Joab VL10 User manual

Base Service
Lift Dumpers
www.joab.se
13160 Edition 2 | 2018-10-12 | KM
JOAB Försäljnings AB
Östergärde Industriområde
417 29 Göteborg
Telephone
031-705 06 00
Telefax:
031-705 06 09
E-post:
[e-mail]

ii Service Instruction: Skip-Loader | 13160 Edition 2 | 2018-10-12

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Service Instruction: Skip-Loader | 13160 Edition 2 | 2018-10-12
Table of Contents
Introduction v
Overview 1
Required Equipment 2
Group 1 – Replace Service Components 3
Group 2 – Torque the Chassis Brackets 5
Group 3 – Operation and Function Check 7
Group 4 – Inspection and Adjustment 11
Group 5 – Hydraulic Pressure Control 21
Group 6 – Lubrication 23
Contact Information 25
Service Packets and Warranty 25

iv Service Instruction: Skip-Loader | 13160 Edition 2 | 2018-10-12
Table of Contents

v
Introduction
This instruction describes how to perform a base service on a skip-loader, models VL10 –
VL18.
This instruction is based on the original mounted equipment only. Refer to the relevant sup-
plier’s documentation for all other optional or auxiliary equipment.
JOAB takes no responsibility for consequences that occur due to work carried out by non-pro-
fessionals.
The specifications, constructions, and illustrations found in this manual are not binding.
JOABAB retains the right to make changes without prior notice.
Before performing a service on a skip-loader make sure that you have read and are fully
aware of all safety warnings in the skip-loader's operator manual. Failure to do so can lead to
serious injury or damage to equipment.
Always bare in mind that it is the operator that is responsible for handling the skip-loader.
© JOABAB
Service Instruction: Skip-Loader | 13160 Edition 2 | 2018-10-12

vi Service Instruction: Skip-Loader | 13160 Edition 2 | 2018-10-12
Introduction

1
Overview
The following image provides an overview of the skip-loader and its components. These com-
ponents will be referred to throughout this procedure. Items marked with an asterisk (*) are
optional equipment.
A. Bulk head
B. Safety-wire controls*
C. Container-stop
D. Folding-arm
E. Boom pipe
F. Lifting chains and plates
G. Folding-arm cylinder
H. Lifting-arm
I. Extending body*
J. Tipping-hook*
K. Support leg (X2)
L. Lifting-arm cylinder
M. Skip-loader controller
N. Tipping-hook and rpm controller
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2
Required Equipment
The following table lists the materials required to carry out the base service.
Material Required Quantity Part Number Viscosity
Filter kit (Base) 1 1008902 --
Hydraulic filter - included in filter kit (1) (1651)
Air filter - included in filter kit (1) (4650) --
O-ring (return filter) - included in filter kit (1) (1631-3) --
Hydraulic oil (can be customer specific) 70 – 230 litres -- SHS 32/46
Lubricating grease: NLGI0 or thicker -- -- --
Table 1: Required materials
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Overview

3
Group 1 – Replace Service Components
1:1 Thoroughly clean the area around the cap for the air-filter (1) and the area around the
hydraulic-filter (2), on the hydraulic tank. Then replace the following items with new
ones:
1. The air filter.
2. The hydraulic filter.
3. The O-ring for the hydraulic filter
1:2 Clean the area around the hydraulic-tank's drain plug (1). Unscrew the plug and com-
pletely drain the oil. Then replace the drain plug and refill the tank with new oil. Refer
to "Required Equipment", on page 2 for details of the correct oil to use.
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Group 1 – Replace Service Components

5
Group 2 – Torque the Chassis Brackets
2:1 Inspect and make sure that all shims for the chassis's fastening brackets, where
applicable, are not loose and correctly positioned.
NOTE: Before the chassis brackets are first fastened, during assembly, the gap
between them is measured, as shown below. If the gap is greater than 2 mm, shims
are placed in between them before torquing of the bolts.
2:2 Check all of the chassis’s fastening brackets and make sure that all bolts are correctly
torqued. Use the toque settings listed below in Table 2 for all bolts, except head bolts.
For head bolts, use a torque value of 40 Nm.
Thread (Metric) Class 8.8 Class 10.9
M14 128 Nm 181 Nm
M16 197 Nm 277 Nm
Table 2: Torque setting for chassis brackets
Provide below are some examples of the chassis brackets
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Group 2 – Torque the Chassis Brackets

