jlg 20mvl maintenance manual
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jlg 20mvl maintenance manualWe have 2 JLG 20MVL Series manuals available for free PDF download: Service Maintenance Manual, Operation And Safety Manual. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others or damage to the equipment. Reservoir HO - Check Hyd. Oil Level HO - Change Hyd. Oil 2 - Per Section Chain Lube - Brush or Spray 3 6 MONTHS MONTHS 1 YEAR 2 YEARS ? ? COMMENTS Check fluid level every day. (c) Change hydraulic oil every 2 years. Inspect, lubricate if dry or rusting. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service. Page 28 SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Type Frequency Primary Responsibility Service Qualification Reference Pre-Start Inspection Prior to use each day; or At each Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form. Page 31 SECTION 2 - GENERAL 2.3 SERVICING AND MAINTENANCE GUIDELINES structure and the component becomes less than 90 degrees. General The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter. Safety and Workmanship Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of component weight. Page 32 SECTION 2 - GENERAL Hydraulic Lines and Electrical Wiring Mast Chain Inspection Procedure Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit. This will assure that they are correctly reinstalled. Hydraulic System Keep the system clean.http://atomleasing.ru/media/jdb1100aws_manual.xml
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If evidence of metal or rubber particles is found in the hydraulic system, drain and flush the entire system. Disassemble and reassemble parts on clean work surface. Page 33 SECTION 2 - GENERAL are on the verge of cracking. Fatigue and ultimate strength failures on JLG Lifts are incurred as a result of severe abuse as design specs are well within the rated lifting capacity of these chains. Tight Joints: All joints in the leaf chain should flex freely. Page 34 SECTION 2 - GENERAL 2.4 LUBRICATION INFORMATION Hydraulic Oil Hydraulic System The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenance, or by permitting the pump to cavitate due to insufficient system warm-up or leaks in the pump supply. Page 35 SECTION 3 - BASE COMPONENTS SECTION 3. BASE COMPONENTS 3.1 BASE ASSEMBLY COMPONENTS Figure 3-1. Base Components. 1. 2. 3. 4. 3121231 Base Mounted Beacon Battery Charger Cover Front Tie Down Lug Battery Charger Assembly 5. 6. 7. 8. Base Frame Front Caster Wheel Assembly Left Drive Motor Assy. Rear Tie Down Lug 11. Right Drive Motor Assy. Following the recommended sequence, tighten lug nuts per wheel torque. Tire Wear and Damage Table 3-1. Wheel Torque Chart Inspect tires periodically for wear or damage. Tires with worn edges or distorted profiles require replacement. Tires with significant damage in the tread area or side wall, require immediate evaluation before replacing the machine into service. Page 38 SECTION 3 - BASE COMPONENTS 3.5 WHEEL DRIVE ASSEMBLY - SERVICING The component parts of the left and right drive motor assemblies are identical. The left drive motor is run in the reverse direction of the right motor.http://aj-logistics.com/stock/userfiles/jdbc-manual-commit.xml Roll And Leak Testing Torque-Hub units should always be roll and leak tested before disassembly and after assembly to make sure that the unit's gears, bearings and seals are working properly. The following information briefly outlines what to look for when performing these tests. Page 39 SECTION 3 - BASE COMPONENTS Wheel Drive Assembly - Removal From Machine The electric wheel drive assemblies are mounted independent of each other in the base frame at the rear of the machine. The wheel drive assembly consists of an 24V DC electric motor driving a 30.68:1 ratio gear box, the assembly also included a friction disk parking brake assembly. This brake assembly is mounted internally on the drive assembly between the drive motor and the gear box assembly. 1. Page 40 SECTION 3 - BASE COMPONENTS Wheel Drive Disassembly - Main Components Drive Motor Disassembly - Main Components NOTE: If possible, remove the wheel drive assembly from the machine frame. 6. Remove the Brake Housing (B1) and the Spacers (B4). 