JLG DVSP Service Manual

Service & Maintenance Manual

Model(s)

DVL &

DVSP

Series

P/N - 3121136

September 27, 2005

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

MAINTENANCE SAFETY PRECAUTIONS

A. GENERAL

This section contains the general safet y precautions which must b e o bs erved d uri ng mai nt ena nce o f th e a er ial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible i njury to them selves or ot hers or damage to the equipment. A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe to operate.

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

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

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

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIE LD INSPECTION AND MAINTENANC E, SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER/ OPERATOR.

C. MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.

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

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

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

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

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

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

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

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

B. HYDRAULIC SYSTEM SAFETY

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

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

3121136 – JLG Lift – a

INTRODUCTION - REVISION LOG

October 4, 2001 – Original Issue of Manual October 25, 2001 – Manual Revised November 12, 2001 – Manual Revised December 13, 2001 – Manual Revised February 22, 2002 – Manual Revised October 29, 2002 – Manual Revised January 22, 2003 – Manual Revised Feburary 18, 2003 – Manual Revised July 18, 2003 – Manual Revised October 1, 2003 – Manual Revised August 16, 2004 – Manual Revised September 27, 2005 – Manual Revised

REVISION LOG

b – JLG Lift – 3121136

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

MAINTENANCE SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

A GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

B HYDRAUL IC SYSTEM SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

C MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

REVISION LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

SECTION 1 - MACHINE SPECIFICATIONS

1.1 CAPACITIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Drive Motor GearBox (gear oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.2 COMPONENT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Hydraulic Pump/ Pump Motor Assembl y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Rear Wheel Drive Mot ors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Batteries/Batt e ry Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.3 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Platform Capacit ies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Platform Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Machine Height (platform stowed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Base Footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.4 TORQUE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.5 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Lubrication Spec ifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.6 HYDRAULIC PR ESSURE SETTINGS AND ADJU STMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Hydraulic Pressure Gauge Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

After Filter Pre s su re Che c k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.7 CYLINDER SPECI FI CATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.8 SERIAL NUMBER LOCA TI ON S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Annual Machine Ins pection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Preventative Ma intenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Inspection and M a intenance Codes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Footnotes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.3 SERVICING AND MAINTEN ANCE GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Safety and Workma ns hip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

3121136 – JLG Lift – i

TABLE OF CONTENTS

Components Remov al and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Component Disas s e mbly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Pressure-Fit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -6

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Hydraulic Line s and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Lubricatio n and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -7

Mast Chain Inspection Proc edure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2.4 LUBRICATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Changing Hyd ra u lic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Lubricatio n Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2.5 POSITIONING LIFT FOR ACCESS TO COMPONENTS LOCATED UNDER THE BASE FRAME. .2-9

SECTION 3 - BASE COMPONENTS

3.1 BASE ASSEMBLY COMPON EN TS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 BASE FR A M E COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Drive Motor Cover - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Battery Charger Cover - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.3 DRIVE AN D CASTER WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Drive Motor Wheel (Std.) - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Caster Wheels - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Wheel Retention for Rough Terrain Drive Wheel (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3.4 DRIVE M O TOR COMPONENT - SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Torque Limiting Clutch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Visual Inspection and Limiting Torque Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Check Clutch Torque Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Torque Limiting Clutch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Drive Wheel Alignment - (Machines built prior to S/N-0130005271) . . . . . . . . . . . . . . . . . . .3-5

3.5 DRIVE MOTOR ASSEMBLY - SERVICING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Drive Motor Assembly - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Drive Motor Bra k e Removal and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Brake Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Brake Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 2

Checking/Adjusting Armature Plate Gap Se t t ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -12

Brake Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Drive Motor Boo t As sembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

Drive Motor Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

Brush Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

Brush Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

Brush Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

Gear Box Disassembly/Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

Gear/Pinion Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

Drive Shaft As s e mbly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

Final Gear Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

3.6 POT HOLE PROTECTION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3.7 BATTER Y /BATTERY CHARGER - SERVICE PROC E D U RES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -22

Battery Low Volt age Warning Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 2

Battery Condi t i on Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

ii – JLG Lift – 3121136

Battery Replacem e nt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Battery Charger Ge neral Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Battery Charger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Battery Charge/ Fl ash Code LED Indicator on Pla t form Control Console . . . . . . . . . . . . . .3-24

Battery Charging Stat us Indicators Mounted on Ground Control St ation Cover . . . . . . . . .3-24

Wet/VRLA Battery - Charging Profile Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

General Component Installation Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Battery Charger Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Cover Installa t ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

AC Line Fuse Install ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Interlock Relay Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

Wet/VRLA Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

Shunt Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

SCR Rectifier Ins t al la t ion (Either Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

Transformer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Printed Circuit Board Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

DC Circuit Breaker/Voltage Select Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

SECTION 4- CONTROL COMPONENTS

4.1 CONTROL COMPONENTS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2 CONTROLS COVER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Battery Cover Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 2

Center, Left and Rig ht Lo we r Cove rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.3 CONTROL COMPONENTS - INS TAL L A TION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Ground Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Traction Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Platform Control Console Installati o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Battery Instal l at ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Horn Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Alarm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Battery Instal la t ion (EE Spec Machines Onl y ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Fuse Box - (EE Spec Machines Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Master Disconnect Switch - (EE Spec Machines Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4.4 GROUND CONTROL MO DU L E - SERVICE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Cover Removal/In s t allation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Power Selector /EStop Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4.5 GROUND CONTROL MO DU L E - PROGR AM M IN G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Programming Le v e l s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Activating Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Entering Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Programming Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Selecting Programmable Item to Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Adjusting Programmable Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Service Programming Mode - (Level-2 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Operator Programming Mode - (Level-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4.6 PLATFORM CONTROL CONSOLE - SERVICE PROCEDURES -

(MACHINES S/N - 0130007616 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Remove Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Display/Controller Module Electrical Connectio ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Mounting Bracke t - Inst all/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Rear Cover - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Display/Cont roller Module - Inst al l /Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Drive/Lift Mod e Switch - Install/R e move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Horn Button Switc h - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

TABLE OF CONTENTS

3121136 – JLG Lift – iii

TABLE OF CONTENTS

Key Switch - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

E-Stop/Shut D own Switch - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -17

Joystick Assembly - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 1 7

4.7 PLATFORM CONTROL CONSOLE - SERVICE PROCEDURES -

(MACHINES PRIOR TO S/N - 0130007616) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

