Service 20VP

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 OPER-
ATING 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 SITUA- WARNING INDICATES A POTENTIALLY HAZARDOUS SITU-
TION WHICH, IF NOT AVOIDED WILL RESULT IN SERIOUS ATION WHICH, IF NOT AVOIDED COULD RESULT IN SERI-
INJURY OR DEATH. OUS INJURY OR DEATH.
CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUA- IMPORTANT OR INSTRUCTIONS PROCEDURES ESSENTIAL

TION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR FOR SAFE OPERATION AND WHICH, IF NOT FOLLOWED
MODERATE INJURY. IT MAY ALSO BE USED TO ALERT MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE
AGAINST UNSAFE PRACTICES. MACHINE.
Also in this Manual "Notes:" are used to provide infor-

mation of special interest.
JLG INDUSTRIES, INC. MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT. CONTACT JLG INDUS-
TRIES, INC. OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLE-
TINS 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.
This page left intentionally blank.
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 per- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
sonnel pay strict attention to these warnings and precau- THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON-
tions to avoid possible injury to themselves or others or NEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
damage to the equipment. A maintenance program must
be established by a qualified person and must be followed • REMOVE ALL RINGS, WATCHES, AND JEWELRY
to ensure that the machine is safe to operate. 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
MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY IN EQUIPMENT.
A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST
• OBSERVE AND OBEY ALL DANGER, WARNING, CAU-
AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA-
TION AND OTHER INSTRUCTIONS ON MACHINE
TION.
AND IN SERVICE MANUAL.
The specific precautions to be observed during machine • KEEP STANDING SURFACES AND HAND HOLDS
maintenance are inserted at the appropriate point in the FREE OF OIL, GREASE, WATER, ETC.
manual. These precautions are, for the most part, those • NEVER WORK UNDER AN ELEVATED PLATFORM
that apply when servicing hydraulic and larger machine UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED
component parts. FROM ANY MOVEMENT BY BLOCKING OR OVER-
HEAD SLING.
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
be conscious of component weight and never attempt to PERFORMING ANY OTHER MAINTENANCE, SHUT
move heavy parts without the aid of a mechanical device. OFF ALL POWER CONTROLS.
Do not allow heavy objects to rest in an unstable position. • BATTERY SHOULD ALWAYS BE DISCONNECTED
When raising a portion of the equipment, ensure that ade- DURING REPLACEMENT OF ELECTRICAL COMPO-
quate support is provided. NENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACH-
MENTS STOWED IN THEIR PROPER PLACE.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON- • USE ONLY APPROVED, NONFLAMMABLE CLEANING
TROL OVER THE FIELD INSPECTION AND MAINTENANCE, SOLVENTS.
SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER/
OPERATOR.
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 dis-
connecting 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 compo-
nents can then be disconnected with minimal fluid
loss.
3120728 – JLG Lift – a

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b – JLG Lift – 3120728

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
3120728 – JLG Lift – c

EFFECTIVITY PAGE
d – JLG Lift – 3120728

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
3120728 – JLG Lift – i

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
ii – JLG Lift – 3120728

TABLE OF CONTENTS
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
3120728 – JLG Lift – iii

TABLE OF CONTENTS
iv – JLG Lift – 3120728

SECTION 1. SPECIFICATIONS
Batteries/Battery Charger
1.1 CAPACITIES
Batteries (2) – 12 Volt / 80 Amp Hour –
System Voltage Deep CycleMarine - RV
All VP Models –24 Volt DC (2 - 12 volt DC batteries) Battery Charger –
U.S.A./CAN. –120 Volt A.C. / 60 Hz input
Hydraulic Oil Reservoir
Brazil - 220 Volt A.C./ 60 Hz input
All VP Models – 5 qts. U.S. (4.7 ltr.) 24 volt, 10 amp output -
with 2 amp finish
1.2 COMPONENT DATA Reset Circuit Breaker
Automatic Charge Circuit
Hydraulic Pump/Pump Motor Assembly Plug Interlock Circuit
Pump Motor - 24 Volt DC motor
Pump Displacement –
1.3 PERFORMANCE DATA
10 & 15VP – .098 cu. in./rev. (1.6cc/rev.)
20VP – .049 cu. in./rev. (0.8cc/rev ) Platform Capacity(All Platforms except
Pump Output (Max.) – Extendible)
10 & 15VP - 1.20 gpm @ 2200 psi 10VP –350 lbs. (160 kg)
20VP – 0.65 gpm @ 2200 psi 15VP –350 lbs. (160 kg)
Hydraulic System Pressure Setting – 20VP –350 lbs. (160 kg)
10 & 15VP - 1000 psi (68.95 bar)
Extendible Platform Capacity
20VP - 2500 psi (172.3 bar)
ANSI (U.S.) – 300 lbs. (136 kg)
Rear Wheel Drive Motors
CSA (CAN.) – 250 lbs. (114 kg)
DriveMotors -
Platform Size
24 Volt DC w/perm. magnet
Right angle gear Standard Platform – 26 in. x 26 in.
(66cm) x (66cm)
Maintenance free sealed gear
Brake shaft and drive shaft,Integral to Motor Machine Height (In Stowed Position)
Parking Brake (must be released for pushing)
VP Series - 79 in. (201cm) height
Table 1-1.
Machine GVW and Wheel Loads
DRIVE WHEEL CASTER PSI PSI
VP MODEL CONFIG. GVW (no load)
(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
3120728 – JLG Lift – 1-1

Base Footprint
1.5 LUBRICATION
VP Series - 32 in. (81cm) width 56 in. (1.42m) length
Hydraulic Oil
Max. Platform Height (mast extended) Hydraulic oils must have anti-wear qualities at least to API
10VP – 10 ft. 6 in.(3.2m) Service Classification GL-3, and sufficient chemical stabil-
ity for mobile hydraulic system service. JLG Industries,
15VP – 15 ft.(4.5m) recommends Mobilfluid 424 hydraulic oil, which has an
20VP – 19 ft. 9 in.(5.9m) SAE viscosity of 10W-30 and a viscosity index of 152.
For cold weather applications, i.e. when temperatures
Platform Working Height (average) remain consistently below +20°F (–7°C) JLG recom-
10VP –16 ft. 6 in.(4.8m) mends using Mobil DTE 13 hydraulic oil.
15VP –21 ft.(6.4m) Aside from JLG recommendations, it is not advisable to
mix oils of different brands or types, as they may not con-
20VP –25 ft. 9 in.(7.6m)
tain the same required additives or be of comparable vis-
Machine Drive Speed (max.)* cosities. If use of hydraulic oil other than Mobilfluid 424 is
desired, contact JLG Industries for proper recommenda-
Platform Lowered - 2 mph (3.22 kph) tions.
Platform Elevated - 0.5 mph (.81 kph) Table 1-2. Hydraulic Oil Operating Range
(reduced by limit switch)
HYDRAULIC SYSTEM OPERATING SAE VISCOSITY
* Variable to maximum with speed cut back. TEMPERATURE RANGE GRADE
Amperage Draw (average) 0° F to +23° F
10W
(-18° C to -5° C)
Lift - 12 amps.Drive - 20 amps. 0° F to +210° F
10W-20, 10W-30
(-18° C to +99° C)
Interlock Switch Operating Conditions
50° F to 210° F
Table 1-4. shown, lists machine response to various inter- 20W-20
(+10° C to +210° C)
lock switch positions.
Lubrication Specifications
1.4 TORQUE REQUIREMENTS
Table 1-3. Lubrication Specifications
When maintenance becomes necessary or a fastener has
loosened, refer to the Torque Chart, Figure 1-3., Torque KEY SPECIFICATIONS
Chart. to determine proper torque value. Multipurpose Grease having a minimum dripping point
of 350° F. Excellent water resistance and adhesive qual-
MPG -
ities, and being of extreme pressure type. (Timken OK
40 pounds minimum.)
Extreme Pressure Gear Lube (oil) meeting API service
EPGL -
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.
Drive Cutout
Mast Elevation (PHP System) Tilt Status Brake Status Controller Response
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
1-2 – JLG Lift – 3120728

1.6 HYDRAULIC PRESSURE ADJUSTMENT
Adjust system pressure so that platform will raise with RETURN

rated capacity in platform. LINE
The following are recommended factory pressure set-
tings; EXTEND
REPLACE ELBOW LINE
VP10,VP15 –1000 psi WITH A T-FITTING
VP20 – 2500 psi TO CONNECT
Turning adjustment screw clockwise increases system PRESSURE GAUGE PRESSURE
HERE GAUGE
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
Figure 1-2. Hydraulic Pressure Gauge Installation.
1.7 CYLINDER SPECIFICATIONS

ADJUSTMENT
SCREW CAP NOTE: All dimensions are given in inches (in), with the met-
ric equivalent, centimeters (cm), given in parenthe-
ses.
Table 1-5. Cylinder Specifications
BORE STROKE ROD DIA.

DESCRIPTION
in./(cm) in./(cm) in./(cm)
Figure 1-1. Hydraulic Pressure Setting - Adjustment
Lift Cylinder - 1.50 54.50 1.125
Screw Located at Base of Pump Motor
10VP (3.81) (138.43) (2.86)
(Remove Hex Head Cap as Shown)
Lift Cylinder - 1.50 54.50 1.125
15VP (3.81) (138.43) (2.86)
Lift Cylinder - 1.50 54.50 1.125
ONLY OPEN HYDRAULIC SYSTEM LINES WITH THE MAST LOW- 20VP (3.81) (138.43) (2.86)
ERED TO RELIEVE PRESSURE IN THE SYSTEM. CAREFULLY
LOOSEN REQUIRED FITTINGS, WEAR SAFETY PROTECTION
EQUIPMENT WHEN WORKING WITH HYDRAULIC SYSTEMS. 1.8 SERIAL NUMBER LOCATION
For machine identification, a serial number plate is affixed
Connect pressure gauge as shown in Figure 1-2., Hydrau-
to the machine. The plate is located on the back of the
lic Pressure Gauge Installation.
mast, just above the mast support bracket.
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.
3120728 – JLG Lift – 1-3

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

2
3
4, 5
Figure 1-4. Lubrication Chart.
Table 1-6.Lubrication Intervals for Various Components
INTERVAL HOURS
NO/TYPE 3 6 1 2
ITEM COMPONTENT LUBE/METHOD 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.
Drive Wheel
2
Bearings
4 - Grease Fittings MPG- Pressure Gun ✔
Drive Wheel Change only when serviced
3 2 - Gear Box Gear Oil
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 ✔
Chain Lube - Brush or
6 Mast Chains * 2 - Per Section
Spray ✔ Inspect, lubricate if dry or rusting.
* 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.
3120728 – JLG Lift – 1-5

1-6 – JLG Lift – 3120728

SECTION 2. SERVICE PROCEDURES
selves. As soon as a line or component is disconnected,

2.1 GENERAL cap or cover all openings to prevent entry of foreign mat-
This section provides general information to assist in the ter.
performance of maintenance on the personnel lift. Clean and inspect all parts during servicing or mainte-
Descriptions, techniques and specific procedures are nance, and assure that all passages and openings are
designed to provide the safest and most efficient mainte- unobstructed. Cover all parts to keep them clean. Be sure
nance for use by personnel responsible for ensuring the all parts are clean before they are installed. New parts
correct installation and operation of machine components should remain in their containers until they are ready to be
and systems. used.
Components Removal and Installation

WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES Use adjustable lifting devices, whenever possible, if
CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE mechanical assistance is required. All slings (chains,
NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND cables, etc.) should be parallel to each other and as near
TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK perpendicular as possible to top of part being lifted.
IS RESUMED.
Should it be necessary to remove a component on an
angle, keep in mind that the capacity of an eyebolt or sim-
ilar bracket lessens, as the angle between the supporting
2.2 SERVICING AND MAINTENANCE
structure and the component becomes less than 90
GUIDELINES degrees.
If a part resists removal, check to see whether all nuts,
General
bolts, cables, brackets, wiring, etc., have been removed
The following information is provided to assist you in the and that no adjacent parts are interfering.
use and application of servicing and maintenance proce-
dures contained in this chapter. Component Disassembly and Reassembly
When disassembling or reassembling a component, com-
Safety and Workmanship
plete the procedural steps in sequence. Do not partially
Your safety, and that of others, is the first consideration disassemble or assemble one part, then start on another.
when engaging in the maintenance of equipment. Always Always recheck your work to assure that nothing has been
be conscious of component weight. Never attempt to overlooked. Do not make any adjustments, other than
move heavy parts without the aid of a mechanical device. those recommended, without obtaining proper approval.
Do not allow heavy objects to rest in an unstable position.
When raising a portion of the equipment, ensure that ade- Pressure-Fit Parts
quate support is provided.
When assembling pressure-fit parts, use an “anti-seize” or
molybdenum disulfide base compound to lubricate the
mating surface.
NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT-
FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT Bearings
BY BLOCKING OR OVERHEAD SLING.
When a bearing is removed, cover it to keep out dirt and
Cleanliness abrasives. Clean bearings in nonflammable cleaning sol-
vent and allow to drip dry. Compressed air can be used
The most important single item in preserving the long ser- but do not spin the bearing.
vice life of a machine is to keep dirt and foreign materials
Discard bearings if the races and balls (or rollers) are pit-
out of the vital components. Precautions have been taken
ted, scored, or burned.
to safeguard against this. Shields, covers, seals, and fil-
ters are provided to keep the wheel bearings, mast sec- If bearing is found to be serviceable, apply a light coat of
tions and oil supply clean; however, these items must be oil and wrap it in clean (waxed) paper. Do not unwrap
maintained on a scheduled basis in order to function reusable or new bearings until they are ready to install.
properly. Lubricate new or used serviceable bearings before instal-
At any time when oil lines are disconnected, clear adja- lation. When pressing a bearing into a retainer or bore,
cent areas as well as the openings and fittings them-
3120728 – JLG Lift – 2-1

apply pressure to the outer race. If the bearing is to be Mast Chain Inspection Procedure
installed on a shaft, apply pressure to the inner race.
Gaskets
MAST CHAINS TO BE INSPECTED AND LUBRICATED EVERY
Check that holes in gaskets align with openings in the THREE MONTHS.
mating parts. If it becomes necessary to hand-fabricate a
gasket, use gasket material or stock of equivalent material Inspect mast chains for the following conditions:
and thickness. Be sure to cut holes in the right location, as Wear: Always inspect that segment of chain that operates
blank gaskets can cause serious system damage. over a sheave. As the chain flexes over the sheaves, joints
and plate edges very gradually wear. Chain “stretch” can
Bolt Usage and Torque Application be measured using a manufacturers wear scale or steel
tape. When chains have elongated 3% they must be
Use bolts of proper length. A bolt which is too long will removed and replaced. Refer to Table 2-1 for proper chain
bottom before the head is tight against its related part. If a specifications and allowable stretch tolerances. Peening
bolt is too short, there will not be enough thread area to and wear of chain plate edges are caused by sliding over
engage and hold the part properly. When replacing bolts, a chain worn contact face of a sheave, or unusually heavy
use only those having the same specifications of the origi- loads. All of the above require replacement of the chain
nal, or one which is equivalent. and correction of the cause. Chain side wear, noticeable
Unless specific torque requirements are given within the when pin heads and outside plates show a definite wear
text, standard torque values should be used on heat- pattern, is caused by misalignment of the sheave/chain
treated bolts, studs, and steel nuts, in accordance with anchors and must be corrected promptly. Do not repair
recommended shop practices. (See Figure 1-1.) chains; if a section of chain is damaged, replace the entire
chain set.
Hydraulic Lines and Electrical Wiring Rust and Corrosion: Rust and corrosion will cause a
Clearly mark or tag hydraulic lines and electrical wiring, as major reduction in the load carrying capacity of the chain,
well as their receptacles, when disconnecting or removing because these are primary reasons for side plate crack-
them from the unit. This will assure that they are correctly ing. The initial lubrication at the factory is applied in a hot
reinstalled. dip tank to assure full penetration into the joint. Do not
steam clean or degrease chains. At time of chain installa-
Hydraulic System tion, factory lube must be supplemented by a mainte-
nance program to provide a film of oil on the chains at all
Keep the system clean. If evidence of metal or rubber par- times. If chains are corroded, they must be inspected,
ticles is found in the hydraulic system, drain and flush the especially the outside plates, for cracks in-line with the
entire system. pins. If cracks are found, replace the chain; if no cracks
Disassemble and reassemble parts on clean work sur- are discovered, lubricate the chains by dipping in heated
face. Clean all metal parts with non-flammable cleaning oil, and reinstall on the machine. Keep chains lubricated.
solvent. Lubricate components, as required, to aid assem-
Table 2-1. Chain Stretch Tolerance
bly.
Pin to Pin
Lubrication and Servicing Chain Size Allowable Stretch
Measurement
Components and assemblies requiring lubrication and .50" pitch 12" or 24 pitches .24 in./12 in. span
servicing are shown in the Lubrication Chart, (See Figure .625 pitch 15" or 24 pitches .30 in./15 in. span
1-2.). Service applicable components with the amount,
type, and grade of lubricant recommended in this manual,
Fatigue Cracks: Fatigue is a phenomenon that affects
at the specified intervals. When recommended lubricants
most metals, and is the most common cause of chain
are not available, consult your local supplier for an equiva-
plate failures. Fatigue cracks are found through the link
lent that meets or exceeds the specifications listed.
holes, perpendicular (90 degrees) from the pin in-line
position. Inspect chains carefully after long time use and
Batteries heavy loading for this type of crack. If any cracks are dis-
Clean batteries, using a non-metallic brush and a solution covered, replace all chains, as seemingly sound plates
of baking soda and water. Rinse with clean water. After are on the verge of cracking. Fatigue and ultimate
cleaning, thoroughly dry batteries and coat terminals with strength failures on JLG Lifts are incurred as a result of
an anti-corrosion compound. severe abuse as design specs are well within the rated lift-
ing capacity of these chains.
2-2 – JLG Lift – 3120728

Tight Joints: All joints in the leaf chain should flex freely. Inspection should be more frequent as cables approach
On leaf chain, tight joints are usually caused by rust/corro- the end of their useful lives.
sion, or the inside plates “walking” off the bushing. Limber Only the surface wires of the cable require inspection, do
up rusty/corroded chains (after inspecting care fully) with not attempt to open the cable. Any deterioration resulting
a heavy application of oil (preferably a hot oil dip). Tap in any loss of original strength, such as described below,
inside “walking” plates inward; if “walking” persists, shall be noted, and then a determination made if further
replace the chain. This type of problem is accelerated by use would constitute a hazard.
poor lubrication maintenance practice, and most tight
Mast cables must be replaced after machine has been in
joint chains have been operated with little or no lubrica-
service for five (5) years, regardless of cable condition, or
tion. Tight joints on leaf chain are generally caused by:
sooner if conditions dictate.
a. Bent pins or plates.
Conditions such as the following shall be sufficient reason
b. Rusty joints. for questioning continual use of the [cable] or increasing
c. Peened plate edges. the frequency of inspection:
Oil rusty chains, and replace chains with bent or peened 1. In running ropes, six randomly distributed broken
chain components. Keep chains lubricated. wires in one lay or three broken wires in one strand
Protruding or Turned Pins: Chains operating with inade- in one lay.
quate lube generate tremendous friction between the pin 2. One outer wire broken at the point of contact with
and plates (pin and bushing on leaf chain). In extreme the core of the rope which has worked its way out of
cases, this frictional torque can actually turn the pins in the rope structure and protrudes or loops out from
the outside press-fit plates. Inspect for turned pins, which the rope structure. Additional inspection of this sec-
can be easily spotted as the “V” flats on the pin heads are tion is required.
no longer in line. Replace all chains showing evidence of
3. Wear of one-third the original diameter of outside
turned or protruding pins. Keep chains lubricated.
individual wires.
Chain Anchors and Sheaves: An inspection of the chain
must include a close examination of chain anchors and 4. Kinking, crushing, birdcaging or any other damage
sheaves. Check chain anchors for wear breakage and resulting in distortion of the rope structure.
misalignment. Anchors with worn or broken fingers should 5. Evidence of any heat damage from any cause.
be replaced. They should also be adjusted to eliminate 6. Reductions from nominal diameter of more than;
twisting the chain for an even load distribution.
a. 1/64th in. (0.4mm) for diameters up to and
Inspect the sheaves, sheave bearings, sheave grooves
including 5/16th in. (8mm);
and pins for extreme wear, replace as necessary. A worn
sheave can mean several problems, as follows: NOTE: A good indicator of a stretched extend/retract cable
a. Chains too tight. is if the adjusting nuts are bottomed out. If no adjust-
ment remains the cables have stretched and need
b. Sheave bearings/pin bad.
replacement.
c. Bent/misaligned chains.
Also check for cracked, bent, worn, severely corroded, or
Mast Cable Inspection Procedure improperly installed cable ends.
Inspect sheaves, sheave grooves, and sheave pins for
excessive wear, replace as necessary.
MAST CABLES ARE TO BE INSPECTED EVERY THREE MONTHS
OR MORE FREQUENTLY AS DESCRIBED FOLLOWING.
2.3 LUBRICATION INFORMATION
Hydraulic System
WEAR PROTECTIVE GLOVES TO PROTECT HANDS WHEN HAN-
The primary enemy of a hydraulic system is contamina-
DLING CABLE.
tion. Contaminants enter the system by various means,
e.g., using inadequate hydraulic oil, allowing moisture,
The periodic inspection shall cover the entire length of the
grease, filings, sealing components, sand, etc., to enter
cable. The inspection frequency shall be based on such
when performing maintenance, or by permitting the pump
factors as expected cable life as determined by experi-
to cavitate due to insufficient system warm-up or leaks in
ence on the particular application or similar installations,
the pump supply.
severity of environment, percentage of capacity lifts, fre-
quency rates of operation, and exposure to shock loads. The design and manufacturing tolerances of the compo-
nent working parts are very close, therefore, even the
smallest amount of dirt or foreign matter entering a system
3120728 – JLG Lift – 2-3

can cause wear or damage to the components and gener-

ally results in faulty operation. Every precaution must be 2.4 POSITIONING LIFT FOR ACCESS TO
taken to keep hydraulic oil clean, including reserve oil in COMPONENTS LOCATED UNDER THE
storage. BASE FRAME
Cloudy oils indicate a high moisture content which per- Access to the underside of the VP lift can be obtained by
mits organic growth, resulting in oxidation or corrosion. If lifting the machine with a fork lift truck, using the fork lift
this condition occurs, the system must be drained, pockets in the base frame.
flushed, and refilled with clean oil.
It is not advisable to mix oils of different brands or types, Lifting with a Fork Truck (See Figure 2-1.)
as they may not contain the same required additives or be 1. Choose a fork lift truck capable of safely handling
of comparable viscosities. Good grade mineral oils, with the full weight of the machine.
viscosities suited to the ambient temperatures in which
the machine is operating, are recommended for use. 2. Locate work area on a firm, level surface.
NOTE: Metal particles may appear in the oil of new

machines due to the wear-in of meshing compo- KEEP MACHINE LEVEL OR SLIGHTLY TILTED TOWARD FORKLIFT
nents. TRUCK WHEN LIFTING TO PREVENT MACHINE FROM SLIDING
OFF LIFTING TINES.
Hydraulic Oil
For best performance, JLG recommends the use of ISO- 3. When lifting with a fork truck, lift only using the fork
Vg grade 32, 46 oil with a viscosity range between 15-250 lift-truck pockets running the length of the machine’s
SUS at 100 degrees F (32-54 cST at 40 degrees C). Refer base frame from rear to front.
to Section 1-5 of this Service Manual for recommended 4. After lifting machine to desired work height, place
hydraulic oils. support stands under the machine. The support
stands must reach from the floor to the bottom of the
Changing Hydraulic Oil machine and be capable of safely handling the
weight of the machine.
Use of any of the recommended hydraulic oils eliminates
the need for changing the oil on a regular basis. If it is nec-
essary 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 syn-
thetic 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 LIFT USING ONLY THE
FORK LIFT POCKETS
another, be sure to clean all possible contaminants from RUNNING THE LENGTH
the service container. OF THE BASE FRAME
While the unit is shut down, a good preventive mainte-
nance 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. PLACE
SUPPORT
STAND
Lubrication Specifications BETWEEN
MACHINE
Specified lubricants, as recommended by the component AND
FLOOR
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 evalua-
tion. Refer to Table 1-3 in this Service Manual for an expla-
nation of the lubricant key designations appearing in the Figure 2-1. Accessing Machine Underside
Lubrication Chart. Components by Lifting with a Fork Truck.
2-4 – JLG Lift – 3120728

