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Service & Maintenance Manual

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2. 7 Pump Motor Tank Assembly 8 Obstruction Sensor System DVSP Option 3121136 Figure 4 1 Control Components Location DVL DVSP JLG Lift 4 1 SECTION 4 CONTROL COMPONENTS 4 2 CONTROLS COVER INSTALLATION Battery Cover Doors 1 LeftSide Cover 2 MastSupport Column 1 Right Side Cover 2 MastSupport Column Center Left and Right Lower Covers Lower Left Cover Front View Center Cover Lower Leftand Right Covers Rear View Note Center Cover requires unplugging the Charger AC Receptacle and LED Indicator wires when removing Lower RightCover Front View 4 2 J LG Lift 3121136 SECTION 4 CONTROL COMPONENTS 4 3 CONTROL COMPONENTS INSTALLATION IMPORTANT BEFORE REMOVING ANY COMPONENT FROM THE ELECTRICAL SYSTEM DISCONNECT THE POSITIVE TERMINAL FROM THE LEFT SIDE BATTERY Ground Control Module The Ground Control Module is located under the center cover atthe rear of the machine and is mounted on the mast support column All electrical components
3. mm Loctite CLAMP pay on LOCTITE SIZE PITCH area LH 24208 LOAD OORT 2420R 271 263 271 5 3 13 1 9 3 5 6 6 78 4 22 3 0 2 2 24 33 4 7 8 78 5 47 44 3 3 3 5 4 8 5 8 14 2 8 85 8 9 6 6 7 1 9 7 6 1 20 1 12 5 15 11 12 17 7 1 28 9 18 25 19 20 28 8 1 25 36 6 22 8 37 27 29 40 10 1 5 58 0 36 1 72 54 58 79 12 1 75 84 3 52 5 126 95 101 139 14 2 115 71 6 200 150 160 220 16 2 157 97 8 313 235 250 344 18 2 5 192 119 5 430 323 344 473 20 2 5 245 152 5 610 458 488 671 22 2 5 303 189 0 832 624 665 915 24 3 353 220 0 1060 792 845 1170 21 3 459 286 0 1540 1160 1240 1690 30 3 5 561 349 5 2100 1570 1680 2310 33 3 5 694 432 5 2600 2140 2280 2860 36 4 817 509 0 3660 2150 2930 4020 42 4 5 1120 698 0 5860 4400 4690 6440 Note These torque values do notapply to cadmium plated fasteners METRIC CLASS 8 8 METRIC CLASS 10 9 Figure 1 6 Torque Chart Metric Class Fasteners 1 8 J LG 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 i
4. IMPORTANT The 3 Levels of Battery Low Voltage Warning indication will only activate on DVL DVSP machines with version 29 orlater Ground Con trol Module software implemented 8 2004 However machines with earlier versions of software must follow the same LED BAR indicator guide lines and battery charging cycles to maximize battery life WARNING INDICATOR LOCATION RESULT ACTION REQUIRED TO LEVEL PLATFORM CONTROL LED GROUND CONTROL LCD CLEAR FAULT 3 LEDs BARS Flashing with Charge batteries to a levelof four Emi an audible beep 4 LEDs BARS ormore before LEVEL 1 X 000000 Machine will Operate No ENS LOU BATTERY Control Functions Locked Out 2 LEDs BARS Flashing with Charge batteries for a minimum E an audible offour 4 continuous hours or LEVEL 2 HL 5210000020 438 Platform Lift UP Function is eight 8 LEDs BARS lit before MAS CHARGE BATTERY 4 Locked Out operating a 38 1 LED BAR Flashing with an Charge batteries for a minimum _ i et audible offour 4 continuous hours or LEVEL 3 ull X 000000 439 Drive and Platform Lift UP eight 8 LEDs BARS lit before CHARGE BATTERY 2 Functions Locked Out operating a 39 NOTE a To maximize battery life it is recommended that the factory supplied batteries be charged continuously for a minimum of 4 hours or until 8 bar
5. 3 15 Brush Removal resin iae aa RU RA MN IW E 3 15 Brush lt lt 3 16 Gear 5 55 5 3 17 Gear Pinion Shaft 55 3 18 Drive Shaft he 3 18 Final Gear Box Assembly 3 19 3 6 POTHOLE PROTECTION SYSTEM ssesseses e hen 3 20 3 7 BATTERY BATTERY CHARGER SERVICE 5 3 22 Battery Low Voltage Warning Indicators isis 3 22 DiaQnOStics doe bes eeu dn dat Roh tei ute eaae 3 22 Battery Condition Testing 3 22 i J LG Lift 3121136 TABLE OF CONTENTS Battery 3 23 Battery Charger General Information 3 23 Battery Charger Troubleshooting 3 23 Battery Charge Flash Code LED Indicator on Platform Control Console 3 24 Battery Charging Status Indicators Mounted on Ground Control Station Cover 3 24 Wet VRLA Battery Charging Profile
6. 6 9 Mast Troubleshooting RACER UR 6 9 Hydraulic Leak 5 6 9 Base Frame Components Troubleshooting 6 9 Drive System Troubleshooting 6 9 6 6 SPECIFICATIONS FOR VARIOUS 6 10 6 7 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS 6 10 6 8 FAULT CODE TROUBLESHOOTING TABLES 0 cc cece ccc n hrs 6 11 Machine in Drive Speed Cut Back Turtle Mode All The Time 6 11 Obstruction Sensor System Detection 6 12 Battery Voltage Low Warning Level 3 Three 3 LED LCDs lit 6 12 Code 02 Left PHP hs 6 13 Gode 03 RighEPHP Bar UP ais cya E Cie REC Ce Debs ew Cp a oe onde 6 13 Code 04 Tilt Condito Nie sici Hm n 6 14 Code 05 Reseed cii cese eee CER E e 6 14 Code 06 Reserved ehh he 6 14 Code 07 Left Drive Motor 5 6 14 Code 08 Right Drive Motor 5 6 15 Code 09 Left Brake lt 6 15 Code
7. 6 33 Platform Lift Up And Down Jerky 6 33 Mast Noisy When Lifting And Lowering 6 34 Platform Mast Won t Stay 0 6 35 Platform Mast Descends Too 5 6 35 6 11 HYDRAULIC LEAK TROUBLESHOOTING 0 0c ccc ce ns 6 36 Miscellaneous Hydraulic Leak 6 36 6 12 BASE FRAME COMPONENTS TROUBLESHOOTING eee eee 6 37 Caster Wheels Not Operating 6 37 Pot Hole Protection PHP Bars will not 6 37 6 13 DRIVE SYSTEM TROUBLESHOOTING 0 00 ccc 6 38 Wont dene Cr Lad debe tod p see p beet eee 6 38 Machine Drives in Opposite 6 39 Machine Won t Drive 6 40 Noise From Drive Assembly 6 41 vi J LG Lift 3121136 TABLE OF CONTENTS LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Hydraulic Pressure Adjustment Screw Machine Rear Covers 1 3 1 2 Typical Hydraulic Pressure Gauge Installation Hydraulic Filler
8. Level 2 Service Level Settings OnLCD Display YES HIGH T Level 3 Operator Level Settings NO X Low FACTORY LEVEL PROGRAMMABLE ITEM PRESET SETTING RANGE 2 Back to Main Return to Programming Menu 1 English 6 Italian Set Language 2 German 7 Swedish 1 3 Dutch 8 Brazilian Portuguese 3 NOTE There are two production modules available at this 4 French 9 Finnish time one for North South American and European 5 Spanish Languages and one for Asian Languages 2 1 English 3 J apanese 2 Chinese 2 Set Maximum Lift Up Speed 100 0 100 2 Set Maximum Lift Down Speed 100 0 100 2 Zero the On Board Tilt Sensor NO YES NO 2 3 Set Sleep Time 5 MINS 0 60 MINS 2 Set Polarity Of Left PotHole Input1 2 0 Disabled 1 LOW 2 HIGH 2 Set Polarity Of Right Pot Hole Input 2 2 0 Disabled 1 LOW 2 HIGH 2 Set Polarity Of Up Limit elevation Input HIGH HIGH LOW 2 Set Polarity Of Charger Inhibit HIGH HIGH LOW 2 3 Set Polarity Of The Keypad Code LOW HIGH LOW 2 Set Polarity Of Ancillary Input 1 LOW a HIGH LOW 2 Set Polarity Of Ancillary Input2 LOW b HIGH LOW 2 3 Enable Detection Of Horn Open Circuit NO c YES NO 2 3 Enable Detection Of Beacon Open Circuit NO c YES NO 2 Enable Obstruction Sensor System OSS NO YES NO 2 Enable Detection Of Aux 1 Open Circuit NO d YES NO 2 Enable Detection Of Aux 2 Open Circuit NO d YES NO 2 Acceleration Platform Lowered 40 1 100 2 Deceleration Platform Lo
9. 4 19 Emergency Stop Switch Installation 4 19 Upper Lower Shell Component lt 4 19 Button Pad Installation 02 seed pede adele isk GERNE EAE EPOR Gd 4 19 J oystick Assembly Installation 4 20 J oystick Calibration 4 20 4 8 PUMP MOTOR ASSEMBLY SERVICE PROCEDURE 4 21 General OWN 4 21 Inline Hydraulic Filter Installation _ 4 21 Pump Motor Tank 1 4 21 Motor Cap Motor Installation 4 22 Motor Brush Installation 4 22 Brush Housing Final Assembly lt 5 4 23 Tank Installation mh 4 24 Pump Installation vem RIS ue RIEN aa EIC IR RR RR 4 24 Filter Screen Installation _ 4 24 Pressure Adjust Valve Installation _ 4 25 Pressure Check Valve Installation 4 25 4 9 OBSTRUCTION SENSOR SYSTEM SERVICE PROCEDURE DVSP
10. 6 23 Code28 Reserved hh hn 6 23 Gode 29 Reseived ic oo e axe nye C UA YN P Fo Dm ga UC ENG Rc 6 23 Code 30 Traction Module No Communication with Ground Control Module 6 24 Code 31 Platform Control Console No Communication with Ground Control Module 6 25 Code 32 Pump Motor Over 6 25 Code 33 Both 5 6 26 Code 38 Battery Voltage Low Warning Level 2 Two 2 LED LCDs lit 6 26 3121136 J LG Lift V TABLE OF CONTENTS Code 39 Battery Voltage 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 Sensor 1 through 6 Fault 6 28 Codes 100 199 Ground Control Module 6 29 Codes 200 299 Platform Control Console Fault 6 30 Codes 300 399 Traction Control Module Fault 6 31 6 9 MAIN POWER CIRCUIT TROUBLESHOOTING sssesseee ee m mn 6 32 Machine Will 6 32 6 10 MAST hh 6 33 Platform Will Not Lower