1. Drain the oil from the Gearbox (1) by removing the cover plugs in the cover. NOTE: The brake wires will have some silicone sealant at the slot through the motor flange. It is okay to pull the wire out of the motor flange slot. Page 41 SECTION 3 - BASE COMPONENTS Replacing Drive Motor Brushes THE MOTOR MUST BE DISASSEMBLED FROM THE GEARBOX AND DISCONNECTED FROM THE MACHINE CONTROLLER BEFORE BEGINNING THIS PROCEDURE. Install the brush housing onto the end of the motor frame and armature. You may need to use a softtipped mallet to tap the brush housing onto the bearing of the armature. Once the brush housing is partially on the armature, the brush retaining pins must be removed. 22. Tighten the motor bolts to 65 in-lbs. 23. Look at the timing marks to make sure that they are still aligned. If not, loosen bolts, line up the marks, and then retighten the bolts. 24. Page 43 SECTION 3 - BASE COMPONENTS Gear Box Main Disassembly Gear Box Main Disassembly 1.http://www.familyreunionapp.com/family/events/boss-ava-650-manual Using a screwdriver, pry the end of the Retaining Ring (G19) out of the groove in the Hub Subassembly, then grasp the loose end of the Retaining Ring and pull the rest of the way out.The screws will push against the outer race of the main bearing. This bearing will have to be replaced afterwards. 2. Page 44 SECTION 3 - BASE COMPONENTS Input Carrier Disassembly Input Carrier Disassembly 1. Remove Retaining Rings (G18) from each of the three Planet Shafts (G6). 9. Remove the three Planet Shafts (G6) from the Input Carrier. NOTE: Do not overstress these Retaining Rings when removing them. NOTE: The Planet Shafts (G6) are held in with a press fit. To avoid damage to the parts, use an arbor or hydraulic press to remove the Planet Shafts (G6). 2. Remove Thrust Plate (G23). 3. Page 45 SECTION 3 - BASE COMPONENTS Hub - Disassembly Hub Disassembly 1. Remove Main Wheel Bearing (G14). 2. Remove main Lip Seal (G16). NOTE: This part is held in the hub with a press fit. To remove have the hub setting seal side up. Use a plate or rod with a large enough diameter push in the inner race of the bearing. Apply force to the push the bearing out. This bearing will need to be replaced upon reassembly. 3121231 NOTE: This Lip Seal (G16) is also held in with a press fit. Page 46 SECTION 3 - BASE COMPONENTS Spindle Disassembly Spindle Disassembly 1. Place Spindle Sub-Assembly on bench with Planet Gears (G9) facing up. NOTE: Do not damage or scratch the seal surface of the Spindle (G1) during disassembly. NOTE: This bearing is held in with a press fit. You will need to pry against the Spindle (1) to remove it. A new bearing should be used when the unit is reassembled. 6. Flip over the Spindle (G1). 2. Remove three Output Planet Shafts (G10). Page 47 SECTION 3 - BASE COMPONENTS Spindle Sub-Assembly Spindle Sub-Assembly 1. Place the spindle (G1) on the bench with the carrier portion facing up. NOTE: NOTE: The Seal has a thin outer shell that can be easily damaged if not installed with care.http://www.dbgroup-portugal.com/images/cardiris-for-scansnap-user-manual.pdf Page 49 SECTION 3 - BASE COMPONENTS Input Carrier Sub-Assembly Input Carrier Sub-Assembly 1. Use the Input Planet Shaft (G6) as a pressing tool to install the Planet Bushing (G26) into the bore of each Planet Gear (G5). Remove any debris or burrs that may be present. NOTE: 2. Apply a coating of grease to the Lip Seal (not shown) in the Hub Sub-Assembly. 7. Install the Input Carrier Subassembly into mesh. Page 51 SECTION 3 - BASE COMPONENTS Motor, Brake and Gear Box Assembly Motor, Brake and Gear Box Assembly 1. Place the Motor (2) shaft up on the bench. 8. Pull the Brake Lead through the through the slot in the motor flange. Make sure the leads are all the way in the bottom of the slot. 2. Place the Brake Friction Plate (B3) onto face of the motor flange. Line up the three holes of the Brake Friction Plate (B3) with the tapped holes in the motor flange.This LED indicator set is plugged directly into a connector on the back of the battery charger and indicates current charging status. Page 59 SECTION 4 - CONTROL COMPONENTS 4.3 CONTROL COMPONENTS INSTALLATION Traction Control Module The Traction Control Module is mounted below the Ground Control Module on the mast support column.Page 60 SECTION 4 - CONTROL COMPONENTS Platform Control Console Installation Horn Installation The platform control console is located in the platform and mounted on the right side platform rail. Alarm Installation 1 Platform Control Console - Installation 1. Page 61 SECTION 4 - CONTROL COMPONENTS 4.4 BATTERIES - SERVICE PROCEDURES Battery Condition Testing NOTE: Batteries in storage should be kept at 12.5V or higher. Battery Replacement JLG MACHINES EQUIPPED WITH DELTA-Q BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES. APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG’S