Remove Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

Upper/Lower Shell Attach Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

Emergency Sto p Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -19

Upper/Lower Sh ell Component Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

Button Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

Joystick Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

Joystick Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4.8 PUMP-M OT O R ASSEMBLY - SERVICE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

Inline Hydraulic Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

Pump/Motor/Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

Motor Cap/Motor I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

Motor Brush Ins t allation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

Brush Housin g F inal Assembly Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 2 3

Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Pump Installati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 2 4

Filter Screen Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Pressure Adjust V al v e Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

Pressure Check Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

4.9 OBSTRU CTION SENSOR SYSTEM - SERVICE P RO CEDURE (DVSP - OPTION) . . . . . . . . . . . .4-2 6

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

Transducer Sensor Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

OSS Component Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

SECTION 5 - MAST COMPONENTS

5.1 MAST COMPONENTS OVER VI EW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Mast Chain/Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Sequencing Cab l e Adj us t ment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.3 SEQUENCE CABLE REPLACEMENT KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Remove Old Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Replacement Ca bl e Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Clamp Installat i on (Drum/Socket Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5.4 HYDRAUL IC LIFT CYLINDER - REMOVAL , IN SPECTION AND REBUILD . . . . . . . . . . . . . . . . . . .5-7

Lift Cylinder Re moval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Cylinder Disa s s e mbly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

Lift Cylinder Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

Cylinder Insta l lation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

5.5 MAST ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

Mast Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5.6 MAST A SSE M BLY AND DISASSEMBLY PROC ED URES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

Mast Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

Mast Assembly - DVL/DVSP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

5.7 DVSP - STOCKPICKER PLATFORM - INSTALL A TION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -24

5.8 DVSP - STOCKPICKER PLATFORM - MID-GATE I N T ER L O CK INSTALLATION. . . . . . . . . . . . . .5-25

5.9 MAST BEACON - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25

iv – JLG Lift – 3121136

SECTION 6- TROUBLESHOOTING

6.1 GENER AL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.2 TROUBLESHOOTING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.3 HYDRAULIC CIRCUIT CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.4 ELECTRICAL CIRCUIT CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Ground Control Module LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6.5 TROUBLESHOOTING TABLES INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

Specifications For Various Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

Special Pin Extract or Tools F or Ele c t r ic al Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

Fault Code Troub le s hooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

Main Power Circuit Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

Mast Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

Hydraulic Leak Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

Base Frame Components Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

Drive System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

6.6 SPECIFICATION S FOR VARIOUS COM PONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6.7 SPECIAL PIN EXTRACTOR TOOL S FOR ELECTRICAL CONNECTORS . . . . . . . . . . . . . . . . . . .6-10

6.8 FAULT CODE TROUBLESH OOTI N G TABL ES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

Machine in Drive Spee d Cut- Back (Turtle) Mode All The Tim e . . . . . . . . . . . . . . . . . . . . . .6-11

Obstruction Sensor System - Detectio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

Battery Voltage Low - Warning Level 3 - Three (3) LED/LCDs lit. . . . . . . . . . . . . . . . . . . . .6-12

Code 02 - Left PHP Bar - UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

Code 03 - Right PHP Bar - UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

Code 04 - Tilt Condit ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

Code 05 - Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

Code 06 - Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

Code 07- Left Drive Mo t or - D is c onnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

Code 08 - Right Drive Mot o r - D is connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

Code 09 - Left Brake - Dis co n nected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

Code 10 - Right Brake - Dis connected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

Code 11 - Left Drive Motor - Shor t Circ uit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

Code 12 - Right Drive Motor - Sh ort Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

Code 13 - Traction Mod ul e - In Fol d Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

Code 14 - Pump Motor - Dis connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

Code 15 - Lift Down Val v e - Disc onnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

Code 16 - Lift Down Val v e - Sho r t Circ uit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

Code 17 - Ground Cont rol M odule - In Fold Back. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

Code 18 - Alarm - Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

Code 19 - Alarm - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19

Code 20 - Beacon - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19

Code 21 - Beacon - Disc onnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

Code 22 - Horn - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

Code 23 - Horn - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21

Code 24 - Auxiliary #1 Circui t - Sh ort Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21

Code 25 - Auxiliary #1 Circu it - Di s co n nected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

Code 26 - Auxiliary #2 - Sh ort Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

Code 27 - Auxiliary #2 - Dis connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23

Code 28 - Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23

Code 29 - Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23

Code 30 - Traction Mod ul e - No Com m unication with Ground Control Module. . . . . . . . .6-24

Code 31 - Platform Control Con sol e - No Communication with Ground Control Module .6-25

Code 32 - Pump Motor - Over Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25

Code 33 - Both PHP Bars - UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26

Code 38 - Battery Volt age Low - Warning Level 2 - Two (2 ) LED/LCDs lit . . . . . . . . . . . . .6-26

TABLE OF CONTENTS

3121136 – JLG Lift – v

TABLE OF CONTENTS

Code 39 - Battery Vo l t age Low - Warning Level 3 - One (1) LED/LCDs lit . . . . . . . . . . . . .6-26

Code 40 - Obstruction Sensor System - No Communication with Ground Control Module6-27

Codes 41 thru 46 - OSS - Se nsor 1 through 6 - Fault Conditi on . . . . . . . . . . . . . . . . . . . . .6-28

Codes (100 - 199) Ground Control Module - Fault Condition . . . . . . . . . . . . . . . . . . . . . . .6-29

Codes (200 - 299) Platform Control Console - Fault Condition. . . . . . . . . . . . . . . . . . . . . .6-30

Codes (300 - 399) Traction Control Module - Fault Condition. . . . . . . . . . . . . . . . . . . . . . .6-31

6.9 MAIN POW E R CIRCUIT TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32

Machine Will Not Power Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32

6.10 M AST TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33

Platform Will Not Lower Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33

Platform Lift Up And Down Jerky . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33

Mast Noisy When L if t ing And Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34

Platform (Mast ) Wo n’t Stay Elevated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35

Platform (Mast ) Descends Too Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35

6.11 H Y D RAULIC LEAK TROUBLESHOO TING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36

Miscellaneous Hydraulic Leak Troubles hooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36

6.12 B A SE FRAME COMPONENTS TROUBL ESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37

Caster Wheels No t Operating Freely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37

Pot Hole Protecti on (PHP) Bars will not Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37

