using Mobil DTE 13 hydraulic oil.

Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommendations.

Table 1-2. Hydraulic Oil Operating Range

HYDRAULIC SYSTEM OPERATING	SAE VISCOSITY
TEMPERATURE RANGE	GRADE

0° F to +23° F

10W

(-18° C to -5° C)

0° F to +210° F

10W-20, 10W-30

(-18° C to +99° C)

50° F to 210° F

20W-20

(+10° C to +210° C)

1.4TORQUE REQUIREMENTS

When maintenance becomes necessary or a fastener has loosened, refer to the Torque Chart, Figure 1-3., Torque Chart. to determine proper torque value.

Lubrication Specifications

Table 1-3. Lubrication Specifications

	KEY	SPECIFICATIONS
		Multipurpose Grease having a minimum dripping point
	MPG -	of 350° F. Excellent water resistance and adhesive qual-
		ities, and being of extreme pressure type. (Timken OK
		40 pounds minimum.)
	EPGL -	Extreme Pressure Gear Lube (oil) meeting API service
		classification GL-5 or MIL-Spec MIL-L-2105.
	HO -	Hydraulic Oil. ISO-Vg grade 32, 46.

Table 1-4. Machine Interlock Switch Operating Conditions.

	Mast Elevation	Drive Cutout	Tilt Status	Brake Status	Controller Response
		(PHP System)
	mast retracted	bars raised	(not tilted)	engaged	Full Drive and Lift
	mast retracted	bars raised	(not tilted)	disengaged	Drive and Lift Disabled
	mast extended	bars lowered	(not tilted)	engaged	Drive 25% maximum
	mast extended	bars raised (blocked)	(not tilted)	engaged	Drive Disabled
	mast extended	bars lowered	(tilt)	engaged	Drive and Lift disabled
	mast retracted	bars raised	(tilt)	engaged	Lift Disabled
	mast retracted	bars raised/battery charger	(not tilted)	engaged	Drive Disabled
		plugged-in

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1.6HYDRAULIC 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 decreases system pressure.

Make pressure adjustment with oil at normal operating temperature. If pressure is set when oil is cold, platform may not raise rated load after oil has warmed.

PRESSURE

ADJUSTMENT

SCREW

ADJUSTMENT

SCREW CAP

Figure 1-1. Hydraulic Pressure Setting - Adjustment

Screw Located at Base of Pump Motor

(Remove Hex Head Cap as Shown)

ONLY OPEN HYDRAULIC SYSTEM LINES WITH THE MAST LOW-

ERED TO RELIEVE PRESSURE IN THE SYSTEM. CAREFULLY LOOSEN REQUIRED FITTINGS, WEAR SAFETY PROTECTION EQUIPMENT WHEN WORKING WITH HYDRAULIC SYSTEMS.

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 (.562 x 18 THD) and gauge fitting as required.

	RETURN
	LINE
REPLACE ELBOW	EXTEND
	LINE
WITH A T-FITTING
TO CONNECT
PRESSURE GAUGE	PRESSURE
HERE	GAUGE

Figure 1-2. Hydraulic Pressure Gauge Installation.

1.7CYLINDER SPECIFICATIONS

NOTE: All dimensions are given in inches (in), with the metric equivalent, centimeters (cm), given in parentheses.

Table 1-5. Cylinder Specifications

	DESCRIPTION	BORE	STROKE	ROD DIA.
		in./(cm)	in./(cm)	in./(cm)
	Lift Cylinder -	1.50	54.50	1.125
	10VP	(3.81)	(138.43)	(2.86)
	Lift Cylinder -	1.50	54.50	1.125
	15VP	(3.81)	(138.43)	(2.86)
	Lift Cylinder -	1.50	54.50	1.125
	20VP	(3.81)	(138.43)	(2.86)

1.8SERIAL NUMBER LOCATION

For machine identification, a serial number plate is affixed to the machine. The plate is located on the back of the mast, just above the mast support bracket.