AFTERMARKET PARTS DISTRIBUTION CENTERS OR JLG’S AFTERMARKET PROGRAMS. Page 62 SECTION 4 - CONTROL COMPONENTS Battery - Installation - (2-12V Batteries) To gain access to the batteries, requires opening or removal of the upper half of the rear covers, see Section 4.2, Controls Cover Installation. Procedure for removal is same for both batteries. On installation, batteries set in machine with the posts to the inside.Page 73 SECTION 4 - CONTROL COMPONENTS 4.7 PLATFORM CONTROL CONSOLE SERVICE PROCEDURES General DO NOT ATTEMPT TO DISASSEMBLE THE PLATFORM CONTROL BOX IF MACHINE IS STILL UNDER WARRANTY.CAREFULLY LOOSEN REQUIRED FITTINGS, WEAR SAFETY PROTECTION EQUIPMENT WHEN WORKING WITH HYDRAULIC SYSTEMS. Adjust system pressure so that platform will raise with maximum rated capacity in platform. Recheck the hydraulic pressure and compare with the previous readings when filter was removed. No internal parts to the hydraulic pump are serviced by JLG except for a pump installation seal kit. Also the only parts serviceable internal to the pump electric motor is the motor brush kit. Page 80 SECTION 4 - CONTROL COMPONENTS Motor Brush Installation Once brush housing has been removed, inspect the rotor commutator for excessive wear before installing a new brush set. New Brush Installation 1. Brush Terminal Screw 4. Brush Spring 2. Brush 5. Page 81 SECTION 4 - CONTROL COMPONENTS Brush Housing Final Assembly Tips It is easier to install the brush housing assembly by sliding the rotor assembly completely out of the other end of the motor housing, then attach the brush housing first. The OSS Control Module communicates with the Ground Control Module through the platform electrical junction box also mounted on the mast behind the platform decal billboard. Page 87 SECTION 4 - CONTROL COMPONENTS Transducer Sensor Check Perform the following daily Pre-Start Inspection to check if each transducer sensor is working properly. 1. Power up machine by setting the Power Selector (Key) Switch to Ground Control Mode. 2. Raise the platform approximately four (4) to five (5) feet. The Ground Control Module can also display the following sensor detection information when in Level 2 password Service and Maintenance Settings mode. Page 89 SECTION 4 - CONTROL COMPONENTS 2 3 3 1 2 4 2 1 5 Transducer Sensor Installation (Typical) 1. Mounting Screws (a) 2. Bushings 3. Transducer Sensor (b) 4. DO NOT Pressure Wash Decal 5. Sensor Side Deflector Notes: (a) Apply Loctite 222 to screw threads and torque to 15 in. lb. (b) Mount sensor with (circular) membrane facing down. Sensor Side Deflectors 1. Sensor Side Deflector (a) 2. Pop Rivet 3. Platform Side Frame Note: (a) One deflector required on each side of platform. Page 90 SECTION 4 - CONTROL COMPONENTS This page intentionally left blank. Lanyard Attach 11. Chain Guard 12. Sheave Assemblies 13. Adjust the nut the amount required to raise or lower the top of the mast section to match the side profile shown in Figure 52.Chain Lock Nut 11. Page 94 SECTION 5 - MAST COMPONENTS 5.3 SEQUENCE CABLE REPLACEMENT KIT A sequence cable replacement kit is available from the JLG Parts Department to service broken or worn sequence cables. This kit consists of a replacement sequence cable with the threaded (top) end attached same as the top end of the factory cable. Use the following procedure to install the replacement cable and clamp kit.Using the plug driver, a metal tube or pliers, bend the outer strands toward the center strands enough that the socket can be slipped over all the strands. 1. Inspection Hole 3. Four Threads or Less Showing 2. Install Socket and Tighten 8. Inspect for proper assembly prior to loading the cable.Any damage to this surface will require replacement of the rod. 2. Extend the rod until the piston bottoms out against the cylinder head. 3. Page 103 SECTION 5 - MAST COMPONENTS Cylinder Assembly (See Figure 5-4.) 1. Rinse the inside of the tube with hydraulic fluid and allow to drain. A high-pressure rinse followed by a wipe with a lint-free rag is preferable. Clean all internal components of any foreign material. 