6.13 DRIVE SYSTEM TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38

Won’t Climb Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38

Machine Drive s in Opposite Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3 9

Machine Won’t Drive Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40

Noise From Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41

vi – JLG Lift – 3121136

TABLE OF CONTENTS

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Hydraulic Pressure Adjustment Screw . (M achine Rear Covers Removed) . . . . . . . . . . . . . . . . . .1-3

1-2. Typical Hydraulic Pres s ure Gaug e In stallation (Hydraulic Filter Removed).. . . . . . . . . . . . . . . . .1-4

1-3. Typical Hydraulic Pre s s ure Gaug e Installation (After Hydraulic Filter).. . . . . . . . . . . . . . . . . . . . .1-4

1-4. Torque Chart. (ANSI Spec.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-5. Torque Chart. (ANSI t o M E TRI C Conversion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1-6. Torque Chart (Metric Class Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

2-1. Accessing Machin e Un de rs id e Components by Liftin g wit h a Fork Truc k.. . . . . . . . . . . . . . . . . .2-9

3-1. Base Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-2. Drive Motor Assembly Components. (Mach ines built prior to S/N-0130005271). . . . . . . . . . . . .3-7

3-3. Drive Motor Assembly Components. (Mach ines built since S/N-0130005271) . . . . . . . . . . . . . .3-7

3-4. Drive Motor Component Assembly (Mach i nes bui lt prior to S/N-0130005271) . . . . . . . . . . . . . .3-9

3-5. Drive Motor Component Assembly (Mach i nes bui lt since S/N-0130005271). . . . . . . . . . . . . . . .3-10

3-6. Torque Limiting Clutch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

3-7. Brake Assembly Com ponents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3-8. Drive Motor Gear Box Assem bly - DV L /D VSP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3-9. Pot-Hole-Prote c t ion Sys t e m Com ponents.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3-10. DVL/DVSP - SCR Dual Voltage - Battery Charger Wiring Diagram.. . . . . . . . . . . . . . . . . . . . . . . .3-28

4-1. Control Components Location - DVL/DVSP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-2. Component Electrical Connections.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-3. Ground Control Module Components.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-4. Platform Control Console Component s.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-5. Platform Control Console Component s.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

5-1. Mast Component s . (D VL/DVSP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-2. DVL/DVSP - Mast Chain and Sequence Cable Adjustment Com ponents. . . . . . . . . . . . . . . . . . .5-3

5-3. Machine Positio ne d fo r Cy l inder Re m ov al.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

5-4. Lift Cylinder Component Cross-Section (DVL/DVSP ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5-5. Mast Section - Assembly Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5-6. Mast Chain Routin g D iagram. - DVL/DVSP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

5-7. Mast Bottom End - Slid e Pa d Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

5-8. Mast Top End - Slide Pa d Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17

5-9. DVSP - StockPicker Plat form Ins t all ation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

6-1. Component Electrical Connections.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

6-2. Overview of Electr ic al Sys t e m Components. (DVL /D VSP) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . .6-42

6-3. Electrical Diagram . (DVL/DVSP) (Sheet 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -44

6-4. Electrical Diagram - (with Load Sensing System) (DVL/DVSP ) (S hee t 2 ) . . . . . . . . . . . . . . . . . . .6-46

6-5. Hydraulic Diagram . ( D VL /DVSP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 DVL and DVSP - Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-2 Hydraulic Oil Operat ing Rang e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-3. Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-4. Cylinder Speci f ic at ions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-5 Lubrication Interv al s for Vario us Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

2-1 Inspection and Mai nt e nance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2-2 DVL/DVSP - Preventive Maintenance & Inspection Schedule.. . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2-3 Chain Stretch Tolera nce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

3-1 Battery Low Voltage Warning Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

4-1 DVL/DVSP Ground Control Module - Field Programmable Settings and Factory Preset.. . . . . . .4-13

4-2 Obstruction Se ns or Sys tem Components (Platform Cutawa y ) . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

5-1 DVL/DVSP Mast Component Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

6-1 LCD Display - Service Fault Code Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

3121136 – JLG Lift – vii

TABLE OF CONTENTS

6-2 Ohm Ratings for Various Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6-3 Amper age Draw for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6-4 Speci a l Pin Extractor Tools for Elect rical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6-5 Machine In Drive Speed Cut-Back (Turtle) Mode All The Time . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

6-6 Obstr uction Sensor System - Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6-7 Code 02 - L e f t PH P Bar - UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

6-8 Code 03 - Right PHP Bar - UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

6-9 Code 04 - T il t Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6-10 Code 07 - Left Dri v e Mo t or - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6-11 Code 08 - Right Dr iv e M otor Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

6-12 Code 0 9 - Left Brake - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

6-13 Code 10 - Right Brake - Disconnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

6-14 Code 11 - Left Dri v e Mot or - Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

6-15 Code 12 - Right Dr iv e M otor - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

6-16 Code 13 - Tractio n M odule - In Fold Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

6-17 Code 14 - Pump Motor - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

6-18 Code 15 - Lift Dow n V al v e - D is connected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

6-19 Code 16 - Lift Down Valve - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

6-20 Code 17 - Ground Co nt r ol Module - In Fold Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

6-21 Code 18 - Alarm - Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

6-22 Code 19 - Alarm - Disconnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19

6-23 Code 20 - Beacon - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19

6-24 Code 21 - Beacon - Sh or t D isconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 -20

6-25 Code 2 2 - Horn - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6- 20

6-26 Code 23 - Horn - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21

6-27 Code 24 - Auxil iary #1 Circuit - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21

6-28 Code 25 - Auxil ia ry #1 Circuit - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

6-29 Code 2 6 - Auxil iary #2 - Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6-30 Code 2 7 - Auxil iary #2 - Disconnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23

6-31 Code 30 - Tractio n Module - No Communication with Grou nd Control Module . . . . . . . . . . . . . .6-24

6-32 Code 31 - Platfor m Control Console - No Communica t ion with Ground Control Modu le. . . . . . .6-25

6-33 Code 32 - Pump Motor - Over Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25

6-34 Code 33 - Both PHP Bars - UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26

6-35 Code 40 - OSS - No Communication with Ground Control Module . . . . . . . . . . . . . . . . . . . . . . .6-27

6-36 Codes 4 1 th ru 46 - OSS - Sensor 1 through 6 - Faul tCondition . . . . . . . . . . . . . . . . . . . . . . . . . .6-28