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Figure 1-3. Torque Chart.

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6

1

2

3

								4, 5
				Figure 1-4. Lubrication Chart.
			Table 1-6.Lubrication Intervals for Various Components
						INTERVAL HOURS
ITEM	COMPONTENT		NO/TYPE	LUBE/METHOD	3	6		1		2	COMMENTS
			LUBE POINTS
					MONTHS	MONTHS		YEAR		YEARS
					150 Hrs.	300 Hrs.		600 Hrs.		1200 Hrs.
		Fill To Line on		HO - Check Hyd. Oil							Check Hydraulic Oil every 10 hrs.
1	Hydraulic Oil	Reservoir		Level							Change Hydraulic Oil every 1200
		5 Qt. Reservoir		HO - Change Hyd. Oil							hrs.
2	Drive Wheel	4	- Grease Fittings	MPGPressure Gun
	Bearings
3	Drive Wheel	2	- Gear Box	Gear Oil							Change only when serviced
	Gear Box										requires 6 oz. (175 cc’s) to fill.
4	Caster Axles	2	- Grease Fitting	MPG - Pressure Gun
5	Swivel Raceways	2	- Front Casters	MPG - Pressure Gun
6	Mast Chains *	2	- Per Section	Chain Lube - Brush or							Inspect, lubricate if dry or rusting.
				Spray

* Applies Only to Mast Sections with Chains.

Key to Lubricants: MPG - Multipurpose Grease

HO - Hydraulic Oil - See Section 1.5, "Lubrication" in Service Manual.

GEAR OIL - Good Quality Worm Gear Oil - SAE 90 - AGMA#5 - EP Compounded

Notes: 1. Be certain to lubricate like items on each side of the machine.

2.Recommended lubricating intervals are based on normal use. If machine is subjected to severe operating conditions,

such as a high number of cycles, location, corrosive/dirty environment, etc., user must adjust lubricating requirements accordingly.

3.Prior to checking hydraulic oil level, operate machine through one complete cycle of lift function (full up and down). Failure to do so will result in incorrect oil level reading on the hydraulic reservoir.

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SECTION 2. SERVICE PROCEDURES

2.1GENERAL

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.

WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE

NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK

IS RESUMED.

2.2SERVICING AND MAINTENANCE GUIDELINES

General

The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter.

Safety and Workmanship

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of component weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING.

Cleanliness

The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provided to keep the wheel bearings, mast sections and oil supply clean; however, these items must be maintained on a scheduled basis in order to function properly.

At any time when oil lines are disconnected, clear adjacent areas as well as the openings and fittings them-

selves. As soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter.

Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their containers until they are ready to be used.

Components Removal and Installation

Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be parallel to each other and as near perpendicular as possible to top of part being lifted.

Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90 degrees.

If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., have been removed and that no adjacent parts are interfering.

Component Disassembly and Reassembly

When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.

Pressure-Fit Parts

When assembling pressure-fit parts, use an “anti-seize” or molybdenum disulfide base compound to lubricate the mating surface.

Bearings

When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing.

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) paper. Do not unwrap reusable or new bearings until they are ready to install.

Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore,

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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. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent.

Unless specific torque requirements are given within the text, standard torque values should be used on heattreated bolts, studs, and steel nuts, in accordance with recommended shop practices. (See Figure 1-1.)

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit. This will assure that they are correctly reinstalled.

Hydraulic System

Keep the system clean. If evidence of metal or rubber particles is found in the hydraulic system, drain and flush the entire system.

Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate components, as required, to aid assembly.

Lubrication and Servicing

Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart, (See Figure 1-2.). Service applicable components with the amount, type, and grade of lubricant recommended in this manual, at the specified intervals. When recommended lubricants are not available, consult your local supplier for an equivalent that meets or exceeds the specifications listed.

Batteries

Clean batteries, using a non-metallic brush and a solution of baking soda and water. Rinse with clean water. After cleaning, thoroughly dry batteries and coat terminals with an anti-corrosion compound.