2. Lubricate the head and all seals with hydraulic fluid prior to installation. Install the seal, wiper, o-ring, back-up ring, and retraining ring to the cylinder head. 1 3. Lubricate the piston and all components with hydraulic fluid. Page 104 SECTION 5 - MAST COMPONENTS 2 3 4 5 1 6 Lift Down Valve and Manual Release Installation 1. Lift Down Valve (a) 2. Valve Solenoid (b) 3. Manual Release Assembly 4. O-Ring with Backing Rings (a) 5. Valve O-Ring (a) 6. Solenoid O-Ring (a) Notes: (a) Coat all o-rings with clean hydraulic fluid before assembling. (b) Mount with electrical terminals pointing to right side of machine. The mast sections are interlocked into each other when assembled, by internally mounted slide pads at the top and bottom of each mast section. Page 107 SECTION 5 - MAST COMPONENTS 5. Carefully slide mast section-5 out the BOTTOM of mast section-4 rails. Disassemble slide pads, shims and chain anchor plate from mast section-5, if necessary. Mast Section-4 - Removal 6. Remove chain adjust nuts from threaded ends of chains attached to the chain anchor plate (lower) on BOTTOM end of mast section-4. Push threaded ends of chains through anchor plate. 7. At TOP of mast section-4, pull chains out and allow to hang loose. Page 108 SECTION 5 - MAST COMPONENTS Figure 5-6. Mast Chain Routing Diagram. Slide mast out over end of work surface far enough to allow access to the chain anchor attach hole near the top of the mast. Page 110 SECTION 5 - MAST COMPONENTS c. Check mast section for side play. Insert shims until the shims cannot be inserted halfway by hand with the mast pulled to the opposite side. 11. Lift cylinder installation into the bottom of Mast Section 1 and 2. d. When mast slide pads are shimmed properly, there should be no side to side movement of slide pad in rail channel. Page 111 SECTION 5 - MAST COMPONENTS 15. Page 113 SECTION 5 - MAST COMPONENTS pin keeper. Chains will be adjusted later in assembly. Page 115 SECTION 5 - MAST COMPONENTS 3. Complete the following steps to determine shim stock thickness required for section-5; tight, remove section-5, disassemble slide pad and reduce thickness of shim stock. NOTE: Always use the an even amount of shim material behind slide pads on both sides of the mast rails. This will keep mast sections centered in rail channels and prevent any distortion of the section. e. Page 116 SECTION 5 - MAST COMPONENTS 6. Slide mast section-5 back into mast section-4 until bottom ends of masts are even. Page 122 SECTION 6 - TROUBLESHOOTING machine’s electrical components occurs, the platform console LED’s will flash a number of LEDs to help indicate the problem to the Operator in the platform. The Fault Codes and LED Flash Codes are outlined in the following sub-sections of this chapter. NOTE: For aid in troubleshooting electrical problem, refer to Figure 6-7. for an ELECTRICAL DIAGRAM of the various circuits. Page 124 SECTION 6 - TROUBLESHOOTING Continuity Measurement Current Measurement Figure 6-3. Continuity Measurement Figure 6-4. Page 125 SECTION 6 - TROUBLESHOOTING Continuity Measurement Over Long Distances When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a particular wire in the harness. Page 126 SECTION 6 - TROUBLESHOOTING 6.6 ELECTRICAL SWITCH TESTING Basic Check The following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected. 1. De-energize the circuit. 2. Isolate the switch from the rest of the circuit if possible. If not possible, keep in mind it may affect readings. 3. Access the terminals to the switch. 4. Page 127 SECTION 6 - TROUBLESHOOTING Automatic Switches If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch to test it. Do this either by applying heat or pressure, for example, to the switch. Page 128 SECTION 6 - TROUBLESHOOTING 6.7 GROUND CONTROL MODULE LCD DISPLAY At power-up and during operation the LCD display on the Ground Control Module displays the current machine operating status. Page 131 SECTION 6 - TROUBLESHOOTING Table 6-1. LCD Display - Service Fault Code Conditions FAULT CODE PLATFORM CONSOLE LEDs FLASHING 09 6 LCD SYMBOL SCREEN 00000.0 10 11 6 12 6 13 6 00000.0 00000.0 00000.0 16 7 17 7 18 — 00000.0 00000.0 00000. Page 132 SECTION 6 - TROUBLESHOOTING Table 6-1. LCD Display - Service Fault Code Conditions FAULT CODE PLATFORM CONSOLE LEDs FLASHING 22 — LCD SYMBOL SCREEN 00000. This is detected with a drive speed cut-back (proximity) switch mounted at the base of the mast assembly and a target mounted on the mast assembly. Page 152 SECTION 6 - TROUBLESHOOTING Code 33 - Both PHP Bars - UP Table 6-35. Code 33 - Both PHP Bars - UP STEP ACTION SPEC YES NO 1. Perform steps in Code 2, Left PHP Bar UP then, Code 3, Right PHP Bar UP. Do either of these steps correct the problem? — Done Go to Step 2 2. Perform steps in Table 6-5 - Machine In Drive Speed Cut-Back (Turtle) Mode All The Time, of this section. Page 153 SECTION 6 - TROUBLESHOOTING Table 6-37. STEP ACTION SPEC YES NO 1. Check to see of the platform will lower from the Ground Control Station