6-37 Codes (100 - 199) Ground Cont rol Mo dule - Fa ult Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29

6-38 Code (200 - 299) Platform Control Console - Fault Condition. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30

6-39 Codes ( 30 0 - 3 9 9) Traction Control Module - Fault Conditio n. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31

6-40 Machine Will Not Power UP.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32

6-41 Platform Will Not Lower Manually. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33

6-42 Platform Lift Up and Down Jerky . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33

6-43 Mast Noisy when Lifting and Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34

6-44 Platform (Mast) Won’t Stay Elevated.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35

6-45 Platform (Mast) Descends Too Slowly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35

6-46 Hydra ul ic Leak Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36

6-47 Caster Wheels Not Operating Freely.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37

6-48 Pot Hole Protect ion (PHP) Bars will not Lower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37

6-49 Won’t Climb Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38

6-50 Machine Dri v e in Opp os i t e D ire ction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39

6-51 Machine Won’t Drive Straight.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 0

6-52 Noise from Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41

viii – JLG Lift – 3121136

SECTION 1 - MA CHINE SPECIFICATIONS

SECTION 1. MACHINE SPECIFICATIONS

Table 1-1. DVL and DVSP - Machin e Spec i fications

15DVL 20DVL 15DVSP 20DVSP

Maximum Occupants: 1 Maximum W ork Load (Capacity) :

(DVL-Std. Platform / DVSP - Stockpicker Platform)

Maximum T r avel Grade (Gradeabilit y):

(Platform STOWED ONL Y)

Maximum T ravel Grade (Side Slope):

(Platform STOWED ONL Y)

Maximum Vertical Platform Height:

500 lb.

(230 kg)

15 ft.

(4.57 m)

350 lb.

(160 kg)

19.5 ft.

(5.94 m)

500 lb.

(230 kg)

20%

5°

15 ft.

(4.57 m) Maximum Wheel Load (Per Wheel): 800 lb. (360 kg) Maximum Drive Speeds (Operator Variabl e): 0.5 - 2 mph (0.8 - 3.2 kph) Max. Platform Speeds (w/Max. Load): Platform Up:

Platform Down:

Gross Machine Weight (Platform Empty):

20 sec. 22.5 sec. 20 sec.

15 - 21 sec. 21 - 26 sec. 15 - 21 sec. 21 - 26 sec.

2,105 lb. (955 kg)

2,105 lb.

(955 kg)

2,150 lb.

(975 kg)

400 lb.

(180 kg)

19.5 ft.

(5.94m)

22.5 sec.

2,150 lb.

(975kg)

3121136 – JLG Lift – 1-1

SECTION 1 - MACHINE SPECIFICATIONS

1.1 CAPACITIES

System Voltage

All Models – 24 Volt DC

Hydraulic System

All Models – 5 qts. U.S. (4.7 L)

Drive Motor GearBox (gear oil)

All Models – 6 oz. (175cc)

1.2 COMPONENT DATA

Hydraulic Pump/Pump Motor Assembly

Pump Motor - 24 Volt DC motor, Standard Duty Pump Displacement –

DVL/DVSP – .098 cu. in./rev. (1.6cc/rev.)

Pump Output (Max.) –

DVL/DVSP - 1.20 gpm @ 2200 psi @ 23.5 volts and 105

amps @ 45 centistrokes (200 SSU)

Reservoir Capacity –

DVL/DVSP - 1 Gallon (3.78 L)

Rear Wheel Drive Motors

Drive Motors -

1/2 HP, 24 Volt DC, Variable Right Angle, Sealed Gear Box, 40:1 ratio Brake Shaft and Drive Shaft - Integral to Moto r Parking Brake ( m ust be released for pushing)

Batteries/ Battery Charger

Batteries (2) – 12 Volt / 100 Amp Hour –

Deep Cycle Marine - RV

Weight – 65.7 lb. (29.8 Kg) - Per Battery

1.3 PERFORMANCE DATA

Platform Cap a cities

Standard - 15DVL - 500 lb. (230kg)

20DVL - 350 lb. (160kg)

StockPicker - 15DVSP - 500 lb. (230kg)

20DVSP - 400 lb. (180kg)

Extendible - 15DVL/ 15DVSP - 500 lb. (230kg )

20DVL Series - 350 lb. (160kg)

Molded - 15DVL/15DVSP - 500 lb. (230kg)

20DVL Series - 350 lb. (160kg)

NOTE: Distribute weight evenly in platform when loading.

Reference the c apa city de cal on th e machi nes’ de cal billboard mounted on mast.

Platform Size

Standard - 26in.-W x 26 in.-L (66cm) x (66cm) Stockpicker - 28in.-W x 48in.-L (71cm x 122cm) Extendible - 26in.-W x 49in.-L (66cm x 124cm) Moulded - 25in.-W x 26in.-L (64cm x 66cm)

Machine Height (platform stowed)

DVL/DVSP - 78 in. (198cm) height

Base Footprin t

DVL/DVSP - 29.25in.-W x 52in.-L (74cm) x (132cm)

1.4 TORQUE REQUIREMENTS

When maintenance becomes necessary or a fastener has loosened, refer to the applicable Torque Chart in this section of the manual, to determine proper torque values.

Battery Charger –

Microprocessor Controlled/SCR Circuit Monitor 120/240 Volt A.C. Selectable / 50/60 Hz input 24 volt, 20 amp output - with 2 amp finish Reset Circuit Breaker Automatic Charge Circuit Plug Interlock Circuit Wet/VRLA Battery Switch

NOTE: The batteries on DVL/DVSP machines require

approximately five (5) hours to fully charge when drained to LOW BATTERY VOLTAGE warning on the Ground Control Module LCD display.

1-2 – JLG Lift – 3121136

SECTION 1 - MA CHINE SPECIFICATIONS

1.5 LUBRICATION

Hydraulic Oil

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

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

Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required add itives o r be of comp arable vis cosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industr ies for pr oper recommen dations.