Mast Chain Inspection Procedure

MAST CHAINS TO BE INSPECTED AND LUBRICATED EVERY THREE MONTHS.

Inspect mast chains for the following conditions:

Wear: Always inspect that segment of chain that operates over a sheave. As the chain flexes over the sheaves, joints and plate edges very gradually wear. Chain “stretch” can be measured using a manufacturers wear scale or steel tape. When chains have elongated 3% they must be removed and replaced. Refer to Table 2-1 for proper chain specifications and allowable stretch tolerances. Peening and wear of chain plate edges are caused by sliding over a chain worn contact face of a sheave, or unusually heavy loads. All of the above require replacement of the chain and correction of the cause. Chain side wear, noticeable when pin heads and outside plates show a definite wear pattern, is caused by misalignment of the sheave/chain anchors and must be corrected promptly. Do not repair chains; if a section of chain is damaged, replace the entire chain set.

Rust and Corrosion: Rust and corrosion will cause a major reduction in the load carrying capacity of the chain, because these are primary reasons for side plate cracking. The initial lubrication at the factory is applied in a hot dip tank to assure full penetration into the joint. Do not steam clean or degrease chains. At time of chain installation, factory lube must be supplemented by a maintenance program to provide a film of oil on the chains at all times. If chains are corroded, they must be inspected, especially the outside plates, for cracks in-line with the pins. If cracks are found, replace the chain; if no cracks are discovered, lubricate the chains by dipping in heated oil, and reinstall on the machine. Keep chains lubricated.

Table 2-1. Chain Stretch Tolerance

	Chain Size	Pin to Pin	Allowable Stretch
		Measurement
	.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 chain plate failures. Fatigue cracks are found through the link holes, perpendicular (90 degrees) from the pin in-line position. Inspect chains carefully after long time use and heavy loading for this type of crack. If any cracks are discovered, replace all chains, as seemingly sound plates are on the verge of cracking. Fatigue and ultimate strength failures on JLG Lifts are incurred as a result of severe abuse as design specs are well within the rated lifting capacity of these chains.

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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. This type of problem is accelerated by poor lubrication maintenance practice, and most tight joint chains have been operated with little or no lubrication. Tight joints on leaf chain are generally caused by:

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 between the pin and plates (pin and bushing on leaf chain). In extreme cases, this frictional torque can actually turn the pins in the outside press-fit plates. Inspect for turned pins, which can be easily spotted as the “V” flats on the pin heads are no longer in line. Replace all chains showing evidence of turned or protruding pins. Keep chains lubricated.

Chain Anchors and Sheaves: An inspection of the chain must include a close examination of chain anchors and sheaves. Check chain anchors for wear breakage and misalignment. Anchors with worn or broken fingers should be replaced. They should also be adjusted to eliminate twisting the chain for an even load distribution.

Inspect the sheaves, sheave bearings, sheave grooves and pins for extreme wear, replace as necessary. A worn sheave can mean several problems, as follows:

a.Chains too tight.

b.Sheave bearings/pin bad.

c.Bent/misaligned chains.

Mast Cable Inspection Procedure

MAST CABLES ARE TO BE INSPECTED EVERY THREE MONTHS OR MORE FREQUENTLY AS DESCRIBED FOLLOWING.

WEAR PROTECTIVE GLOVES TO PROTECT HANDS WHEN HAN-

DLING CABLE.

The periodic inspection shall cover the entire length of the cable. The inspection frequency shall be based on such factors as expected cable life as determined by experience on the particular application or similar installations, severity of environment, percentage of capacity lifts, frequency rates of operation, and exposure to shock loads.

Inspection should be more frequent as cables approach the end of their useful lives.

Only the surface wires of the cable require inspection, do not attempt to open the cable. Any deterioration resulting in any loss of original strength, such as described below, shall be noted, and then a determination made if further use would constitute a hazard.