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Group 3 – Operation and Function Check
3:1 Use the external controls and operate all of the skip-loader's main hydraulic functions,
as listed below. The controls are located on the left side of the vehicle, as shown.
lExtending-body
lLeft-support-leg
lRight-support-leg
lFolding-arm
lLifting-arm
Verify that they function fully and correctly, even when under load. When operating
the functions under load, listen for any unusual noises, especially from the hydraulic
pump.
3:2 Use the cab mounted controller and operate all of the skip-loader's main hydraulic
functions, as listed above. In addition, also operate the tip-hook and verify that it func-
tions correctly.
NOTE: The cab mounted controller is optional equipment.
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3:3 Verify that the external switch for increasing the engine's speed functions correctly.
The switch is located on the tipping-hook and r pm controller, as shown below.
NOTE: This is optional equipment
3:4 Operate the external switch for the tip-hook, as shown above, and make sure that the
tip-hook functions correctly. Also check that the cylinder damping function of the tip-
hook works correctly.
3:5 Operate all optional hydraulic and air operated functions that the skip-loader has,
such as a rotator, or safety-wire-system, and verify that they function fully and cor-
rectly. Use the standard controls for the safety-wire-system. See "Overview", on page
1.
3:6 Operate the radio controller for the skip-loader (where applicable) and verify that it
functions correctly for all standard and optional equipment, as listed below.
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Group 3 – Operation and Function Check

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Service Instruction: Skip-Loader | 13160 Edition 2 | 2018-10-12
Group 3 – Operation and Function Check
NOTE: This is optional equipment
1. Verify that the emergency stop button on the controller functions correctly.
2. Check that all LEDs function correctly.
3. Verify that all applicable functions and their buttons work correctly. Provided
below in Table 3 is a list of all functions available. Depending on the skip-
loader being serviced, different functions will be applicable. A number of the
functions listed below are optional. Optional function are marked with an aster-
isks.
Button Func._1 Func._2 Func._1+2*
1 Lifting-arm UP Lifting-arm UP Front-left-safety-wire -
Release*
2 Lifting-arm DOWN Lifting-arm DOWN Front-left-safety-wire -
Tighten*
3 Folding-arm - UP Folding-arm - UP Front-right-safety-wire -
Release*
4 Folding-arm - DOWN Folding-arm - DOWN Front-right-safety-wire -
Tighten*
5 Left support-leg - DOWN Left support-leg - DOWN Rear-right-safety-wire -
Release*
6 Left support-leg - UP Left support-leg - UP Rear left-safety-wire -
Tighten*
7 Right support-leg -
DOWN
Right support-leg -
DOWN
Rear left safety-wire -
Release*
8 Right support-leg - UP Right support-leg - UP Rear-right-safety-wire -
Tighten*
9 Tipping-hook - UP and
DOWN
-- --
0 Switch Function mode Switch Function mode Switch Function mode
Table 3: Radio controller function for skip-loaders
3:7 Operate all external lights on the skip-loader and make sure that they function cor-
rectly, including the reverse lights.
3:8 Inspect and make sure that all lighting on the driver's display panel functions correctly.

10
3:9 Operate and make sure that all buttons and lights inside the cab for operating the
skip-loader function correctly.
NOTE: The buttons and warning lights inside the cab may differ to those shown
below. In addition, the vehicle may have indicator lights for the hydraulic-pump in the
driver's display. Make sure that you are aware of all the vehicle's equipment related to
the skip-loader and that it functions.
1. Turn the hydraulic pump for the skip-loader ON and verify that the warning lamp
(s) for the hydraulic pump illuminate, indicating that the pump is active.
NOTE: The appearance of the button for starting the pump varies for different
manufacturers.
2. If the vehicle is equipped with a tow-hitch, verify that the "Locked" and the
"Open" LED lights function correctly on the tow-hitch LED panel, as shown
below.
NOTE: This is optional equipment.
3. Verily that the emergency stop button for the skip-loader functions correctly.
Activate the emergency stop while the skip-loader is working to verify that it
stops the skip-loader. Then deactivate the emergency stop, restart the vehicle
and verify that it is resets correctly, and the skip-loader can function again.
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Group 3 – Operation and Function Check

