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This service manual PDF download for the DVL & DVSP Series JLG Personnel Lift has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
JLG Lift DVL Series
JLG Lift DVSP Series
TABLE OF CONTENTS :
Section 1. MACHINE specifications
1.1 Capacities
1.2 Component Data
1.3 Performance Data
1.4 Torque Requirements
1.5 Lubrication
1.6 Hydraulic Pressure settings and Adjustment
1.7 Cylinder Specifications
1.8 Serial Number Locations
Section 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
2.2 Preventive Maintenance and Inspection Schedule
2.3 Servicing and Maintenance Guidelines
2.4 Lubrication Information
2.5 Positioning Lift for Access to Components Located Under The Base Frame
SECTION 3. BASE COMPONENTS
3.1 Base Assembly Components
3.2 Base Frame Covers
3.3 Drive And Caster Wheels
3.4 Drive Motor component – servicing
3.5 Drive Motor Assembly – Servicing
3.6 Pot Hole Protection System
3.7 Battery/Battery Charger – Service Procedures
SECTION 4. CONTROL COMPONENTS
4.1 CONTROL Components Overview
4.2 Controls Cover Installation
4.3 Control Components – Installation
4.4 Ground Control Module – Service Procedure
4.5 Ground Control Module – Programming
4.6 Platform Control Console – Service Procedures (machines s/n – 0130007616 to present)
4.7 Platform Control Console – Service Procedures (machines prior to s/n – 0130007616)
4.8 Pump-Motor Assembly – Service Procedure
4.9 obstruction sensor system – service procedure (dvsp – option)
SECTION 5. MAST COMPONENTS
5.1 Mast Components Overview
5.2 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT
5.3 sequence cable replacement kit
5.4 Hydraulic Lift Cylinder – Removal, Inspection and rebuild
5.5 Mast Assembly Installation
5.6 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES
5.7 DVSP – Stockpicker Platform – Installation
5.8 DVSP – Stockpicker Platform – Mid-Gate Interlock Installation
5.9 mast beacon – Installation
Section 6. troubleshooting
6.1 General
6.2 Troubleshooting Information
6.3 Hydraulic Circuit Checks
6.4 ELECTRICAL CIRCUIT CHECKS
6.5 TROUBLESHOOTING TABLES Index
6.6 SPECIFICATIONS FOR VARIOUS COMPONENTS
6.7 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS
6.8 FAULT CODE TROUBLESHOOTING TABLES
6.9 MAIN POWER CIRCUIT TROUBLESHOOTING
6.10 MAST TROUBLESHOOTING
6.11 HYDRAULIC LEAK TROUBLESHOOTING
6.12 BASE FRAME COMPONENTS TROUBLESHOOTING
6.13 DRIVE SYSTEM TROUBLESHOOTING
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 3121136
Total Pages : 164
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Maintenance safety precautions
a. GENERAL
b. HYDRAULIC SYSTEM SAFETY
c. MAINTENANCE
REVISION LOG
TABLE OF CONTENTS
Section 1. MACHINE specifications
1.1 Capacities
System Voltage
Hydraulic System
Drive Motor GearBox (gear oil)
1.2 Component Data
Hydraulic Pump/Pump Motor Assembly
Rear Wheel Drive Motors
Batteries/Battery Charger
1.3 Performance Data
Platform Capacities
Platform Size
Machine Height (platform stowed)
Base Footprint
1.4 Torque Requirements
1.5 Lubrication
Hydraulic Oil
Lubrication Specifications
1.6 Hydraulic Pressure settings and Adjustment
Hydraulic Pressure Gauge Connection
After Filter Pressure Check
1.7 Cylinder Specifications
1.8 Serial Number Locations
Section 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
General
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance
2.2 Preventive Maintenance and Inspection Schedule
Inspection and Maintenance Codes:
Footnotes:
2.3 Servicing and Maintenance Guidelines
General
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication and Servicing
Batteries
Mast Chain Inspection Procedure
2.4 Lubrication Information
Hydraulic System
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications
2.5 Positioning Lift for Access to Components Located Under The Base Frame
SECTION 3. BASE COMPONENTS
3.1 Base Assembly Components
3.2 Base Frame Covers
Drive Motor Cover – Installation
Battery Charger Cover – Installation
3.3 Drive And Caster Wheels
Drive Motor Wheel (Std.) – Installation
Caster Wheels – Installation
Wheel Retention for Rough Terrain Drive Wheel (Option)
3.4 Drive Motor component – servicing
Torque Limiting Clutch Maintenance
Diagnostics
Visual Inspection and Limiting Torque Checking Procedure
Check Clutch Torque Setting
Torque Limiting Clutch Adjustment
Drive Wheel Alignment – (Machines built prior to S/N-0130005271)
3.5 Drive Motor Assembly – Servicing
Drive Motor Assembly – Removal
Drive Motor Brake Removal and Adjustment
Brake Operation (See Figure 3-7.)