11. 6 17 6 18 Code 15 Lift Down Valve lt 6 17 6 19 Code 16 Lift Down Valve Short Circuit susa nmn 6 18 6 20 Code 17 Ground Control Module In Fold 6 18 6 21 Code 18 Alarm Short Circuit c hh 6 18 6 22 Code 19 5 6 19 6 23 Code 20 Beacon Short Circuit i heh 6 19 6 24 Code 21 Beacon Short Disconnected 6 20 6 25 Code 22 ShortCircuit sui ia aia ii e n ioa hh 6 20 6 26 Code 23 Horn Disconnected ananuna 6 21 6 27 Code 24 Auxiliary 1 Circuit Short 6 21 6 28 Code 25 Auxiliary 1 Circuit 6 22 6 29 Code 26 Auxiliary 2 Short Circuit sess He 6 22 6 30 Code 27 Auxiliary 2 15 6 23 6 31 Code 30 Traction Module No Communication with Ground Control 6 24 6 32 Code 31 Platform Control Console No Communication with Ground Control Module 6 25 6 33 Code 32 Pump Motor 6 25 6 34 Code 33 Both PHP 5
12. 1 4 1 3 Typical Hydraulic Pressure Gauge Installation After Hydraulic Filter 1 4 1 4 Torque Chart ANSISpeG eek Ce gue wks qe pet N 1 6 1 5 Torque Chart ANSI to METRIC 1 7 1 6 Torque Chart Metric Class lt 1 8 2 1 Accessing Machine Underside Components by Lifting with a Fork 2 9 3 1 Base Components e Eh dO Re Ree nada E E Ra 3 1 3 2 Drive Motor Assembly Components Machines built prior to S N 0130005271 3 7 3 3 Drive Motor Assembly Components Machines built since S N 0130005271 3 7 3 4 Drive Motor Component Assembly Machines built prior to S N 0130005271 3 9 3 5 Drive Motor Component Assembly Machines built since 5 0130005271 3 10 3 6 Torque Limiting Clutch 3 11 3 7 Brake Assembly Components 3 12 3 8 Drive Motor Gear Box Assembly 5 3 17 3 9 Pot Hole Protection System 3 20 3 10 DVL DVSP SCR Dual Voltage Battery Charger Wiring 3 28 4 1 Control
13. 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 J LG Lift 2 9 SECTION 2 GENERAL This page intentionally left blank JLG Lift 3121136 SECTION 3 BASE COMPONENTS SECTION 3 BASE COMPONENTS 3 1 BASE ASSEMBLY COMPONENTS 1 Base Mounted Beacon 2 Battery Charger Cover 3 Battery Charger Assembly 4 Base Frame 5 Front Caster Wheels 6 Front Tie Down Lug 7 Pot Hole Protection System 10 Drive Motor Cover 8 Drive Motor Mount Assy To S N 0130005270 11 Rear Tie Down Lug 9 Drive Motor Mount Assy Since S N 0130005271 3121136 Figure 3 1 Base Components J LG Lift 3 1 SECTION 3 BASE COMPONENTS 3 2 BASE FRAME COVERS 3 3 DRIVE AND CASTER WHEELS Drive Motor Cover Installation Drive Motor Wheel Std Installation 1 Wheel Retaining Screw a 4 Drive Wheel 2 Retaining Washer 5 Drive Shaft Key 1 Hex Head Screws Washers 3 Drive Motor Mount Apply Loctite 242 4 Motor Mount Interlock Slots 3 2mm x 10mm Dia Washer b 6 Drive Shaft Key Slot 2 Front Support Tab 5 Static Strap Note a On assembly apply Loctite 242 torque to 35 ft Ib b Install as required Must be 005 minimum distance between retaining washer item 2 and wheel hub fac
14. 6 14 Code 08 Right Drive Motor 5 6 15 Code 09 Left Brake lt 6 15 Code 10 Right Brake lt 6 15 Code 11 Left Drive Motor Short Circuit 6 16 Code 12 Right Drive Motor Short nnn 6 16 Code 13 Traction Module In Fold 6 16 Code 14 Pump Motor 6 17 Code 15 Lift Down Valve lt 6 17 Code 16 Lift Down Valve Short 6 18 Code 17 Ground Control Module In Fold 6 18 Code 18 Alarm Short hh ran 6 18 Code 19 Alarm lt 6 19 Code 20 Beacon Short 6 19 Code 21 Beacon lt 6 20 Code 22 Short Circuit sauaina i kie rh 6 20 Code 23 Disconnected 6 21 Code 24 Auxiliary 1 Circuit
15. 6 26 6 35 Code 40 OSS No Communication with Ground Control Module 6 27 6 36 Codes 41 thru 46 OSS Sensor 1 through 6 Fault 6 28 6 37 Codes 100 199 Ground Control Module Fault Condition 6 29 6 38 Code 200 299 Platform Control Console Fault 6 30 6 39 Codes 300 399 Traction Control Module 6 31 6 40 Machine Will Not 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 0 ccc cece eect hh 6 35 6 45 Platform Mast Descends Too 1 eh 6 35 6 46 Hydraulic Leak 5 6 36 6 47 Caster Wheels Not Operating 6 37 6 48 Pot Hole Protection PHP Bars will not Lower 6 37 6 49 Won t Climb hmmm hh 6 38 6 50 Machine Drive in Opposite Direction
16. 3 2 Wheel Retention for Rough Terrain Drive Wheel Option 3 3 3 4 DRIVE MOTOR COMPONENT 5 m 3 3 Torque Limiting Clutch Maintenance 3 3 Diag NOSES coc sea tack ia waited Is deer Ra NERIS puberes Nha ur tegi ie 3 3 Visual Inspection and Limiting Torque Checking 3 4 Check Clutch Torque Setting 3 4 Torque Limiting Clutch 5 3 5 Drive Wheel Alignment Machines built prior to 5 0130005271 3 5 3 5 DRIVE MOTOR ASSEMBLY 3 6 Drive Motor 55 3 6 Drive Motor Brake Removal and 5 3 11 Brake Operation e Ros eg Tuque RIS Wee MI 3 12 Brake Assembly 3 12 Checking Adjusting Armature Plate Gap Setting 3 12 Brake Assembly Installation 3 13 Drive Motor Boot Assembly Installation _ 3 14 Drive Motor Brush 3 15 Brush Cleaning and 1 5
17. JUNCTION BOX ES QUT YELLOW BLACK ES IN YELLOW 80 70 586 SHIELD B BLACK RS485B BLUE RS485A ORANGE AUX 1 SIGNAL B RED BLACK AUX 1 RETURN BLUE BLACK 0 5 5 SUPPLY 24V DC RED 0 5 5 DIGITAL RETURN BROWN SPARE ORANGE BLACK 6 44 TRACTION MODULE Figure 6 3 Electrical Diagram DVL DVSP Sheet 1 JLG Lift SHIELD 1 SPARE BROWN BLACK SPARE BLACK RED 1 1 H 1 1 OPTIONAL O S S 0 5 5 DIGITAL RETURN T O S S SUPPLY 24V DC 1O 1 i 9S oO O 70 1 40 so 1 B 1 B BLACK ON OFF BLUE COM WHITE GROUND STATION MODULE 12 Tz zz ead PE m I 5 gt MOTOR wa 2 g 5 E 35 8 43 B z JN m B 24 0 19 VELIL se MAX B TBLAGC TI Af OPTIONAL MASTER SWITCH p 240 ELUEZORANGE 57 7 ALARM BLACK 5 Ax WHITE TT NCS MAX BLUE ORANGE 57 3 Ine gt cS NUN P RIGHT 5 5 MOTOR RAK
18. 3121136 J LG Lift 4 9 SECTION 4 CONTROL COMPONENTS 4 5 GROUND CONTROL MODULE PROGRAMMING General The DVL DVSP machine Ground Control Module allows on board programming of various component and control func tion personality settings Programming may be required under circumstances such as Replacement of the Ground Control or Traction Control Module some components or optional equipment may not be enabled under the standard default settings of the replacement unit Optional equipment has been added to the machine in the field and that function must be enabled before operation Customizing the machine to fit a specific application such as changing the LCD display language program ming operating speeds such as braking turning or lift ing speeds Programming Levels There are three 3 password protected programming lev els from highest to lowest the levels e Level 1 J LG Engineering Settings Level 2 Service and Maintenance Settings Level 2 Password 91101 Level 3 Operator Settings Level 3 Password 33271 IMPORTANT THE LEVEL 1 J LG ENGINEERING SETTINGS ARE NOT DISPLAYED IN THE PROGRAMMABLE SETTINGS UNDER PASSWORD LEVEL 2 OR LEVEL 3 LEVEL 1 SETTINGS MUST NOT BE MODIFIED UNLESS DIRECTED BY J LG ENGINEERING DEPARTMENT PERSONNEL Level 1 J LG Engineering Settings include voltage amper age and ohm output settings that are within the operating param
19. 4 3 Battery Installation _ 4 4 Horn Installation eser rt yere qe er gom eR ec doe Ra T aoe 4 4 Alatm Installation e Ron ec en eo toan esr eet a qe 8 An i oS soni a ads 4 4 Battery Installation EE Spec Machines 4 5 Fuse EE Spec Machines Only 4 5 Master Disconnect Switch EE Spec Machines Only 4 5 4 4 GROUND CONTROL MODULE SERVICE PROCEDURE 4 7 Cover Removal Installation 4 8 Power Selector EStop Switch Installation _ 4 9 4 5 GROUND CONTROL MODULE PROGRAMMING 0 cece IK A 4 10 General usd ot dp se topi iion ie d Maka AUR ORI PIER 4 10 Programming Levels nol sot ace a pev uA RR iR RR DRIED ER RR RAS 4 10 Activating Programming Mode 4 10 Entering Password hes 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 Operato
20. 5 Hex Head Screws 2 1 2 inch 2 Nut 4 Hex Head Screws 2 inch 6 Platform Bumper Rest a Note a Once mounted adjust bumper rests on both sides evenly so the platform rests on the bumpers when in stowed position Figure 5 9 DVSP StockPicker Platform Installation 5 24 J LG Lift 3121136 SECTION 5 MAST COMPONENTS 5 8 DVSP STOCKPICKER PLATFORM MID GATE INTERLOCK INSTALLATION V DVSP Platform Mid Gate Interlock Switch Installation 1 Pop Rivets 4 Mounting Holes 2 Interlock Switch 5 Mid Gate 3 Spacer 6 Wire Harness Clamp SUM DVSP Platform Mid Gate Interlock Switch Wiring Harness Routing 1 Interlock Switch 2 Wire Routing 3 Connection atJ unction Box 4 Platform J unction Box Notes Decal billboard removed in above illustration 3121136 5 9 MAST BEACON INSTALLATION Mast Mounted Beacon Installation DVL DVSP 1 Beacon Mounting Bracket 2 Bracket Screws Nuts Washers 3 Beacon Screws Nuts Washers 4 Beacon Assembly 5 Beacon Guard a Notes a Guard on UL EE specification machines only JLG Lift 5 25 SECTION 5 MAST COMPONENTS This page intentionally left blank 5 26 J LG