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Group 4 – Inspection and Adjustment
4:1 Inspect the skip-loader's main valve block, located on the left side of the vehicle, as fol-
lows.
1. Turn the vehicle OFF.
2. Operate the control-lever for each section
of the valve block. Both upwards and down-
wards. Verify that the control-levers move
easily, without any restriction, and that
there is no evidence of malfunction in the
movement of them.
3. Check for oil leaks around the: control-
levers, plugs, nipples, and hoses.
4. Inspect and verify that all of the pneumatic-control-valves function correctly.
Make sure that there is no leakage of air or oil when operated.
4:2 Inspect the hydraulic-safety-wire's valve block, located on the right side of the vehicle,
as follows.
NOTE: This is optional equipment.
1. Turn the vehicle OFF.
2. Operate the control-lever for each section
of the valve block. Both upwards and down-
wards. Verify that the control-levers move
easily, without any restriction, and that
there is no evidence of malfunction in the
movement of them.
3. Check for oil leaks around: the control-
levers, plugs, nipples, and hoses.
4. Inspect and verify that all of the pneumatic-control-valves on the valve block
function correctly. Make sure that there is no leakage of air or oil when oper-
ated.
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4:3 Verify that the hydraulic-pump for the skip-loader functions correctly, as listed below:
1. Check that the pump does not make any unusual
noises, when under load, that could indicate a prob-
lem with its function.
2. Inspect the hydraulic-pump's connections and
hoses, to and from it. Verify that there is no dam-
age.
3. Make sure that all hose clamps are correctly
tightened.
4. Inspect and make sure there are no leaks.
4:4 Inspect all hydraulic hoses, pipes, and connections for the skip-loader's entire
hydraulic system. Check for cracks and any other signs of damage. Make adjustments
as necessary to ensure that there is no risk of damage to the pipes and hoses, due to
poor routing of them.
4:5 Check all valves for the skip-loader and make sure that they function correctly and
that they do not leak.
4:6 Perform a leak check on the OC valve (over center valve) for the folding-arm and the
and the lifting arm, as follows.
1. Extend the folding-arm and leave it there. Then observe it carefully to see if it
moves. If there is leak the folding-arm will move.
2. Extend the lifting-arm so that it hangs over the rear of the vehicle and leave it
there. Then observe it carefully to see if it moves. If there is leak the folding-arm
will move downwards.
4:7 Inspect the hydraulic tank as follows:
1. Make sure that the tank is secure and that there are no loose items.
2. Check the connections to and from the tank and make sure that there are no
leaks.
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Group 4 – Inspection and Adjustment

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Service Instruction: Skip-Loader | 13160 Edition 2 | 2018-10-12
Group 4 – Inspection and Adjustment
4:8 Inspect the skip-loader's hydraulic cylinders for leaks (see "Overview", on page 1).
Check the following cylinders:
1. The folding-arm cylinders.
2. The lifting-arm cylinders
4:9 Inspect the hydraulic cylinders' piston-rods. Check for: scratches, dis-colouring, and
impact damage.
4:10 Check and make sure that all electrical wiring for the skip-loader is free from damage
or deterioration. Inspect the following:
1. Check the wiring harnesses for damage. Make sure that they are correctly
secured and routed. Make adjustments as necessary.
2. Check all cables and their contacts for damage. Make sure that the cables are
properly attached to there contact points. If it is suspected that a wire or contact
does not function correctly, perform a test of it. Perform an insulation and res-
istance test as required.
4:11 Open the skip-loader's Tipping-hook and rpm controller (solenoid box), as shown
below, and inspect the following items. Make sure there is no corrosion or other dam-
age.
1. the cables
2. the relays
3. the solenoid valves

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4:12 Open the solenoid box for the safety-wire-system, as shown below, and inspect the fol-
lowing items. Make sure there is no corrosion or other damage.
NOTE: This is optional equipment.
1. the cables
2. the relays
3. the solenoid valves
4:13 Extend the right-support-leg and inspect it and its ground-plate for mechanical dam-
age.
4:14 Extend the left-support-leg and inspect it and its ground plate for mechanical damage.
4:15 Visually inspect the lifting-arms for mechanical damage (see "Overview", on page 1).
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Group 4 – Inspection and Adjustment