Table 1-2. Hydraulic Oil Operating Range

HYDRAULIC SYSTEM OPERATING

TEMPERATURE RANGE

+0˚ F to +180˚ F

(-18˚ C to +83˚ C)

+0˚ F to +210˚ F

(-18˚ C to +99˚ C) +50˚ F to +210˚ F

(+10˚ C to +99˚ C)

SAE VISCOSITY

GRADE

10W

10W-20, 10W-30

20W-20

1.6 HYDRAULIC PRESSURE SETTINGS AND ADJUSTMENT

Adjust system pressure so that p latform will rai se with ma ximum rated capacity in platform.

The following pressure setting are factory recommended (initial) settings;

MODEL PRESSURE SETTING

15DVL/15DVSP 2600 PSI 20DVL 1800 PSI 20DVSP 2800 PSI

Turning adjustment screw clockwise increases sy stem pressure, turning screw counterclockwise decreases system pressure. (See Figure 1-1., Hydraulic Press ure Adjust-

ment Screw. (Machine Rear Covers Removed))

Perform pressure ad justment with oil at normal operat ing temperature. If pressure is set when oil is cold, platform may not raise rated load after soil has warmed.

Lubrication Specifications

Table 1-3. Lubrication Specifications

KEY SPECIFICATIONS

MPG - Multipurpose Grease having a minimum dripping point

of 350° F . Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)

EPGL - Extreme Pressure Gear Lu be (oil) meeting AP I service

classification GL-5 or MIL -Spec MIL -L-2105.

HO - Hydraulic Oil. ISO- Vg grade 32, 46.

CL - Chain Lube. Use a good quality chain lubricant.

1. Remove Adjust Screw Cap 2. P ressure Ad justment Screw

Note: Machine rear covers must be removed to access pump motor.

Figure 1-1. Hydraulic Pressure Adjustment Screw.

(Machine Rear Covers Removed)

3121136 – JLG Lift – 1-3

SECTION 1 - MACHINE SPECIFICATIONS

Hydraulic Press u r e Gaug e Connection

ONLY OPEN HYDRAULIC SYSTEM LINES WITH THE MAST FULLY LOWERED TO RELIEVE PRESSURE IN THE SYSTEM. CAREFULLY LOOSEN REQUIRED FITTINGS, WEAR SAFETY PROTECTION EQUIPMENT WHEN WORKING WITH HYDRAULIC SYSTEMS.

Remove the hydraulic oil filter and ins tall a t-fitting between the pump and the extend line to connect a hydraulic pressure gauge as shown in Figure 1-2., Typical Hydraulic Pressure Gauge Installation (Hydraulic Filter Removed).

CHECK, and if necessary, ADJUST the hydraulic pressure to initial settings shown in table at the beginning of this section. Cycle the hydraulic system several times with the maximum load capacity in the platform, then recheck pressure setting. When pressure has stabilized continue to "After Filter Pressure Check" following.

3 4

1. Pressure Gauge Assembly 3. T- Fitting

2. Extend Line 4. Return Line

Figure 1-2. Typical Hydrauli c P re s s ure Gauge

Installation (Hydraulic Filter Removed).

After Filter Pressure Check

Reinstall the hydraulic oil filter and install the t-fitting between the hydraulic filter and the extend line to the cylinder. Recheck the hydraulic pressure and compare with the previous r eadings when filter wa s removed. If a signi ficant drop in pressure reading has occurred, replace the hydraulic filter and recheck the "after filter" pressure reading.

1. Hydraulic Oil Filter 3. Pressure Gauge Assembly

2. T- Fitting 4. Extend Line

Figure 1-3. Typical Hydraulic Pressure Gauge

Installation (After Hydraulic Filter).

1.7 CYLINDER SPECIFICATIONS

NOTE: All dimensions are given in inches (in), with the met-

ric equivalent, centimeters (cm), given in parentheses.

Table 1-4. Cylinder Specifications

DESCRIPTION

15DVL/15DVSP Lift Cylinder

20DVL/20DVSP Lift Cylinder

BORE

in./(cm)

1.63

(4.10)

1.63

(4.10)

STROKE in./(cm)

41.50

(105.4)

54.0

(137.1)

ROD DIA.

in./(cm)

1.375 (3.49)

1.8 SERIAL NUMBER LOCATIONS

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

1-4 – JLG Lift – 3121136

SECTION 1 - MA CHINE SPECIFICATIONS

Table 1-5.Lubrication Intervals for Various Components

ITEM COMPONENT

1Hydraulic Oil

Drive Wheel

Bearings Drive Wheel

Gear Box

4 Cas ter Axles 2 - Grease Fittings MPG - Pressure Gun 5 Swivel Raceways 2 - Front Casters MPG - Pressure Gun

6Mast Chains 2 - Per Section

Key to Lubr icants: MPG - Multipurpose Grease

HO - Hydraulic Oil - ISO-Vg grade 32, 46. GEAR OIL - Good Quality Worm Gear Oil - SAE 90 - AGMA# 5 - EP Compounded CL - Chain Lube. Use a good quality chain lubricant

NO/TYPE

LUBE POINTS

Fill T o Line on Reservoir 5 Qt. Rese rvoir

2 - Gear Boxe s G ear Oil

(a)

LUBE/METHOD

HO - Check Hyd. Oil Level HO - Change Hyd. Oil

— — Permanently Sealed.

Chain Lube - Brush or Spray

INTERVAL

MONTHS6MONTHS1YEAR2YEARS

(b)

COMMENTS

Check fluid level every day .

✔

Change hydraulic oil every 2 years.

Change only when serviced requires 6 oz. (175 cc’s) to fill.

(c)

✔ ✔

✔

Inspect, lubricate if dry or rusting.

Notes: (a) Be certain to lubricate like items on each side of the machine.

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

(b) Recommended lubricating intervals are based on normal use. If machine is subjected to severe operating conditions, (c) Prior to checking hydraulic oil level, operate machine through one complete cycle of lift function (full up and down). F ailure to do so

will result in incorrect o il level readi ng on the hydrau lic reservoir .

3121136 – JLG Lift – 1-5

SECTION 1 - MACHINE SPECIFICATIONS

Figure 1-4. Torque Chart. (ANSI Spec.)

1-6 – JLG Lift – 3121136

UNPLATED

CAP SCREWS

SECTION 1 - MA CHINE SPECIFICATIONS

SAE GRADE 5 SAE GRADE 8

VALUES FOR ZINC PLATED BOLTS ONLY

Note: These torque values do not apply to cadium plated fasteners.