21. Pressure Adjust Valve Installation 1 Adjust Valve Cap 4 Valve Ball 2 Adjustment Screw 5 Adjust Valve Port 3 Valve Spring 6 Extend Pressure Port Shown Plugged Note Adjust pressure per specification shown in Section 1 of this Service Manual Pressure Check Valve Installation 1 Check Valve Assembly 5 Check Valve Port 2 O Ring Seal 6 Extend Pressure Port 3 O Ring Seal 7 Return Port 4 Backing Ring Note Extend Pressure and Return Ports Shown Plugged 3121136 J LG Lift 4 25 SECTION 4 CONTROL COMPONENTS 4 9 OBSTRUCTION SENSOR SYSTEM SERVICE PROCEDURE DVSP OPTION General The Obstruction Sensor System OSS Control Module is mounted between the rails of the mast platform header sec tion under the platform decal billboard at the rear of the DVSP model platform see illustration below The OSS Control Module communicates with the Ground Control Module through the platform electrical junction box also mounted on the mast behind the platform decal bill board The OSS Control Module circuit board monitors six 6 chan nels each channel is wired to an individual transducer sen sor mounted under the DVSP model platform The sensors are mounted in a manner to provide a detection zone beneath the platform and detect if an object has entered that zone when the platform is being lowered NOTE The OSS only operates normally when the Ground Control Modu
22. Printed Circuit Board Installation Y a 69 66 N 279 Circuit Board Remove Install 1 Circuit Board 3 Board Screws Nuts Washers 2 2 Spacer 2 4 Charger Face Plate 3121136 J LG Lift 3 27 SECTION 3 BASE COMPONENTS AC BROWN SOLDER CONNECTION BLUE CIRCUIT GROUND SCREW YLW GRN AC 120V INLET VARISTOR 120 240 SWITCH CIRCUIT BREAKER 4 WHT ORG AC BLUE SPLICE NOTE VARISTOR LEADS MUST BE COVERED WITH VARFLEX SCREW CONNECTION W VARFLEX DC FUSE OR CIRCUIT BREAKER CIRCUIT BOARD HARNESS 001 OHM SHUNT BE 000 DC NEG BLACK WET SEALED SWITCH REMOTE LIGHTS CONNECTOR BLACK PIN 1 WHITE PIN 2 Figure 3 10 DVL DVSP SCR Dual Voltage Battery Charger Wiring Diagram 3 28 J LG Lift 3121136 SECTION 4 CONTROL COMPONENTS SECTION 4 CONTROL COMPONENTS 4 1 CONTROL COMPONENTS OVERVIEW 1 Platform Control Console 2 Ground Control Module 3 Traction Control Module 4 12 Volt Sealed Batteries 5 Horn 6 Alarm
23. ett ole Eee org 5 12 5 6 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES 5 13 Mast Disassembly 5 13 Mast Assembly DVL DVSP sssssssssssse e ees 5 16 5 7 DVSP STOCKPICKER PLATFORM INSTALLATION 5 24 5 8 DVSP STOCKPICKER PLATFORM MID GATE INTERLOCK INSTALLATION 5 25 59 MAST BEACON INSTAELATION exustus bua ETE CE LESER gr RN wie Y D C e 5 25 iv J LG Lift 3121136 TABLE OF CONTENTS SECTION 6 TROUBLESHOOTING GENERAL ruit apte ee sene aries exa iip get ated bots then Caesarea d d 6 1 6 2 TROUBLESHOOTING INFORMATION cece cece eet has 6 1 6 3 HYBRAUEIC CIRGUIT CHEGCKS 3 c rto Cane der ate eU de c zoe ue o aes 6 1 6 4 EEECTRIGAL CIRCUIT CHECKS inia een E CR a edo aea Eon aid 6 1 General S ea Re ees rr eek e RAT ra Re De eR e He 6 1 Ground Control Module LCD 5 6 2 65 TROUBLESHOOTING TABLES INDEX 0 ccc ccc hh hs 6 8 Specifications For Various 6 8 Special Pin Extractor Tools For Electrical Connectors 6 8 Fault Code Troubleshooting Tables 6 8 Main Power Circuit
24. 4 26 General xs eni ay a CURA RE eae Nb i de SO S na 4 26 Transducer Sensor Check 4 27 OSS 1 lt 4 28 SECTION 5 MAST COMPONENTS 5 1 MAST COMPONENTS OVERVIEW Rh hr hs 5 1 5 2 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT 5 2 MastChain Cable Adjustment isses n 5 2 Sequencing Cable 5 5 2 5 3 SEQUENCE CABLE REPLACEMENT KIT isses ae xr Lek RR EYE Y PCR Ra ew cued 5 4 Remove Old Cable xo e xe E Wack oh e e den a 5 4 Replacement Cable 1 lt 5 4 Clamp Installation Drum Socket Type 5 4 5 4 HYDRAULIC LIFT CYLINDER REMOVAL INSPECTION AND REBUILD 5 7 Life Cylinder Removal tct RC UI Sea ae ba gcn CRGA 5 7 Cylinder Disassembly rr emt herr ene eere cre Rx E 5 9 Lift Cylinder Component Inspection 5 9 Cylinder 5 hers 5 10 1 lt 5 11 5 5 MAST ASSEMBLY INSTALLATION o chere Oct 5 12 MastRetri Val v iai aru DURER aaa Wat Tas TUI TA A Woah nS 5 12 Mast
25. 1 Adjust the programmable setting using the Platform UP DOWN buttons 1 see Table 4 1 for range of set tings for the item selected 2 Once parameter is set for the programmable item press the Brake Release button 2 this will enter the parameter and return you to the Programmable Set tings Menu 3121136 J LG Lift TO EXIT Programming Mode after entering programma ble settings power machine off with either the Main Power Selector Switch or E mergency Stop Button SECTION 4 CONTROL COMPONENTS Service Programming Mode Level 2 In the Service Programming Mode the following items are shown on the main menu Reset Timers Program Tilt Sensor OSS Sensor NOTE There are two production modules available at this time one for North South American and European languages and one for Asian languages All pro grammable items between these modules are identi cal with the exception of language selection Reset Timers This setting displays five 5 timers as described following Trip Time This timer shows total accumulated hours since last trip timer reset This is the hour meter read ing displayed on the Ground Control Module LCD Dis play during normal machine operation Traction Time Displays the amount of accumulated DRIVE hours on the machine s current drive compo nents Lift UP Time Displays the amount of accumulated time the machine has operated the Lift
26. 3 24 General Component Installation 3 25 Battery 1 5 3 25 Cover Installation s hh 3 25 AC Line Fuse Installation _ 3 25 Interlock Relay Installation _ 3 26 Wet VRLA Switch Installation _ 3 26 Shunt Assembly Installation _ 3 26 SCR Rectifier Installation Either Side 3 26 Transformer Installation eta 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 ssse HR mmm 4 1 4 2 CONTROLS COVER 1 5 eee hmm rh 4 2 Battery Cover suere e xanh aed hd a oed E Reha E 4 2 Center Leftand Right Lower Covers 4 2 4 3 CONTROL COMPONENTS INSTALLATION e RA HH mmn 4 3 Ground Control rr 4 3 Traction Control ees 4 3 Platform Control Console Installation _
27. N 1 Plug Driver 3 Insert Plug in this Position 2 Plug 5 5 SECTION 5 MAST COMPONENTS Reclamp the assembly in the vise on the flats of the sleeve Using the plug driver a metal tube or pliers bend the outer strands toward the center strands enough that the socket can be slipped over all the strands 1 Use Plug Driver Metal Tube or Pliers 2 Shape Strands Around Plug NOTE When assembling stainless steel parts all threads 5 6 must be coated with a dry lubricant or an anti seize lubricantto prevent seizing Coat the threads of the socket and sleeve with lubri cant and install the socket by twisting it over the strands of the cable and engage the threads of the Sleeve with the socket Tighten until four threads or fewer are visible If more than four threads are visi ble proof load the cable and retighten the socket fit ting There is no specific requirement for torque 1 Inspection Hole 2 Install Socket and Tighten 3 Four Threads or Less Showing 8 NOTE J LG Lift Inspect for proper assembly prior to loading the cable Strands visible through the inspection hole are your assurance of a proper assembly The end ofthe rope may not be visible in the inspec tion hole after loading Install cable on machine and adjust per instructions shown previously in Section 5 2 MAST CHAINS AND SEQUENCING CABLES ADJ USTMENT 3121136 SECTION 5 MAST
28. 6 39 6 51 Machine Won t Drive Straight isisssssssesee e mmm 6 40 6 52 Noise from Drive Assembly mm rmn 6 41 viii J LG Lift 3121136 SECTION 1 MACHINE SPECIFICATIONS SECTION 1 MACHINE SPECIFICATIONS Table 1 1 DVL and DVSP Machine Specifications 15DVL 20DVL 15DVSP 20DVSP Maximum Occupants 1 Maximum Work Load Capacity 500 Ib 350b 500 Ib 40016 DVL Std Platform DVSP Stockpicker Platform 230 kg 160 kg 230 kg 180 kg Maximum Travel Grade Gradeability 20 Platform STOWED ONLY Maximum Travel Grade Side Slope 5 Platform STOWED ONLY Maximum Vertical Platform Height ae im ER admi Maximum Wheel Load Per Wheel 800 Ib 360 kg Maximum Drive Speeds Operator Variable 0 5 2 mph 0 8 3 2 kph Max Platform Speeds w Max Load Platform Up 20 sec 22 5 sec 20sec 22 5 sec Platform Down 15 21sec 21 26 sec 15 21 sec 21 26sec Gross Machine Weight Platform Empty Task e A 3121136 J LG Lift 1 1 SECTION 1 MACHINE SPECIFICATIONS 1 1 CAPACITIES System Voltage 1 3 PERFORMANCE DATA Platform Capacities Models 24 Volt DC Hydraulic System All Models 5 gts U S 4 7 L Drive Motor GearBox gear oil All Models 6 oz
29. 3 Compress the head retraining ring enough to allow the cylinder head to be removed 4 Carefully slide the head rod piston assembly out of the cylinder tube A gentle tap on the head assembly may be required to remove the head from the cylin der tube 5 Place the head rod piston assembly on a surface that will not damage the chrome 6 Remove the piston locknut and separate the piston from the rod 7 Slide the head off the rod from the piston end NOTE When removing the old seals use only blunt tools be sure there are no sharp edges that may damage the seal grooves during removal Scratching the groove may cause by pass 8 Remove and discard all old seals Lift C ylinder Component Inspection Cylinder Rod There should be no scratches or pits deep enough to catch the fingernail Pits that go to the base metal are unaccept able Scratches that catch the fingernail but are not to the base metal less than 0 5 inch long and primarily in the cir cumferential direction are acceptable provided they cannot cut the rod seal Chrome should be present over the entire surface of the rod and the lack thereof is unacceptable In the event that an unacceptable condition occurs the rod should be repaired or replaced Cylinder Head Visually inspect the inside bore for scratches or polishing Deep scratches are unacceptable Polishing indicates uneven loading and when this occurs the bore should be checked for out of round