Checking Clutch - Torque Setting (ft. lb.)

2.5 DRIVE MOTOR COMPONENT SERVICE
PROCEDURES NOTE: Check that the machines brakes are engaged before
applying torque to the rear drive wheels.
Torque Limiting Clutch Maintenance
1. Remove the drive wheels from the drive axles.
VP Series machines are equipped with a torque limiting
2. Select a torque wrench capable of setting a torque
clutch coupling on each drive axle. The clutch is mounted
of at least 185 ft. lb. Insert special tool (P/N-
inline on the drive axle between the drive wheel and the
0080229) into a 3/4" socket on the torque wrench.
drive motor gear box. The clutch is designed to slip at a
pre-set torque if the machines rear wheels are over-driven 3. Slide the tool onto the end of the drive axle aligning
while the machine is being towed, pushed or forklifted, the key on the axle shaft (install key on axle, if nec-
thus preventing damage to the drive gear box. Although essary), with key slot in the tool. (See Figure 2-2.)
factory pre-set, the clutch assembly and torque should be 4. Turn the torque wrench and note the torque setting
checked at the following interval: when the torque limiting clutch releases. The torque
• Every 3 months. (slip) setting should be set at 185 ft. lb. Check both
rear drive axles.
Visual Inspection and Limiting Torque
NOTE: The allowable breaking torque for the torque limiting
Checking Procedure clutch can be set as much as 35 ft. lb. less than the
1. Locate the machine on a firm level surface. 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

KEEP MACHINE LEVEL OR SLIGHTLY TILTED TOWARD FORKLIFT lower machine, IF NOT, see the following note.
TRUCK WHEN LIFTING TO PREVENT MACHINE FROM SLIDING
NOTE: If torque setting is outside the allowable range of
OFF LIFTING TINES.
specifications, the torque limiting clutch will need
adjustment. See Torque Limiting Clutch Adjustment
2. Carefully raise the lift to gain access to the under-
following.
side of the base frame. Refer to Section 2.4, "Posi-
tioning Lift For Access to Components Located
Under the Base Frame".
SERVICE TOOL
3. Locate the clutch assembly on each rear drive axle
P/N-0080229
and check for the following;
(REQUIRES A 1-3/4” SOCKET)
a. Check the coupling chains for any loose or miss-
ing parts, i.e. pins, links, etc., replace if neces-
sary.
b. Check that the allen-head set screws on the
(large) clutch adjusting nut are in place and
secure. Tighten or replace if necessary. TORQUE
c. Check for any debris wedged in or wrapped LIMITING
CLUTCH
around the clutch coupling chains and axle
LOCATION
shafts. Remove debris and clean area if neces-
sary.
Figure 2-2. Check Torque Limit Clutch -

Torque Setting.
3120728 – JLG Lift – 2-5

Torque Limiting Clutch Adjustment Drive Motor Brake Adjustment/Removal
NOTE: The large adjusting nut on the side of the clutch (See Figure 2-4. & Figure 2-5.)
assembly is a standard type thread. Mounted onto the front of each drive motor housing is a
If the torque (slip) setting of the clutch assembly is brake assembly. The brakes are normally ENGAGED
under spec (by more than 35 ft. lb.), the large adjust- (brakes on) when the machine is parked and are
ing nut must be (tightened) turned clockwise to RELEASED electrically (brakes off) under normal driving
increase the torque setting. conditions, when the joystick is enabled and pushed in
If the torque (slip) setting is over spec (over 185 ft. any direction. The brakes can also be RELEASED manu-
lb.) the large adjusting nut must be (loosened), ally using the manual brake release lever mounted on the
turned counter-clockwise to decrease the torque set- side of the mast.
ting.
NOTE: The brakes are intended only as parking brakes to
keep the machine from moving while at rest. The
1. Loosen the two (2) adjusting nut setscrews located
brakes are not used to stop the machine during driv-
on the large adjusting nut on the clutch assembly.
ing operations, this braking is controlled by the drive
(See Figure 2-3.)
motors themselves. Under normal driving conditions,
2. Hold the drive axle steady using service tool (P/N- once released the brakes are not engaged again
0080229) and the torque wrench used to check the until the machine comes to a complete stop.
torque setting.
3. Depending on how far off the original torque setting
was (see note at beginning of this procedure), MANUAL MAGNETIC
tighten or loosen the adjusting nut accordingly, then BRAKE COIL
RELEASE HOUSING
recheck the (slip) torque setting. ARM
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.
LIMIT
(MICRO)
SWITCH
MOUNTING
PLATE
ARMATURE FRICTION
ADJUSTING NUT PLATE BRAKE
DISK
SET SCREWS
TORQUE LIMIT
CLUTCH
ADJUSTING NUT
SPRINGS
SHIM WASHERS
(AS REQUIRED)
SPACER
Figure 2-3. Torque Limit Clutch -

Adjustment Components. Figure 2-4. Brake Assembly Components
2-6 – JLG Lift – 3120728

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
ARMATURE FRICTION
MANUAL MANUAL
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.) 3. With the brakes ENGAGED measure the air gap
When the magnetic coil is not energized (brake on), the between the armature plate and the magnetic coil
armature plate is pushed away from the magnetic coil sur- housing. The correct setting should be .006", how-
face by heavy springs internally mounted in the magnetic ever the brakes will operate properly if the measure-
coil housing. This pressure forces the armature plate ment is a minimum of .004" and a maximum of .010".
against the friction brake disk holding it tight between the (See Figure 2-5.)
armature plate and the mounting plate. The brake is not 4. If the air gap falls outside the maximum allowable
released until either the magnetic coil is energized pulling setting of .010" the friction disk has worn. To correct
the armature plate away from the friction brake disk or the this replace the disk with a new one.
brake is manually released using the manual brake 5. It the air gap is below the minimum allowable setting
release handle. of .004", recheck the areas between the magnetic
A correctly adjusted brake will ideally have a measurment coil housing, armature plate, friction disk and
of approximately .006" (but will operate normally at .004" to mounting plate for debris. Clean as neccessary. Also
.010") between the armature plate and magnetic coil check that the manual release arm screws are not
housing surface when the brakes are ENGAGED (brakes tightened to tight.
on).
Never allow any type of lubricant (oil, grease, hydraulic Manual Release Arm - Screw Adjustment
fluid, etc.) to come in contact with the brake friction disk or
it’s contacting surfaces. Also if the brake becomes NOTE: Always check the armature plate gap setting is within
clogged with debris or dirt the brake may not release spec before attempting to adjust the manual release
properly. arm screw adjustment.
1. With the brakes ENGAGED (brakes on) the air gap

Checking/Adjusting Armature Plate Gap Setting under the head of the manual release arm screw to
1. First inspect that all parts of the brake assembly are the surface of the armature plate should be set at
tight and secure. Tighten as necessary. .020". Adjust using the locknut on the release arm
end of the screw.
2. Inspect the brake for any debris which may be
lodged in the air gap between the armature plate 2. With the brakes electrically RELEASED (brakes off)
and magnetic coil when the brakes are ENGAGED the air gap under the screw head increases to
(brakes on); on either side of the friction disk when approximately .026" due to the armature plate move-
the brake is RELEASED (brakes off); or any dirt or ment towards the magnetic coil, releasing the fric-
debris lodged between the manual release arm and tion brake disk. When the brakes are RELEASED
the magnetic coil housing. Clean and remove debris (brakes off) manually the screw head pulls in against
as necessary. the armature plate releasing the friction brake disk.
3120728 – JLG Lift – 2-7

Brake Assembly Removal 6. Reconnect the manual release brake cable to the
manual release lever (Y shaped lever) and adjust
1. Lift the machine to gain access to the underside
cable so brakes are released when manual release
(See Section 2-4., "Positioning Lift For Access To
lever is in the down position. (See Figure 2-6.)
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. MANUAL TO MANUAL
RELEASE RELEASE
3. Disconnect the manual brake release cable from the BRAKE
BRAKE
manual brake release arm attached to the brake CABLE HANDLE
assembly. MOUNTED
ON SIDE OF
4. Lower machine back down to ground level.
MAST
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.
SET MANUAL BRAKES
BRAKE RELEASE ARE RELEASED
NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT- HANDLE TO WHEN CABLE
FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT FREE WHEELING PULLS LEVER
BY BLOCKING OR OVERHEAD SLING. AND ADJUST HERE IN THIS DIRECTION
UNTIL BRAKE DISK
6. Remove the four (4) hex cap screws securing the IS COMPLETELY
brake assembly to the end of the drive motor and RELEASED
remove the brake assembly from the end of the
drive motor. Figure 2-6. Manual Release Brake Cable Adjustment.
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 slid-
ing 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 assem-
bly 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 wir-
ing connectors to their respective wiring harness
connectors.
2-8 – JLG Lift – 3120728

Drive Motor Removal 5. Disconnect the wiring connectors to the drive motor
and the brake assembly on either or both sides,
(See Figure 2-7.) depending on which drive assembly(ies) is being
The VP drive motors consist of three sections, the gear removed.
box atttached to the rear of the drive motor, the electric 6. Disconnect the manual release brake cable from the
drive motor itself, and the brake assembly mounded at the brake assembly arm on either or both drive motors if
front of the drive motor. Each drive motor is mounted inde- removing the complete drive assembly.
pendently of the other on a completely removable drive
assembly weldment at the back of the machine. NOTE: If removing each drive motor seperately continue to
Step 7. If removing the complete drive assembly
1. Disconnect the positive battery terminal from the left
with both motors attached go to Step 11.
side battery.
2. Remove the rear plate weldment from the machine, 7. Remove the one (1) bolt, nut, and two (2) washers
(plate with the tie down lug) and set aside. Three (3) from the front of the drive motor mounting plate.
bolts hold the top of the rear plate weldment to the 8. While holding the drive motor in place, remove the
base frame, four (4) bolts attach it to the motor cover remaining two (2) bolts with washers holding the
weldment (located under machine) at the back and drive motor mounting plate to the drive motor
on the sides. assembly weldment.
3. Carefully raise the lift to gain access to the under- 9. Slide the drive motor and torque limiting clutch
side of the base frame. Refer to Section 2.4, "Posi- assembly towards the center of the machine, sliding
tioning Lift For Access to Components Located the torque limiting clutch off the outer drive shaft.
Under the Base Frame".
10. Move drive motor assembly and torque limiting
4. Remove the remaining two (2) bolts attaching the clutch to a suitable work bench for disassembly.
motor cover to the base frame and set it aside.
DRIVE MOTOR
DRIVE MOTOR/ ASSEMBLY
DRIVE MOTOR
BRAKE WIRING WELDMENT
ASSEMBLY WELDMENT
CONNECTORS ATTACH BOLTS
(2 EACH INSIDE FORK LIFT POCKET)
DRIVE MOTOR MOUNT
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.
3120728 – JLG Lift – 2-9

Gear Box Disassembly/Assembly

IF REMOVING THE COMPLETE DRIVE ASSEMBLY, IT WEIGHS (See Figure 2-8.)
APPROXIMATELY XX LB. AND WILL REQUIRE ASSISTANCE TO The drive motor gear box is mounted on the rear of each
LOWER. PREFERABLY USE A MOVABLE TRANSMISSSION OR drive motor transferring power from the electric drive
OTHER HYDRAULIC JACK TO CAREFULLY LOWER ASSEMBLY motor to the rear drive wheels. It is a right angle worm
FROM UNDER MACHINE. gear type box with a 50:1 reduction drive ratio. The inter-
nal gears and bearings of the gear box are lubricated by
11. Carefully remove the four (4) nuts and washers 175cc’s of gear oil in an unvented aluminum alloy hous-
(outer most holes on the drive assembly weldment) ing. Early VP machines included a oil drain plug on the
from the carriage bolts attaching the drive motor rear surface of the gear box housing, later model
assembly to the base frame. Be aware of the weight machines do not. The following procedures disassemble
of the assembly before completely removing the fas- and assemble the gear box housing internal components.
teners, see the CAUTION above.
12. Lower the drive assembly and place on a suitable Gear Box Disassembly (See Figure 2-8.)
work surface. 1. Remove the drive motor/gear box/brake assembly
from the machine using the procedure outlined pre-
viously in this section of the manual.
Figure 2-8. Drive Motor Gear Box Assembly.
2-10 – JLG Lift – 3120728

NOTE: The gear oil can be drained out when the side cover Gear/Pinion Shaft Assembly (See Figure 2-9.)
is removed in the next step. Remove the side cover
1. Locate the pinion gear/shaft, place the key for the
from the gear box with the drive shaft side pointing
(brass) worm gear into the slot on the gear shaft.
down, then tilt drive motor/gear box assembly to
drain the oil into a suitable container. 2. Press the (brass) worm gear onto the pinion shaft
and align the keyway in the (brass) worm gear with
2. Remove the four (4) hex cap screws securing the the key on the pinion shaft. Press the (brass) worm
side cover to the gear box housing, and remove the gear onto the shaft until it bottoms out against the
side cover and rubber seal ring. (Note: Early model pinion gear teeth.
machines did not have the rubber seal ring and were
sealed with sealant only.) Be careful not to scratch or NOTE: Press bearings onto the shaft pressing only against
gouge the mating surfaces between the cover and the bearing inner race. Do not press against the
the gear box housing. This area is sealed by the rub- outer race or damage could occur to the bearing.
ber ring/sealant and may leak oil if damaged.
3. Press the small (32mm) bearings onto the ends of
3. Remove the wave washers from atop the large and the pinion shaft. The inner race of the bearing on the
small bearings and lay inside their respective holes pinion gear side can be bottomed out against the
in the side cover. pinion gear. Do not press the bearing on the (brass)
4. Using a suitable catch container, drain the gear oil worm gear side of the shaft in tight against the
from the gear box housing. (brass) worm gear. This bearing must be flush with
the end of the shaft on the outside, yet have clear-
5. Remove the drive shaft assembly from the housing. ance from the (brass) worm gear on the inside, so it
Place the drive motor/gear box assembly on a can rotate freely.
hydraulic press with the open side of the gear box
housing facing down. Support the gear box housing
Drive Shaft Assembly (See Figure 2-10.)
surface but do not block the free travel of the drive
gear and bearings, on the drive shaft or the pinion 1. Slide the (housing side), 42mm x 25mm x 12mm
gear assembly. (thinner) bearing onto the long end of the drive shaft.
Press the bearing inner race until it bottoms against
6. With the open surface of the housing properly sup-
the shaft shoulder between the drive gear and the
ported, carefully press the drive shaft down through
bearing.
until it is free of the housing. When the drive shaft
assembly is free, slide it completely out of the hous- 2. Slide the narrow spacer onto the drive gear end of
ing. the shaft and press the (cover side) 42mm x 20mm x
14mm (wider) bearing onto the drive shaft until it
7. To remove the large (47mm) (cover side) bearing
bottoms against the spacer. This bearing should be
and (housing side) bearing from the drive shaft, use
flush with the end of the drive shaft.
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 SIDE PROFILE
gear (brass) and pinion assembly, use a suitable WORM
hydrauic press and press the bearing(s) off the gear GEAR LEAVE
(BRASS) GAP HERE
and pinion shaft.
PINION GEAR/
9. To remove the (brass) worm gear from the pinion 32mm SHAFT 32mm
assembly, use a suitable hydraulic press and press BEARING BEARING
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 nec-
essary.
WORM GEAR
KEY
Figure 2-9. Gear/Pinion Shaft Assembly.
3120728 – JLG Lift – 2-11

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
1. If necessary, install a new drive shaft lip seal into the
next step.
drive shaft hole in the gear box housing before
assembling the drive shaft gear set into the gear 6. With the gear box still positoned with the open cover
box. Install the seal so it is even with the bottom of side up, fill the gear box with six (6) ounces (U.S.)
the chamfer in the drive shaft hole on the outside of (175cc’s) of good quality worm gear oil (Specifica-
the housing and flush with the bearing seat on the tion - SAE 90 weight - AGMA#5 - EP Compounded).
inside of the housing. When pouring the gear oil, wet the gears and bear-
ings with the oil.
2. Lube the drive shaft seal with a thin film of oil before
sliding the drive shaft over the seal. 7. Wet with gear oil and place the large wave washer
on the end of the drive shaft bearing and the small
3. Position the gear box with open cover side up, allow
wave washer on the end of the gear and pinion bear-
space under the gear box for the drive shaft to
ing.
extend through without obstruction.
8. Clean the mating surfaces of the side cover and the
4. Hold the gear and pinion, and drive shaft assembies
gear box and check that the cover dow guide pins
together with the pinion gear and the ring gear on
are properly installed in the cover.
the drive shaft meshing. Now carefully slide these
assemblies into the gear box housing sliding the 9. On older model gear boxes apply sealant to the
drive shaft through the drive shaft lip seal. cover mating surface on the gear box. On newer
model gear boxes insert the rubber seal into the
NOTE: While assembling the gear assemblies into the gear groove in the cover.
box housing, be careful with the drive shaft seal and
the softer brass worm gear and brass drive worm 10. Using the cover dow guide pins, place the cover
gear from the drive motor. onto the gear box housing.
11. Secure using the four (4) hex cap screws, torque
5. Continue to drop the gear assemblies into the gear screws evenly to 90 in. lbs.
box, align the bearings with the bearing seats in the
housing on both assemblies. Drop the gear and pin- 12. Install the drive motor back onto the machine.
ion (smaller) bearing into it’s seat first, while wiggling
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.
2-12 – JLG Lift – 3120728

Drive Motor Brush Replacement Brush Removal (See Figure 2-12.)