in Ground Control Mode. Page 161 SECTION 6 - TROUBLESHOOTING Mast Noisy When Lifting And Lowering Overview Of Procedure This procedure examines components of the mast itself and as well as it’s lifting components for dirt, debris, proper lubrication and operation. Table 6-46. Mast Noisy when Lifting and Lowering. STEP SPEC YES NO 1. Do slide pads and slide pad channels need to be cleaned of dust, dirt, or other debris? — Clean Pads and Channels Go to Step 2 2. Page 162 SECTION 6 - TROUBLESHOOTING Platform (Mast) Won’t Stay Elevated Overview Of Procedure The following procedure requests that the lift down, dump, and pump internal valves be checked to see if any are stuck open, it also examines the lift down and dump valve circuits. Also suggests that the lift cylinder packing could be leaking internally. STEP ACTION SPEC YES NO 1. Page 163 SECTION 6 - TROUBLESHOOTING 6.14 HYDRAULIC LEAK TROUBLESHOOTING Miscellaneous Hydraulic Leak Troubleshooting Overview Of Procedure This series of steps gives remedies for various areas of the machine where leaks could occur. Table 6-49. Hydraulic Leak Troubleshooting STEP ACTION SPEC YES NO 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 extend or return line fittings. STEP ACTION SPEC YES NO 1. Is the caster rotating freely? — Go to Step 2 Lubricate or Replace Caster Housing 2. Is the wheel spinning freely? — Go to Step 3 Lubricate or Replace Wheel 3. Page 165 SECTION 6 - TROUBLESHOOTING 6.16 DRIVE SYSTEM TROUBLESHOOTING Won’t Climb Grade Overview Of Procedure The following procedure checks the drive motor and attached components for component failure, misadjustment due to wear. Page 166 SECTION 6 - TROUBLESHOOTING Machine Won’t Drive Straight Overview Of Procedure The following procedure examines the drive motor assembly weldments attaching the drive motors to the base frame. Also internal components of the drive motors, gear box and a check of the components between the gear box and the drive wheels. Page 167 SECTION 6 - TROUBLESHOOTING Noise From Drive Assembly Overview Of Procedure The following procedure examines the drive motor assembly weldments attaching the drive motors to the base frame. Also internal components of the drive motors, gear box and a check of the components between the gear box and the drive wheels. Page 168 SECTION 6 - TROUBLESHOOTING Figure 6-6. Overview of Electrical System Components. Page 169 SECTION 6 - TROUBLESHOOTING Figure 6-2. Overview of Electrical System Components. JLG has also provided what they call “Point and Go” technologies so that a single joystick controls the mobile vertical lift. This is all backed by a low-maintenance anodized aluminum mast and a pothole protection system that will make sure your supports are strong and balanced, even if it has been extended to its maximum height. Here are some of the technical specifications that you’ll find with the JLG 20MVL mobile vertical lift. It also provides options for those with outdoor use needs thanks to its rugged design. Use it for warehousing needs as well with the included fork truck pockets. Whether you take advantage of this model’s load sensing system, stay safer with the lanyard attachment anchor, or use the on-board diagnostics to stay productive, this is the mobile vertical lift that will maximize your productivity. Let our team show you the full potential of this JLG man lift today. We can customize any product for any size job. Operators always standing by, (888) 730-8377. Our service kits are set up to help you identify the correct parts for the JLG equipment in your fleet. Proper boom maintenance will help you achieve optimum productivity with your equipment.Eliminates extensive research. Contain wear pads, shims, and required hardware. Great for boom reconditioning or applicable OSHA required boom teardownsThese kits can be installed on models built prior to May 2007. The coiled cable provides better management of the platform workspace allowing movement in and out with the platform extension, while staying out of the operator’s way and off of the platform floor. This helps prevent damage to the cable and helps to reduce your cost of ownership. Kits Include: ? Installation instructions. Conner hook for cable storage. All required hardware Install Time: 30 Minutes Proper maintenance of your equipment increases productivity and helps maintain the life span of your equipment. These kits helps guarantee that you have the correct filters.The kits are easily installed, no tools required. Glass windshield and skylight. Quick installation. JLG 