30. J LG Lift vii TABLE OF CONTENTS 6 2 Ohm Ratings for Various amp 6 10 6 3 Amperage Draw for Various Components 6 10 6 4 Special Pin Extractor Tools for Electrical Connectors 6 10 6 5 Machine In Drive Speed Cut Back Turtle Mode All The Time 6 11 6 6 Obstruction Sensor System 6 12 6 7 Code 02 Left PHP Bar UP icut yw ko HERR ac a o xe E ec dogs 6 13 6 8 Code 03 Right PHP Bar UP Lie 6 13 6 9 Code 04 Tilt Condition roe cR A ae a E ROCA CAT Run 6 14 6 10 Code 07 Left Drive Motor Disconnected 6 14 6 11 Code 08 Right Drive Motor Disconnected 6 15 6 12 Code 09 Left Brake Disconnected 6 15 6 13 Code 10 Right Brake 6 15 6 14 Code 11 Left Drive Motor Short Circuit s sse hn 6 16 6 15 Code 12 Right Drive Motor Short Circuit mm 6 16 6 16 Code 13 Traction Module In Fold 6 16 6 17 Code 14 Pump Motor Disconnected
31. Machine Will 6 32 MAST TROUBLESHOOTING Platform Will Not Lower Manually 6 33 Platform Lift Up And Down 6 33 Mast Noisy When Lifting And 6 34 Platform Mast Won t Stay 6 35 Platform Mast Descends Too 510 6 35 HYDRAULIC LEAK TROUBLESHOOTING Miscellaneous Hydraulic Leak Troubleshooting 6 36 BASE FRAME COMPONENTS TROUBLESHOOTING Caster Wheels Not Operating Freely 00 cece cect n 6 37 Pot Hole Protection PHP Bars will not 6 37 DRIVE SYSTEM TROUBLESHOOTING Won t Climb Y Dee Grade Ga SU SP PLES NIC 6 38 Machine Drives in Opposite 6 39 Machine Won t Drive Straight 00 00 cece ees 6 40 Noise From Drive eee 6 41 3121136 J LG Lift 6 9 SECTION 6 TROUBLESHOOTING 6 6 SPECIFICATIONS FOR VARIOUS COMPONENTS The following table contains specifications for DVL Series and DVSP machine components Table 6 2 Ohm Ratings for Various Components COMPONENT NOMINAL RESISTANCE TEMPERAT
32. X T ip Be TAN 3 1 d VALVE SPARE BLACK 4 1 4 PAM 4 8 VDC 5 AMP MAX mn LIFT DOWN BAKA VALVE BLACK 5 RED C 1 AUX 1 OUTPUT 24 0 5 YELLOW RED 2 11 MIMICKS BEACON n BLACK e B BLACK 8 5 i AUX 2 OUTPUT 24065 AWP MAX LYELLO RED 2 71 WHITE st SHARED WITH 055 B BLACK LEFT LEFT BRAKE gt 5 BLACK 4933184 D 1 3121136 SECTION 6 TROUBLESHOOTING RS485A ORANGE AUX 1 SIGNAL B RED BLACK Mov18 8 NMONS Nunl38 1911910 S S O Q34 5v18 34vdS ania 8sgvsu MOV18 NMONS 3NVdS 32v18 39NvNO 34vVdS MOT13A NI S3 x0v18 034 8 TWNOIS 1 xnv x5v18 3n18 0138 xnv PLAT ORM 90 AvZ AlddNS S S O PLATFORM AUX 1 ere AUX INPUT 1 B BLACK B BLACK gt 99989 4 ON OFF BLUE ON OFF BLUE COM WHITE a nil HE P1 P4 P5 z 4 RRRA JA JA H BECURITY LOCK OPTIONAL SIGNAL IN YELLOW RED 2 41 B VOLTAGE HIGH REF TILT SWITCH RETURN INHIBITS LIFT DRIVE B TILT SWITCH B POWER AUX 2 SIGNAL SPARE DIGITAL INPUT 2 AUX 2 RETURN INHIBITS LIFT B AUX 1 SIGNAL INHIBITS DRIVE AUX 1 RETURN 8 TTO PLUGGED IN OPEN NOTE EI ELEVATION 4 PEED AUX 2 I
33. 1 Be sure the charger is plugged into the proper receptacle and there is power to that receptacle 2 Besure all battery connections are tight 3 If charger does not come on check connections at the charger Make sure all connections are tight 4 If charging over night ensure there is power to the receptacle at all times and not being turned off at the end of the shift J LG Lift 3 23 SECTION 3 BASE COMPONENTS Battery Charge Flash Code LED Indicator on Platform Control Console NOTE Normal battery charging will occur with a voltage reading as low as 24V On normal power up and operation this series of LEDs visu ally indicates the amount of charge left in the batteries GREEN LEDs lit indicate maximum charge RED LED s lit indicate minimum charge remaining The number of LEDs lit will change depending on the level of charge in the batteries If battery voltage falls below 16 8 volts a fault condition will occur and the machine will stop operating The batteries will need recharged Battery Charging Status Indicators Mounted on Ground Control Station Cover The battery charging status indicators are mounted just above the Charger AC input receptacle on the center cover section at the rear of the machine When first plugged in the charger runs through a self diag nostic test lighting the LEDs in sequence then charging will begin The following descriptions indicate charging s
34. Short 6 21 Code 25 Auxiliary 1 Circuit 6 22 Code 26 Auxiliary 2 Short Circuit mn 6 22 Code 27 Auxiliary 2 6 23 Code 28 Reser ed sees shag wr vs ew E tives eee USENET der UID Db De t 6 23 Code 29 Reserved ce M e iA V tie Did riti 6 23 Code 30 Traction Module No Communication with Ground Control Module 6 24 Code 31 Platform Control Console No Communication with Ground Control Module 6 25 Code 33 Both PHP Bars xe eT ADRESSE ER me a 6 26 Code 38 Battery Voltage Low Warning Level 2 Two 2 LED LCDs 6 26 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING Code 39 Battery Voltage Low Warning Level 3 One 1 LED LCDs 6 26 Code 40 Obstruction Sensor System No Communication with Ground Control Module 6 27 Codes 41 thru 46 OSS Sensor 1 through 6 Fault 6 28 Codes 100 199 Ground Control Module 6 29 Codes 200 299 Platform Control Console Fault 6 30 Codes 300 399 Traction Control Module Fault 6 31 MAIN POWER CIRCUIT TROUBLESHOOTING
35. When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 3 out BOTTOM of sec tion 2 Remove slide pads and shims if necessary MAST SECTION 2 REMOVAL 17 18 19 20 21 NOTE 22 Slide mast section 2 out TOP of mast section 1 far enough to allow access to the chain assembly anchor block sheave wheel assembly Remove countersunk flathead screws securing chain anchor block sheave wheel assembly attach bars on both side rails at TOP of mast section 2 Slide the chain anchor block sheave wheel assem bly and hydraulic cylinder out the TOP of mast sec tion 2 far enough to allow removal of the sheave wheel attach bars sheave wheels and sheave pin from chain assembly anchor block Remove the setscrew holding the hydraulic cylinder rod onto the chain assembly anchor block Lay chain assembly anchor block to side Remove the hydraulic cylinder through BOTTOM of mast section 2 be careful notto nick or score cylin der rod surface while removing When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 2 out BOTTOM of sec tion 1 Remove slide pads and shims if necessary MAST SECTION 1 DISASSEMBLY 23 24 Slide the TOP of remaining mast section 1 out over edge of work surface and remove the pins attaching the chain anch
36. gre 19 6v 89 YS 8r 19 8 8 le ly bec 69610 9l 1 L 9z Ly ve lz ve 6c ez 6L 9c 8 91 2 0 acero vt 1155 Ly 0 GZ ve 92 ez 8l z 1550 8l 6l 69 pi 6l 889 9 Ob Pi 2801 96600 8 amp 8l 8 et 9L 166 ek 6 n 96 890800 0 9 8 v 9 96 80500 ae 5 1 v G gos 67700 96870 vc O y 5 668 9c 7 00 T 9 EI e ELS S ws y sor 95500 Ol 8 zZ Z Z 88700 Or ze 95 2200 0 9 2 zz 6L 8900 8r Z oz 1 ZI 55000 2700 oy WN WN 5 WN WN ow 3A139931 SE LLZ Y0 202 5 e LLZ HO 27 COM QVOT aion aeyn 97 NS W9 dWY19 IOON dWV19 63315 3218 MAHOS 409 AYAH 120905 SINN s1108 avs avs 0v3381 XINO SLO HOd SINMA 3121136 SECTION 1 MACHINE SPECIFICATIONS VALUES FOR ZINC PLATED YELLOW CHROMATE FASTENERS ONLY CLASS 8 8 METRIC BOLTS amp CLASS 10 9 METRIC BOLTS amp CLASS 8 METRIC NUTS CLASS 10 METRIC NUTS
37. 5 Power machine off and begin operation OSS Sensor Displays current Obstruction Sensor System status Detec tion YES NO Also if an object is detected the sensor s detecting the object and distance the object is from the sen sor is displayed 1 DETECTION NO 2 1 Bin 0 4 Bin 0 2 in 0 50 0 4 3 8 Bin 0 8Bin 0 OSS Sensor LCD Display Mode 3 Object distance from sensor 4 Signal strength 1 Detection Indicator Yes No 2 Sensor numbers Note This screen can be viewed while another person performs the transducer sensor check see Section 4 9 Operator Programming Mode Level 3 In the Operator Programming Mode the following items are shown on the main menu Also See Table 4 1 Tilt Sensor Program NOTE There are two production modules available at this time one for North South American and European languages and one for Asian languages All pro grammable items between these modules are identi cal with the exception of language selection Tilt Sensor Allows viewing current tilt sensor individual X and Y direction degree reading Program Allows the Operator to program Level 3 items shown in Table 4 1 3121136 SECTION 4 CONTROL COMPONENTS Table 4 1 DVL DVSP Ground Control Module Field Programmable Settings and Factory Preset