Removal of the brushes also requires the removal of the
Each drive motor contains two (2) brushes, the brushes
drive motor(s) from the machine, see procedure
are located under the two (2) large round slotted brush
described earlier in this section for instructions to remove
caps on the front end of each drive motor.
the drive motors. If not already done, disconnect the posi-
tive (+) battery cable from the left side battery before pro-
ceding.
BRUSH CAP
1. Unscrew the large round brush caps from each side
of the drive motor, use as large a screw driver as
possible.
DRIVE MOTOR
2. The brushes are retained by constant-force, roll-type
springs. To remove the springs, press inward on the
end of the spring retaining bracket using the tip of a
BRUSH pair of long nose pliers or other appropriate tool.
ASSEMBLIES The brushes should pop out, if not, they can be
LOCATED removed by pulling outward on the spring brackets
INSIDE with a pair of long nose pliers after the inside ends
HERE are unhooked.
3. Now pull the brush out of the brush box by it’s wire
(pig-tail).
BRUSH CAP
NOTE: If only inspecting the brushes, it is not necessary to
BRAKE
remove the pig-tail terminal from it’s connection to
ASSEMBLY the brush box.
4. Loosen the the screw securing the pig-tail terminal

end to the brush box and slide the terminal end out
Figure 2-11. Drive Motor Brush Location.
from under the screw completely removing the
brush from the drive motor.
DISCONNECT THE POWER LEADS FROM THE POWER SOURCE SPRING BRACKET
BEFORE INSPECTING OR REPLACING BRUSHES. BRUSH BOX
SPRING
Brush Cleaning and Inspection BRUSH BOX
BRACKET
Brush wear rate varies depending on the individual appli- INSULATOR
HOOKS
cation’s duty cycle, and should be inspected at frequent
intervals to determine an appropriate inspection schedule.
Brushes should be replaced before they are less than .375
in. (9.5mm) in length. Carbon dust accumulation should
be removed periodically. If the end shield has been BRUSH
removed from the drive, a clean, dry, non-linting cloth can
be used for cleaning. DO NOT use solvents as they my
damage non-metallic parts and adversely affect subse-
quent brush commutation.
SPRING BRACKET
PIGTAIL WIRE
Figure 2-12. Drive Motor Brush Installation.
3120728 – JLG Lift – 2-13

Brush Reassembly (See Figure 2-12.)
MAKE CERTAIN THAT THE GROUND WIRE IS SECURELY RECON-

NECTED TO THE GROUND TERMINAL IF REMOVED. LEADS, CORRECT
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

INCORRECT
screw on the brush box in the same manner as the
old brush that was removed and tighten the screw.
2. Slide the body of the brush into the brush box, be Figure 2-13. Correct/Incorrect Brush Spring Bracket
Positions.
certain that the wire (pig-tail) is aligned with the slot
in the base of the brush box so that it can "feed" into
the brush box slot as the brush wears down.
NOTE: The pig-tail wire should be formed to rest against the

nonmetallic insulator. It must be spaced from any THE SPRING BRACKET MUST BE ALSO LIE COMPLETELY INSIDE
metallic surfaces other than the brush box by a mini- THE BRUSH BOX AND NOT OUT OVER THE EDGE. THE ROLL
mum of .125 in. (3mm). END OF THE SPRING MUST BE CENTERED ON THE TOP OF THE
BRUSH. (SEE FIGURE 2-13.)
3. Now install the brush retaining spring bracket. Grasp
the tip of the spring bracket such that the roll-type 8. Also apply slight pressure by pulling up on the
spring will be on the "brush side" of the brush box, spring bracket to be certain it is hooked securely
and resting on top of the brush when the brush around the brush box wall at the bottom of the brush
spring is completely installed. box.
4. Push the spring bracket slowly into it’s slot while let- 9. Screw the brush caps back into the end shield using
ting it’s two attaching hooks slide on the wall of the the largest possible screwdriver.
brush box. 10. Reinstall the drive motor(s) to the machine and
5. Stop, but do not release the spring bracket when it’s reconnect the power source.
hooks slip around the edge of the brush box.
6. While still grasping the spring bracket with the pliers,
slowly bring the spring back out of the brush box NEW BRUSHES MAY BE SEATED BY RUNNING THE DRIVE
until the hooks latch around the edge of the brush MOTOR AT NO LOAD. PROPER SEATING IS REQUIRED FOR
box. LOWEST BRUSH NOISE LEVEL.
7. Now release the spring bracket and check that it is
lying flat against the brush box wall. If it is "cocked" it
is improperly seated and will have to be reinstalled.
2-14 – JLG Lift – 3120728

3. Turn on power to the platform control, nine (9) LED’s

2.6 PLATFORM CONTROL BOX SERVICE will flash rapidly on the platform control touch pad.
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. Move the joystick to the maximum forward position The joystick calibration is now complete.
and hold it there.
NOTE: Joystick will be held in the maximum forward position

until asked to release it in Step 5.
JOYSTICK
JOYSTICK ASSEMBLY ASSEMBLY
S/N- 02996 TO PRESENT PRIOR TO
(INCLUDES DRIVE ENABLE BUTTON) S/N- 02996
(USED THE
TOUCH PAD
TOUCH PAD ENABLE
SWITCH SWITCH)
UPPER
HOUSING
INTREGRATED
CIRCUIT
BOARD
LOWER
SPEED
HOUSING
CONTROL
KNOB
EMERGENCY
STOP SWITCH
BUTTON
SPEED
CONTROL
SWITCH
EMERGENCY
STOP SWITCH
Figure 2-14. Platform Control Box Assembly (Exploded View)
3120728 – JLG Lift – 2-15

Platform Control Box Disassembly Lower Half Of Housing Removal

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.
DO NOT ATTEMPT TO DISASSEMBLE THE PLATFORM CONTROL
BOX IF MACHINE IS STILL UNDER WARRANTY. OPENING THE 2. Lay screws and lower housing aside.
PLATFORM CONTROL BOX WHILE THE MACHINE IS UNDER
WARRANTY WILL VOID THE WARRANTY. IF UNDER WARRANTY
REQUEST A REPLACEMENT BOX FROM THE FACTORY.
The VP Series platform control box allows for replacement

of five (5) components internal to the box.
• Controller Integrated Circuit Board

• Joystick Assembly
• Emergency Stop Switch
• Speed Control Switch
• Touch Pad Switch Assembly
Except for the touch pad switch assembly, which plugs

into the circuit board, replacement of each component
requires unsoldering, then soldering each replacement
components’ wiring to the controller’s integrated circuit
board. Due to the small contact area when connecting
each wire to the circuit board this soldering requires pre-
cise temperatures and neatness of the soldered point Joystick Assembly Removal
itself so as not to destroy the circuit board or cross any of
the circuit paths on the board. NOTE: To completely remove the joystick assembly, its wir-
ing will need to be unsoldered from the intregrated
circuit board.
ELECTROSTATIC DISCHARGE CAN DAMAGE COMPONENTS ON 1. Remove the four (4) screws from the top of the bezel
THE INTEGRATED CIRCUIT BOARD. PLACE THE PLATFORM around the base of the joystick and slide the joystick
CONTROL BOX ON A NON-CONDUCTIVE SURFACE WHEN OPEN- assembly out of the upper housing.
ING THE BOX AND WORKING DIRECTLY WITH THE CIRCUIT
2. Unplug the touchpad switch ribbon connector from
BOARD.
the circuit board connector socket.
Removing Control Box From Platform
1. Turn off all power to the platfom control box.
2. Unhook the wiring harness cable at the quick-dis-
connect coupling. (Early VP models were not
equipped with the quick-disconnect coupling, skip to
Step 4.)
3. Remove the platform control box and box mount to
a suitable work surface.
4. Remove the control box from the control box mount
by removing the four (4) nuts from the studs on the
bottom of the control box.
5. Unplug the wiring harness cable connector on the
back of the lower housing half.
6. Lay control box mount and wiring harness assembly
aside.
2-16 – JLG Lift – 3120728

3. Remove the four (4) screws attaching the circuit Emergency Stop Switch Removal
board to the upper housing.
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 unsolder-

ing component wires DO NOT OVERHEAT BOARD.
4. Position the circuit board and unsolder the wires

from the joystick assembly at the J2, J3 and J7 loca-
tions on the circuit board. (See Figure 2-15.)
NOTE: (VP model joystick assemblies prior to S/N- 02996 2. Position the circuit board and locate the emergency
did not have the drive enable button on the joystick stop switch wires connected at locations J8, J9, J10
knob. Wires from this design were attached in the J3 and J11. Unsolder the four (4) wires to the switch to
location on the circuit board only.) remove the switch from the board. (See Figure 2-15.)
5. With all the joystick wiring unsoldered remove joy-
stick assembly from the control box.
J8 - J9
J10 - J11
EMERGENCY
STOP
SWITCH
(4 WIRES)
J2 - J7
JOYSTICK J3
TOUCHPAD
WIRING JOYSTICK
SWITCH
(2 WIRES) WIRING
CONNECTOR
(Later Models With (5 WIRES)
Enable Button On
SOCKET
Knob Only)
J5
SPEED
CONTROL
SWITCH
(3 WIRES)
Figure 2-15. Platform Control - Circuit Board Component Wiring Connections.
3120728 – JLG Lift – 2-17

3. Remove the reset button part of the emergency stop Touch Pad Switch Removal
switch by unscrewing the collar on the inside end of
1. Unplug the touch pad ribbon cable connector from
the reset button assembly.
the circuit board connector socket. (See Figure 2-
15.)
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. Remove the speed control knob by pulling up on the
knob until it is free of the switch shaft.
2. Loosen and remove the retaining nut and lock
washer from the switch collar and pull the switch out Platform Control Box Assembly
of the housing.
To assemble the components back into the control box
follow the previously outlined disassembly procedure and
reverse the steps for the component being installed. The
following are additional guidelines for assembling each
component.
NOTE: Be careful when soldering component wires to the

circuit board DO NOT OVERHEAT BOARD.
Joystick Installation
1. Use the following illustrations to reattach the wires
from the joystick to the circuit board.
3. Position the circuit board and locate the speed con-

trol switch wires connected at location J5. (See Fig- J3
ure 2-15.) Unsolder the three (3) wires to the switch
to remove the switch from the platform box. YELLOW
CIRCUIT BOARD BLUE
COMPONENT SIDE BLACK
RED
WHITE
WIRES FROM JOYSTICK

CONTROL
2-18 – JLG Lift – 3120728

Speed Control Switch Installation

1. Use the following illustrations to reattach the wires
from the speed control switch to the circuit board.
WIRES WHITE (light gauge)

FROM
JOYSTICK
CONTROL
(Later Model
YELLOW (light guage)
Joystick
w/Drive
CIRCUIT BOARD CIRCUIT BOARD
Enable
COMPONENT SIDE COMPONENT SIDE
on Knob)
ORANGE
WHITE W/ORG
GREEN
J5
2. If damaged replace the gasket between upper hous-
ing surface and the joystick mounting surface before
assembling. WIRES FROM SPEED
CONTROL SWITCH
Emergency Stop Switch Installation
Touch Pad Switch Installation
1. Use the following illustration to reattach the wires
from the emergency stop switch to the circuit board. 1. Thoroughly clean the surface of the upper housing
where the touch pad switch adheres to the upper
housing.
2. Remove all traces of silicone sealant from around
the slot where the ribbon cable connector passes
through the housing.
CIRCUIT
BOARD RED (PIN 21)
COMPONENT BLACK (PIN 13)
SIDE BLACK (PIN 14)
RED (PIN 22)
WIRES FROM
EMERGENCY
STOP SWITCH
2. If damaged replace the gasket between the stop APPLY SILICONE

switch base plate and the upper housing mounting SEALANT HERE
surface. IN THIS SLOT
3. Remove the adhesive backing off the new touch pad

switch, keep this surface clean and free of debris
during assembly.
4. Assemble the new touch pad switch to the upper
housing surface by first sliding the ribbon cable con-
3120728 – JLG Lift – 2-19

nector from the touch pad switch through the slot at

the top of the housing. Before pressing the touch 2.7 BATTERY CHARGER ASSEMBLY AND
pad adhesive side to the upper housing mounting DISASSEMBLY
surface, visually align the touch pad edges with the
edges of the recess in the housing mounting sur- General Information
face.
5. Once the touch pad is installed, on the underside of
the housing apply just enough silicone sealant to fill DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGER
the small slot around the ribbon cable to help seal IF MACHINE IS STILL UNDER WARRANTY. OPENING THE BAT-
the slot and also strengthen the ribbon cable con- TERY CHARGER WHILE THE MACHINE IS UNDER WARRANTY
nection at the touch pad surface. WILL VOID THE CHARGER WARRANTY. IF UNDER WARRANTY
6. Re-install the circuit board and plug the ribbon cable REQUEST A REPLACEMENT CHARGER FROM THE FACTORY.
connector into the circuit board cable socket.
ALSO BE FORE REPL AC ING ANY COMPO NENT, USE TH E
Lower Half Housing Installation CHARGER MANUFACTURERS TROUBLESHOOTING GUIDE
INCLUDED WITH THE MACHINE FOR CHECKING THE INTERNAL
1. Before installing the lower half housing apply a non- AC AND DC CIRCUITS TO DETERMINE WHICH COMPONENT HAS
conductive grease to the square holes of the wiring FAILED. COMPLETE WIRING DIAGRAMS PERTAINING TO YOUR
harness connector socket on the inside of the hous- MODEL CHARGER ARE ALSO INCLUDED IN THE MANUFACTUR-
ing socket. This will help keep out dirt and moisture. ERS CHARGER MANUAL.
The VP Series battery charger allows for replacement of

the following internal components. Consult your Illustrated
Parts Manual for part numbers of these components
which are available from the JLG Parts Department:
WIRING HARNESS
CONNECTOR SOCKET • Transformer
• Printed Circuit Board
• Shunt Assembly
• Interlock Relay
• SCR Rectifier
• AC Circuit Breaker
• DC Circuit Breaker
Replacement and troubleshooting of these components

requires removal of the battery charger from it’s mounting
position on the machine.
Battery Charger Removal

1. Remove the rear cover from the machine.
2. Carefully slide the lower housing onto the upper half 2. Unbolt and lower the MC-1 Controller Box.
of the platform control box assembly until seated
3. Remove the four (4) capscrews securing the charger
completely against the upper housing edges.
to it’s mounting plate.
3. Secure lower half housing to the upper half housing
4. Disconnect the DC wiring from the positive/negative
using the six (6) screws removed during dissassem-
battery terminals and interlock connector from the
bly.
wiring harness.
5. Remove the charger from the machine.
2-20 – JLG Lift – 3120728

Battery Charger Part Replacement Printed Circuit Board Replacement

1. Disconnect the wide wiring connector from the end
Cover Removal
of the circuit board.
1. Remove the eight (8) screws on the sides of the
2. Remove the four (4) screw attaching the card to the
charger cover and remove cover.
front face of the charger chassis.
3. Remove the circuit board.
Shunt Assembly Replacement

1. Carefully remove the screw from each end of the
Transformer Replacement shunt assembly. The white insulator may need to be
restrained to keep it from turning while removing the
1. Disconnect the wiring connecting the the trans- shunt assembly fasteners. Also make note of the
former to other components within the charger position of each washer, nut and wire connector
assembly. when removing for later assembly.
2. Remove the four nuts from the cap screws securing
the transfromer brackets to the base of the charger
chassis.
3. Remove transformer.
3120728 – JLG Lift – 2-21

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 2. Remove the two (2) nuts securing the AC breaker to
to the chassis base. 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. Remove the nut securing the rectifier to the insulated DC Circuit Breaker Replacement
aluminum chassis bracket. 1. Remove the wiring from the DC breaker terminals.
3. Remove the SCR Rectifier. 2. To remove the breaker from the front face of the
charger, on the inside of the charger front face, push
in on the tabs located on the sides of the breaker
assembly and remove the breaker out the front of
the charger.
LOCKING
TABS
2-22 – JLG Lift – 3120728

2.8 HYDRAULIC LIFT CYLINDER -

REMOVAL, INSPECTION AND REBUILD
HYDRAULIC CYLINDERS ARE DESIGNED TO HOLD HYDRAULIC

FLUID UNDER HIGH PRESSURE. BE SURE ALL APPROPRIATE
MEASURES ARE TAKEN TO RELIEVE RESIDUAL PRESSURE IN
THE CYLINDER BEFORE DISCONNECTING LINES.
Lift Cylinder Removal

Removal of the hydraulic lift cylinder without removing the
mast from the machine requires laying the machine on it’s
back (hood side) with the platform end on top.
1. Remove the hood from the rear of the machine.
2. Disconnect and remove the batteries from the AVOID DAMAGE TO SUPPORT
machine, to prevent acid leakage. CONTROLS IN MAST
THIS AREA
3. Seal the vented cap on the hydraulic fluid reservoir
by removing the cap, covering the hole with a few
layers of plastic wrap or equivalent, then install and Figure 2-16. Machine Positioned for Cylinder
tighten the cap over the plastic wrap. Removal.
NOTE: If a quick-change platform is attached to the machine

remove the platform to help reduce the weight of the Cylinder Disassembly
machine during machine lay back.
1. Before disassembling the cylinder, clean away all
4. Use a forklift truck or overhead crane and carefully dirt and foreign substances from openings, particu-
lay the machine on it’s back, place a support under larly the head area.
the mast end. (See Figure 2-16.)
NOTE: Always protect the chrome surface of the cylinder
5. Manually extend the mast assembly approximately rod during assembly and disassembly. Any damage
two (2) feet, to allow access to the sheave wheel- to this surface will require replacement of the rod.
anchor block at the top of mast section-2.
6. Remove the set screw securing the lift cylinder rod 2. Extend the rod until the piston bottoms out against
to the sheave wheel anchor block at the top of mast the cylinder head.
section-2. 3. Compress the head retraining ring enough to allow
7. Under the base assembly remove the four (4) bolts the the cylinder head to be removed.
attaching the PHP bar actuator assembly to the lift 4. Carefully slide the head/rod/piston assembly out of
cylinder mount. Secure the assembly out of the way. the cylinder tube. A gentle tap on the head assembly
8. Carefully disconnect and cap the extend and return may be required to remove the head from the cylin-
lines and fittings from the lift cylinder, drain any der tube.
hydraulic fluid into a container. 5. Place the head/rod/piston assembly on a surface
9. Remove the bolt securing the lift cylinder to the cyl- that will not damage the chrome.
inder mount. 6. Remove the piston locknut and separate the piston
10. Remove the four (4) bolts, washers and nuts attach- from the rod.
ing the cylinder mount to the base frame. Remove 7. Slide the head off the rod from the piston end.
the mount and lay aside.
NOTE: When removing the old seals use only blunt tools, be
11. At the bottom of mast section 2, slide the lift cylinder sure there are no sharp edges that may damage the
assembly out and place on a suitable work surface. seal grooves during removal. Scratching the groove
may cause by-pass.
8. Remove and discard all old seals.
3120728 – JLG Lift – 2-23

Lift Cylinder Component Inspection Cylinder Assembly

Cylinder Rod (See Figure 2-17.)
There should be no scratches or pits deep enough to 1. Rinse the inside of the tube with hydraulic fluid and
catch the fingernail. Pits that go to the base metal are allow to drain. A high-pressure rinse followed by a
unacceptable. Scratches that catch the fingernail but are wipe with a lint-free rag is preferable. Clean all inter-
not to the base metal, less than 0.5 inch long and primarily nal components of any foreign material.
in the circumferential direction are acceptable provided 2. Lubricate the head and all seals with hydraulic fluid
they cannot cut the rod seal. Chrome should be present prior to installation. Install the seal, wiper, o-ring,
over the entire surface of the rod and the lack thereof is back-up ring, and retraining ring to the cylinder
unacceptable. In the event that an unacceptable condition head.
occurs, the rod should be repaired or replaced.
3. Lubricate the piston and all components with
Cylinder Head hydraulic fluid. Install the seal and wear ring to the
piston.
Visually inspect the inside bore for scratches or polishing.
Deep scratches are unacceptable. Polishing indicates NOTE: Re-check that seals are not twisted or pinched and
uneven loading and when this occurs, the bore should be are properly seated.
checked for out-of-roundness. If out-of-roundness exceed
0.007", this is unacceptable. Check the condition of the 4. Place the rod on a clean table. Install the static o-
dynamic seals (wiper, rod seals) looking particulary for ring seal into the groove on the piston end of the
metallic particles embedded in the seal surface. It is nor- rod.
mal to cut the static seal on the retaining ring groove upon 5. Install the head followed by the piston onto the rod
disassembly. Remove the rod seal, static o-ring and noting the proper orientation of each component.
backup and rod wiper. Damage to the seal grooves, par- Torque the piston nut to 175-200 ft. lbs.
ticularly on the sealing surfaces, is unacceptable. In the 6. When the rod assembly is ready to be installed into
event that an unacceptable condition occurs, the head the tube, liberally apply an anti-seize lubricant to the
should be replaced. head outer surface, especially the static seal.
Piston 7. Next dip the entire rod assembly into hydraulic fluid
and stuff this assembly into the tube. Watch the
Visually inspect the outside surface for scratches or pol- seals as they pass over the rod port (if visible) to be
ishing. Deep scratches are unacceptable. Polishing indi- sure they are not nicked or cut.
cates uneven loading and when this occurs, the diameter
should be checked for out-of-roundness. If out-of-round- 8. Install the head until the retaining ring seats in it’s
ness exceeds 0.007", this is unacceptable. Check the con- groove.
dition of the dynamic seals and bearings looking
particularly for metallic particles embedded in the bearing Cylinder Installation
and in the piston seal surface. Remove the seals and
To install the lift cylinder reverse the Lift Cylinder Removal
bearings. Damage to the seal grooves, particularly on the
instructions at the start of this section, however perform
sealing surfaces, is unacceptable. In the event that an
the following additional steps during re-assembly.
unacceptable condition occurs, the piston should be
replaced. 1. Apply Loctite #222 (purple) to the setscrew securing
the lift cylinder rod to the sheave wheel anchor block
Tube Assembly at the top of mast section-2.
Visually inspect the inside bore for scratches and pits. 2. Torque the four (4) cylinder lift mounting bolts to 34
There should be no scratches or pits deep enough to ft. lb.
catch the fingernail. Scratches that catch the fingernail but
are less than 0.5 inch long and primarily in the circumfer-
ential direction are acceptable provided they cannot cut
the piston seal. The roughness of the bore should be
between 10 and 20 µ inches RMS. Significant variation
(greater than 8 µ inches difference) are unacceptable. In
the event that an unacceptable condition occurs, the tube
assembly should be repaired or replaced.
2-24 – JLG Lift – 3120728