10VP 15VP 20VP Operator and Safety manual.. Service and Maintenance Manual Model 10VP 15VP 20VP 3120728 June 14 2001 ANSI. FOREWORD The purpose of this manual is to provide users with the operating procedures essential for the promotion of proper machine operation for its intended purpose. It is important to over-stress proper machine usage. All information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the machine. YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL - Keep it with the machine.INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A. MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others or damage to the equipment.Platform Height (mast extended) Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. SECTION 2 - SERVICE PROCEDURES SECTION 2. SERVICE PROCEDURES 2.1 GENERAL This section provides general information to assist in the performance of maintenance on the personnel lift. Descriptions, techniques and specific procedures are designed to provide the safest and most efficient maintenance for use by personnel responsible for ensuring the correct installation and operation of machine components and systems. SECTION 2 - SERVICE PROCEDURES apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race. Gaskets Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious system damage. Bolt Usage and Torque Application Use bolts of proper length. SECTION 2 - SERVICE PROCEDURES Tight Joints: All joints in the leaf chain should flex freely. Tap inside “walking” plates inward; if “walking” persists, replace the chain. SECTION 2 - SERVICE PROCEDURES can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage. 2.4 POSITIONING LIFT FOR ACCESS TO COMPONENTS LOCATED UNDER THE BASE FRAME Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil. SECTION 2 - SERVICE PROCEDURES 2.5 DRIVE MOTOR COMPONENT SERVICE PROCEDURES Torque Limiting Clutch Maintenance Checking Clutch - Torque Setting (ft. Lb.) NOTE: Check that the machines brakes are engaged before applying torque to the rear drive wheels. Remove the drive wheels from the drive axles. VP Series machines are equipped with a torque limiting clutch coupling on each drive axle. The clutch is mounted inline on the drive axle between the drive wheel and the drive motor gear box. If the torque (slip) setting of the clutch assembly is under spec (by more than 35 ft. Lb.), the large adjusting nut must be (tightened) turned clockwise to increase the torque setting. If the torque (slip) setting is over spec (over 185 ft. SECTION 2 - SERVICE PROCEDURES Drive Motor Removal 5. Disconnect the wiring connectors to the drive motor and the brake assembly on either or both sides, depending on which drive assembly(ies) is being removed. (See Figure 2-7.) The VP drive motors consist of three sections, the gear box atttached to the rear of the drive motor, the electric drive motor itself, and the brake assembly mounded at the front of the drive motor.SECTION 2 - SERVICE PROCEDURES NOTE: The gear oil can be drained out when the side cover is removed in the next step. Remove the four (4) hex cap screws securing the side cover to the gear box housing, and remove the side cover and rubber seal ring. SECTION 2 - SERVICE PROCEDURES Final Gear Box Assembly that gear set align the drive shaft bearing and wiggle it into it’s seat. When both are seated continue to next step. If necessary, install a new drive shaft lip seal into the drive shaft hole in the gear box housing before assembling the drive shaft gear set into the gear box. SECTION 2 - SERVICE PROCEDURES Brush Removal (See Figure 2-12.) Drive Motor Brush Replacement Each drive motor contains two (2) brushes, the brushes are located under the two (2) large round slotted brush caps on the front end of each drive motor. BRUSH CAP Removal of the brushes also requires the removal of the drive motor(s) from the machine, see procedure described earlier in this section for instructions to remove the drive motors. SECTION 2 - SERVICE PROCEDURES Brush Reassembly (See Figure 2-12.) MAKE CERTAIN THAT THE GROUND WIRE IS SECURELY RECONNECTED TO THE GROUND TERMINAL IF REMOVED. Install the brush (pig-tail) terminal end under the screw on the brush box in the same manner as the old brush that was removed and tighten the screw. SECTION 2 - SERVICE PROCEDURES 2.6 3. Turn on power to the platform control, nine (9) LED’s will flash rapidly on the platform control touch pad. PLATFORM CONTROL BOX SERVICE PROCEDURES 4. Depress the horn switch pad, the alarm will sound for about one (1) second, then release the horn pad.