38. Align the inner and outer bearing collar set screws item 3 inline with each other on the same side of the drive shaft before tightening into the drive shaft This will push the shaft equally to the same side of both bearings preventing drive shaft misalignment and undue stress on these components b Apply a light film of Loctite Moly Paste Lubricant to the motor and drive shafts in the area of contact with the torque clutch and to the inside diameter of the torque clutch bore before assembling c There are two 2 clutch to motor shaft set screws one is tightened on the flat of motor shaft the other is tightened on the motor shaft key d When assembling apply Loctite 242 to the threads of item 9 motor mounting screws and item 11 clutch set screws Figure 3 5 Drive Motor Component Assembly Machines built since S N 0130005271 3 10 J LG Lift 3121136 SECTION 3 BASE COMPONENTS 2 Lock Tab Washer 5 Friction Disk b 8 Bushing 11 Cotter Pin 3 Spring Washers 6 Outer Chain Sprocket b 9 Torque Limiting Hub b 12 Joining Pin b When assembling check that disk mating surfaces are free of oil dirt and moisture 1 Adjusting Nut a 4 Pressure Plate b 7 Friction Disk b 10 DualSprocket Chain c 13 Drive Hub Sprocket Notes Adjust on machine see adjustment procedure this section of manual c DO NOT lubricate chain Figure 3 6 Torque Limiting Clutch Assembly Driv
39. BASE COMPONENTS 3 8 Drive Motor Mount Mounting Screw Locations Machines built prior to S N 0130005271 1 Drive Motor Mount Attach Hex Head Screws Same Both Sides a Notes Apply Loctite 242 to threads of screw nut fastener on final assembly Stud uses a lock nut 1 2 p 5 m 15 8 enu _ od ien Drive Motor Mount Mounting Screw Locations Machines built since S N 0130005271 1 Drive Motor Mount Frame 2 Drive Motor Mount Attach Screws Same Both Sides a Notes Apply Loctite 242 to threads of screw nut fastener on final assembly Stud uses a lock nut JLG Lift 3121136 SECTION 3 BASE COMPONEN TS 1 Drive Shaft 5 Shaft Outer Roll Pin b 9 Clutch Set Screws c 13 Drive Assembly Mount 2 Shaft Outer Bearing a 6 Shaft Inside Roll Pin b 10 Motor Mount Plate c 14 Wheel Alignment Shims d 3 Shaft Bearing Mounting Plate 7 Drive Shaft Clutch Key 11 Clutch Motor Shaft Key 4 Shaft Inner Bearing a 8 Torque Limiting Cl
40. round din plug Repairor Replace _ Note This harness contains 6 wires only 3 are used SeeFigure 6 Wiring 3 Electrical Diagram 3121136 JLG Lift 6 31 SECTION 6 TROUBLESHOOTING 6 9 MAIN POWER CIRCUIT TROUBLESHOOTING Machine Will Not Power Up Check For These Obvious Conditions First ule lugs Battery voltage is 24 volts Sufficient Charge in Batteries to Operate Machine Main Power Selector Switch key positioned to either Platform or Ground Control Mode Positive and negative battery cable connections clean and tight at both the Batteries and the Ground Control Mod Emergency stop buttons on both the Ground Control Module and the Platform Control Console in the RESET position out Table 6 40 Machine Will Not Power UP STEP ACTION SPEC YES NO 1 Checkfor24V DC atthe positive and negative main power Replace the 175 cable connections on the Ground Control Module 24V DC Go to Step 2 Amp Inline Fuse onthe Positive power cable 2 Check continuity of the Emergency Stop wires running to the Plat Replace the form Control Console pins 10 and 1 on the P4 connector atthe Ground Control Go to Step 3 Ground Control Module Module 3 Removethe9 pin Platform Control Console connector at the Plat Replacethe form unction Boxand check continuity between pins 1 and 2 to the GotoStep4 Platform Control Emergency Stop Switch in the Platform Control Console cab
41. see Section 3 10 of your Operators Manual for additional machine power up steps 3121136 SECTION 4 CONTROL COMPONENTS Entering Password Selecting Programmable Item to Adjust M 9 dub 1 2 3 Entering Password 1 The Brake Release button 1 moves the box around digit from left to right to select which digit to change 2 Platform UP button 2 increases the numerical digit 3 Platform DOWN button 3 decreases the numerical digit 4 Change all five digits 4 to match password level then press the Brake Release button 1 again SUGEP x lt Selecting Programmable Item to Adjust 1 Use the Platform UP DOWN buttons 1 to scroll through the list of programmable items available to your programming level 2 Once a programmable item to be adjusted is selected press the Brake Release button 2 to enter that set tings adjustment mode Adjusting Programmable Setting Programming Mode Selection Programming Mode Selection 1 Use Platform UP DOWN buttons 1 to move the selection box 2 up or down to select item to pro gram 2 Press the Brake Release button 3 to enter selected mode then move on to Selecting Programmable Item to Adjust A E Adjusting Programmable Setting
42. 036 thick shim and a 075 thick shim per side at each slide pad b Slide shims into place between slide pad and mast rail Tighten the slide pad mounting bolts be sure there are no air gaps between shims shim and mast or shim and slide pad when tight ened 3121136 SECTION 5 MAST COMPONENTS NOTE c Check mast section for side play If play exists add 015 shims dividing the thickness equally between both sides of mast Insert shims until the shims cannot be inserted halfway by hand with the mast pulled to the opposite side d When mast slide pads are shimmed properly there should be no side to side movement of slide pad in rail channel Mast sections should be snug in channels but still be able to slide in channel by hand Insert slide pads into the slide pad channels top of mast between section 1 and 2 one on each side of the mast with beveled surface facing in towards section 2 Before fastening and shimming the slide pad on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher 1 Slide Pads 3 Sequence Cable Bracket 2 Shim Stock 4 Slide Pad Bolts Washers a Note a Apply Loctite 242 to threads Figure 5 8 Mast Top End Slide Pad Installation 9 10 3121136 Typical Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in mast sec
43. 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 1Gallon 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 Motor Parking Brake must 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 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 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 12 J LG Lift Standard 15DVL 500 Ib 230kg 20DVL 350 Ib 160kg StockPicker 15DVSP 500 Ib 230kg 20DVSP 400 Ib 180kg Extendible 15DVL 15DVSP 500 Ib 230kg 20DVL Series 350 Ib 160kg Molded 15DVL 15DVSP 500 Ib 230kg 20DVL Series 350 Ib 160kg NOTE Distribute weight evenly in platform when l
44. 26 X 00000 0 39 439 Driveand Platform Lift UP Functions Locked Out Obstruction Sensor System 055 i 40 5 Y no conns 24 No Communication With ioca X 00000 0 40 40 Ground Control Station 9 6 6 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING Table 6 1 LCD Display Service Fault Code Conditions PLATFORM FAULT CONSOLE FAULT DESCRIPTION FOR TROUBLESHOOTING CODE QS LCD SYMBOL SCREEN LCD TEXT SCREEN MACHINE CONDITION REFER TO 41 E 4 4 Internal OSs 1 See Table 6 36 X 00000 0 41 41 Fault Condition Page 6 28 42 E s NN ee Internal OSS Sensor 2 SSee Table 6 36 X 00000 0 42 42 Fault Condition Page 6 28 43 e WA o os g Internal OSS Sensor 3 See Table 6 36 X 00000 0 43 43 Fault Condition Page 6 28 44 2 lt gt nn 2 Internal OSS Sensor 4 See Table 6 36 X 00000 0 44 244 Fault Condition Page 6 28 45 4 NS s 4 Internal OSs Sensor 5 See Table 6 36 X 00000 0 45 445 Fault Condition Page 6 28 46 E e WA ete 2 Internal OSS Sensor 6 See Table 6 36 X 00000 0 446 446 Fault Condition Page 6 28 GROUND MODULE Ground Control Module See Table 6 37 nmm e m an 0 4400 gt _ 4400 Fault Condition Page 6 29 200 10 WA o Platform Control Console See Table 6 38 X 00000 0 4200 4200 Fault Condition Page 6 30 COO TRACTION MODULE Traction Control Module See Table 6 39 ix X 000000 48
45. 898 GELL 65 CiOvZ 1 L8 90986 962 oos 6967 1065 vozi 1801 G68 BPSLZ CVV 7 ga L891 Olorc 8681 968 zoel SELL 2908 BELL 896 vi8 SOL 186 08861 Z zL 006 C 6201 00 99 080 2 166 898 617 6v6 Zole 09891 Ob 887 12 evel 6 cco 0021 0952 916 S87 89 898 60594 26591 8 L98 8802 86 8 9 G68 9 02 SOL OG ze9 169 6061 cor Y gj 6 96602 968 969 veo vi8 0488 7 ezo vtv 886 9555 6 61691 169 99 vtr OLS tresi tot 867 20 96 01 0760 osos 9k pe G6y OSISL 0 8 gor ose GIG 8998 zee See ble 855 Z996 verso OL 862 68 Liz re oze eeror ese zoz 921 vez 20990 8 gc 82 ISZOL 9c bec 862 1606 vez 8l 6 VOZ 2559 07 50 LL vec goze 85c 602 91i 8 08 eer erl eet e9 0 85 95150 gory 8l gri 9628 72 88 6 vOZ 655 90L eel 601 6 2925 9 0 21 9 60 _ eel orl 91 eso 801 98 cci 98 1900 ooz 00 1579 9 05 60 6 885 SIL Z6 GZ zo 90 70950 20 veces ech 56 8 60 Ser 18 89 89 SZ Seve GI0 0 00 G6 zzy 60 8 GZ 6 zeer GZ L9 89 6906 00 20 w 89 5865 GZ 19 8v 89 5896 vG vt orse 06220 ezoso TC