Brake Assembly Removal
Checking/Adjusting Armature Plate Gap Setting
Brake Assembly Installation
Drive Motor Boot Assembly Installation
Drive Motor Brush Replacement
Brush Cleaning and Inspection
Brush Removal
Brush Reassembly
Gear Box Disassembly/Assembly
Gear/Pinion Shaft Assembly
Drive Shaft Assembly
Final Gear Box Assembly
3.6 Pot Hole Protection System
3.7 Battery/Battery Charger – Service Procedures
Battery Low Voltage Warning Indicators
Diagnostics
Battery Condition Testing
Battery Replacement
Battery Charger General Information
Battery Charger Troubleshooting
Battery Charge/Flash Code LED Indicator on Platform Control Console
Battery Charging Status Indicators Mounted on Ground Control Station Cover
Wet/VRLA Battery – Charging Profile Switch
General Component Installation Notes
Battery Charger Installation
Cover Installation
AC Line Fuse Installation
Interlock Relay Installation
Wet/VRLA Switch Installation
Shunt Assembly Installation
SCR Rectifier Installation (Either Side)
Transformer Installation
Printed Circuit Board Installation
DC Circuit Breaker/Voltage Select Switch Installation
SECTION 4. CONTROL COMPONENTS
4.1 CONTROL Components Overview
4.2 Controls Cover Installation
Battery Cover Doors
Center, Left and Right Lower Covers
4.3 Control Components – Installation
Ground Control Module
Traction Control Module
Platform Control Console Installation
Battery Installation
Horn Installation
Alarm Installation
Battery Installation (EE Spec Machines Only)
Fuse Box – (EE Spec Machines Only)
Master Disconnect Switch – (EE Spec Machines Only)
4.4 Ground Control Module – Service Procedure
Cover Removal/Installation
Power Selector/EStop Switch Installation
4.5 Ground Control Module – Programming
General
Programming Levels
Activating Programming Mode
Entering Password
Programming Mode Selection
Selecting Programmable Item to Adjust
Adjusting Programmable Setting
Service Programming Mode – (Level-2)
Operator Programming Mode – (Level-3)
4.6 Platform Control Console – Service Procedures (machines s/n – 0130007616 to present)
General
Remove Platform Control Console
Display/Controller Module Electrical Connections
Mounting Bracket – Install/Remove
Rear Cover – Install/Remove
Display/Controller Module – Install/Remove
Drive/Lift Mode Switch – Install/Remove
Horn Button Switch – Install/Remove
Key Switch – Install/Remove
E-Stop/ShutDown Switch – Install/Remove
Joystick Assembly – Install/Remove
4.7 Platform Control Console – Service Procedures (machines prior to s/n – 0130007616)
General
Remove Platform Control Console
Upper/Lower Shell Attach Screws
Emergency Stop Switch Installation
Upper/Lower Shell Component Connections
Button Pad Installation
Joystick Assembly Installation
Joystick Calibration Procedure
4.8 Pump-Motor Assembly – Service Procedure
General
Inline Hydraulic Filter Installation
Pump/Motor/Tank Installation
Motor Cap/Motor Installation
Motor Brush Installation
Brush Housing Final Assembly Tips
Tank Installation
Pump Installation
Filter Screen Installation
Pressure Adjust Valve Installation
Pressure Check Valve Installation
4.9 obstruction sensor system – service procedure (dvsp – option)
General
Transducer Sensor Check
OSS Component Installation
SECTION 5. MAST COMPONENTS
5.1 Mast Components Overview
5.2 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT
Mast Chain/Cable Adjustment
Sequencing Cable Adjustment
5.3 sequence cable replacement kit
Remove Old Cable
Replacement Cable Installation
Clamp Installation (Drum/Socket Type)
5.4 Hydraulic Lift Cylinder – Removal, Inspection and rebuild
Lift Cylinder Removal