RETAINING RING
GROOVE WEAR
RING CYLINDER
HEAD
PISTON
O-RING RETAINING
SEAL
RING
BACKUP
O-RING RING
ROD
SEAL ROD
WIPER
CYLINDER
TUBE
ASSEMBLY
LOCKNUT
(Torque
PISTON
175-200 Ft. Lb.)
WHEN ASSEMBLING
CYLINDER
APPLY ANTI-SEIZE
COMPOUND CYLINDER
HEAD CYLINDER
AROUND THE HEAD
ROD
IN THIS AREA ONLY
Figure 2-17. Lift Cylinder Internal Component Assembly Cross-Section.
3120728 – JLG Lift – 2-25

tions even). Applying silicone spray onto the slide pads

2.9 MAST ASSEMBLY AND DISASSEMBLY and slide pad channels before assembly will help mast
PROCEDURES sections slide easier after slide pads have been properly
The VP Series personnel lift mast sections are contructed shimmed.
of extruded aluminum, protected with an anodized surface
finish. The mast sections are interlocked into each other Mast Disassembly Procedure
when assembled, by internally mounted slide pads at the
top and bottom of each mast section. These slide pads NOTE: Reference to mast sections-3/-4/-5 (platform mount-
run up and down in slide pad channels on each side of ing section) depends on which VP model lift you are
the mast. working on.
Each VP model mast assembly contains a different num- 1. After the mast assembly has been removed from the
ber of mast sections as shown following; machine, lay the mast assembly down on a suitable
work table with the platform mounting section on
Table 2-2. VP Series Mast Component Features top, facing up.
No. of Mast Extend/Retract 2. Remove the sequencing cables and hardware from
Model
Sections Device the sides of the mast assembly. Also remove the
cover from the top of the mast assembly.
10VP 3 Cable
15VP 4 Cable 3. Remove cable adjust nuts from threaded ends of
cable attached to the cable anchor plate on BOT-
20VP 5 Chain & Cable TOM end of mast section-3/-4/-5 (platform mounting
section). Push threaded ends of cable through
Assembly procedures for all mast sections is basically the anchor plate.
same, carefully slide the mast sections together from bot-
4. At the TOP of mast section—3/-4/-5, pull cables out
tom until mast ends are even. (When sliding the mast sec-
and allow to hang loose.
tions together, be careful not to scratch the anodized
surface). Assemble the hardware to the bottom of mast NOTE: When sliding mast sections apart, be careful not to
section first, slide this section out the top of previous sec- scratch or score the anodized surface in the slide
tion and assemble hardware to the top of mast, (See Fig- pad channels.
ure 2-1.). Always install slide pad shims with slide pads
inserted into the slide pad channels, (ends of mast sec-
OPEN RAIL
(REFERS TO OPEN RAIL
FRONT OF MAST SECTION) TOP
(REFERS TO TOP END
OF MAST SECTION
WHERE COVER AND
SHEAVE WHEELS
ARE ATTACHED)
BOTTOM
CLOSED RAIL (REFERS TO BOTTOM END OF
(REFERS TO CLOSED RAIL MAST SECTION WHICH SETS IN
BACK OF MAST SECTION) MACHINE’S BASE FRAME)
Figure 2-18. Mast Section - Assembly Reference.
2-26 – JLG Lift – 3120728

5. Carefully slide mast section-3/-4/-5 out BOTTOM of 15. While mast section-3 is still extended from section-2
mast section-2/-3/-4 rails. Disassemble slide pads, remove the bolts attaching the two (2) cable assem-
shims and cable anchor plate from mast section-3/- bly anchor eyelets to the TOP of mast section-3.
4/-5, if necessary. Remove cables.
NOTE: Steps 6 through 10 apply to removal of mast section- NOTE: When sliding mast sections apart, be careful not to
4 on model 20VP lifts which have five (5) mast sec- scratch or score the anodized finish in the slide pad
tions. If servicing a 15VP mast, go to step 11, or a channels.
10VP go to step 17.
16. Carefully slide mast section-3 out BOTTOM of sec-
6. Remove cable adjust nuts from threaded ends of tion-2. Remove slide pads, shims and chain anchor
cables attached to the cable anchor plate on bottom plate, if necessary.
end of mast section-4. Push threaded ends of
cables through anchor plate. NOTE: Removal of mast section-2 (cylinder attach section)
is basically the same for all VP model lifts except
7. At top of mast section-4, pull cables out and allow to where noted.
hang loose.
17. Slide mast section-2 out TOP of mast section-1 far
8. Slide mast section-4 out the TOP of mast section-3
enough to allow access to the cable/chain assembly
far enough to allow access to the cable sheave
anchor block/sheave wheel assembly.
wheel assembly.
18. Remove countersunk-flathead screws securing
9. Remove countersunk-flathead screws securing
cable/chain anchor block/sheave wheel assembly
cable sheave wheel assembly attach bars on both
attach bars on both side rails at TOP of mast sec-
side rails at top of mast section-4 and remove
tion-2.
sheave wheel assembly.
19. Slide the cable/chain anchor block/sheave wheel
NOTE: When sliding mast sections apart, be careful not to assembly and hydraulic cylinder out the TOP of
scratch or score the anodized finish in the slide pad mast section-2 far enough to allow removal of the
channels. sheave wheel attach bars, sheave wheels and
10. Carefully slide mast section-4 out BOTTOM of sec- sheave pin from cable/chain assembly anchor
tion-3. Remove slide pads, shims and cable anchor block.
plate, if necessary. 20. Remove the setscrew holding the hydraulic cylinder
rod into the chain assembly #444 anchor block. Lay
NOTE: Steps 11 through 16 apply to removal of mast sec- chain assembly #444 to side.
tion-3 on 15VP (cable actuated) & 20VP (cable/chain
actuated) lifts. If servicing a 10VP mast, go to step 21. Remove the hydraulic cylinder through BOTTOM of
17. mast section-2, be careful not to nick or score cylin-
der rod surface while removing.
11. Remove cable/chain adjust nuts from threaded ends
of cable/chain attached to the cable/chain anchor NOTE: When sliding mast sections apart, be careful not to
plate on BOTTOM end of mast section-3. Push scratch or score the anodized finish in the slide pad
threaded ends of cable/chain through anchor plate. channels.
12. At TOP of mast section-3, pull cables/chains out and 22. Carefully slide mast section-2 out BOTTOM of sec-
allow to hang loose, (be certain floor surface is clean tion-1. Remove slide pads and shims, if necessary.
and free of any metal chips or debris which may stick 23. Slide the TOP of remaining mast section-1 out over
to lubricated chains). edge of work surface and remove the bolts attaching
13. Slide mast section-3 out TOP of mast section-2 far the cable/chain anchor blocks to mast section-1.
enough to allow access to the cable/chain sheave Remove cable/chain assemblies from mast and lay
wheel assembly. aside.
14. Remove countersunk-flathead screws securing 24. Remove slide pads and shims from mast section-1.
cable/chain sheave wheel assembly attach bars on Mast disassembly should now be complete.
both side rails at TOP of mast section-3 and remove
the sheave wheel assembly.
NOTE: Step 15 applies only to 20VP lift models which have

five (5) mast sections. If servicing a 15VP mast, go
to step 16.
3120728 – JLG Lift – 2-27

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

3120728 – JLG Lift – 2-29

2-30 – JLG Lift – 3120728

Mast Assembly sure there are no air gaps (on flat side of slide
pad) between shims, shim and mast or shim and
(See Figure 2-18., 2-19., 2-20. & 2-21.) slide pad when tightened.
1. Place mast section-1, rail (open) side up on a clean, c. All mast sections are to be shimmed to provide a
flat surface (preferably a table or work bench capa- measurable gap between the slide pad (beveled
ble of supporting the weight of the entire mast side) and mast channel of 0.012" to 0.025" per
assembly). Slide mast out over end of work surface side.
far enough to allow access to the chain anchor d. When mast slide pads are shimmed properly,
attach holes at top of mast. the mast sections should be able to slide in
2. Locate the two (2) single cable/chain assemblies. channel by hand.
Lay out each cable/chain assembly with anchor 8. Insert slide pads into the slide pad channels (top of
block end towards mast, and threaded end away mast) between section-1 and -2, (one on each side
from mast, (be certain floor surface is clean and free of the mast), with beveled surface facing in towards
of any metal chips or debris which may stick to lubri- section-2.
cated chains).
9. Thread slide pad attaching bolts, (two (2) 1/4"-
3. Insert the block anchor end into the top of mast sec- 20UNC x 3/8" long hex head bolts, place a flat
tion-1 and secure using two (2) 3/8"-16UNC x 2-1/2" washer under head of each bolt), through holes in
(chain) 1-1/4" (cable) long hex head bolts, flatwash- mast section-1 outside rail (top of mast) and into the
ers and nuts for each attach block. Place a flat- slide pad inserts. Thread in enough to hold pad in
washer under bolt head and nut. place.
NOTE: When sliding mast sections together, be careful not 10. Shim per instructions in step 7.
to scratch or score the anodized finish in the slide
pad channels. NOTE: If hydraulic cylinder needs to be extended, the pro-
tective caps on the extend and return ports will need
4. Locate mast section-2, carefully slide mast section-2 to be removed. Be careful not to nick or scour rod
closed rail into section-1 open rail. Slide sections surface when extending, also catch any oil draining
together until ends are even. out of cylinder to avoid spillage onto work area.
NOTE: Do not attach mast slide pads and shims to mast 11. Locate the hydraulic lift cylinder, slide the lift cylinder
sections before assembling sections. If assembled in into the closed rail side of mast section-2 with rod
this manner, due to the tight fit of the slide pads in end to top and port end to bottom of mast. Cylinder
the slide pad channels, the anodized finish could be should extend out of mast on both ends. Return
removed from the receiving mast’s slide pad chan- tube should be on right side when facing bottom of
nels. mast assembly.
5. Insert slide pads into the slide pad channels at bot- NOTE: Top of cylinder assembly steps 12 and 13 applies to
tom end of mast between section-1 and -2, (one on 20VP only. For 10VP & 15VP continue to step 14.
each side of the mast), with beveled surface facing
out towards section-1. 12. Locate chain assembly #444 (single anchor block
with two narrow chains). Lay out chain assembly
6. Thread slide pad attaching bolts, (two (2) 1/4"- with anchor block end towards mast, (be certain
20UNC x 3/8" long hex head bolts, place a flat floor surface is clean and free of any metal chip or
washer under head of each bolt), through holes in debris which may stick to lubricated chains).
mast section-2 inside rail, into the slide pad inserts.
Thread in enough to hold pad in place. 13. Insert hydraulic cylinder rod end into chain assem-
bly #444, anchor block. Secure cylinder rod to
7. Shim slide pads using the following steps: anchor block with a 1/4"-28UNF x .50" long - Type C
NOTE: Always use the an even amount of shim material setscrew. Coat threads with blue Loctite # 242
behind slide pads on both sides of the mast rails. before assembly.
This will keep mast sections centered in rail chan- NOTE: When sliding mast sections together, be careful not
nels and prevent any distortion of the mast section. to scratch or score the anodized finish in the slide
a. Use two shim pieces per slide pad, a thick one pad rails.
and a thin one. a. Locate mast section-3, carefully slide section-3
b. Start with a total thickness of approximately a closed rail into section-2 open rail. Slide sec-
.025" thick shim and a .055" thick shim.Slide tions together until ends are even. Locate one
shims into place between slide pad and mast (1) of the chain/cable anchor plates (one with
rail. Tighten the slide pad mounting bolts, be threaded holes horizontally aligned to outside of
3120728 – JLG Lift – 2-31

bracket). Attach using outer set of holes in bot- f. On outside of spacer tubes place a sheave pin
tom of mast section-3 with two (2) 1/4"-20UNC x attach bar, (rectangular plate with threaded holes
3/4" long bolts, place a flatwasher under head of on each side of pin bore hole).
each bolt. g. Before sliding this assembly into the top of mast
14. Slide mast section-3, approximately two feet out of section two, locate two (2) mast extension cable
the top of mast section-2. assemblies and lay their anchor ends into the
slots of the cable mounting tube.
15. Insert threaded ends of cable/chain-assembly #466
(attached to top of mast section-1), through holes in h. Slide the assembly with sheave pin, wheels and
anchor plate attached to bottom of mast section-3. pin attach bars into top of mast section-2.
Loosely thread two (2) 3/8"-16UNC nuts onto stud i. Attach to top of mast section-2 using two (2) 3/
threads on each chain. Cables/chains will be 8"-16UNC x 1/2" long socket head-countersunk-
adjusted later in assembly. flathead cap screws each side. Coat threads
16. Slide mast section-2 out of mast section-1 approxi- with Loctite #171 and tighten.
mately one foot. 20VP Top of Cylinder Assembly
10VP Top of Cylinder Assembly 19. Assemble chain sheaves on chain assembly #444
19. Assemble cable sheave wheels to cylinder rod end anchor block (attached to cylinder rod end) and
and attach to mast section-2 using following steps; attach to mast section-2 using following steps;
a. Attach cable mounting tube to top of hydraulic a. Insert sheave pin through anchor block on cylin-
cylinder using one (1) 1/4"-28NF x 5/8" cap- der rod end.
screw. b. Place sheave wheels (for wide chain) on sheave
b. Insert sheave pin through cylinder cable mount- pin, one each side of anchor block.
ing tube on cylinder rod end. c. On outside of each sheave wheel, place a
c. Place a spacer tube on each side of mounting sheave pin attach bar, (rectangular plate with
tube. threaded holes on each side of pin bore hole).
d. Next slide sheave wheels on onto sheave pin d. Slide the whole anchor block assembly with
against spacer, on each side of mounting tube. sheave pin, wheels and pin attach bars into top
of mast section-2. (Position anchor block with
e. On outside of each sheave wheel, place another narrow chains facing mast section-3).
spacer tube.
e. Attach to top of mast section-2 using two (2) 3/
f. On outside of spacer tubes place a sheave pin 8"-16UNC x 1/2" long socket head-countersunk-
attach bar, (rectangular plate with threaded holes flathead cap screws each side. Coat threads
on each side of pin bore hole). with Loctite #171 and tighten.
g. Slide the assembly with sheave pin, wheels and
20. Slide mast section-2 back into section-1 until end
pin attach bars into top of mast section-2.
are even.
h. Attach to top of mast section-2 using two (2) 3/
8"-16UNC x 1/2" long socket head-countersunk- NOTE: Step 23 and 24 applies to 20VP mast assembly only.
flathead cap screws each side. Coat threads 10VP and 15VP mast assembly continue at step 25.
with Loctite #171 and tighten.
21. Locate two mast extension cable assemblies. Attach
15VP Top of Cylinder Assembly the eyelet anchor end of each cable to the outside
19. Assemble cable sheave wheels to cylinder rod end holes near top of mast section-3 using 3/8"-16UNC x
and attach to mast section-2 using following steps; 1-1/4" long hex head bolts, nuts and flatwashers.
Place a flatwasher under bolt head and nut.
a. Attach cable mounting tube to top of hydraulic
cylinder using one (1) 1/4"-28NF x 5/8" cap- NOTE: When sliding mast sections together, be careful not
screw. to scratch or score the anodized finish in the slide
b. Insert sheave pin through cylinder cable mount- pad channels.
ing tube on cylinder rod end. 22. Carefully slide mast section-3 into section-2 until
c. Place a spacer tube on each side of mounting ends are even. Check to make sure chain assembly
tube. #466 (wide chains) are seating properly in chain
d. Next slide sheave wheels on onto sheave pin #444 anchor block chain sheave wheels attached to
against spacer, on each side of mounting tube. mast section-2.
e. On outside of each sheave wheel, place another NOTE: Do not attach mast slide pads and shims to mast
spacer tube. sections before assembling sections. If assembled in
2-32 – JLG Lift – 3120728

this manner, due to the tight fit of the slide pads in NOTE: When sliding mast sections together, be careful not
the slide pad channels, the anodized finish could be to scratch or score the anodized finish in the slide
removed from the receiving mast’s slide pad chan- pad channels.
nels.
33. Slide mast section-4 back into mast section-3 except
23. Insert slide pads into the top end mast rails between for about a foot or more. Allow enough slack in
section-2 and -3, (one on each side of the mast), cables/chains to mount sheave wheels to top of
with beveled surface facing inward towards section- mast section-3.
3. 34. Extend mast section-3 out far enough from section-2
24. Thread slide pad attaching bolts, (two (2) 1/4"- mast to gain access to top of section-3.
20UNC x 3/8" long hex head bolts, place a flat 35. Assemble cable/chain sheaves to top of mast sec-
washer under head of each bolt), through holes in tion-3 as follows;
outside rail, on top of mast section-2 and into the
slide pad inserts. Thread in enough to hold pad in a. Locate the two cable/chain sheave wheels and
place. slide onto sheave pin.
25. Shim per instructions in step 7. b. Slide two (2) short spacer tubes onto sheave
pin, one each end of sheave pin to outside of
26. Insert slide pads into the bottom end mast rails sheave wheels.
between section-2 and -3, (one on each side of the
c. Place two (2) sheave pin attach bars, one each
mast), with beveled surface facing out towards sec-
end of sheave pin to outside of space tubes.
tion-2.
d. Holding complete sheave wheel assembly, slide
27. Thread slide pad attaching bolts, (two (2) 1/4"-
assembly into top of mast section-3 and align
20UNC x 3/8" long hex head bolts, place a flat
threaded holes in sheave pin attach bars with
washer under head of each bolt), through holes on
holes in mast rails.
inside rail, on bottom end of mast section-3 and into
the slide pad inserts. Thread in enough to hold pad e. Attach to top of mast section-3 using two (2) 3/
in place. 8"-16UNC x 1/2" long socket head-countersunk-
flathead cap screws, each side. Coat threads
28. Shim per instructions in step 7. with Loctite #171 and tighten.
NOTE: Assembly of 10VP mast should now be complete. To NOTE: When sliding mast sections together, be careful not
continue with 15VP assembly go to step 48. 20VP to scratch or score the anodized finish in the slide
assembly continues following. pad channels.
NOTE: When sliding mast sections together, be careful not 36. Slide mast section-3 back into section-2 until ends
to scratch or score the anodized finish in the slide are even. (Mast section-2 may need to be restrained
pad channels. to keep its slide pads from pushing out the bottom
29. Locate mast section-4, carefully slide section-4 of mast section-1).
closed rail into section-3 open rail. Slide sections 37. While mast section-4 is still extended from section-3;
together until ends are even. locate two cable assemblies. Attach the eyelet
30. Locate one (1) of the chain/cable anchor plates (one anchor end of each cable to the inside set of holes
with two threaded holes vertically aligned in center of near top of mast section-4 using 3/8"-16UNC x 1-1/4"
bracket). Attach through inner (vertical) set of holes long hex head bolts, nuts and flatwashers. Place a
at bottom of mast section-4 using two (2) 1/4"- flatwasher under bolt head and nut.
20UNC x 3/4" long bolts, place a flatwashers under 38. While mast section-4 is still extended from section-3,
head of each bolt. assemble cable sheaves to top of mast section-4 as
31. Slide mast section-4 out the top of mast section-3 so follows;
the chain/cable anchor plate on bottom of mast sec- a. Locate the wide tube spacer and slide onto
tion-4 is easily accessible at top end of mast section- sheave pin.
3. Rest the top end of mast section-4 on a support b. Slide two (2) cable sheave wheels onto sheave
while performing next step. pin, one each end of sheave pin to outside of
32. Insert threaded ends of cable/chain assembly tube spacer.
(attached to anchor block on top mast section-2) c. Place two (2) large flat washers, one each end of
through the chain/cable anchor plate located on bot- sheave pin to outside of cable sheave wheels.
tom of extended mast section-4. Loosely thread two
d. Place two (2) sheave pin attach bars, one each
(2) 3/8"-16UNC nuts onto stud threads on each
end of sheave pin to outside of large flatwash-
chain. Chains will be adjusted later in assembly.
ers.
3120728 – JLG Lift – 2-33