46. Components Location DVL DVSP 4 1 4 2 Component Electrical 4 6 4 3 Ground Control Module 4 7 4 4 Platform Control Console 4 14 4 5 Platform Control Console 4 18 5 1 Mast Components DVL DVSP 0 cece cect hmm 5 1 5 2 DVL DVSP Mast Chain and Sequence Cable Adjustment Components 5 3 5 3 Machine Positioned for Cylinder 5 7 5 4 Lift Cylinder Component Cross Section 5 10 5 5 Mast Section Assembly Reference 5 13 5 6 Mast Chain Routing Diagram 1 5 5 15 5 7 Mast Bottom End Slide Pad Installation Typical 5 16 5 8 Mast Top End Slide Pad Installation Typical 5 17 5 9 DVSP StockPicker Platform Installation o a ccc 5 24 6 1 Component Electrical 6 3 6 2 Overview of Electrical System Components DVL DVSP 5 10 2 6 42 6 3
47. Go to Step 2 Replace Sensor 2 Disconnectthe OSS Control Module connection to the Platform J unction Box mounted on the mast platform header section above B Go to Step 3 Replace Ground the OSS Control Module Does the Ground Control Module now Control Module show a Fault Code 5 3 Reconnectthe OSS Control Module connection to the Platform Replace OSS J unction Box Check for original faultcondition System Battery Voltage Low Warning Level 3 Three 3 LED LCDs lit 3LEDS BARS Flashing with an audible beep Machine will Operate No Control Functions are Locked Out When batteries are drained to Warning Level 3 charge batteries until a level of four 4 LEDs Platform or BARS Ground Control Module or more before operating Failure to do so will eventually result in a fault Code 38 Battery Voltage Low Warning Level 2 NOTE If battery is not charging properly see Battery Battery Charger Servicing Section 3 of this Manual JLG Lift 3121136 SECTION 6 TROUBLESHOOTING Code 02 Left PHP Bar UP Check For These Obvious Conditions First Obstruction under LEFT pot hole bar Obstruction around the actuator assembly atthe base ofthe mast Table 6 7 Code 02 Left PHP Bar UP STEP ACTION SPEC YES NO CHECK THE FOLLOWING WITH THE PLATFORM ELEVATED 3 TO 4 FEET 1 TO 1 5m 1
48. Gotothe20 pin molex connector atthe Ground Control Module Replace Ground back probeto check for continuity of pin 10 BLK 8 wire with pin Control Modul Goto Step 2 20 ORG RED 49 1 wire Is there continuity Mi 2 Checktheactuator cables for adjustmentor damage AdjustorReplace GotoStep3 3 CheckthePHP limitswitch s atboth sides of the machine for dam Replace Adjust age adjustmentand for continuity through switch to ground when bars are down orRepair Wiring Code 03 Right PHP Bar UP Check For These Obvious Conditions First Obstruction under RIGHT pot hole bar Obstruction around the actuator assembly at the base of the mast Table 6 8 Code 03 Right PHP Bar UP STEP ACTION SPEC YES NO CHECK THE FOLLOWING WITH THE PLATFORM ELEVATED 3 TO 4 FEET 1 TO 1 5m 1 Go to the 20 pin molex connector atthe Ground Control Module Replace Ground back probe to check for continuity of pin 9 BLK 9 wire with pin C i IModul Goto Step 2 19 ORG RED 49 2 wire Is there continuity onmo MOS Checkthe actuator cables for adjustmentor damage AdjustorReplace GotoStep3 Check the PHP limitswitch s at both sides of the machine for dam Replace Adjust age adjustmentand for continuity through switch to ground when pace nc bars are down orRepair Wiring 3121136 JLG Lift 6 13 SECTION 6 TROUBLESHOOTING Code 04 Tilt Condition Check For These Obvious Conditions First I
49. Head Pin a 2 Cable Attach Pin 6 Actuator Cable 4 Flat Washer Notes a Apply White Lithium Grease to shaft J LG Lift 3121136 SECTION 3 BASE COMPONENTS Actuator Cable Adjustment Bars DOWN Engaged 1 Actuator Cable Assembly 4 No Tension On Cable 2 Cable Attach Bracket 5 Bar Resting Against Frame 3 Adjusting Nuts Notes Adjust so cable is just released of tension item 4 Replace cable if excessively frayed in this area fe d 4 Actuator Cable Adjustment Bars UP Disengaged 1 Actuator Cable Assembly 4 Cable Retracted 2 Cable Attach Bracket 5 Bar Above Base Frame 3 Adjusting Nuts PHP Limit Switch Adjustment 1 Limit Switch 3 Set Screws b 2 Cam w Countersunk Hole a 4 Bar in DOWN Position Notes Loosenset screws and adjust cam till limit switch roller rests in countersunk hole in cam when the pothole bar is DOWN Switch Closed b Apply Loctite 242 to set screws on final tightening Notes Adjust until pothole bar is above bottom of base frame 3121136 J LG Lift 3 21 SECTION 3 BASE COMPONENTS 3 7 BATTERY BATTERY CHARGER SERVICE PROCEDURES Battery Low Voltage Warning Indicators The Platform Control Console and Ground Control Station indicate battery low voltage at three 3 Warning Levels Table 3 1 Battery Low Voltage Warning Indicators
50. IMPORTANT DO NOT ATTEMPT TO DISASSEMBLE THE PLATFORM CONTROL BOX IF MACHINE IS STILL UNDER WARRANTY THE PLATFORM CONTROL BOX WHILE THE MACHINE IS UNDER WAR RANTY WILL VOID THE WARRANTY IF UNDER WARRANTY REQUEST A REPLACEMENT BOX FROM THE FACTORY The DVL Series and DVSP platform control console allows for replacement of four 4 components internal to the box Joystick Assembly Emergency Stop Switch Upper Lower Shell Gasket Button Pad Switch ELECTROSTATIC DISCHARGE CAN DAMAGE COMPONENTS ON THE INTEGRATED CIRCUIT BOARD BE CERTAIN TO DISSIPATE ANY ELECTROSTATIC ENERGY FROM YOURSELF BEFORE DIRECTLY TOUCHING THE CIRCUIT BOARD INSIDE THE CONTROL UNIT PLACE THE PLATFORM CONTROL BOX ON A NON CONDUCTIVE SURFACE WHEN OPENING THE BOX AND WORKING DIRECTLY WITH THE CIR CUIT BOARD Remove Platform Control Console First remove the platform control console completely from the platform assembly See Section 4 3 Control Compo nents Installation Platform Control Console Installation 1 Cover Attach Screws 4 2 Lower Console Shell 3 Circuit Board 4 Lower Upper Shell Seal 5 Joystick Assembly 6 Emergency Stop Switch 7 Upper Console Shell 8 J oystick Knob Switch 9 Button Pad Switch Figure 4 5 Platform Control Console Components 4 18 JLG Lift 3121136 SECTION 4 CONTROL COMPONENTS Upper Lower Shell Attach Screws Upper Lower Shell Component Connections
51. OPENING THE PLATFORM CONTROL BOX WHILE THE MACHINE IS UNDER WARRANTY WILL VOID THE WARRANTY IF UNDER WARRANTY REQUEST A REPLACEMENT BOX FROM THE FACTORY The platform control console allows for replacement of nine 9 components Emergency Stop Switch Key Switch Joystick Assembly Display Controller Module Drive Lift Mode Selector S witch Horn Button Switch Rear Cover Wiring Harness Connector Socket Mounting Bracket Remove Platform Control Console First remove the platform control console completely from the platform assembly See Section 4 3 Control Compo nents Installation Platform Control Console Installation Figure 4 4 Platform Control Console Components 1 E Stop Shut Down Switch 5 Drive Lift Mode Selector Switch 2 ON OFF Key Switch 6 Horn Button Switch 3 Joystick Assembly 7 Rear Cover 4 Display Controller Module 8 Wiring Harness Connector 4 14 J LG Lift 3121136 SECTION 4 CONTROL COMPONENTS Display Controller Module Electrical Connections The internal switches and joystick controller of the plat form console plug directly into the Display Controller Module This module then relays the signals from these switches to the Ground Control Box through the commu nications cable running to the platform junction box mounted to the mast under the platform 3 Platf
52. Operating Range HYDRAULIC SYSTEM OPERATING SAE VISCOSITY TEMPERATURE RANGE GRADE 0 F to 180 F 10W 18 C to 83 C 0 F to 210 F 18 C to 99 C 450 to 210 F 10 C to 99 C 10W 20 10W 30 20W 20 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 qual ities and being of extreme pressure type Timken OK 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API service classification GL 5 or MIL Spec MIL L 2105 HO Hydraulic Oil ISO Vg grade 32 46 CL Chain Lube Usea good quality chain lubricant 3121136 1 6 HYDRAULIC PRESSURE SETTINGS AND ADJ USTMENT Adjust system pressure so that platform will raise with maxi mum 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 system pressure turning screw counterclockwise decreases sys tem pressure See Figure 1 1 Hydraulic Pressure Adjust ment Screw Machine Rear Covers Removed Perform pressure adjustment with oil at normal operating temperature If pressure is set when oil is cold platform may not raise rated load after