Figure 1-5. T orque Chart. (ANSI to METRIC Conversion)

3121136 – JLG Lift – 1-7

SECTION 1 - MACHINE SPECIFICATIONS

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY

CLASS 8.8 ME TRIC BOLTS &

CLASS 8 METRIC NUTS

TORQUE

LUB

LOCTITE

262

LOCTITE

242 OR

271

CLAMP

SIZE PITCH

TENSILE

STRESS

AREA

CLAMP

LOAD

DRY OR

LOCTITE

263

sq. mm KN N, m N, m N, m N, m KN N, m N, m N, m N, m

3 .5 5.03 2.19 1.3 1.0 1.2 1.4 3.13 1.9 1.4 1.5 2.1

3.5 .6 6.78 2.95 2.1 1.6 1.9 2.3 4.22 3.0 2.2 2.4 3.3 4 .7 8.78 3.82 3.1 2.3 2.8 3.4 5.47 4.4 3.3 3.5 4.8 5 .8 14.2 6.18 6.2 4.6 5.6 6.8 8.85 8.9 6.6 7.1 9.7 6 1 20.1 8.74 11 7.9 9.4 12 12.5 15 11 12 17 7 1 28.9 12.6 18 13 16 19 18 25 19 20 28

81.2536.615.92519232822.837272940

10 1.5 58.0 25.2 50 38 45 55 36.1 72 54 58 79 12 1.75 84.3 36.7 88 66 79 97 52.5 126 95 101 139 14 2 115 50.0 140 105 126 154 71.6 200 150 160 220 16 2 157 68.3 219 164 197 241 97.8 313 235 250 344 18 2.5 192 83.5 301 226 271 331 119.5 430 323 344 473 20 2.5 245 106.5 426 320 383 469 152.5 610 458 488 671 22 2.5 303 132.0 581 436 523 639 189.0 832 624 665 915 24 3 353 153.5 737 553 663 811 220.0 1060 792 845 1170 27 3 459 199.5 1080 810 970 1130 286.0 1540 1160 1240 1690 30 3.5 561 244.0 1460 1100 1320 1530 349.5 2100 1570 1680 2310 33 3.5 694 302.0 1990 1490 1790 2090 432.5 2600 2140 2280 2860 36 4 817 355.0 2560 1920 2300 2690 509.0 3660 2750 2930 4020 42 4.5 1120 487.0 4090 3070 3680 4290 698.0 5860 4400 4690 6440

CLASS 10.9 METRIC BOLTS &

CLASS 10 METRIC NUTS

LOAD

DRY OR

LOCTITE

263

LUB

TORQUE

LOCTITE

262

LOCTITE

242 OR

271

Note: These torque value s do not apply to cadmium plated fa steners.

METRIC CLASS 8.8 METRIC CLASS 10.9

Figure 1-6. Torque Chart (Metric Class Fasteners)

1-8 – JLG Lift – 3121136

SECTION 2. GENERAL

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.

Preparation, Inspection, and Maintenance

It is important to establish and conform to a comprehensive inspection and preventive maintenance program. The following table outlines the periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult your national, regional, or local regu lat io ns for further requirements for aerial work platforms. The frequenc y of inspections and maintenance must be increased as environment, severity and frequency of usage requires.

Pre-Start Inspection

It is the User’s or Operator’s primary responsibility to perform a Pre-Start Inspection of the machine prior to use daily or at each change of operator. Reference the Operator’s and Safety Manual for completion procedures for the Pre-Start Inspection. The Operator and Safety Manual must be read in its entirety and understood prior to performing the Pre-Start Inspection.

Pre-Delivery Inspection and Frequent Inspection

The Pre-Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, tra ini ng, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject JLG product model.

The Pre-Delivery Inspection and Frequent Inspection procedures are performed in the same manner, but at different times. The Pre-Delivery Inspection shall be performed prior to each sale, lease, or rental delivery. The Frequent Inspection shall be accomplished for each machine in service for 3 months; out of service for a period of more than 3 months; or when purchased used. The frequency of this inspection must be increased as environment, severity and frequency of usage requires.

Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requirin g inspection during the performance of these inspections. Reference the appropriate areas of this manual for servicing and maintenance procedures.

Annual Machine Inspection

The Annual Machine Inspection must be performed by a qualified JLG equipment m echan ic on an annual b asis, n o later than thirteen (13) months from the date of the prior Annual Machine Inspection. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a person who has successfully completed the JLG Servic e Training School for the subject JLG product model. Reference the machine Service and Maintenance Manual and appropriate JLG inspection form for performance of this inspection.

Reference the JLG Annual Machine Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the performance of this inspection. Reference the appropriate areas of this manual for servicing and maintenance procedures.

For the purpose of receiving safety-related bulletins, it is important that JLG Industries, Inc. has updated ownership information for each machine. When performing each Annual Machine Inspection, notify JLG Industries, Inc. of the current machine ownership.

Preventative Maintenance

In conjunction with the specified inspections, maintenance shall be p erformed by a qualifie d JLG equipment mechanic. JLG Industries, Inc. recognizes a qualified JLG equipment mechan ic as a pe rson who, by p osse ssio n of a recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the ability an d profici ency to service , repair, and mainta in the subject JLG product model .

Reference Table 2-2, DVL/DVSP - Preventive Maintenance & Inspection Schedule., and the approp riate areas of this manual for servicing and maintenance procedures. The frequency of service and maintenance must be increased as environment, severity and frequency of usage requires.

3121136 – JLG Lift – 2-1

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Type Frequency

Pre-Start Inspection

Pre-Delivery Inspection

Frequent Inspection

Annual Machine Inspection

Preventative Maintenance

Prior to use each day; or At each Operator change.

Prior to each sale, lease, or rental delivery.

In service for 3 months; or Out of service for a period of more than 3 months; or Purchased used.

Annuall y, no lat er than 13 months from the date of the prior inspecti on.

At intervals as specified in the Service and Maintenance Manual.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner , Dealer , or User Qualified JLG

Service

Qualification

Mechanic

Reference

Service and Maintenance Manual and applicable JLG ins pection form.

Service and Maintenance Manual

2-2 – JLG Lift – 3121136

2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

(See T able 2-2.)