e. Holding complete cable sheave wheel assem- 46. Locate the remaining mast section-4/-5 (platform
bly, slide assembly into top of mast section-4 mounting- mast section). Lay mast section on flat
and align threaded holes in sheave pin attach stable surface.
bars with holes in mast rails. 47. Attach the remaining chain/cable anchor plate (one
f. Attach to top of mast section-4 using two (2) 3/ with threaded holes vertically aligned in center of
8"-16UNC x 1/2" long socket head-countersunk- bracket). Attach through inner (vertical) set of holes
flathead cap screws, each side. Coat threads in bottom of mast section-4/-5 with two (2) 1/4"-
with Loctite #171 and tighten. 20UNC x 3/4" long bolts, place a flatwasher under
head of each bolt.
NOTE: When sliding mast sections together, be careful not
to scratch or score the anodized finish in the slide 48. Complete the following steps to determine shim
pad channels. stock thickness required for section-4/-5;
39. Carefully slide mast section-4 back into section-3 NOTE: Always use the an even amount of shim material
until ends are even. Check to make sure cable/chain behind slide pads on both sides of the mast rails.
assemblies are seating properly in cable/chain This will keep mast sections centered in rail chan-
sheave wheels attached to top of mast section-3. nels and prevent any distortion of the section.
NOTE: Do not attach mast slide pads and shims to mast a. Use two shim pieces per slide pad, a thick one
sections before assembling sections. If assembled in and a thin one.
this manner, due to the tight fit of the slide pads in b. Start with a total thickness of approximately
the slide pad rails, the anodized finish could be .035" and .075" thick shim stock.
removed from the receiving mast’s slide pad chan-
nels. NOTE: To protect the anodized finish when sliding the
assembled mast section-4/-5 into section-3/-4, grind
40. Insert slide pads into the top end mast rails between top and bottom edges of slide pads to approximately
section-3 and -4, (one on each side of the mast), a 1/4" radius.
with beveled surface facing inward towards section-
4. c. Attach shim stock and slide pads to both sides
of mast section-4/-5 using five (5) 1/4"-20UNC x
41. Thread slide pad attaching bolts, (two (2) 1/4"- 1-1/4" long, hex head cap screws per side, with
20UNC x 3/8" long hex head bolts, place a flat flatwasher under each bolt head. (Assemble
washer under head of each bolt), through holes in shim stock and slide pad to mast section rail with
outside rail, on top of mast section-3 and into the shim stock against rail and slide pad with bev-
slide pad inserts. Thread in enough to hold pad in eled side out).
place.
d. Carefully thread the slide pad mounting bolts
42. Shim per instructions in step 7. with flatwashers through slide pads and shim
43. Insert slide pads into the bottom end mast rails stock into threads in mast section-4/-5. Be cer-
between section-3 and -4, (one on each side of the tain there are no air gaps between shims, shim
mast), with beveled surface facing out towards sec- and mast or shim and slide pad when tightened.
tion-3.
NOTE: When sliding mast section-4/-5 into section-3/-4 note
44. Thread slide pad attaching bolts, (two (2) 1/4"- amount of force required to push sections together.
20UNC x 3/8" long hex head bolts, place a flat Fit should be very snug but still be able to be pushed
washer under head of each bolt), through holes on together by hand. If too tight, remove section-4/-5,
inside rail, on bottom end of mast section-4 and into disassemble slide pad from section-4/-5 and reduce
the slide pad inserts. Thread in enough to hold pad thickness of shim stock. Open rails of section-3/-4
in place. may be sprayed with silicone spray to help section-4/
45. Shim per instructions in step 7. -5 slide easier.
NOTE: The platform mounting section (section—4 on 15VP e. Begin sliding top of mast section-4/-5 with
and section-5 20VP machines) slide pads, are closed rail down engaging the slide pads into
assembled differently than the slide pads for the slide pad channels at bottom of mast section-3/-
other mast sections. Mast section-4/-5 slide pads 4’s open rail. Continue to push section-4/-5 into
may need to be assembled/disassembled several section-3/-4 until BOTTOM ends of mast sec-
times in order to determine the correct shim stock tions are even.
required for proper fit. f. Check mast section for side play. If play exists
use thicker shims dividing thickness equally
between both sides of mast.
2-34 – JLG Lift – 3120728

g. When mast slide pads are shimmed properly,

there should be no side to side movement of 2.10 MAST TO BASE FRAME INSTALLATION
slide pad in rail channel. Mast sections should
be very snug in channels but still be able to slide
in channel by hand. IF BATTERIES ARE STILL MOUNTED, REMOVE BATTERIES FROM
49. Slide mast section-4/-5 to top of section-3/-4. THEIR TRAYS BEFORE LAYING THE BASE FRAME IN A HORIZON-
TAL POSITION.
50. Insert threaded ends of cable assembly (attached to
top of mast section—2/3) through the chain/cable
1. Using an overhead crane or suitable lifting device
anchor plate located on bottom of extended mast
capable of supporting the weight of the base frame,
section-4/-5. Loosely thread two (2) 3/8"-16UNC
attach a sling strap or chain to the front crossmem-
nuts onto stud threads on each chain. Chains will be
ber of the base frame. Carefully tilt the base frame
adjusted later in assembly.
back until the front is pointing up and the back is
51. Slide mast section-4/-5 back into mast section-3/-4 resting on the counterweight/battery trays. Be sure
until bottom ends of masts are even. Check to make base is very stable and at a 90° angle to work sur-
sure cable set attached to top of section-2/-3 is seat- face before proceeding.
ing properly in cable sheave wheels attached to top
2. Using a sling and suitable lifting equipment (i.e.
of mast section-3/-4. (Mast sections-2, -3 and -4 may
overhead crane) lift the mast assembly (balanced in
need to be restrained to keep their slide pads from
middle) into position in front of the base frame.
pushing out the bottom of mast sections-1, -2 and -
3). 3. Extend hydraulic cylinder out from bottom of mast
assembly approximately one (1) foot. (Caps on
52. At bottom of mast assembly, thread all chain/ cable
extend and return ports will need to be removed to
adjusting nuts on threaded ends until they are snug
extend cylinder. Catch any hydraulic fluid expelled
against the anchor plates and all slack is removed
from return port in a container to prevent spillage
from chains and cables. Check that chains and
onto work area).
cables are seated in their sheave wheels at top of
mast assembly. Also, ends of mast sections should 4. Carefully position the mast into base frame assem-
be even with each other. bly, (base frame and mast assembly must be held at
90° angle to each other).
Mast assembly should now be complete.
5. Slide port end of hydraulic cylinder through hole in
base frame cylinder mounting channel. (Return port
(tube side) of cylinder must be on right side facing
bottom of base and mast).
6. Align threaded hole in side of hydraulic cylinder
head with hole in tab on bottom side of cylinder
mounting channel. Secure hydraulic cylinder to cyl-
inder mounting channel tab using a 5/16"-18UNC x
5/8" long hex head bolt and flat washer.
7. Carefully push mast assembly and base assembly
together until the four (4) holes on bottom rear of
mast align with holes in the base frame mast support
crossmember.
8. Attach mast to base using four (4) 3/8"-16UNC x 1"
long hex head bolts, locknuts and flatwashers,
(place a flatwasher under bolt head and nut and
mount with nuts on inside of frame).
9. Locate the two (2) mast support braces, attach to
sides of base frame using a 3/8"-16UNC x 1" long
hex head bolt, nut and flatwashers each brace,
(place a flatwasher under bolt head and nut and
mount with nuts on inside of frame. Use access hole
in bottom of frame to attach nut inside frame).
10. Before setting machine upright on base, install a
short 90° elbow fitting, flow control valve and
another short 90° elbow fitting on the end of the flow
3120728 – JLG Lift – 2-35

control valve in the extend (left) port on bottom of

hydraulic cylinder. Install a long 90° elbow fitting on 2.11 MAST CHAINS/CABLES AND
return (right) port. Use sealant tape on fitting SEQUENCING CABLES ADJUSTMENT
threads. Cap ports until hydraulic lines are installed.
11. Carefully set machine in an upright position on its
Mast Chain/Cable Adjustment
base frame wheels. The intention of this procedure is to assure equal load dis-
12. Locate the mast support bracket. Attach mast sup- tribution between the individual chains/cables of a mast
port bracket to mounting holes halfway up back of section chain/cable set.
mast using four (4) 3/8"-16UNC x 2-3/4" long hex Adjust using the following procedure;
head bolts, locknuts and flatwashers. (Place a flat-
1. With mast retracted, step into the platform and
washer under bolt head and nut and mount with nuts
bounce your weight up and down a few times to be
on inside of frame).
certain platform is at the bottom of travel. Be certain
13. Using a 4 ft. level, ensure the mast is set to vertical all chain/cable sets are seated in their sheaves prop-
(plumb) on the base frame. erly at the top of each mast section.
14. When mast is vertical (plumb), attach support 2. Then with no load in the platform check the side pro-
braces, (bolted to base), to the mast support file of the top of the mast for the amount of adjust-
bracket, (bolted to mast), using 3/8"-16UNC x 2-3/4" ment necessary to make the mast sections even for
long hex head bolts, nuts and flatwashers. (Place a mast sections-3 and up. (See Figure 2-22.)
flatwasher under bolt head and nut and mount with
nuts on inside of bracket). NOTE: Mast section-1 is fixed to the base and mast section-
2 is attached to the lift cylinder, these sections
15. After securing mast to base frame, using 4 ft. level
require no adjustment.
again check that mast is vertical (plumb) on base
frame. 3. Adjust one mast section at a time starting from the
16. Continue installing remaining components to mast back (section-3, section-4, etc.) of the mast and
assembly, (i.e. hydraulic pump/motor/reservoir, bat- work forward. (i.e.. if three is OK, then jump to four,
tery charger, etc.) until machine is complete. etc.)
4. Elevate the platform until the chain/cable anchor
adjust nuts are accessible at the front and bottom of
each mast section.
NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT-

FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT
BY BLOCKING OR OVERHEAD SLING.
5. Start with the mast section which needs adjustment

and loosen the bottom (jam) nut on each chain/
cable.
6. Tighten (to raise mast section), or loosen (to lower
mast section) the adjusting nut against the anchor
plate on each chain/cable. Adjust the nut the
amount required to raise or lower the top of the mast
section so it is even with the previous mast section
when the mast is retracted. Be certain each chain/
cable pair is adjusted to equal tension. (The
threaded end of the chain/cable will need to be
restrained while tightening the adjust nut to keep the
chain/cable from twisting.)
7. Retract the mast all the way and check if the top of
the mast sections appear as shown in Figure 2-22.
8. Repeat steps (1) through (7) for remaining mast sec-
tions. ENSURE THAT ALL CHAIN/CABLE PAIRS
HAVE EQUAL TENSION.
2-36 – JLG Lift – 3120728

MAST SIDE PROFILE MAST CHAIN/CABLE ADJUSTERS

MAST COVER
ADJUST UNTIL TOPS OF MAST
SHOWN REMOVED
SECTIONS ARE EVEN
SEQUENCE CABLE
ADJUST NUT
SECTION-1
FIXED
TO BASE
SECTION-2
EXTENDED BY
CYLINDER
SECTION-3
EXTENDED BY
CHAIN
SECTION-4
EXTENDED BY
CHAIN/CABLE
SECTION-5
(PLATFORM
HEADER SECTION)
EXTENDED BY CHAIN/CABLE
CHAIN/CABLE ANCHOR PLATE
ADJUST NUT
Note: When chain adjustment
JAM NUT
is complete, before
tightening the jam nut
against the adjust nut, THREADED
apply Loctite #242 to the CHAIN/CABLE
threads under the jam nut. END
.
Figure 2-22. Mast Chain/Cable/Sequence Cable Adjustment Components.
9. Once mast section adjustment is completed, apply 2. Tighten nylock-nut just enough to remove excessive
loctite #242 to the threads under the (jam) nuts that slack from sequencing cable. The springs should
were loosened. Then re-tighten the loosened (jam) not be compressed more than 25% after adjusting.
nuts until tight against the top (adjust) nut. Chain/ 3. Run mast through several cycles to verify cable/
cable should have slight tension but should not be chain adjustments and ensure no interference exists
taut. between chain anchor brackets and mast.
Sequencing Cable Adjustment

1. Retract mast completely, and check each sequenc-
ing cable on outside of masts for excessive slack.
Adjust only to remove slack from cable.
3120728 – JLG Lift – 2-37

Clamp Installation (Drum/Socket Type)

2.12 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 THE MANUFACTURER OF THE DRUM/SOCKET CLAMP RECOM-
sequence cable with the threaded (top) end attached MENDS THE USE OF THEIR CABLE CLAMP ASSEMBLY KIT (JLG
same as the top end of the factory cable. Also included is P/N - 7023275) TO ASSEMBLE THE CLAMP TO THE WIRE ROPE.
a clamp (drum/socket type) to secure the bottom end of THE KIT CONSISTS OF VISE JAWS TO HOLD THE WIRE ROPE IN
the cable. Use the following procedure to install the A VISE PROPERLY WITHOUT DAMAGING ANY ROPE STRANDS
replacement cable and clamp kit. AND A PLUG DRIVER TO DRIVE THE PLUG INTO THE CENTER OF
THE WIRE ROPE AND IS ALSO USED TO FORM THE STRANDS OF
Remove Old Cable THE ROPE DURING ASSEMBLY.
1. Remove the locking nut from the threaded end of NOTE: The tools in the clamp assembly kit may be frabri-
the cable at the top of the mast and then remove the cated if necessary. The vise clamp consists of vise
spring cap, spring, and spacer washers if installed. jaws with a hole drilled 1/32 in. smaller than the
diameter of the wire rope you are working with (i.e.
2. Slide the threaded top end out of the upper anchor
1/8 in. rope - 3/32 in. hole.)
bracket, then at the bottom end pull the cable out
The plug driver is a metal tube with a hole in the bot-
though the sheave pulley/anchor bracket until it is
tom to allow the strands of the wire rope to be
completely clear of the machine.
shaped after the plug has been tapped into the cen-
ter of the wire rope.
Replacement Cable Installation
1. Using the recommended vise jaws, clamp the wire
1. Be certain the mast is completely retacted and at the rope into a vise with the bottom edge of the black
bottom of travel. Check the mast "Side Profile" at the mark made on the wire rope resting just above the
top of the mast as shown in Figure 2-22., adjust vise jaws.
mast sections to proper height if necessary.
2. To determine where the clamp will be installed at the
bottom of the replacement cable, temporarily
assemble the new replacement cable to the top
cable anchor bracket on the mast using the wash-
ers, spring, spring cap and lock nut previously dis-
assembled. Thread the lock nut on until
approximately 1/8 in. (3mm) of threads are exposed.
3. At the bottom of the mast, thread the loose end of
the replacement cable through the proper sheave
pulley and through the hole in the sheave pully/
anchor bracket on the mast section ahead of the
sheave pulley.
4. Grasp the cable and pull on the cable until the 2. Twist the sleeve from the clamp kit onto the rope
spring at the top of the cable is slightly compressed. until it is flat against the vise jaws at the mark made
Use a black marker to mark the cable on the top made on the wire rope.
side of the sheave pully/anchor bracket. This will
determine where the clamp (drum/socket) sleeve will
be positioned on the cable.
DO NOT CUT THE CABLE AT THE MARKED POINT ON THE

CABLE THIS IS ONLY USED AS A REFERENCE FOR POSITIONING
THE CABLE SLEEVE WHICH WILL REST AGAINST THE ANCHOR
BRACKET ONCE INSTALLED.
2-38 – JLG Lift – 3120728

3. Use a suitable tool and cut the cable as shown in the 6. Reclamp the assembly in the vise on the flats of the
illustration following. For 1/8 in. cable the recom- sleeve. Using the plug driver, a metal tube or pliers,
mended length is 5/8 in. past the end of the sleeve. bend the outer strands toward the center strands
enough that the socket can be slipped over all the
strands.
4. Unlay the cable strands by gently forcing a screw-

driver between the outer strands to unlay the cable.
When done properly the outer strands will form a
symmetrical basket. Do not straighten out the spiral NOTE: When assembling stainless steel parts all threads
lay of the strands, unlay any wires that make up the must be coated with a dry lubricant or an anti-sieze
strand, or allow the strands to cross each other lubricant to prevent seizing.
inside the sleeve. 7. Coat the threads of the socket and sleeve with lubri-
cant and install the socket by twisting it over the
strands of the cable and engage the threads of the
sleeve with the socket. Tighten until four threads or
fewer are visible. If more than four threads are visi-
ble, proof load the cable and retighten the socket fit-
ting. (There is no specific requirement for torque.)
5. Install the plug supplied with the kit by placing the

plug in the center of the strands starting with the
small tapered end of the plug. Use a metal tube
(plug driver) and hammer to drive the plug into the
sleeve while assuring that the strands are spaced
somewhat equally around the plug. Drive the plug
until it is firmly seated and no more than 1/3 of the
plug is visible from above the sleeve.
8. Inspect for proper assembly prior to loading the

cable. Strands visible through the inspection hole
are your assurance of a proper assembly.
NOTE: The end of the rope may not be visible in the inspec-
tion hole after loading.
9. Install cable on machine and adjust per instructions

shown previously in Section 2.11, MAST CHAINS/
CABLES AND SEQUENCING CABLES ADJUST-
MENT.
3120728 – JLG Lift – 2-39

The checks and services listed in this schedule are not

2.13 PREVENTIVE MAINTENANCE AND intended to replace any local or regional regulations that
INSPECTION SCHEDULE may pertain to this type of equipment nor should the lists
(See Table 2-2.) be considered as all inclusive. Variances in interval times
may occur due to climate and/or conditions and depend-
The preventive maintenance and inspection checks are
ing on the location and use of the machine.
listed and defined in the following table (See Table 2-2.,
this chapter). This table is divided into two basic parts, the JLG Industries requires that a complete annual inspection
“AREA” to be inspected and the “INTERVAL” at which the be performed in accordance with the “Annual Machine
inspection is to take place. Under the “AREA” portion of Inspection Report” form. Forms are supplied with each
the table, the various systems along with the components new machine and are also available from JLG Customer
that make up that system are listed. The “INTERVAL” por- Service. Form must be completed and returned to JLG
tion of the table is divided into five columns representing Industries.
the various inspection time periods. The numbers listed
within the interval column represent the applicable inspec-
tion code for which that component is to be checked. JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL
INSPECTION BE PERFORMED IN ACCORDANCE WITH THE
“ANNUAL MACHINE INSPECTION REPORT” FORM.
2-40 – JLG Lift – 3120728

Table 2-3. Preventive Maintenance & Inspection Schedule.
AREA ON MACHINE INTERVAL

(10 HRS.) (50 HRS.) (200 HRS.) (500 HRS.) (1000 HRS.) (2000 HRS.)
PLATFORM
DAILY WEEKLY MONTHLY 3 MONTHS 6 MONTHS 1 YEAR
Platform Controller (all functions) 1,11
Placards and Decals 1,2
Control Tags 1,2
Electrical Cables 1,8
Handrail and Bar Gate 1,4
MAST
Mast Chains/Cables/and all component parts 1,4,7,9 12
Mast Sections 1,4,7
Mast Sequencing Cables 1,4,7,9
Speed/PHP Limit Switches 1,7,9
BASE FRAME
Batteries 1,3 5
Battery Charge 1
Power Cables To Platform 1,8
Electric Motor/Hydraulic Pump Unit 1 5
Hydraulic Hoses and Fittings 1 5
Hydraulic Oil Reservoir * 3 5 4
Hydraulic Oil Reservoir Breather 6,14
Manual Descent Valve 1,7
Lift Cylinder 1 5,6,13 4
Placards and Decals 1,2
Wheels and Casters 1 8,9 12
Wheel Bearings 8 12
Electric Drive Wheel Motors 1,7
Electric Drive Wheel Gear Box **
Torque Limiting Clutch 1,6,9
Power Switch (Ground Control Box) 1,11
Control Tags 1,2
Hoses and Cables 1,8
Bubble Level Indicator 1,2
* Inspection and Maintenance Code 10 to be performed every two years.
** Maintenance Code 10 to be performed only when serviced, requires 6 oz. (175 cc’s) to fill.
Inspection and Maintenance Codes:

1. Check for proper and secure installation. 8. Check for excessive wear or damage.
2. Check for visible damage and legibility. 9. Check for proper tightness and adjustment.
3. Check for proper fluid level. 10. Drain, clean and refill.
4. Check for any structural damage; cracked or broken 11. Check for proper operation while pump/motor is
welds; bent/warped surfaces; broken cable strands. running.
5. Check for leakage. 12. Check for proper lubrication.
6. Check for presence of excessive dirt or foreign 13. Check for evidence of scratches, nicks or rust and
material. for straightness of rod.
7. Check for proper operation and freedom of move- 14. Check for condition of element; replace as neces-
ment. sary.
3120728 – JLG Lift – 2-41

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

SECTION 3. TROUBLESHOOTING
3.1 GENERAL
This section contains troubleshooting information to be used for locating and correcting most operating problems on a VP
Series Personnel Lift. 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.
3.2 TROUBLESHOOTING INFORMATION

Troubleshooting procedures applicable to the VP machine are listed and defined starting with Section 3.5, TROUBLE-
SHOOTING SECTION - TABLE OF CONTENTS in this chapter of the manual.
Each malfunction within an individual group or system is followed by a listing of probable causes which will enable determi-
nation of the applicable remedial action. The probable causes and the remedial action should, where possible, be checked
in the order listed in the tables.
It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems.
It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electri-
cal systems. For this reason, every effort has been made to ensure that all likely problems in these areas are given the fullest
possible treatment. In the remaining machine groups, only those problems which are symptomatic of greater problems
which have more than one probable cause and remedy are included. This means that problems for which the probable
cause and remedy may be immediately obvious are not listed in this section.
The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if the cir-
cuit is lacking hydraulic oil and electrical control power. This can be ascertained by overriding the bypass valve (mechani-
cally or electrically) so that oil is available to the function valve, then overriding the function valve mechanically. If the function
performs satisfactorily, the problem exists with the control circuit.
3.3 HYDRAULIC CIRCUIT CHECKS