Mast cables must be replaced after machine has been in service for five (5) years, regardless of cable condition, or sooner if conditions dictate.

Conditions such as the following shall be sufficient reason for questioning continual use of the [cable] or increasing the frequency of inspection:

1.In running ropes, six randomly distributed broken wires in one lay or three broken wires in one strand in one lay.

2.One outer wire broken at the point of contact with the core of the rope which has worked its way out of the rope structure and protrudes or loops out from the rope structure. Additional inspection of this section is required.

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);

NOTE: A good indicator of a stretched extend/retract cable is if the adjusting nuts are bottomed out. If no adjustment remains the cables have stretched and need replacement.

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.

2.3LUBRICATION INFORMATION

Hydraulic System

The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenance, or by permitting the pump to cavitate due to insufficient system warm-up or leaks in the pump supply.

The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system

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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.

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.

It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is operating, are recommended for use.

NOTE: Metal particles may appear in the oil of new machines due to the wear-in of meshing components.

Hydraulic Oil

For best performance, JLG recommends the use of ISOVg grade 32, 46 oil with a viscosity range between 15-250 SUS at 100 degrees F (32-54 cST at 40 degrees C). Refer to Section 1-5 of this Service Manual for recommended hydraulic oils.

Changing Hydraulic Oil

Use of any of the recommended hydraulic oils eliminates the need for changing the oil on a regular basis. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils. JLG Industries recommends changing the hydraulic oil annually.

Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to clean all possible contaminants from the service container.

While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service.

Lubrication Specifications

Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose grease requirements. Should any question arise regarding the use of greases in maintenance stock, consult your local supplier for evaluation. Refer to Table 1-3 in this Service Manual for an explanation of the lubricant key designations appearing in the Lubrication Chart.

2.4POSITIONING 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 truck, using the fork lift pockets in the base frame.

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.

KEEP MACHINE LEVEL OR SLIGHTLY TILTED TOWARD FORKLIFT

TRUCK WHEN LIFTING TO PREVENT MACHINE FROM SLIDING OFF LIFTING TINES.

3.When lifting with a fork truck, lift only using the fork lift-truck pockets running the length of the machine’s base frame from rear to front.

4.After lifting machine to desired work height, place support stands under the machine. The support stands must reach from the floor to the bottom of the machine and be capable of safely handling the weight of the machine.

LIFT USING ONLY THE

FORK LIFT POCKETS

RUNNING THE LENGTH

OF THE BASE FRAME

PLACE

SUPPORT

STAND

BETWEEN

MACHINE

AND

FLOOR

Figure 2-1. Accessing Machine Underside

Components by Lifting with a Fork Truck.

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SECTION 2 - SERVICE PROCEDURES

2.5DRIVE MOTOR COMPONENT SERVICE PROCEDURES

Torque Limiting Clutch Maintenance

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. The clutch is designed to slip at a pre-set torque if the machines rear wheels are over-driven while the machine is being towed, pushed or forklifted, thus preventing damage to the drive gear box. Although factory pre-set, the clutch assembly and torque should be checked at the following interval:

• Every 3 months.

Visual Inspection and Limiting Torque

Checking Procedure

1. Locate the machine on a firm level surface.

KEEP MACHINE LEVEL OR SLIGHTLY TILTED TOWARD FORKLIFT TRUCK WHEN LIFTING TO PREVENT MACHINE FROM SLIDING

OFF LIFTING TINES.

2.Carefully raise the lift to gain access to the underside of the base frame. Refer to Section 2.4, "Positioning Lift For Access to Components Located Under the Base Frame".

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 necessary.

b.Check that the allen-head set screws on the (large) clutch adjusting nut are in place and secure. Tighten or replace if necessary.

c.Check for any debris wedged in or wrapped around the clutch coupling chains and axle shafts. Remove debris and clean area if necessary.

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.

2.Select a torque wrench capable of setting a torque of at least 185 ft. lb. Insert special tool (P/N- 0080229) into a 3/4" socket on the torque wrench.

