JLG DVL & DVSP Series Personnel Lift Service & Maintenance Manual (Global) - 3121136

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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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