The preventive maintenance and inspection checks are listed and defined in the following table. This table is divided into t wo basic parts, the “AREA” to be inspected and the “INTERVAL” at which the inspection is to take place. Under the “AREA” portion of the table, the various systems along with the components that make up that system are listed. The “INTERVAL” portion of the table is divided into five col umn s repr ese ntin g t he vari ous i nspe ction time periods. The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked.

The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive. Variances in interval times may occur due to climate and/or c ondition s and de pending on the location and use of the machine.

SECTION 2 - GENERAL

3121136 – JLG Lift – 2-3

SECTION 2 - GENERAL

Table 2-2. DVL/DVSP - Preventive Maintena nce & Inspection Schedule.

INTERVAL

AREA ON MACHINE

PRE-START (a)

INSPECTION

3 MONTH

PREVENTATIVE

MAINTENANCE

MAST ASSEMBL Y 7

Mast Sections 2, 5 2, 5 Chain Systems 14 3, 14 14, 25 Sequence Cable Systems 31, 2, 3 Covers or Shields 1 Sheave Systems 1, 2 1, 2 Bearings 1, 2 Slide Pads 1, 2

PLATFORM ASSEMBLY 7

Platform 11 Guard Rails 1, 2, 4 1, 2, 4 Gate 1, 5 1, 5 Floor 1, 2 1, 2 Extension Deck Assembly 1, 5 1, 5 Lanyard Anch orage Point 1, 4 1, 4

CHASSIS ASSEMBL Y 7

Pot Hole Protection System 55 Battery and Valve Covers or Doors 1, 7 1, 7 Static Strap Caster Wheels 1, 2 14 1, 2 1, 2 Drive Wheels/Axle Assembly 22 Gear Box Assembly * Drive Motor Brushes 2, 20 T orque Limit Clutch ** 1, 7 3 Brake Release 55

FUNCTIONS/CONTROLS 7

Platform Controls 5, 6, 7 5, 6, 7 Ground Controls 5, 6 5, 6, 14 Functi on Control Lo cks, Guards, o r Detents 55 Function Enable System Emergency Stop Switches (Ground & Platform) 5 Functi on Limit or Cuto ut Switch Syste ms 5 Drive Brakes 5 Manual Descent or Auxiliary Power 55

POWER SYSTEM

Batteries 19 9 18 Battery Charger 5

HYDRAULIC/ELECTRIC SYSTEM 9

Hydraulic Pump 1, 2, 9 1, 2, 5, 9 Hydraulic Cylinder 2, 7, 9 2, 9 Cylinder Attachment Pins and Pin Retainers 1, 2 1, 2 Hydraulic Hoses, Lines, and Fittings 1, 9 1, 9 Hydraulic R eservoir , Cap, and Breather 5, 7 5, 7

6 MONTH PREVENTATI VE MAINTENANCE

PRE-DELIVERY (b) OR FREQUENT (c )

INSPECTION

ANNUAL (d)

(YEARLY)

INSPECTION

2-4 – JLG Lift – 3121136

SECTION 2 - GENERAL

Table 2-2. DVL/DVSP - Preventive Maintenance & Inspection Schedule. (Continued)

INTERVAL

AREA ON MACHINE

PRE-START (a)

INSPECTION

3 MONTH PREVENTATIVE MAINTENANCE

Hydraulic Filter Hydraulic Fluid *** 11 11 11 Electrical Connections 20 20 Instruments, Gauges, Switches, Lights, Ho rn 5

GENERAL

Operator and Safety Manuals in Storage Box 21 21 21 ANSI and EMI M anuals/Handbooks I nstalled 21 21 21 Capacity Decals Ins talled, Secure, Legible 21 21 21 All Decals/Placards In stalled, Secure, Legible 21 21 21 "Walk-Around" Inspection Performed 22 Annual Machine Inspection Due 21 No Unauthorized Modifications or Additions 21 21 All Relevant Saf ety Publications Incorporat ed 21 21, 22 General Structural Condition and Welds 2, 4 2, 4 All Fasteners, Pins , Shields, and Covers 1, 2 Grease and Lubricate to Specifications 22 22 Function Test of All Systems 22 22 Paint and Appearance 77 Stamp Inspec tion Date on Fra me 22 Notify JLG of Machine Ownership 22 * Change only when serviced, requires 6 oz. (175cc’s) to fill.

** If the lift is moved via fork truck on a regular or frequent basis, then the torque set ting should be checked every 3 months per Section 3 (of this

manual) - Drive Motor Component Servicing.

*** Drain and refill with fresh hydraulic fluid every two years.

6 MONTH PREVENTATI VE MAINTENANCE

PRE-DELIVERY (b) OR FREQUENT (c )

INSPECTION

ANNUAL (d)

(YEARLY)

INSPECTION

Inspection and Maintenance Codes:

1. Check for proper and secure installation.

2. V isual inspection for damage, cracks, disto rtion, or

excessive wear.

3. Check for proper adjustment.

4. Check for cracked or broken welds.

5. Operates properly.

6. Returns to neutral or "off" position when released.

7. Clean and free of debris.

8. Interlocks function properl y.

9. Ch eck for signs of leakage.

16. No gouges, excessive wear, or cords showing.

17. Properly inflated and seated around rim .

18. Proper and authorized components.

19. Fully charged.

20. No loose connections, corrosion, or abrasions.

21. Verify.

22. Perform.

23. Sealed properly.

24. Overrides Platform controls.

25. Inspected per Ser vice and Maintenance Manual.

Footnotes:

10. Decals installed and legible.

11. Check for proper fluid level.

12. Check for chafing and proper routing.

13. Check for proper tolerances.

14. Properly lubricated.

15. Torqued to proper specification.

(a) Prior to use each day; or at each Operator change (b) Prior to each sale, lease, or deliv ery (c) In service for 3 months; or Out of service for 3 months

or more; or Purchased used

(d) Annually, no later than 13 months from the date of the prior inspection

3121136 – JLG Lift – 2-5

SECTION 2 - GENERAL

2.3 SERVI CING AND MAINTENANCE GUIDELINES

General

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

Safety and Workmanship

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

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

Cleanliness

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

At any time when oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter.

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

Components Removal and Installation

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

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

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

Component Disassembly and Reassembly

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

Pressure-Fit Parts

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

Bearings

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

Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.

If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearings until they are ready to install.

Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, 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-f abricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious system damage.