3.Slide the tool onto the end of the drive axle aligning the key on the axle shaft (install key on axle, if necessary), with key slot in the tool. (See Figure 2-2.)

4.Turn the torque wrench and note the torque setting when the torque limiting clutch releases. The torque (slip) setting should be set at 185 ft. lb. Check both rear drive axles.

NOTE: The allowable breaking torque for the torque limiting clutch can be set as much as 35 ft. lb. less than the factory setting of 185 ft. lb., but never more than the 185 ft. lb. factory setting.

5.If torque setting is OK, re-install the wheels and lower machine, IF NOT, see the following note.

NOTE: If torque setting is outside the allowable range of specifications, the torque limiting clutch will need adjustment. See Torque Limiting Clutch Adjustment following.

SERVICE TOOL

P/N-0080229

(REQUIRES A 1-3/4” SOCKET)

TORQUE

LIMITING

CLUTCH

LOCATION

Figure 2-2. Check Torque Limit Clutch -

Torque Setting.

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SECTION 2 - SERVICE PROCEDURES

Torque Limiting Clutch Adjustment

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.) the large adjusting nut must be (loosened), turned counter-clockwise to decrease the torque setting.

1.Loosen the two (2) adjusting nut setscrews located on the large adjusting nut on the clutch assembly. (See Figure 2-3.)

2.Hold the drive axle steady using service tool (P/N- 0080229) and the torque wrench used to check the torque setting.

3.Depending on how far off the original torque setting was (see note at beginning of this procedure), tighten or loosen the adjusting nut accordingly, then recheck the (slip) torque setting.

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.

ADJUSTING NUT

SET SCREWS

TORQUE LIMIT

CLUTCH

ADJUSTING NUT

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 ENGAGED (brakes on) when the machine is parked and are RELEASED electrically (brakes off) under normal driving conditions, when the joystick is enabled and pushed in any direction. The brakes can also be RELEASED manually using the manual brake release lever mounted on the side of the mast.

NOTE: The brakes are intended only as parking brakes to keep the machine from moving while at rest. The brakes are not used to stop the machine during driving operations, this braking is controlled by the drive motors themselves. Under normal driving conditions, once released the brakes are not engaged again until the machine comes to a complete stop.

	MANUAL	MAGNETIC
	BRAKE
		COIL
	RELEASE	HOUSING
	ARM

LIMIT (MICRO) SWITCH

MOUNTING

PLATE

ARMATURE FRICTION

PLATE BRAKE

DISK

SPRINGS

SHIM WASHERS (AS REQUIRED)

SPACER

Figure 2-3. Torque Limit Clutch -

Adjustment Components.

Figure 2-4. Brake Assembly Components

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SECTION 2 - SERVICE PROCEDURES

	FRICTION BRAKE DISK	MOUNTING PLATE	FRICTION BRAKE DISK	MOUNTING PLATE
	ARMATURE PLATE		ARMATURE PLATE
	MAGNETIC COIL	0.006” GAP	MAGNETIC COIL	0.006” GAP
	(Not Energized)	BETWEEN	(Energized)	BETWEEN
	MANUAL	ARMATURE	MANUAL	FRICTION
		PLATE AND		DISK AND
	RELEASE ARM/		RELEASE ARM/
		MAGNETIC COIL		ARMATURE
	ADJUSTMENT		ADJUSTMENT
				PLATE
	SCREW		SCREW
		0.020” GAP		0.026” GAP
		UNDER		UNDER
		SCREW HEAD		SCREW HEAD
		BETWEEN		BETWEEN
		ARMATURE		ARMATURE
		PLATE		PLATE
	GAP SETTINGS - BRAKE ON		GAP SETTINGS - BRAKE RELEASED
	(Magnet Not Energized)		(Magnet Energized)

Figure 2-5. Brake Armature Plate & Brake Disk Adjustment.