(See Figure 3-6.)
The first reference for improper function of a hydraulic system, where the cause is not immediately apparent, should be the
Hydraulic Diagram Circuit. The best place to begin the problem analysis is at the power source (pump). Once it is deter-
mined that the pump is serviceable, then a systematic check of the circuit components, would follow.
NOTE: For aid in troubleshooting, refer to Figure 3-6. for HYDRAULIC DIAGRAM circuit.
3.4 ELECTRICAL CIRCUIT CHECKS
General
The drive system on the VP series machine requires a microprocessor controlled electrical circuit to operate smoothly and
accurately. All platform control functions are relayed to various machine components (i.e. platform up/down, drive functions,
etc.) through the (MC-1) microprocessor box (mounted under the battery charger support bracket).
To help diagnose any problems with the components associated with the microprocessor, the MC-1 is designed with an
internal fault messaging system which is displayed by LED flash sequences on the platform controller. When operating nor-
mally the LED panel on the platform controller (center LED strip) indicates the battery voltage status using ten (10) green
LEDs. If a malfunction occurs to any of the drive components, the platform controller, or the MC-1 unit itself, these LEDs will
flash a fault code (Warning or Error type) to help locate the problem area. The possible causes of fault codes are outlined in
the following sub-sections of this chapter, see Table 3-1 and Table 3-2.
NOTE: For aid in troubleshooting electrical problem, refer to Figure 3-3. for an ELECTRICAL DIAGRAM of the various circuits.
Also a pictorial overview of the Section, see Figure 3-2. “Pictorial Overview of VP Electrical System”.
3120728 – JLG Lift – 3-1

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.
Fault Code Reference Tables

Their are two types of fault codes which can occur to indicate a problem with the machine, these are WARNING codes and
ERROR codes.
The fault codes can occur either at machine power up or during operation of the machine.
WARNING Codes
(See Table 3-1.)
The WARNING will be indicated for 4 seconds and will be repeated every minute if the problem is not corrected. An audible
three beeps indication is given at the beginning of each warning displayed. WHEN A WARNING CODE IS INDICATED THE
MACHINE WILL USUALLY FUNCTION, however some machine functions may be disabled. See Table 3-1. for explanation of
WARNING codes.
ERROR Codes
(See Table 3-2.)
An ERROR is indicated by an audible beep and continuously fast flashing LED bar. The number of fast (rapidly) flashing
LEDs indicate the particular error message. AN ERROR CONDITION WILL DISABLE THE MACHINE until the problem is cor-
rected. The ERROR message is only reset by turning off the system, however if the problem has not been corrected the
ERROR will be indicated again at machine power-up. See Table 3-2. for explanation of ERROR codes.
NOTE: As shown in the following WARNING and ERROR code tables, a specific number of LEDs flashing can indicate more
than one WARNING or ERROR code. These tables suggest specific areas to check as the probable cause for the fault
code which has occured. The fault code number is shown in the first column of the table and the number of LEDs flash-
ing on the platform controller LED strip is shown in the second column of the table.
3-2 – JLG Lift – 3120728

Table 3-1. MC-1 WARNING CODES

(Indicated by 3 beeps, then slow flashing LED’s)
WARNING LED’S
PROBABLE CAUSE REMEDY
CODE FLASHING
Enter Code - Security Code has been activated and Enter Code or deactivate using MC-1 configuration
0 10
must be entered before operation software.
1 8 Charger Connected Unplug Charger
Brake Status Switch Open - Parking brake manually Reset Parking Brake
3 2
released
Brake manual release lever obstructed (located at Clear obstruction and reset lever
3 2
drive motor brake)
Defective parking brake status switch (located at Replace Switch
3 2
drive motor brake)
Defective pin 11 at X105 (BRN wire) connection or Properly attach wires or pin
3 2
improper wiring
3 2 Improper wiring at parking brake status switch Properly attach wires
Improper wiring from parking brake status switch to Properly attach wires
3 2
ground
Configuration Lost - Drive Characteristic has Reprogram using MC-1 software
4 5
changed
Current Measurement faulty - Drive characteristic Cycle on-off and reprogram if necessary
5 6
may have changed
6 7 High Temperature in controller Reduce power
7 7 Motor Stalled Check drive wheels and motors
9 1 Battery Low ( < 18v) and power reduced Charge Batteries
12 9 Speed Control Potentiometer defective Replace Joystick
Drive Cutout Input Open - PHP bar must be down to Lower PHP
13 4
drive while elevated
PHP bar is down, but drive is disabled - Defective wir- Properly attach wire (RED/BLU) or pin 12 of X105
13 4
ing at D-connector connector
PHP bar is down, but drive is disabled - Defective Properly attach wires
13 4
ground wiring
PHP bar is down, but drive is disabled - Defective Replace switch
14 3
switch
14 3 Tilt Switch open - Slope greater than 2 degrees Lower Platform and move to level ground
No Tilt Switch - open circuit at Pin 2 of X101 (WHT Properly attach pin or wire connections
14 3
wire)
14 3 No Tilt Switch - open circuit to ground Check ground wire connections (BLK1 wire)
25 ---- Joystick E. Stop Counter Controller Log Only
26 ---- Configuration Access Counter Controller Log Only
3120728 – JLG Lift – 3-3

Table 3-2. MC-1 ERROR CODES

(Indicated by rapid LED flashing and periodic beep)
ERROR LED’S
CODE FLASHING
0 8 System Overvoltage - Charger Unplug Charger

0 8 System Overvoltage - Driving down long steep grade Operate ground controls to reduce voltage
1 7 Controller Overtemperature Turn unit off and allow to cool
Drive Motor Plug - Open Circuit - check connectors Properly attach wires or pins A1 & A2
2 8
X103 & X104
Drive Motor Plug - Open Circuit - check motor con- Properly attach wires or pins (WHT & BLK wires)
2 8
nections at motor
3 6 Brake Safety Relay Replace Controller
4 2 Brake Short Circuit Replace Brake
Brake Left Open Circuit - D-connectors to X103 & Switch D-connectors - Left Motor to X103; Right
5 2
X104 switched Motor to X104
Brake Left Open Circuit - Check pins 3 & 5 of X103 Properly attach wires or pins
5 2
and brake wires
Brake Left Open Circuit - Check brake wires or plug at Properly attach wires or pins
5 2
drive motor
Brake Right Open Circuit - Check pins 2 & 5 of X104 Properly attach wires or pins
6 2
and brake wires
Brake Right Open Circuit - Check brake wires or plug Properly attach wires or pins
6 2
at drive motor
7 2 Brake Open Circuit on one or both brakes See above
8 9 Switch Short Circuit (Joystick) Replace Joystick Box
9 6 Power Circuit Defect Replace Controller
10 1 Battery Low (< 16.5 v) Charge Battery
Check pins & wire connections at X102 & joystick Properly attach wires or pins
11 9
box connector
11 9 Joystick defective Replace Joystick Box
Check pins & wire connections at X102 & joystick Properly attach wires or pins
12 8
box connector
12 8 Joystick Box Replace Joystick Box
Current Limiting - Motor Short Circuit - Gearmotor Replace Gearmotor
16 7
defective
21 6 36v supply Replace controller
Configuration Lost Reprogram using MC-1 software, if error reoccours
24 5
then replace controller
25 6 RAM ROM Replace controller
3-4 – JLG Lift – 3120728

Table 3-2. MC-1 ERROR CODES

(Indicated by rapid LED flashing and periodic beep)
ERROR LED’S
CODE FLASHING
If voltage @ pin 5 (RED2) of X101 is 20v w/24v @ Battery or if ground controls and operating lift up clears
error:
26 6
Defective main contactor Replace main contactor
Battery cables loose or corroded Clean & tighten battery cables
If 0v @ pin 5 of X101, check connection @ pin 7 & Properly attach wires or pins
26 6
14 of X102
26 6 Connection @ pin 5 of X101 bad Properly attach wires or pins
26 6 Defective Power Relay Replace Relay
26 6 Defective Power Relay ground wire Properly attach wire
Safety Circuit - Joystick - check pin 6 @ X102 (Red Properly attach wire or pin
27 6
Wire)
Safety Circuit - Joystick - check pin 3 @ joystick Properly attach wire or pin
27 6
connector (Red Wire)
Defective Joystick - Normal voltage @ pin 6 of X102 Replace Joystick
27 6 (Red Wire): Joystick centered 5v, Joystick not cen-
tered 0v
27 6 Safety Circuit - Defective Controller Replace Controller
28 6 Current Measurement Replace Controller
29 6 Drive Circuit Left - Defective Controller Replace Controller
31 6 Drive Circuit Right - Defective Controller Replace Controller
Output driver defect - check for short in Hourmeter, Replace defective component
32 1
Horn, Alarm or Power Relay
32 1 Output Driver Defective - Defective Controller Replace Controller
Communication Error - Check Pins 5 & 13 of X102 Properly attach wires or pins
35 8
(Orange & Blue Wires)
Communication Error - Check Pins 4 & 5 at Joystick Properly attach wires or pins
35 8
(Orange & Blue Wires)
35 8 Defective Joystick Replace Joystick
35 8 Defective Controller Replace Controller
36 6 Watch Dog Replace Controller
38 6 EEPROM Replace Controller
39 6 Software Error Replace Controller
3120728 – JLG Lift – 3-5

BATTERY BATTERY
(LEFT SIDE) (RIGHT SIDE)
(–) (+)
(+) TO PUMP (–)

MOTOR
SOLENOID
HORN
BEACON
ALARM
F
COROM
NN X10
HOURMETER EC 1
TO
R
TO (—)
BATTERY
TERMINAL
GROUND MAIN
CONTROL CONTACTOR
BOX RELAY
05
X1 R
O M C TO
FR NNE
CO
CO F
PUMP START N RO
CONTACTOR RE TA M
LA CT
MANUAL
Y OR
DUMP
OVERRIDE/
VALVE
LIFT DOWN
VALVE EARLY
DESIGN
LATER
PUMP/MOTOR DESIGN
ASSEMBLY
POT-HOLE
PROTECTION
LIMIT
SWITCHES
Figure 3-2. Overview of Standard Electrical System. (Sheet 1 of 2)
3-6 – JLG Lift – 3120728

LAPTOP COMPUTER
(remove existing connector
at X105 port on the MC-1 controller box PLATFORM
and plug-in the laptop computer. CONTROL
Requires P/N-2900868 Configuration Kit.) BOX
TILT
SENSOR
SWITCH
TO (+) TO (—)
BATTERY BATTERY
TERMINAL TERMINAL
USE WIRING
DIAGRAM
FIGURE 3-3.
THIS SECTION
OF THE
MANUAL WITH
THIS PICTORIAL TO
WIRING DIAGRAM BATTERY
CHARGER
ELEVATION CUTOUT
LIMIT SWITCH
SWITCH
X105
FROM X101 X101
CONNECTO
R X104
05
X1 R
O M CTO PLATFORM MC-1
FR NNE CONTROLLER CONTROLLER BOX
CO
GROUND X103
CONTROLS DRIVE MOTOR
SWITCH POWER LEADS
(LIFT UP/LIFT DOWN) BRAKE
GROUND RELEASE
CONTROLS WIRING
RELAY
EXTERNAL
DRIVE/HORN
RELAY BRAKE
CONTACTOR RELEASE
RELAY WIRING
BRAKE LIMIT
SWITCH
WIRING
TO MAIN
CONTACTOR
RELAY
DRIVE MOTOR MOTOR/BRAKE

ASSEMBLY
POWER LEADS MOTOR/BRAKE (RIGHT SIDE)
ASSEMBLY
(LEFT SIDE)
Figure 3-2. Overview of Standard Electrical System. (Sheet 2 of 2)
3120728 – JLG Lift – 3-7

X101 PIN E-STOP SWITCH TO PIN 2

ON METAL BOX AND TO
X105 PIN
B+ A1 PIN 1 ON PLASTIC BOX. PINS USED FOR RX DO - RECEIVE DATA 7
COMMUNICATION
B+ CONTROL 3 TO SERIAL PORT TX DO - TRANSMIT DATA 8
PIN 1 ON METAL JOYSTICK
MAIN POWER DISCONNECT 5 PIN 2 ON PLASTIC JOYSTICK ON LAPTOP OR PC. GROUND 13
ELEVATION SWITCH 1 LIFT UP 4
TILT CUTOUT 2 LIFT DOWN 6
CHARGER INTERLOCK 4 PUMP CONTACTOR 5
B– A2 DRIVE CUTOUT 12
JOYSTICK
BOX 7 9 2 6 5 4 3 1 8
BRAKE STATUS 11
X102 PIN HORN 15
B+ 15 ALARMS 14
EMERGENCY STOP 14 HOURMETER 3
CAN-LO 13
CAN-HI 5
RED/BLK
BLU/BLK
CENTER DETECT 6
ORG
BRN
RED
BLU
BLK
YEL
B– 1
EMERGENCY STOP SWITCH

EMERGENCY STOP 7
EMERGENCY STOP
CENTER DETECT
LOGIC POWER
CAN-H
X103 – LEFT MOTOR PIN X104 – RIGHT MOTOR PIN
CAN-L
24V
0V
MOTOR 1 A1 MOTOR 1 A1
BRAKE 1 5 BRAKE 1 5
BRAKE2 3 BRAKE 2 2
15 8 7 13 5 6 14 1
X102
+
BLACK ORN/RED 49-1
14 12
ORANGE 55-6 (10) MC-1
A1
CONTROLLER BLU/ORN 52-1

ORANGE 55-4
5 1 3 4 2
ORN/RED 49-3
11
BRAKE
X104
X105
RIGHT TAN 4-1

ORANGE 55-5
5 4 6
MOTOR TAN 3-1

RIGHT ORANGE 55-3 (10)
A2
TAN 55-1
BLU/ORN 52-2
WHITE
15 3
BLU/ORN 52-3
+
BLACK
ORANGE 55-7(10) YEL/RED 2-5(10)
A1
A1
ORANGE 55-8 YEL/RED 2-2

5 1 2 4 3
LEFT YEL/RED 2-3

X103
BRAKE
X101
ORANGE 55-9 ORN/RED 49-5

1
LEFT ORN/RED 49-6

ORANGE 55-10(10)
2
MOTOR
A2
ORN/RED 49-7
A2 4
WHITE BLACK (10)
X105 X101 X104
X102 X103
END VIEW OF MC-1 BOX

4932960 A SHOWING X CONNECTOR LOCATION
Figure 3-3. VP Electrical Diagram. (VP Series - Standard)
3-8 – JLG Lift – 3120728

LEFT PHP RIGHT PHP

LIMIT SWITCH LIMIT SWITCH
ORN/RED 49-2 BLACK
A
TRAVEL, DESCENT,
MOTION ALARM
OPTION
BLACK
A
RIGHT BRAKE LEFT BRAKE
LIMIT SWITCH LIMIT SWITCH
ORN/RED 49-4 BLACK
A
N.O.H.C. N.O.H.C.
ORN/RED 49-1
BLACK 55-2
BLU/ORN 52-1
ORN/RED 49-3
TAN 55-1
LIFT UP/DOWN
GROUND CONTROL SWITCH
YEL/RED 2-5
FUSE MOTOR
5 AMP PUMP
YEL/RED 2-6
TAN 4-1
LIFT DOWN LIFT UP
YEL/RED 2-6
YEL/RED 2-6
PUMP
ORN/RED 49-1 CONTACTOR
BLU/ORN 52-1
ORN/RED 49-3
TAN 4-1
TAN 3-1
TAN 55-1
TAN 55-1 HOURMETER
YEL/RED 2-2 A
BLU/ORN 52-2 OPTION BLACK 00000 GROUND
BLU/ORN 52-3 KEY SWITCH E-STOP CONTROL
EXTERNAL A RELAY
86 HORN A YEL/RED 2-1 87
OPTION 87A
BLACK BLU/ORN B YEL/RED 2-7
87 RED 1-1 YEL/RED 2-8
85 52-4 30
YEL/RED 2-4 86 85
RED 1-1
A 30 87A MAIN GROUND CONTROL BOX

BLACK
87 87A CONTACTOR
HORN
RELAY YEL/RED 2-4
86 85
A
BLACK
30 5 AMP
YEL/RED 2-5 BLACK FUSE
POWER
RELAY A
YEL/RED 2-5(10) A A 12V 12V
YEL/RED 2-2
YEL/RED 2-3 ELEVATION / SPEED

CUTBACK SWITCH
ORN/RED 49-5 BLACK
ORN/RED 49-6 RED (10)
A
ORN/RED 49-7 BLACK (10)
BLACK (10)
YEL/RED 2-5
KEY SWITCH
BLACK
1 2 3
A X
B X
GREEN
1 = PLATFORM
CHARGER 2 = OFF
WHITE 3 = GROUND
TILT SENSOR
BLACK BLACK 1.5°
A 4932960 A
Figure 3-3. VP Electrical Diagram. (VP Series - Standard)
3120728 – JLG Lift – 3-9

BATTERY BATTERY
(LEFT SIDE) (RIGHT SIDE)
(–) (+)
(+) TO PUMP (–)

MOTOR
SOLENOID
BEACON
MASTER ON/OFF
SWITCH
HORN
MAIN
CONTACTOR
MOTION RELAY
ALARM
80 AMP FUSE
FR
HOURMETER CONOM X101
NEC
TO R
TO
BATTERY
TERMINAL
GROUND
CONTROL
BOX
5
CIRCUIT BREAKER PANEL FROM X10 R
O N N E C TO
C
PUMP START
CONTACTOR
MANUAL DUMP
OVERRIDE/
VALVE
LIFT DOWN
VALVE
PUMP/MOTOR
ASSEMBLY
POT-HOLE
PROTECTION
LIMIT
SWITCHES
Figure 3-4. Overview of VP UL-EE Approved Optional Electrical System. (Sheet 1 of 2)
3-10 – JLG Lift – 3120728

LAPTOP COMPUTER
(remove existing connector
at X105 port on the MC-1 controller box PLATFORM
and plug-in the laptop computer. CONTROL
Requires P/N-2900868 Configuration Kit.) BOX
TILT
SENSOR
SWITCH
TO + TO
BATTERY BATTERY
TERMINAL TERMINAL
USE WIRING
DIAGRAM
FIGURE 3-3.
THIS SECTION
OF THE
MANUAL WITH
THIS PICTORIAL TO
WIRING DIAGRAM BATTERY
CHARGER
ELEVATION CUTOUT
LIMIT SWITCH
SWITCH
X105
FROM X101 X101
CONNECTO
R X104
05
X1 R
O M CT O PLATFORM MC-1
FR NNE CONTROLLER CONTROLLER BOX
CO
GROUND X103
CONTROLS DRIVE MOTOR
SWITCH POWER LEADS
(LIFT UP/LIFT DOWN) BRAKE
GROUND RELEASE
CONTROLS WIRING
RELAY
EXTERNAL
DRIVE/HORN
RELAY BRAKE
CONTACTOR RELEASE
RELAY WIRING
BRAKE LIMIT
SWITCH
WIRING
DRIVE MOTOR MOTOR/BRAKE

ASSEMBLY
POWER LEADS MOTOR/BRAKE (RIGHT SIDE)
ASSEMBLY
(LEFT SIDE)
Figure 3-4. Overview of VP UL-EE Approved Optional Electrical System. (Sheet 2 of 2)
3120728 – JLG Lift – 3-11

X101 PIN X105 PIN

B+ A1 PINS USED FOR RX DO 7
B+ CONTROL 3 COMMUNICATION
TX DO 8
TO SERIAL PORT
MAIN POWER DISCONNECT 5 ON LAPTOP OR PC. GROUND 13
ELEVATION SWITCH 1 LIFT UP 4
TILT CUTOUT 2 LIFT DOWN 6
CHARGER INTERLOCK 4 PUMP CONTACTOR 5
B– A2 DRIVE CUTOUT 12
BRAKE STATUS 11
X102 PIN
HORN 15
B+ 15
ALARMS 14
EMERGENCY STOP 14
HOURMETER 3
CAN-LO 13
CAN-HI 5
CENTER DETECT 6
B– 1
EMERGENCY STOP 7
X103 – LEFT MOTOR PIN X104 – RIGHT MOTOR PIN

BRAKE 1 5 BRAKE 1 5
BRAKE2 3 BRAKE 2 2
HORN
RELAY
X105 X101 X104
X102 X103
END VIEW OF MC-1 BOX

SHOWING X CONNECTOR LOCATION
Figure 3-5. VP Electrical Diagram. (with UL-EE Approved Option)
3-12 – JLG Lift – 3120728

MOTION
ALARM
BREAKER
PUMP FUSE
POWER
RELAY
BEACON BRKR.
PUMP VALVES
TILT BEAKER
BREAKER
KEY SWITCH BREAKER
4933134_A
Figure 3-5 VP Electrical Diagram. (with UL-EE Approved Option)
3120728 – JLG Lift – 3-13

CYLINDER
PRES.
COMPENSATED RETURN TUBE
FLOW VALVE
SOLENOID
WITH
EXTEND TUBE MANUAL
OVERRIDE
SOLENOID
TWO POSITION/TWO FILTER/SCREEN
WAY DUMP VALVE
CHECK
FILTER/
VALVE
SCREEN
ADJ. RELIEF
PUMP ENDHEAD
VALVE
MOTOR PUMP
TANK FILTER/SCREEN
1282953
Figure 3-6. Hydraulic Diagram. (VP Series)
3-14 – JLG Lift – 3120728

3.5 TROUBLESHOOTING SECTION - TABLE OF CONTENTS
OHM RATINGS FOR VARIOUS COMPONENTS PAGE

Ohm Ratings for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
MAIN POWER CIRCUIT TROUBLESHOOTING

Unit Will Not Power Up From Ground Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
No Power At Platform Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
DRIVE TRAIN TROUBLESHOOTING
Won’t Drive (Platform Lowered Or Elevated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Won’t Drive (Platform Elevated Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Won’t Climb Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Drives In Opposite Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Will Only Drive A Short Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Won’t Drive Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Noise From Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
MAST TROUBLESHOOTING
Platform Will Not Lift Up Using Platform Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Platform Will Not Lower Using Platform Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Platform Will Not Lift Up From Ground Control Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Platform Will Not Lower From Ground Control Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Platform Will Not Lower Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Platform Lift Up And Down Jerky . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Mast Noisy When Lifting And Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Platform (Mast) Won’t Stay Elevated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Platform (Mast) Descends Too Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
HYDRAULIC LEAK TROUBLESHOOTING

Miscellaneous Hydraulic Leak Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
BASE FRAME COMPONENTS TROUBLESHOOTING

Caster Wheels Not Operating Freely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Pot Hole Protection (PHP) Bars Will Not Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3120728 – JLG Lift – 3-15

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
Main Contactor 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
Brake Coil 44.7ohm - 52ohm @ 68deg F 31.4ohm - 65.3ohm
Drive Motor (Bodine) .1 to .3ohm

(Can change depending on the rotation of the N/A
armature and temperature.)
3-16 – JLG Lift – 3120728

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.
• Key switch positioned to Ground (GRND) control.
• Emergency stop switch pulled out. (Reset Position)
Table 3-4. Unit will not Power Up From Ground Control.