53. STEP ACTION SPEC YES NO 1 AttheGround Control Module P1 connector check the voltage Replace Ground across pins 14 and 7 to the horn Is reading within specification 0 2V DC Go to Step 2 Control Module 2 Remove the wire terminals atthe horn check continuity of each of R i j eplace the Repair or the wires from pins 14 and 7 onthe P1 connector to the horn end Horn Replace Wiring J LG Lift 3121136 SECTION 6 TROUBLESHOOTING Code 23 Horn Disconnected Check For These Obvious Conditions First s machine equipped with a horn unit Table 6 26 Code 23 Horn Disconnected STEP ACTION SPEC YES NO 1 1 machine equipped with a horn unit Go to Step 3 Gotto Step 2 2 AttheGround Control Moduleenterthe programming mode check Re s i d D place Ground if the horn open circuit detectionis enabled Disable It Control Module 3 Check voltage atthe P1 connector on the Ground Control Module Replace Ground between pin 14 and pin 7 Is reading within specification 2 4VDC Control Module Goto Step 4 4 Removethe wire terminals atthe horn check continuity of each of Replace the Repair or the wires from pins 14 and 7 onthe P1 connectorto the horn end js Replace Wiring Code 24 Auxiliary 1 Circuit Short Circuit Check For These Obvious Conditions First Damaged wiring in the Auxiliary 1 Component wiring harness or a damaged Component T
54. TERIES WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY 3121136 Battery Charger General Information IMPORTANT DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGER IF MACHINE IS STILL UNDER WARRANTY OPENING THE BATTERY CHARGER WHILE THE MACHINE IS UNDER WARRANTY WILL VOID THE CHARGER WARRANTY IF UNDER WARRANTY REQUEST REPLACEMENT CHARGER FROM THE FACTORY ALSO BEFORE REPLACING ANY COMPONENT USE THE CHARGER MANUFACTURERS TROUBLESHOOTING GUIDE SHIPPED WITH THE MACHINE TO CHECK THE INTERNAL AC AND DC CIRCUITS AND DETERMINE WHICH COMPONENT HAS FAILED A WIRING DIAGRAM FOR THIS MODEL DUAL VOLTAGE SCR CHARGER IS INCLUDED AT THE END OF THIS SECTION OF THE MANUAL SEE FIGURE 3 10 The DVL and DVSP battery charger allows for replacement of the following internal components Consult your Illus trated Parts Manual for part numbers of these components which are available from the J LG Parts Department Transformer Printed Circuit Board Shunt Assembly Interlock Relay SCR Rectifier AC Circuit Breaker DC Circuit Breaker AC Voltage Selector S witch Wet VRLA Charging Profile Selector Switch Replacement and troubleshooting of these components requires removal of the battery charger from it s mounting position on the machine Battery Charger Troubleshooting If batteries are not charging properly use the following steps to assist in resolving the problem
55. The Ground Control Module is pre programmed with factory pre set personality settings for each machine function To help diagnose any problems with components plugged into the Ground Control Module the module is designed with an internal fault code and text messaging system displayed on an LCD screen atthe module The platform control console also will display LED Flash Codes using the LED strip at the top of the console When operating normally the LED panel on the platform control console indicates the battery voltage status using ten 10 LEDs red yellow green If a malfunction to the machine s electrical components occurs the platform console LED s will flash a number of LEDs to help indicate the prob lem to the Operator in the platform The Fault Codes and LED Flash Codes are outlined in the following sub sections of this chapter NOTE For aid in troubleshooting electrical problem refer to Figure 6 3 for an ELECTRICAL DIAGRAM of the various circuits Also for a pictorial overview of the connected components See Figure 6 2 Pictorial Overview of the DVL DVSP Elec trical System 3121136 J LG Lift 6 1 SECTION 6 TROUBLESHOOTING Ground Control Module LCD Display lt E mum x 00000 0 ZEN At power up and during operation the LCD display on Ground Control Module displays the current machine operating status The following illustration explains the symbol indications RUN r
56. UP function LiftDOWN Time Displays the amount of accumulated time machine has operated the Lift DOWN function Total Time Displays the total amount of time accumu lated by the Traction Lift UP and Lift DOWN Timers Of these five 5 timers only the Trip Timer can be RESET back to zero 00000 0 Program Allows service personnel to program the Level 2 and Level 3 items shown in Table 4 1 Tilt Sensor Allows service personnel to reset the Ground Control Mod ule s internal digital Tilt Sensor to zero 0 0 degrees in both the X and Y axis A DANGER ZEROING THE TILT SENSOR REQUIRES THE MACHINE TO BE RESTING ON A SURFACE CHECKED WITH A DIGITAL LEVEL MEASURING WITHIN 0 0 DEGREES LEVEL IN BOTH THE X AND Y AXIS DIRECTIONS NOTE When entering this mode the LCD will display in real time the current X and Y degree readings of the tilt sensor The reading being displayed is based on the previous zero setting and may not reflect level of the machines current resting surface 4 12 JLG Lift 1 Position the machine on a level surface verified level in both the X and Y axis with a digital level 2 Select Zero Tilt Sensor from the menu and press the Brake Release button 3 The current tilt sensor readings are displayed zero both the X and Y direction sensor setting to the machines present resting surface press the Brake Release button 4 Select Back to Main Menu and press the Brake Release Button
57. User Qualified J LG Service and Maintenance Man Inspection rental delivery Mechanic ual and applicable J LG inspec tion form Frequent In servicefor3 months or Outof service Owner Dealer or User Qualified J LG Service and Maintenance Man Inspection fora period of more than 3 months or Pur Mechanic ual and applicable J LG inspec chased used tionform Annual Annually no laterthan 13 months Owner Dealer orUser Qualified LG Service and Maintenance Man Machine date ofthe prior inspection Mechanic ual and applicable J LG inspec Inspection tion form Preventative Atintervals as specifiedintheServiceand Owner Dealer orUser Qualified J LG Service and Maintenance Man Maintenance Maintenance Manual Mechanic ual 2 2 J LG Lift 3121136 SECTION 2 GENERAL 2 2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE See Table 2 2 The preventive maintenance and inspection checks are listed and defined in the following table This table is divided into two 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 columns representing the various inspec tion time periods The numbers listed within the interval column represent the applicable inspection code for whi
58. With the platform fully lowered bars raised check for continuity on Repair or Replace Right Side the RightSide PHP barlimitswitch between pins 9 and 19 ontheP2 PHP LimitSwitch connectoratthe Ground Control Module Go to Step 4 4 With the platform fully lowered bars raised check for continuity on the LeftSide PHP bar limits witch between pins 10 and 20 onthe P2 E connector atthe Ground Control Module 3121136 J LG Lift 6 11 SECTION 6 TROUBLESHOOTING Obstruction Sensor System Detection Check For These Obvious Conditions First Look for an obstruction under platform remove obstruction Check for any external damage to sensor s or wiring harness Are the O S S side shield tubes secure to platform frame and not loose or protruding into the sensor detection area Are the isolation bushings in place and undamaged on both the O S S Module and each of the detection sensors Are the detection sensor mounting screws properly tightened not over torqued so not to damage the isolation bush ings Also check that none of the sensor mounting screws are bent thereby touching the inside of the sensor mounting holes Table 6 6 Obstruction Sensor System Detection Are any ofthe Do not pressure wash decals loose and protruding into the sensor detection area STEP ACTION SPEC YES NO 1 Perform Daily Pre StartInspection to test each transducer sensor Did all sensors pass test
59. a Remove rear cover unplug wire remove nut and lock washer then slide switch out of console Key Switch Install Remove Platform Console Key Switch Installaiton 1 Key Switch a 3 Attach Nut 2 Notch 4 Key Note a Remove mounting bracket on bottom of console to gain access to the key switch assembly 3121136 SECTION 4 CONTROL COMPONENTS E Stop ShutDown Switch Install Remove J oystick Assembly Install Remove Platform Console E Stop S witch Installation I Loosen Switch Set Screw 5 Barrel Seal Turn Switch 90 6 Switch to Body Retainer 3 Pull Spring Loaded Hooks a Release Lever Out 7 Switch Retainer Slots 4 Remove Barrel Assembly N Note a Use a small straight blade screwdriver to extend the spring loaded retainer hooks 6 out and release the switch from the body Platform Console J oystick Installation 4 Rubber Boot Gasket 5 Install Remove through the Access Hole in Bottom of Housing a b 1 Joystick Assembly 2 Attach Screws Qty 4 3 Nylon Washers Qty 4 Note a Remove the console mounting bracket b Remove the key switch and e stop switch to remove joystick assembly through access hole in bottom of con sole 3121136 J LG Lift 4 17 SECTION 4 CONTROL COMPONENTS 4 7 PLATFORM CONTROL CONSOLE SERVICE PROCEDURES MACHINES PRIOR TO S N 0130007616 General