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 magnetic coil surface by heavy springs internally mounted in the magnetic coil housing. This pressure forces the armature plate against the friction brake disk holding it tight between the armature plate and the mounting plate. The brake is not released until either the magnetic coil is energized pulling the armature plate away from the friction brake disk or the brake is manually released using the manual brake release handle.

A correctly adjusted brake will ideally have a measurment of approximately .006" (but will operate normally at .004" to

.010") between the armature plate and magnetic coil housing surface when the brakes are ENGAGED (brakes on).

3.With the brakes ENGAGED measure the air gap between the armature plate and the magnetic coil housing. The correct setting should be .006", however the brakes will operate properly if the measurement is a minimum of .004" and a maximum of .010". (See Figure 2-5.)

4.If the air gap falls outside the maximum allowable setting of .010" the friction disk has worn. To correct this replace the disk with a new one.

5.It the air gap is below the minimum allowable setting of .004", recheck the areas between the magnetic coil housing, armature plate, friction disk and mounting plate for debris. Clean as neccessary. Also check that the manual release arm screws are not tightened to tight.

Never allow any type of lubricant (oil, grease, hydraulic fluid, etc.) to come in contact with the brake friction disk or it’s contacting surfaces. Also if the brake becomes clogged with debris or dirt the brake may not release properly.

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 and magnetic coil when the brakes are ENGAGED (brakes on); on either side of the friction disk when the brake is RELEASED (brakes off); or any dirt or debris lodged between the manual release arm and the magnetic coil housing. Clean and remove debris as necessary.

Manual Release Arm - Screw Adjustment

NOTE: Always check the armature plate gap setting is within spec before attempting to adjust 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 to the surface of the armature plate should be set at

.020". Adjust using the locknut on the release arm end of the screw.

2.With the brakes electrically RELEASED (brakes off) the air gap under the screw head increases to approximately .026" due to the armature plate movement towards the magnetic coil, releasing the friction brake disk. When the brakes are RELEASED (brakes off) manually the screw head pulls in against the armature plate releasing the friction brake disk.

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SECTION 2 - SERVICE PROCEDURES

Brake Assembly Removal

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.Disconnect the brake magnetic coil wiring connector and the brake limit (micro) switch wiring connector from their wiring harness connectors.

3.Disconnect the manual brake release cable from the manual brake release arm attached to the brake assembly.

4.Lower machine back down to ground level.

PLACE MACHINE ON A LEVEL SURFACE BEFORE BEFORE REMOVING THE BRAKE ASSEMBLIES. MACHINE MAY ROLL AWAY IF NOT SETTING ON A LEVEL SURFACE.

5.Using the Ground Control Switch, raise the platform to gain access to the brake assemblies mounted on the end of the drive motors located at the base of the mast.

NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT

BY BLOCKING OR OVERHEAD SLING.

6.Remove the four (4) hex cap screws securing the brake assembly to the end of the drive motor and remove the brake assembly from the end of the drive motor.

Brake Assembly Installation

1.Guide the manual release lever, brake coil and brake limit switch wiring connectors through the opening in the drive motor cover and base frame while sliding the brake assembly onto the front of the drive motor. Engage the teeth of the disk brake with the teeth on the drive motor brake gear.

2.If necessary, manually release the brake disk using the manual release lever to allow the brake assembly to turn and align the four holes in the brake mounting plate with the mating holes in the drive motor end plate.

3.Secure the brake assembly to the drive motor using four (4) hex cap screws with washers. Torque evenly to 44 in. lbs.

4.Lift the machine to gain access to the underside (See Section 2-4., "Positioning Lift For Access To Components Located Under The Base Frame").

5.Reconnect the brake coil and brake limit switch wiring connectors to their respective wiring harness connectors.

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.)