Bolt Usage and Torque Application

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

Unless specific torque requirements are given within the text, standard torque values should be used on heattreated bolts, studs, and steel nuts, in accordance with recommended shop practices or Torque Chart in Section

2-6 – JLG Lift – 3121136

SECTION 2 - GENERAL

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic li nes a nd electrical wirin g, as well as their receptacles, when disconnecting or removing them from the unit. This will assure that they are correctly reinstalled.

Hydraulic System

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

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

Lubrication and Servicing

Componen ts and as sembli es requ iring l ubricat ion and servicing are shown in the Lubrication Chart , (See Sec- tion-1). Servi ce applicabl e components wit h the amount, type, and grade of lubricant recommended in this manual, at the specified intervals . When recom mended lubric ants are not available, consult your local supplier for an equivalent that meets or exceeds the specifications listed.

Batteries

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

Mast Chain Inspection Procedure

Inspect mast chains for the follow ing condi t io ns : Wear: Always inspect that segment of chain that operates

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

Rust and Corrosion: Rust and corrosion will cause a major reduction in the load carrying capacity of the chain, because these are primary reasons for side plate cracking. The initial lubric ation at the factory is applied in a hot dip tank to assure full penetration into the joint. Do not

steam clean or degrease chains. At time of chain installation, factory lube must be supplemented by a maintenance program to provide a film of oil on the chain s at all times. If chains are corroded, they must be inspected, especially the outside plates, for cracks in-line with the pins. If cracks are found, replace the chain; if no cracks are discovered, lubricate the chains by dipping in heated oil, and reinstall on the machine. Keep chains lubricated.

Table 2-3. Chain Stretch Tolerance

Chain Size

.50" pitch 12" or 24 pitches .24 in./12 in. span

.625 pitch 15" or 24 pitches .30 in./15 in. span

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

Tight Joints: All joints in the leaf chain should flex freely. On leaf chain, tight joints are usually caused by rust/corrosion, or the inside plates “walking” off the bushing. Limber up rusty/corroded chains (after inspecting care fully) with a heavy application of oil (preferably a hot oil dip). Tap inside “walking” plates inward; if “walking” persists, replace the chain. This type of problem is accelerated by poor lubrication maintenance practice, and most tight joint chains have been operated with little or no lubrication. Tight joints on leaf chain are generally caused by:

a. Bent pins or plates . b. Rusty joints. c. Peened plate edges.

Oil rusty chains, and repl ace chai ns with b ent or pee ned chain components. Keep chains lubricated.

Protruding or Turned Pins: Chains operating with inadequate lube generate tremendous friction between the pin and plates (pin and bushing on leaf chain). In extreme cases, this frictional torque ca n actually turn the pins in the outside press-fit plates. Inspect for turned pins, which can be easily spotted as the “V” flats on the pin heads are no longer in line. Replace all chains showing evidence of turned or protruding pins. Keep chains lubricated.

Chain Anchors and Sheaves: An inspection of the cha in must include a close examination of chain anchors and sheaves. Check chain anchors for wear breakage and misalignment. Anchors with worn or broken fingers should

Pin to Pin

Measurement

Allowable Stretch

3121136 – JLG Lift – 2-7

SECTION 2 - GENERAL

be replaced. They should also be adjusted to eliminate twisting the chain for an even load distribution.

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

a. Chains too tight. b. Sheav e be arings/pin bad. c. Bent/misaligned chains.

2.4 LUBRICATION INFORMATION

Hydraulic System

The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenance, or by permitting the pump to cavitate du e to ins ufficie nt sys tem wa rm-up o r leaks in the pump supply.

The design and manufacturing toler ances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage.

Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs , the system mus t be drained, flushed, and refilled with clean oil.

It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable vi scosities. Good g rade min eral oils, w ith viscosities suited to the ambient temperatures in which the machine is operating, are recommended for use.

NOTE: Metal particles may appear in the oil of new

machines due to the wear-in of meshing components.

Hydraulic Oil

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

Changing Hydraulic Oil

Use of any of the recommended hydraulic oils eliminates the need for changing the oil on a regular basis. If it is necessary to change the oil, use only those oils meeting or exceeding the specifica tions app earing i n this manua l. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oil s. JLG I ndus tri es rec omme nds c ha nging th e hydraulic oil annually.

Use every precaution to keep the hydraulic oil clean. If the oil must be pou red from the origi nal container into another, be sure to clean all possible contaminants from the service container.

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

Lubrication Specifications

Specified lubricants, as recommended by the component manufacturers, are always the be st choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose grease r equirements. Should any question arise regarding the use of greases in maintenance s t ock, cons ul t yo ur lo cal su ppl ier f o r e valu a tion. Refer to Section-1 in this Service Manual for an explanation of the lu bricant key de signatio ns appe aring in the Lubrication Chart.

2-8 – JLG Lift – 3121136

2.5 POSITIONING LIFT FOR ACCESS TO COMPONENTS LOCATED UNDER THE BASE FRAME

Access to the underside of the VP lift can be obtained by lifting the machine with a fork lift truck, using the fork lift pockets in the base frame.

Lifting with a Fork Truck (See Figure 2-1.)

1. Choose a fork lift truck capable of safely handling

the full weight of the machine.

2. Locate work area on a firm, level surface.

SECTION 2 - GENERAL

KEEP MACHINE LEVEL OR SLIGHTLY TILTED TOWARD FORKLIFT TRUCK WHEN LIFTING TO PREVENT MACH INE FROM SLIDING OFF LIFTING TINES.

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

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

1. Lift using only the fork lift pockets in the base frame.

2. Place support stands between machine and floor.

Figure 2-1. Accessing Machine Underside

Components by Lifting with a Fork Truck.

3121136 – JLG Lift – 2-9

SECTION 2 - GENERAL

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2-10 – JLG Lift – 3121136

+ 134 hidden pages

JLG DVSP Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

MAINTENANCE SAFETY PRECAUTIONS

A. GENERAL

C. MAINTENANCE

B. HYDRAULIC SYSTEM SAFETY

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 Cap a cities

Platform Size

Machine Height (platform stowed)

Base Footprin t

1.4 TORQUE REQUIREMENTS

1.5 LUBRICATION

Hydraulic Oil

1.6 HYDRAULIC PRESSURE SETTINGS AND ADJUSTMENT

Lubrication Specifications

Hydraulic Press u r e Gaug e 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 SERVI CING 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