STEP ACTION SPEC YES NO
1. Check the 5 amp inline fuse on the Red 1-1 wire from the battery (+)
terminal to the ground control box, key switch. 24 volts OK, go to Step 2 Replace Fuse
(Under pump/motor cover).
Ground Control Box Assembly (Disassembled)
2. Is there 24 volts or more reading at the key switch, terminal B. Check Wiring
from Battery to
24 volts Go to Step 3
Terminal B.
Repair or Replace
3. Check for 24 volts or more on the Yel/Red, 2-7 wire from the key Repair wiring or
switch to the E-stop switch. 24 volts Go to Step 4 Replace Key
Switch
4. Check for 24 volts or more on the Yel/Red, 2-8 wire from the E-stop Repair wiring or
to the Ground Control Relay, terminal 86. — Go to Step 5 Replace E-Stop
Switch
5. Check for 24 volts or more on the Yel/Red, 2-4 wire from the E-stop Repair wiring or
to the Main Contactor Relay, terminal 87. — Go to Step 6 Replace E-Stop
Switch
Main Contactor Circuit
6. Check for 24 volts or more on the Yel/Red, 2-4 wire from the Main Repair wiring or
Contactor Relay, terminal 87 to the Main Contactor. — Go to Step 7 Replace Main
Contactor Relay
7. Did Main Contactor close? — Go to Step 9 Go to Step 8
8. Is the Black ground wire connection from the Main Contactor to Replace Main Repair Ground
ground OK? —
Contactor Wiring
9. At this point, 24 volts should be present at the following terminal
points; • Terminal 86 on the Ground Control Relay. — — —
• Main Contactor, Yel/Red, 2-4 wire.
10. With Main Contactor engaged, 24 volts or more should be present at
the following terminal points;
• Pump Motor - 21’ cable #1. — — —
• Yel/Red, 2-6 wire on the Pump Contactor.
• Yel/Red, 2-6 wires on the Lift Up/Down Relay.
3120728 – JLG Lift – 3-17

No Power At Platform Control
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.

• Keyswitch is turned to PLAT. (Platform)
• Both Emergency Stop Switches Reset (Ground/Platform). (Out)
• Connection of X102 Cable from MC-1 box to Platform Control, secure on both ends.
Table 3-5. No Power At Platform Control.

1. Check if the inline 5 amp fuse is blown on the Red, 1-1 wire at the
— If OK, go to Step 2 Replace Fuse
ground control station. (Ground control cover must be removed)
2. Check voltage to the Yel/Red, 2-2 wire at the MC-1 box, X101 con- Perform the E-
nector, pin 3. Stop/Key Switch
Circuit Check
(Table 3-17)
3. Check for Ground to the Black wire at the MC-1 box, X101 connec- Check connec-
tor, pin A2. tion/wiring
Ground Go to Step 4
between Battery
and X101, Pin A2
4. Check voltage to the Yel/Red, 2-3 wire at the MC-1 box, X101 con- Replace MC-1
nector, pin 5. Control Box
5. Check voltage to the Yel/Red, 2-5 wire at the MC-1 box, X101 con-
24 volts Go to Step 13 Go to Step 6
nector, pin A1.
6. Check voltage to the Yel/Red, 2-2 wire at the MC-1 box, X101 con- Check the wire
nector, pin 3, from the Power Relay pin 30. between the
24 volts Go to Step7
Power Relay and
Connection
7. Check voltage to the Power Relay, pin 87. 24 volts Go to Step 9 Go to Step 8
8. Check for Ground to the Power Relay on the Black wire pin 85, to Check wiring to
Ground. Ground Replace Relay Ground
Connection
9. Check voltage to the Yel/Red, 2-4 wire at the Main Contactor from Check the Yel/
the Power Relay, pin 87. 24 volts Go to Step 10
Red, 2-4 Wiring
10. Check for Ground, on the Black wire to the Main Contactor. Check wiring to
Ground Go to Step 11 Ground
Connection
11. Check voltage at the Battery Cable from Battery to Main Contactor. Check Battery
Cable
12. Check voltage to the Yel/Red, 2-5 wire at the Main Contactor. Check Yel/Red 2- Replace Main
24 volts
5 Wire Contactor
3-18 – JLG Lift – 3120728

Table 3-5. No Power At Platform Control.
13. Check voltage on the Red/Blk wire at the MC-1 box, X102 connec- Replace MC-1
tor, pin 15, to the Platform Control. Box
14. Check for Ground on the BRN wire at the MC-1 box, X102 connector, Replace MC-1
Ground Go to Step 15
pin 1, to the Platform Control. Box
15. Check voltage on the Red/Blk wire, pin 9 on the Platform Control
24 volts Go to Step 16 Replace Cable
box.
16. Check for Ground on the BRN wire, pin 8 on the Platform Control Replace Platform
box. Ground Replace Cable
Control
3120728 – JLG Lift – 3-19

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
The following procedures check the components and circuits that feed data to the MC-1 Controller box assuring it is receiv-
ing the proper signals and conditions before engaging the machines’ drive motors.

• Joystick Powered On
• Unit will Lift & Lower Platform
• Machine is not Tilted - (3 LEDs flashing at joystick control)
• PHP Device is not Obstructed - (4 LEDs flashing at joystick control)
• Brakes are not Released - (2 LEDs flashing at joystick control)
• Charger is not Plugged In - (8 LEDs flashing at joystick control)
Table 3-6. Won’t Drive. (Platform Lowered or Elevated)

1. Check for ground from elevation limit switch in the X101 connector, Check Elevation
pin 1 (49-5) at MC-1 box. — Go to Step 2 Limit Switch
Circuit (Table 3-7)
2. Check for ground from charger circuit wire in the X101 connector,
pin 4 (49-7) at MC-1 box. (Perform this check with the charger — Faulty Charger Go to Step 3
unplugged)
3. Check for ground from brake limit switches in the X105 connector, Check Brake
pin 11 at MC-1 box. — Go to Step 4 Limit Switch Cir-
cuit (Table 3-8)
4. Check that brakes are releasing, (2 LEDs) when joystick is enabled Check Drive Check Brake
& moved forward. — Motor Circuit Switch/Circuit
(Table 3-9) (Table 3-10)
Table 3-7. Elevation Switch Circuit Check
• Perform these checks at the elevation switch which is located inside the top of mast section-1.
• Check with mast lowered.
1. Check for ground into the switch from ground connection. Repair
— Go to Step 2
Connection
2. Check for ground out of switch to the 49-5 wire. Adjust/Replace
— Go to Step 3
Switch
3. Check for ground from switch to X101, Pin 1. Repair Wire or
— —
Connection
3-20 – JLG Lift – 3120728

Table 3-8. Brake Limit Switch Circuit Check

1. Check for ground into the switch from the ground connection on the Repair
— Go to Step 2
left brake limit switch. Connection
2. Check for ground on the 49-4 wire coming out of left brake limit Adjust/Replace
— Go to Step 3
switch. Switch
3. Check for ground on the 49-4 wire going into the right brake limit Repair/Replace
switch. — Go to Step 4
49-4 wire
4. Check for gound on the 49-3 side of the right brake limit switch. Replace Repair wire or
—
MC-1 box Connection
Table 3-9. Drive Motor/Circuit Check
• Perform these checks with the joystick enabled and pushed to the full forward position.
1. Check for 24 volts at the drive motor on the 55-3 wire on the right Problem with
motor and the 55-7 wire on the left drive motor. (Positive Side) 24 volts Go the Step 2
Motor
2. Check for 24 volts at the 55-3 wire at the X104 connector, pin A2 (for
Check wiring and Problem in MC-1
right motor) and the 55-7 wire at the X103 connector, pin A1 (for left 24 volts
motor). connections box or Joystick
Table 3-10. Brake Switch/Circuit Check
• Perform these checks with the joystick enabled and pushed to the full forward position.
1. Check for 24 volts at the wiring connectors on the 55-4 wire on the Clean, Gap or
right drive motor brake unit and the 55-8 wire on the left drive motor 24 volts Replace Brake Go to Step 2
brake unit. Unit
2. Check for 24 volts at the 55-4 wire at the X104 connector, pin 5(for Check wiring and Problem in MC-1
right motor) and the 55-8 wire at the X103 connector, pin 5 (for left 24 volts
connections box or Joystick
motor).
3120728 – JLG Lift – 3-21

Won’t Drive (Platform Elevated Only)
The following procedures check the components and circuits that feed data to the MC-1 Controller box assuring it is receiv-
ing the proper signals and conditions before engaging the machines’ drive motors.

• Joystick Powered On
• Unit will Lift & Lower Platform
• Machine is not Tilted - (3 LEDs flashing at joystick control)
• PHP Device is not Obstructed - (4 LEDs flashing at joystick control)
• Brakes are not Released - (2 LEDs flashing at joystick control)
• Charger is not Plugged In - (8 LEDs flashing at joystick control)
Table 3-11. Won’t Drive with Platform Elevated

1. Check for ground on tilt circuit at MC-1 box, X101 connector, pin 2, Check Tilt Sensor
(O/R, 49-6 wire). — Go to Step 2 Circuit (Table 3-
12)
2. Check for ground on PHP circuit at MC-1 box, X105 connector, pin Check PHP
Problem in MC-1
12, (O/R, 49-1 wire). — Switch Circuit
controller box
(Table 3-13)
Table 3-12. Tilt Sensor Circuit Check
• No ground at MC-1 box, X101 connector, pin 2, (O/R, 49-6 wire).

1. Is tilt sensor light on showing a tilt condition, even though machine is Adjust tilt sensor
— Go to Step 2
within tilt limit. if necessary
2. Check for ground on the Black wire (direct to ground) running into tilt Repair
— Go to Step 3
sensor. (Continuity to B-) Connection
3. Check for 24 volts at the Green to (Y/R, 2-5) wire from the main con- Check Connec-
tactor relay. — Go to Step 4 tion to Main Con-
tactor Relay
4. Check for ground on the White to (O/R, 49-6) wire at connector. Repair connec-
tion at the X101
Replace
— connector end/
Tilt Sensor
broken wire O/R
49-6
3-22 – JLG Lift – 3120728

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.
1. Check for ground on Black wire (direct to ground) on the right side Repair
— Go to Step 2
PHP limit switch. (Continuity to B –) Connection
2. Check for ground on O/R, 49-2 wire to left PHP limit switch. Adjust/Replace
— Go to Step 3
Right Switch
3. Check for ground on O/R, 49-1 wire to MC-1 box, X105 connector, Repair connec-
Adjust/Replace
pin 12. — tion at the X105
Left Switch
connector end
3120728 – JLG Lift – 3-23

Won’t Climb Grade
The following procedure checks the drive motor and attached components for component failure, misadjustment due to
wear.

• Batteries are Fully Charged (24 Volts)
• Speed Control is Set to Maximum
• Is Grade within the Maximum Allowable Specification of 15% Grade (8.5 degrees)
• Does the Travel Surface allow for Proper Drive Wheel Traction
• Is Platform Load within the Maximum Rated Capacity
Table 3-14. Won’t Climb Grade

1. Does machine drive straight on a level surface? Refer to Machine
Won’t Drive
— Go to Step 2
Straight
(Table 3-18)
2. Are both the left and right drive motor, slip-clutches, located Repair, Replace
between the drive motor and the drive wheels, working properly? — Go to Step 3 or Adjust Slip
Clutch
3. Do the left and right drive motor brakes release properly and allow Dragging?
the drive wheels to rotate freely ? — Go to Step 4 Repair, Replace
or Adjust Brakes
4. Check the amperage output of the on the drive motor leads. They Controller will
should not exceed 70 amps while pulling a grade. Shut Drive Down
— Go to Step 5
and will flash a 7
LED Code
5. Check the condition of the drive motor brushes. Worn down,
— OK, go to Step 6 replace brushes
or drive motor
6. If all above is OK, Drive motors are working properly. Consult Fac-
— — —
tory.
3-24 – JLG Lift – 3120728

Drives In Opposite Direction
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.

• If the Left Drive Motor (X103) connector is switched with the Right Drive Motor (X104) connector at the MC-1 box, you will
immediately get an 2 LED flashing Error Code at the Platform Control when the machine is powered up.
• Check Joystick Calibration (See Procedure in Service Manual, Section-2).
Table 3-15. Drives In Opposite Direction

1. Check the connection of the Orange, 55-3 wire to the right drive * Repair or
motor at both ends;
— Go to Step 2 Replace
• At the X104 connector on the MC-1 box, pin A1.
• And the Black wire at the Drive Motor end. Connection
2. Check the connection of the Orange, 55-6 wire to the right drive * Repair or
motor at both ends;
• And the White wire at the Drive Motor end. Connection
3. Check the connection of the Orange, 55-7 wire to the left drive motor * Repair or
at both ends;
• And the Black wire at the Drive Motor end. Connection
4. Check the connection of the Orange, 55-10 wire to the left drive * Repair or
motor at both ends;
• And the White wire at the Drive Motor end. Connection
5. Is platform control box under warranty? ** — Order New One Go to Step 6

6. Internal to the platform control - check that the joystick assembly Re-install
inside the platform control has not been installed backwards. — Go to Step 7
Correctly
7. Internal to the platform control - check that the joystick assembly Re-install
— Consult Factory
wiring to the platform control circuit card is not wired backwards. Correctly
* Note: If the Orange, 55-3 or 55-6 wires to the right drive motor in the X104 connector or the Orange, 55-7 or 55-10 wires to
the left drive motor in the X103 connector at the MC-1 controller are crossed up that drive motor will run backwards.
** Note: If platform controller is not under warranty, the internal components of the platform controller are replaceable and
can be ordered and replaced seperately from the complete platform control box. See procedures in Section-2 of
this Service Manual for Joystick Assembly/ Disassembly.
3120728 – JLG Lift – 3-25

Will Only Drive A Short Distance
The following procedure will eliminate any problems found in the power circuit to the MC-1 controller box and also any
objectionable environmental conditions.

• Is Battery Voltage 24 Volts? (Fully Charge Batteries)
Table 3-16. Only Drives A Short Distance

1. Is platform controller staying powered up when machine stops driv- Check the E-Stop
ing? & Key Switch
— Go to Step 2
Circuit
(Table 3-17)
2. Check the voltage out of the X101 connector, pin 5, to the power Repair or Replace
relay pin 86. Check continuity at pin 85. 24 Volts Go to Step 3 Wires, or Problem
with MC-1 Box
3. Check the voltage from pin 87 on the power relay to the main con- Repair or Replace
24 Volts Go to Step 4
tactor. (Main contactor should be closed at this point) Wires or Relay
4. Check the voltage on the Yel/Red, 2-5 wire on the X101 connector, Repair or Replace
pin A1, from the main contactor. 24 Volts Go to Step 5 Wires or Main
Contactor
5. What type of surface is machine being operated on? Is surface soft, Machine will not
unstable or up a steep grade? perform well on a
soft or unstable
surface, if motor
— draw is over 70 Go to Step 6
amps, controller
will shut the
machine down.
( 7 LED Code)
6. Are brakes releasing when trying to drive? Repair/Replace
or Adjust Drive
— Go to Step 7 Brakes
(See Procedure in
Service Manual)
7. Is drive system running free? No noise or dragging. Repair/Replace
or Adjust Drive
— Go to Step 8 System
(See Procedure in
Service Manual)
8. Is machine being operated in an environment with high static Machine may be
charge? building static
charge in the MC-
— 1 controller, —
which will make
the drive system
shut down.
3-26 – JLG Lift – 3120728

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.
1. 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 24 Volts Circuit is OK Go to Step 2
X101 connector and pin 30 on the Power Relay.
2. KEY SET TO GROUND: Check voltage on the Yel/Red, 2-4 wire com-
ing out of the ground control box assembly to pin 87 on the power
24 Volts Circuit is OK Go to Step 3
relay, and main contactor. Yel/Red 2-8 wire to pin 86 on the ground
relay.
3. Open the Ground Control Box Assembly (housing with key switch Repair connec-
and E-stop switch mounted inside) and check the voltage on the Yel/
24 Volts tion to or replace Go to Step 3
Red, 2-1 wire leading into the emergency stop switch from the Key
switch. E-Stop switch
4. Check voltage on the Red, 1-1 wire leading into the Key switch. Repair connec-
24 Volts tion to or replace Go to Step 4
key switch
5. Check voltage and continuity through the 5 amp fuse mounted inline Replace Fuse or
outside of the ground control box assembly, on the Red, 1-1 wire. 24 Volts Go to Step 6 Fuse Holder if
damaged
6. Check connection at battery. 24 Volts Circuit OK N/A
3120728 – JLG Lift – 3-27

Won’t Drive Straight
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.

• Nothing is lodged between one of the wheels and the base frame.
• A caster wheel on the front of the machine is seized up, creating resistance.
• Joystick properly calibrated per procedure in Section-2 of Service Manual.
Table 3-18. Won’t Drive Straight.

1. Check for the following on the drive assembly, drive attachment Repair/Replace/
— Go to Step 2
weldment; is bent, has broken welds, or loose hardware. Tighten weldment
2. Check for the following on the drive assembly, drive motor mounting
Repair/Replace/
plates; are bent, are square with drive weldments, or is hardware — Go to Step 3
Tighten weldment
loose?
3. Check for the following on the drive assembly, drive motor hard- Repair/Replace/
ware; is hardware loose, flange bearing - bad/loose, slip clutch - — Tighten compo- Go to Step 4
check torque settings or adjustment. nent
4. Check the left and right drive motor brakes for loose hardware & not Tighten or Adjust
releasing properly. per procedure
— Go to Step 5
in this
Service Manual
5. Inside the drive motor gear box check if; the drive shaft is exces- Repair/Replace
sively loose & conditon of drive shaft bearings. components per
Are any gears broken or gear teeth excessively worn. — Go to Step 6
procedure in this
Service Manual
6. Is the electrical signal and amperage draw to the drive motors 24 volts Recheck Steps
Go to Step 7
equal? 15 amps 1 thru 5
7. Check the drive motor brushes, do they need replaced? Replace per
— procedure in this Go to Step 8
Service Manual
8. Is the X102 wiring harness (from platform contol box to MC-1 box) Repair or Replace
damaged, check wiring harness visually and individual wires with — Harness as Go to Step 9
ohm meter. Required
9. Is joystick control defective? Repair/Replace
— Go to Step 10
If possible, swap out with another platform control. Platform control
10. Is MC-1 control box defective or connections not tight? Tighten Connec-
If possible, swap out with another MC-1 control box. — tions or Replace —
MC-1 box
3-28 – JLG Lift – 3120728

Noise From Drive Assembly
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.

• Nothing is lodged between one of the wheels and the base frame.
• A caster wheel on the front of the machine is seized up, creating resistance.
Table 3-19. Noise from Drive Assembly.

1. Check for the following on the drive assembly, drive attachment Repair/Replace/
weldment; is bent, has broken welds, or loose hardware. — Go to Step 2
Tighten weldment
2. Check for the following on the drive assembly, drive motor mounting
Repair/Replace/
plates; are bent, are square with drive weldments, or is hardware — Go to Step 3
loose? Tighten weldment
3. Check for the following on the drive assembly, drive motor hard- Repair/Replace/
ware; is hardware loose, flange bearing - bad/loose, slip clutch - — Tighten Go to Step 4
check torque settings or adjustment. Component
4. Check the left and right drive motor brakes for loose hardware & not Tighten or Adjust
releasing properly. per procedure
— Go to Step 5
in this
Service Manual
5. Inside the drive motor gear box check if; the drive shaft is exces- Repair/Replace
sively loose & conditon of drive shaft bearings. components per
Are any gears broken or gear teeth excessively worn. — Go to Step 6
procedure in this
Service Manual
6. Is the electrical signal and amperage draw to the drive motors 24 volts Recheck Steps
equal? Go to Step 7
15 amps 1 thru 5
7. Check the drive motor brushes, do they need replaced? Replace per
— procedure in this —
Service Manual
3120728 – JLG Lift – 3-29

3.9 MAST TROUBLESHOOTING
Platform Will Not Lift Up Using Platform Control
This procedure examines the complete pump motor, ground control and pump valves electrical circuits.