	MANUAL	TO MANUAL
		RELEASE
	RELEASE
		BRAKE
	BRAKE
		HANDLE
	CABLE
		MOUNTED
		ON SIDE OF
		MAST

SET MANUAL	BRAKES
BRAKE RELEASE	ARE RELEASED
HANDLE TO	WHEN CABLE
FREE WHEELING	PULLS LEVER
AND ADJUST HERE	IN THIS DIRECTION
UNTIL BRAKE DISK
IS COMPLETELY
RELEASED

Figure 2-6. Manual Release Brake Cable Adjustment.

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SECTION 2 - SERVICE PROCEDURES

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 motor, the electric drive motor itself, and the brake assembly mounded at the front of the drive motor. Each drive motor is mounted independently of the other on a completely removable drive assembly weldment at the back of the machine.

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. Three (3) bolts hold the top of the rear plate weldment to the base frame, four (4) bolts attach it to the motor cover weldment (located under machine) at the back and on the sides.

3.Carefully raise the lift to gain access to the underside of the base frame. Refer to Section 2.4, "Positioning Lift For Access to Components Located Under the Base Frame".

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 sides, depending on which drive assembly(ies) is being removed.

6.Disconnect the manual release brake cable from the brake assembly arm on either or both drive motors if removing the complete drive assembly.

NOTE: If removing each drive motor seperately continue to Step 7. If removing the complete drive assembly with both motors attached go to Step 11.

7.Remove the one (1) bolt, nut, and two (2) washers from the front of the drive motor mounting plate.

8.While holding the drive motor in place, remove the remaining two (2) bolts with washers holding the drive motor mounting plate to the drive motor assembly weldment.

9.Slide the drive motor and torque limiting clutch assembly towards the center of the machine, sliding the torque limiting clutch off the outer drive shaft.

10.Move drive motor assembly and torque limiting clutch to a suitable work bench for disassembly.

	DRIVE MOTOR/		DRIVE MOTOR
		DRIVE MOTOR	ASSEMBLY
	BRAKE WIRING		WELDMENT
		ASSEMBLY WELDMENT
	CONNECTORS		ATTACH BOLTS
	DRIVE MOTOR MOUNT		(2 EACH INSIDE FORK LIFT POCKET)
MANUAL	PLATE FASTENERS
RELEASE	(THREE ON EACH MOUNT
BRAKE	ALSO SEE INSET)
CABLE

DRIVE MOTOR
COVER	DRIVE MOTOR MOUNT
	PLATE

REAR PLATE

WELDMENT

Figure 2-7. Drive Motor Assembly Removal.

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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. Be aware of the weight of the assembly before completely removing the fasteners, see the CAUTION above.

12.Lower the drive assembly and place on a suitable work surface.

(See Figure 2-8.)

The drive motor gear box is mounted on the rear of each drive motor transferring power from the electric drive motor to the rear drive wheels. It is a right angle worm gear type box with a 50:1 reduction drive ratio. The internal gears and bearings of the gear box are lubricated by 175cc’s of gear oil in an unvented aluminum alloy housing. Early VP machines included a oil drain plug on the rear surface of the gear box housing, later model machines do not. The following procedures disassemble and assemble the gear box housing internal components.

Gear Box Disassembly (See Figure 2-8.)

1.Remove the drive motor/gear box/brake assembly from the machine using the procedure outlined previously in this section of the manual.

Figure 2-8. Drive Motor Gear Box Assembly.

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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. (Note: Early model machines did not have the rubber seal ring and were sealed with sealant only.) Be careful not to scratch or gouge the mating surfaces between the cover and the gear box housing. This area is sealed by the rubber ring/sealant and may leak oil if damaged.

3.Remove the wave washers from atop the large and small bearings and lay inside their respective holes in the side cover.

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 hydraulic press with the open side of the gear box housing facing down. Support the gear box housing surface but do not block the free travel of the drive gear and bearings, on the drive shaft or the pinion gear assembly.

6.With the open surface of the housing properly supported, carefully press the drive shaft down through until it is free of the housing. When the drive shaft assembly is free, slide it completely out of the housing.