Cylinder Disassembly
Lift Cylinder Component Inspection
Cylinder Assembly
Cylinder Installation
5.5 Mast Assembly Installation
Mast Removal
Mast Installation
5.6 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES
Mast Disassembly Procedure
Mast Assembly – DVL/DVSP
5.7 DVSP – Stockpicker Platform – Installation
5.8 DVSP – Stockpicker Platform – Mid-Gate Interlock Installation
5.9 mast beacon – Installation
Section 6. troubleshooting
6.1 General
6.2 Troubleshooting Information
6.3 Hydraulic Circuit Checks
6.4 ELECTRICAL CIRCUIT CHECKS
General
Ground Control Module LCD Display
6.5 TROUBLESHOOTING TABLES Index
SPECIFICATIONS FOR VARIOUS COMPONENTS PAGE
SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS
FAULT CODE TROUBLESHOOTING TABLES
MAIN POWER CIRCUIT TROUBLESHOOTING
MAST TROUBLESHOOTING
HYDRAULIC LEAK TROUBLESHOOTING
BASE FRAME COMPONENTS TROUBLESHOOTING
DRIVE SYSTEM TROUBLESHOOTING
6.6 SPECIFICATIONS FOR VARIOUS COMPONENTS
6.7 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS
6.8 FAULT CODE TROUBLESHOOTING TABLES
Machine in Drive Speed Cut-Back (Turtle) Mode All The Time
Obstruction Sensor System – Detection
Battery Voltage Low – Warning Level 3 – Three (3) LED/LCDs lit
Code 02 – Left PHP Bar – UP
Code 03 – Right PHP Bar – UP
Code 04 – Tilt Condition
Code 05 – Reserved
Code 06 – Reserved
Code 07- Left Drive Motor – Disconnected
Code 08 – Right Drive Motor – Disconnected
Code 09 – Left Brake – Disconnected
Code 10 – Right Brake – Disconnected
Code 11 – Left Drive Motor – Short Circuit
Code 12 – Right Drive Motor – Short Circuit
Code 13 – Traction Module – In Fold Back
Code 14 – Pump Motor – Disconnected
Code 15 – Lift Down Valve – Disconnected
Code 16 – Lift Down Valve – Short Circuit
Code 17 – Ground Control Module – In Fold Back
Code 18 – Alarm – Short Circuit
Code 19 – Alarm – Disconnected
Code 20 – Beacon – Short Circuit
Code 21 – Beacon – Disconnected
Code 22 – Horn – Short Circuit
Code 23 – Horn – Disconnected
Code 24 – Auxiliary #1 Circuit – Short Circuit
Code 25 – Auxiliary #1 Circuit – Disconnected
Code 26 – Auxiliary #2 – Short Circuit
Code 27 – Auxiliary #2 – Disconnected
Code 28 – Reserved
Code 29 – Reserved
Code 30 – Traction Module – No Communication with Ground Control Module
Code 31 – Platform Control Console – No Communication with Ground Control Module
Code 32 – Pump Motor – Over Current
Code 33 – Both PHP Bars – UP
Code 38 – Battery Voltage Low – Warning Level 2 – Two (2) LED/LCDs lit
Code 39 – Battery Voltage Low – Warning Level 3 – One (1) LED/LCDs lit
Code 40 – Obstruction Sensor System – No Communication with Ground Control Module
Codes 41 thru 46 – OSS – Sensor 1 through 6 – Fault Condition
Codes (100 – 199) Ground Control Module – Fault Condition
Codes (200 – 299) Platform Control Console – Fault Condition
Codes (300 – 399) Traction Control Module – Fault Condition
6.9 MAIN POWER CIRCUIT TROUBLESHOOTING
Machine Will Not Power Up
6.10 MAST TROUBLESHOOTING
Platform Will Not Lower Manually
Platform Lift Up And Down Jerky
Mast Noisy When Lifting And Lowering
Platform (Mast) Won’t Stay Elevated
Platform (Mast) Descends Too Slowly
6.11 HYDRAULIC LEAK TROUBLESHOOTING
Miscellaneous Hydraulic Leak Troubleshooting
6.12 BASE FRAME COMPONENTS TROUBLESHOOTING
Caster Wheels Not Operating Freely
Pot Hole Protection (PHP) Bars will not Lower
6.13 DRIVE SYSTEM TROUBLESHOOTING
Won’t Climb Grade
Machine Drives in Opposite Direction
Machine Won’t Drive Straight
Noise From Drive Assembly
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JLG DVL & DVSP Series Personnel Lift Service & Maintenance Manual (Global) – 3121136.pdf