• 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.

1. Will platform lift from ground control switch?
— Go to Step 2 See (Figure 3-24)
Note: Key switch must be set to GRND to test this.
2. Does pump motor run? See Pump Circuit
— Go to Step 3 Check
(Table 3-21 )
3. Are the down and dump valves opening/closing properly? See Pump Valves
Note: If machine will not lift and hydraulic oil is visible flowing in the — Go to Step 4 Circuit Check
hydraulic tank, the dump valve is stuck in the open position. (Table 3-22 )
4. Is the pressure set properly on the pump? Set to correct
pressure specifi-
— Go to Step 5
cation per this
Service Manual
5. Is the lift cylinder OK? Rebuild or
— Go to Step 6
Replace Lift Cyl.
6. Are the mast sections operating freely? Check Mast,
Consult
— Rebuild
Factory
if Necessary
3-30 – JLG Lift – 3120728

Table 3-21. Pump Circuit

• Key switch set to Platform .
1. At the pump motor, check for 24 volts at both ends of the battery Tighten
cable running from the main contactor to the pump case stud. (left Connection or
side) 24 volts Go to Step 2
Replace Cable
if Necessary
PUMP CONTACTOR RELAY CIRCUIT
2. Check the connection of the ground cable (attached to 5/16" stud, Tighten
left side) to the pump contactor, is tight and connected on other end Connection or
to B- at the right side battery. Ground Go to Step 3
Replace Cable
if Necessary
3. Check the connection of the ground cable (other side) is tight and Tighten
connected to the pump case stud (center). Connection or
Ground Go to Step 4
Replace Cable
if Necessary
4. Check the Yel/Red, 2-6 wire connected to the positive post on the Tighten/Repair
pump case for tightness and 24 volt reading. 24 volts Go to Step 5
Connection
5. Check the Tan, 55-1 wire connected to both the Ground control
switch and the MC-1 box, X105 connector, pin 5 through the pump Tighten/Repair
Ground Go to Step 6
contactor relay. Without any lift functions activated, it should show Connection
24 volts, with a lift function activated it should show ground.
DUMP VALVE CIRCUIT
6. Check the Yel/Red, 2-6 wire connected to the positive (+) post on Tighten/Repair
the pump case for 24 volts. 24 volts Go to Step 7
Connection
switch and the MC-1 box, X105 connector, pin 4 through the lift up Tighten/Repair
valve. Without any lift function activated, it should show 24 volts, Connection
with a lift function activated it should show ground.
DOWN VALVE CIRCUIT
8. Check the Yel/Red, 2-6 wire connected to the positive (+) post on Tighten/Repair
the pump case for 24 volts. 24 volts Go to Step 9
Connection
switch and the MC-1 box, X105 connector, pin 6 through the lift Tighten/Repair
down valve. Without any lift functions, it should show 24 volts, with Connection
a lift function it should show ground.
MAIN CONTACTOR CIRCUIT
10. Check the battery cable from the B+ (left side) battery for 24 volts. Tighten/Repair
Connection
11. Check the battery cable going out to the pump case (left side) stud Tighten/Repair
for 24 volts. Connection
12. Check the Yel/Red, 2-5 (10 ga.) wire to the MC-1 box, X101 connec- Tighten/Repair
tor, pin A1 for 24 volts. Connection
13. Check the Yel/Red, 2-4 wire to the Power Relay, pin #87 for 24 Tighten/Repair
volts. 24 volts Go to Step 14
Connection
3120728 – JLG Lift – 3-31

Table 3-21. Pump Circuit
14. Check the Black to ground on the pump contactor. Tighten/Repair

Ground Go to Step 15
Connection
POWER RELAY CIRCUIT
15. 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. Tighten/Repair
Note: Power will stop at diode, silver line should be away from the E- Connection
Stop.
16. Check the Yel/Red, 2-2 wire, #30 on the Power Relay to the E-stop Tighten/Repair
and to the MC-1 box, X101 connector pin 3, for 24 volts. Connection
17. Check the Black, #85 pin on the Power Relay for connection to Tighten/Repair
ground at pump contactor. Ground Go to Step
Connection
18. Check the Yel/Red, 2-3 wire, #86 on the Power Relay to the MC-1
Tighten/Repair
box, X101 connector pin 5, for 24 volts when the platform control is — Go to Step
powered up. Connection
Table 3-22. Pump Valves Circuit

• Set key switch to Platform and set the Emergency Stop Button to the RESET position.
• Down Valve should be normal (closed).
• Dump Valve (up) should be normal (open).
• If machine will not lift and hydraulic oil is visible flowing in the hydraulic tank, the dump valve is stuck open.
LIFT UP - (CONDITIONS WHEN PUMP MOTOR IS RUNNING)
1. Pump Contactor Coil: Yel/Red, 2-6 wire - 24 volts
— — —
Tan, 55-1 wire - Ground
2. Lift Up Valve Coil: Yel/Red, 2-6 wire - 24 volts
— — —
LIFT UP - (CHECK WHEN PUMP MOTOR IS NOT RUNNING)
3. Pump Contactor Coil: Yel/Red, 2-6 wire - 24 volts
— — —
Tan, 55-1 wire - 24 volts
4. Lift Up Valve Coil: Yel/Red, 2-6 wire - 24 volts
— — —
LIFT DOWN - (CHECK WHEN DOWN AND ENABLE PADS ARE PUSHED ON THE PLATFORM CONTROL)
5. Lift Down Valve Coil:Yel/Red, 2-6 wire - 24 volts
— — —
LIFT DOWN - (CHECK WHEN NO FUNCTION ARE ENABLED ON THE PLATFORM CONTROL)
6. Lift Down Valve Coil:Yel/Red, 2-6 wire - 24 volts
— — —
3-32 – JLG Lift – 3120728

Platform Will Not Lower Using Platform Control
This procedure tests for ground coming out of the MC-1 box to the dump valve circuit and through to the ground control tog-
gle switch.

• Hydraulic oil is within it’s specified operating temperature range.
Table 3-23. Platform Will Not Lower Using Platform Control.

1. Will machine lower manually, using the manual descent knob? — Go to Step 2 See (Table 3-26)
2. Will machine lower from ground control switch?
— Go to Step 3 See (Table 3-23)
Note: Key switch must be set to GRND to check this.
3. Check for ground on the Tan, 4-1 wire at the MC-1 box, X105 con- Repair/Replace
nector, pin 6. — Go to Step 4 Joystick/
MC-1 Box
4. Check for ground on the Tan, 4-1 wire at the lift down coil. Replace/Repair
— Go to Step 5 Wire or
Connection
5. Check complete pump motor circuit . (See Table 3-21) — — —
3120728 – JLG Lift – 3-33

Platform Will Not Lift Up From Ground Control Toggle Switch
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.

• Emergency stop switch pulled out. (Reset Position)
• Ground control power supply and wiring, OK (Table 3-4).
• Manual descent valve closed.
• 5 amp fuses on power and pump circuits, OK.
• Hydraulic oil level, OK.
• Weight in platform does not exceed machine maximum capacity.
Table 3-24. Unit Will Not Lift Up From Ground Control Toggle Switch.
1. Does the pump motor run when lift up is selected at the ground con- Check Ground
trol switch? Power Circuit
Go to Steps 5,6
— (Table 3-4)
Note: Steps 2 thru 9 are to be performed with LIFT UP selected at the and 10
Before Continu-
ground control. ing to Step 3
2. Check terminal 30 and 85 on the ground control relay for ground. Is Repair Wiring or
Ground Go to Step 3
ground contact OK? Connection
3. Check continuity across terminals 87 and 30 on the ground control
— Go to Step 4 Replace Relay
relay. Is there continuity? (Relay must be energized)
4. Check the Black wire from terminal 87 on the ground control relay to Repair Wiring or
the lift up/down ground control switch. Is there continuity with B –? — Go to Step 5
Connection
5. Check for continuity across the terminals (Black to Tan 3-1 and Tan Replace Lift Up/
55-1) of the lift up/down ground control toggle switch. Is there con- — Go to Step 6 Down Ground
tinuity? Control Switch
6. Check the Tan, 3-1 wire for continuity from the lift up/down ground Repair Wiring or
— Go to Step 7
switch to the lift up coil. Is there continuity? Connection
7. Check the Tan, 55-1 wire from the lift up/down ground switch to the Repair Wiring or
pump contactor for continuity. Is there continuity? — Go to Step 8
Connection
8. Check the Yel/Red, 2-6 wire from the pump motor to the pump con- Repair Wiring or
24 Volts Go to Step 9
tactor and lift-up coil for voltage. Is there voltage? Connection
9. Check the wire from the lift switch (Tan 55-1) pump contactor to the Repair Wiring or
— —
battery (-) terminal for continuity. Is there continuity? Connection
10. Check the pump motor pressure relief setting. Is it within specifica-
— Set as Required
tion per Service Manual?
3-34 – JLG Lift – 3120728

Platform Will Not Lower From Ground Control Toggle Switch
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.

• Emergency stop switch set to the Reset position)
• Ground control power supply and wiring, OK (Table 3-4).
• 5 amp fuses on power and pump circuits, OK.
• Hydraulic oil level, OK.
Table 3-25. Unit Will Not Lower From Ground Control Toggle Switch.
1. Will machine lower manually? — Go to Step 3 Go to Step 2
2. Check for obstructions in the mast, cylinder, hydraulic lines and lift Repair, Replace
— Go to Step 3
down valve. or Adjust
3. Check terminal 30 and 85 on the ground control relay for ground. Is Repair Wiring or
Ground Go to Step 4
ground contact OK? Continuity with B–. Connection
4. Check continuity across terminals 87 and 30 on the ground control
Ground Go to Step 5 Replace Relay
relay. Is there continuity? (Relay must be energized)
5. Check the Black wire from terminal 87 on the ground control relay to Repair Wiring or
the lift up/down ground control switch. Is there continuity with B –? — Go to Step 6
Connection
6. Check for continuity across the terminals (Black to Tan, 4-1 wire) of Replace Lift Up/
the lift up/down ground control toggle switch. Is there continuity — Go to Step 7 Down Ground
with the switch activated? Control Switch
7. Check the Tan, 4-1 wire for continuity from the lift up/down ground Repair Wiring or
— Go to Step 7
switch to the lift-down coil. Is there continuity? Connection
8. Check the Yel/Red, 2-6 wire from the pump motor to the lift-down Repair Wiring or
coil for voltage. Is there voltage? 24 volts —
Connection
3120728 – JLG Lift – 3-35

Platform Will Not Lower Manually
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.

1. Check manual override solenoid with manual override (knob open). Go to Step 2 Open
2. Check Steps 1 thru 6 of ( Table 3-30) Repair Go to Step 3
3. Place the maximum capacity of weight in the Platform.
— Consult Factory
Does it Lower?
3-36 – JLG Lift – 3120728

Platform Lift Up And Down Jerky
The following procedure suggests areas on the machine which might attribute to erratic movement of the platform during lift
up and down.

• 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. Platform Lift Up and Down Jerky.

CONTROLS (ELECTRICAL)
1. Is platform control, enable, up or down pad defective or worn out? — Replace pad Go to Step 2
2. Loose connections , ground and power. Repair
— Go to Step 3
connection
3. Valve coils or solenoids keep opening and closing. Repair Connec-
— tion or Replace Go to Step 4
Valve
4. Problem internal to the MC-1 control box. — Replace box Go to Step 5
HYDRAULIC
5. Are the hydraulic valves working properly. — Replace Valve Go to Step 6
6. Pump drive cavitates. — Replace Pump Go to Step 7
7. Lift cylinder Rebuild or
— —
Replace Cylinder
3120728 – JLG Lift – 3-37

Mast Noisy When Lifting And Lowering
This procedure examines components of the mast itself and as well as it’s lifting components for dirt, debris, proper lubrica-
tion and operation.
Table 3-28. Mast Noisy when Lifting and Lowering.

1. Do slide pads and slide pad channels need to be cleaned of dust, Clean Pads and
dirt, or other debris? — Go to Step 2
Channels
2. Do chain/cables need to be lubricated per JLG specification in the Lubricate as
— Go to Step 3
Service Manual? Required
3. Are the chain/cable sheave wheels dry and need lubrication? Lubricate or
Note: Plastic wheels will howl on the sheave pin when they are dry.
— Replace Sheave Go to Step 4
Sheave wheels may seize to the sheave pin and the pin may turn in
the pin retainer blocks. Pins and Wheels
4. Are the sequence cables (located on the side of mast) chattering

when the springs are compressed? Clean Slide Pads/
Note: This noise is normal at the sequence cable sheave wheels
Channels or Re-
when the mast is completely lowered. However if the sequence — Go to Step 5
shim Mast per
cable chattering is happening no matter what position the mast is in,
it could be a result of the mast being shimmed to tight or dirt and Service Manual
debris in the slide pad channels causing the mast to be tight.
5. Is the bore of the lift cylinder dry? Replace Packing
— Go to Step 6
or Lift Cylinder
6. Are the bearings in the lift pump motor and pump drive worn? Repair or Replace
— Go to Step 7
Pump
7. Are the hydraulic lines vibrating together? Adjust the Posi-
— Go to Step 8
tion of the Lines
8. Check if the pump motor is loose to it’s mounting plate. Tighten pump
— mounting Go to Step 9
fasteners
9. Hydraulic oil could be cavatating inside the pump. Repair or Replace
— —
Pump
3-38 – JLG Lift – 3120728

Platform (Mast) Won’t Stay Elevated
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.

• Manual descent valve is closed tight.
Table 3-29. Platform (Mast) Won’t Stay Elevated.

1. Is the lift down valve stuck open? Repair or Clean
— Go to Step 2
Valve
2. Check the valve inside the pump, it could be stuck open. — Replace Pump Go to Step 3
3. Lift down valves could be open due to incorrect electrical signal. Check Pump
Valve Electrical
— Go to Step 4
Circuit
(Table 3-22)
4. Dump valve could be open due to incorrect electrical signal. Check Pump
Valve Electrical
— Go to Step 5
Circuit
(Table 3-22)
5. Oil could be passing around the lift cylinder bore packing. Replace or
— Rebuild the Lift —
Cylinder
3120728 – JLG Lift – 3-39

Platform (Mast) Descends Too Slowly

The following procedure examines the mast some hydraulic components for obstructions and defects.
Table 3-30. Platform (Mast) Descends Too Slowly.

1. Check mast slide pads shimmed to tight. — Reshim Mast Go to Step 2
2. Is there an obstruction in the mast? Remove
— Go to Step 3
Obstruction
3. The lift cylinder packing could be too tight in the bore of the cylinder Rebuild or
barrel. — Go to Step 4
Replace Cylinder
4. Check the flow valve on the extend hydraulic line for a restriction, i.e. Clean or Replace
— Go to Step 5
dirt. Flow Valve
5. Check if the lift down valve is opening completely. Clean or Replace
— Go to Step 6
Valve
6. Is there a restricted hydraulic line (smashed)? Replace Hydrau-
— —
lic Line
3-40 – JLG Lift – 3120728

3.10 HYDRAULIC LEAK TROUBLESHOOTING
Miscellaneous Hydraulic Leak Troubleshooting
This series of steps gives remedies for various areas of the machine where leaks could occur.
Table 3-31. Hydraulic Leak Troubleshooting

1. Oil leaking around the lift cylinder rod. Replace the Seal
at the end of the
— —
Piston and
Cylinder Barrel
2. Oil leaking around the cylinder fitting/flow valve. Tighten or
— —
Replace Fittings
3. Oil leaking around the hydraulic lines. Tighten or
— Replace —
Hydraulic Lines
4. Oil leaking around the lift up valve. Tight Cartridge in
— —
Pump Case
5. Oil leaking around the lift down valve. Tighten Cartridge
— —
in Pump Case
6. Oil leaking around the (Red) manual descent valve. Replace Lift
— —
Down Valve
Note: Do not overtighten the nut on the solenoid in steps 4, 5, and 6.
3120728 – JLG Lift – 3-41

3.11 BASE FRAME COMPONENTS TROUBLESHOOTING
Caster Wheels Not Operating Freely

• Is machine operating on a smooth, level surface?
Table 3-32. Caster Wheels Not Operating Freely.

1. Is the caster rotating freely? Lubricate or
— Go to Step 2 Replace Caster
Housing
2. Is the wheel spinning freely? Lubricate or
— Go toStep 3
Replace Wheel
3. Is debris stuck in the plastic wheel? Remove Debris or
— —
Replace Wheel
Pot Hole Protection (PHP) Bars Will Not Set

• Obstruction under pot hole bar on either side of machine.
• Obstruction around the actuator assembly at the base of the mast.
Table 3-33. Pot Hole Protection (PHP) Bars Will Not Set.
1. Check the actuator cables for adjustment or damage. — Adjust or Replace Go to Step 2
2. Check the PHP limit switch(s) at both sides of the machine for dam-
Replace, Adjust
age, adjustment and for continuity through switch to ground when — —
bars are down. or Repair Wiring
3-42 – JLG Lift – 3120728

Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Fax: (717) 485-6417
JLG Worldwide Locations

JLG Industries (Australia) JLG Industries (UK) JLG Deutschland GmbH JLG Industries (Italia)
P.O. Box 5119 Unit 12, Southside Max Planck Strasse 21 Via Po. 22
11 Bolwarra Road Bredbury Park Industrial Estate D-27721 Ritterhude/lhlpohl 20010 Pregnana Milanese - MI
Port Macquarie Bredbury Bei Bremen Italy
N.S.W. 2444 Stockport Germany Phone: (39) 02 9359 5210
Australia SK6 2sP Phone: (49) 421 693 500 Fax: (39) 02 9359 5845
Phone: (61) 2 65 811111 England Fax: (49) 421 693 5035
Fax: (61) 2 65 810122 Phone: (44) 870 200 7700
Fax: (44) 870 200 7711
JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska
Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI. Krolewska
80-Suite 71 2132 HJ Foofddorp N-1412 Sofienyr 00-060 Warsawa
13092-310 Campinas-SP The Netherlands Norway Poland
Brazil Phone: (31) 23 565 5665 Phone: (47) 6682 2000 Phone: (48) 91 4320 245
Phone: (55) 19 3295 0407 Fax: (31) 23 557 2493 Fax: (47) 6682 2001 Fax: (48) 91 4358 200
Fax: (55) 19 3295 1025
JLG Industries (Europe) JLG Industries (Pty) Ltd. Plataformas Elevadoras JLG Industries (Sweden)
Kilmartin Place, Unit 1, 24 Industrial Complex JLG Iberica, S.L. Enkopingsvagen 150
Tannochside Park Herman Street Trapadella, 2 Box 704
Uddingston G71 5PH Meadowdale P.I. Castellbisbal Sur SE - 175 27 Jarfalla
Scotland Germiston 08755Castellbisbal Sweden
Phone: (44) 1 698 811005 South Africa Spain Phone: (46) 8 506 59500
Fax: (44) 1 698 811055 Phone: (27) 11 453 1334 Phone: (34) 93 77 24700 Fax: (46) 8 506 59534
Fax: (27) 11 453 1342 Fax: (34) 93 77 11762

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Service and Maintenance Manual

CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUA- IMPORTANT OR INSTRUCTIONS PROCEDURES ESSENTIAL

Also in this Manual "Notes:" are used to provide infor-

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

B. HYDRAULIC SYSTEM SAFETY

2. Relieve system pressure by activating the lift DOWN

3120728 – JLG Lift – a

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b – JLG Lift – 3120728

September 15, 1997 – Original Issue of Manual

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

September 8, 2000 – Revised Complete Manual

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

3120728 – JLG Lift – c

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d – JLG Lift – 3120728

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION INTRODUCTION - - MAINTENANCE SAFETY PRECAUTIONS

3120728 – JLG Lift – i

ii – JLG Lift – 3120728

3-9 Drive Motor/Circuit Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3120728 – JLG Lift – iii

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iv – JLG Lift – 3120728

3120728 – JLG Lift – 1-1

Table 1-4. Machine Interlock Switch Operating Conditions.

1-2 – JLG Lift – 3120728

1.6 HYDRAULIC PRESSURE ADJUSTMENT

Adjust system pressure so that platform will raise with RETURN

Figure 1-2. Hydraulic Pressure Gauge Installation.

1.7 CYLINDER SPECIFICATIONS

Table 1-5. Cylinder Specifications

BORE STROKE ROD DIA.

3120728 – JLG Lift – 1-3

Figure 1-3. Torque Chart.

1-4 – JLG Lift – 3120728

Figure 1-4. Lubrication Chart.

Table 1-6.Lubrication Intervals for Various Components

* Applies Only to Mast Sections with Chains.

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

3120728 – JLG Lift – 1-5

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1-6 – JLG Lift – 3120728

SECTION 2. SERVICE PROCEDURES

selves. As soon as a line or component is disconnected,

Components Removal and Installation

3120728 – JLG Lift – 2-1

2-2 – JLG Lift – 3120728

3120728 – JLG Lift – 2-3

can cause wear or damage to the components and gener-

NOTE: Metal particles may appear in the oil of new

2-4 – JLG Lift – 3120728

Checking Clutch - Torque Setting (ft. lb.)

5. If torque setting is OK, re-install the wheels and

Figure 2-2. Check Torque Limit Clutch -

3120728 – JLG Lift – 2-5

Torque Limiting Clutch Adjustment Drive Motor Brake Adjustment/Removal

Figure 2-3. Torque Limit Clutch -

2-6 – JLG Lift – 3120728