7.To remove the large (47mm) (cover side) bearing and (housing side) bearing from the drive shaft, use a suitable hydraulic press and press the bearing(s) off the shaft. Keep the spacer from between the cover side bearing and the drive shaft gear for reuse during assembly.

8.To remove the small (32mm) bearing(s) from the gear (brass) and pinion assembly, use a suitable hydrauic press and press the bearing(s) off the gear and pinion shaft.

9.To remove the (brass) worm gear from the pinion assembly, use a suitable hydraulic press and press the gear off the pinion shaft. Keep the (brass) gear key for reuse during assembly.

10.Inspect the drive shaft seal for cuts, cracks and wear, or if showing signs of leakage. Replace if necessary.

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 gear shaft.

2.Press the (brass) worm gear onto the pinion shaft and align the keyway in the (brass) worm gear with the key on the pinion shaft. Press the (brass) worm gear onto the shaft until it bottoms out against the pinion gear teeth.

NOTE: Press bearings onto the shaft pressing only against the bearing inner race. Do not press against the outer race or damage could occur to the bearing.

3.Press the small (32mm) bearings onto the ends of the pinion shaft. The inner race of the bearing on the pinion gear side can be bottomed out against the pinion gear. Do not press the bearing on the (brass) worm gear side of the shaft in tight against the (brass) worm gear. This bearing must be flush with the end of the shaft on the outside, yet have clearance from the (brass) worm gear on the inside, so it can rotate freely.

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 shaft. Press the bearing inner race until it bottoms against the shaft shoulder between the drive gear and the bearing.

2.Slide the narrow spacer onto the drive gear end of the shaft and press the (cover side) 42mm x 20mm x 14mm (wider) bearing onto the drive shaft until it bottoms against the spacer. This bearing should be flush with the end of the drive shaft.

SIDE PROFILE

	WORM	LEAVE
	GEAR
	(BRASS)	GAP HERE
	PINION GEAR/
32mm	SHAFT	32mm
BEARING		BEARING

WORM GEAR

KEY

Figure 2-9. Gear/Pinion Shaft Assembly.

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SECTION 2 - SERVICE PROCEDURES

Final Gear Box Assembly

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. Install the seal so it is even with the bottom of the chamfer in the drive shaft hole on the outside of the housing and flush with the bearing seat on the inside of the housing.

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 shaft to extend through without obstruction.

4.Hold the gear and pinion, and drive shaft assembies together with the pinion gear and the ring gear on the drive shaft meshing. Now carefully slide these assemblies into the gear box housing sliding the drive shaft through the drive shaft lip seal.

NOTE: While assembling the gear assemblies into the gear box housing, be careful with the drive shaft seal and the softer brass worm gear and brass drive worm gear from the drive motor.

5.Continue to drop the gear assemblies into the gear box, align the bearings with the bearing seats in the housing on both assemblies. Drop the gear and pinion (smaller) bearing into it’s seat first, while wiggling

that gear set align the drive shaft bearing and wiggle it into it’s seat. When both are seated continue to next step.

6.With the gear box still positoned with the open cover side up, fill the gear box with six (6) ounces (U.S.) (175cc’s) of good quality worm gear oil (Specification - SAE 90 weight - AGMA#5 - EP Compounded). When pouring the gear oil, wet the gears and bearings with the oil.

7.Wet with gear oil and place the large wave washer on the end of the drive shaft bearing and the small wave washer on the end of the gear and pinion bearing.

8.Clean the mating surfaces of the side cover and the gear box and check that the cover dow guide pins are properly installed in the cover.

9.On older model gear boxes apply sealant to the cover mating surface on the gear box. On newer model gear boxes insert the rubber seal into the groove in the cover.

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.

PINION

GEAR

PINION GEAR KEY

SPACER

42mm x 25mm x 12mm BEARING

DRIVE SHAFT

SIDE PROFILE

42mm x 20mm x 14mm BEARING

Figure 2-10. Drive Shaft Assembly.

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