60. breue 2 6 2 6 Bolt Usage and Torque Application 2 6 Hydraulic Lines and Electrical Wiring 2 7 Hydraullc S ystem ce c MR OD E CRT e trea DT RI AA 2 7 Lubrication and Servicing 2 7 Batteries viue vane lone ena ee SR Ee 2 7 Mast Chain Inspection 2 7 2 4 LUBRICATION INFORMATION e mmm hr 2 8 Hydraulie System si i X eir ie Rate E gne 2 8 Hydraulic Oll rl 2 8 Changing Hydraulic 2 8 Lubrication mmm 2 8 2 5 POSITIONING FOR ACCESS TO COMPONENTS LOCATED UNDER THE BASE FRAME 2 9 SECTION 3 BASE COMPONENTS 3 1 BASE ASSEMBLY COMPONENTS se hrs 3 1 3 2 BASE PRAME COVERS n E e NERA 3 2 Drive Motor Cover Installation 3 2 Battery Charger Cover Installation 3 2 3 3 DRIVE AND CASTER WHEELS onieesns HP CR Reeve REXEDUOREGR Nr RA Va 3 2 Drive Motor Wheel Std Installation 3 2 Caster Wheels Installation
61. cL 079 E 9 8 08 709000 Or 80 non 91 uz 81 anuo QVOTANVI9 armoon 807 ani 807 ug ada GVOT yayy HOLVd 13M 901 HLIM ANOYOL dvi anoor dWV19 ss3uig 9 325 1108 3143 0961 OMWHANN SLNN 8 AQVYS 8 51109 8 JVS SLNN zZ 0 EE 5 SM3U9S daiviaNn KINO 1109 031119 9 17 301 SANTWA Figure 1 4 Torque Chart ANSI Spec 3121136 JLG Lift 1 6 SECTION 1 MACHINE SPECIFICATIONS Figure 1 5 Torque Chart ANSI to METRIC Conversion 1 7 J LG Lift 8 3avuo avs 3avuo avs 54949 pejejd uinipeo Ajdde jou op sanjea a 0N cerry Goold 2268 9986 109 Leer O0zzvi 9792 veze 6862 18 6 26109 zzi 06269 octe 0055 086 5 6166 086L OtOc Lecce 1898 9 goes 87965 8907 Seez 99 2 889 0 00 exec BOLL 68 06 ELEC LOVEE Ob 16526 6868 9860 tivo 165 8907 265 267 086 91062 15562 9 6 9 198 862 9602 818E COLL 9191 ZVZ 189 9606 PCLT ezez v96er clde 0 6 8 89vc PGGBE 669
62. means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if the cir cuit is lacking hydraulic oil and electrical control power This can be ascertained by overriding the bypass valve mechani cally or electrically so that oil is available to the function valve then overriding the function valve mechanically If the function performs satisfactorily the problem exists with the control circuit 6 3 HYDRAULIC CIRCUIT CHECKS See Figure 6 5 The first reference for improper function of a hydraulic system where the cause is not immediately apparent should be the Hydraulic Diagram Circuit The best place to begin the problem analysis is atthe power source pump Once it is deter mined that the pump is serviceable then a systematic check of the circuit components would follow NOTE For aid in troubleshooting refer to Figure 6 5 for HYDRAULIC DIAGRAM circuit 6 4 ELECTRICAL CIRCUIT CHECKS General The drive system on the DVL Series and DVSP machines requires a microprocessor controlled electrical circuit to operate smoothly and accurately All platform control console functions are relayed to various machine components i e platform up down drive functions etc through the Ground Control Module microprocessor box mounted at the rear of the machine
63. odule and round connector atthe Traction Control Module Go to Sten 6 RepairorReplace Check continuity of all three 3 wires inthe communications cable Wire s from end to end P5 Pins 2 3 and 4 6 With communications cable still disconnected at both ends check RepairorRepl for continuity between Pins 2 3 and 4 atthe P5 connector end acel Goto Step 7 7 Plugthe communications cableonthe Traction Control Moduleto Replace theround socketon the opposite end ofthe module Does this fix Done Ground Control problem Module 3121136 J LG Lift 6 29 SECTION 6 TROUBLESHOOTING Codes 200 299 Platform Control Console Fault Condition Check For These Obvious Conditions First Damage to Platform Control Console wiring harness e Secure harness connections from Platform Control Console to Platform J unction Box to Ground Control Module Confirm thatthe static ground strap attached under base frame is secure and undamaged Table 6 38 Code 200 299 Platform Control Console Fault Condition STEP ACTION SPEC YES NO 1 Recycle machine power5 times allowing a 10 second interval between each power recycle Does faultclear Done Goto Step 2 2 Which 200 codenumberis displaying Code 200 207 213 GotoStep3 Replace Platform Code 202 205 206 GotoStep4 Control Module 3 Removethe9 pin Platform Control Module connector from the side of the Platform J unction Box and
64. on inside rail on bottom end of mast section 3 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Slide section 4 out the bottom of section 3 approxi mately one 1 foot Locate one 1 of the chain bottom anchor plates one with threaded holes horizontally aligned to cen ter of bracket Attach using holes in bottom of mast section 4 with three 3 1 4 20UNC x 3 4 long bolts place a flatwasher under head of each bolt 3121136 SECTION 5 MAST COMPONENTS Mast Section 4 Chain Anchor Bracket Bottom of Mast 1 Chain Anchor Bracket 2 MastSection 4 Note a Apply Loctite 242 to threads 3 Anchor Bolts Washers a 48 Slide section 4 out the top of section 3 approxi mately one 1 foot 49 Insert threaded ends of chain assembly attached to top of mast section 2 into the opening between mast section 3 and mast section 4 Slide the threaded ends through the holes in bottom anchor plate attached to bottom of mast section 4 Loosely thread two 2 3 8 16UNC nuts onto stud threads on each chain until all slack is taken out of chain Chains will be adjusted later in assembly 3121136 50 Assemble chain sheaves for narrow chain assem bly to top of mast section 4 as follows a Locate the remaining sheave pin and slide the wide tube spacer onto the pin shaft b Place two 2 ofthe narrow chain sheave
65. on the machine operate directly or indirectly through the Ground Control Module The module is currently programmed at the factory with the machines operating profile If replacing a Ground Control Module the new module may require some gramming to enable any optional equipment See Section 4 5 Ground Control Module Programming Ground Control Module Installation 1 Ground Control Module Note See Figure 4 2 for wiring connection instructions 2 Attach Screws Washers 3121136 Traction Control Module The Traction Control Module is mounted below the Ground Control Module on the mast support column This module controls the voltage to the drive motors as reg ulated by the Ground Control Module from signals received from the J oystick Controller located on the Platform Control Module There are no internal parts serviced on this module Traction Control Module Installation 1 Traction Control Module 2 Attach Screws Washers Note See Figure 4 2 for wiring connection instructions Platform Control Console Installation Platform Control Console Installation 1 Platform Control Console 2 Console Cable 3 Cable Quick Disconnect 4 Platform J unction Box J LG Lift 4 3 SECTION 4 CONTROL COMPONENTS Battery Installation Alarm Install
66. other when assem bled by internally mounted slide pads atthe top and bottom of each mast section These slide pads run up and down in slide pad channels on each side of the mast The DVL DVSP model mast assembly contains a different number of mast sections as shown following Table 5 1 DVL DVSP Mast Component Features No of Mast Extend Retract Model Sections Device DVLSeries amp DVSP 5 Chain Assembly procedures for all mast sections is basically the same carefully slide the mast sections together until mast ends are even When sliding the mast sections together be careful not to scratch the anodized surface Assemble the hardware to the bottom of mast section first slide this sec tion out the top of previous section and assemble hardware to the top of mast Always install slide pad shims with slide pads inserted into the slide pad channels ends of mast sections even Applying silicone spray onto the slide pads and slide pad channels before assembly will help mast sec tions slide easier after slide pads have been properly shimmed Mast Disassembly Procedure 1 After the mast assembly has been removed from the machine lay the mast assembly down on a Suitable work table with the platform mounting section on top facing up 2 Remove the sequencing cables and hardware from the sides of the mast assembly Also remove the covers from the top of the mast assembly MAST SECTION 5 REM
67. pouring the gear oil wet the gears and bearings with the oil Wet with gear oil and place the large wave washer on the end of the drive shaft bearing and the small wave washer on the end ofthe gear and pinion bear ing Clean the mating surfaces of the side cover and the gear box and check that the cover dow guide pins are properly installed in the cover Insert the rubber seal into the groove in the cover Using the cover dow guide pins place the cover onto the gear box housing Secure using the four 4 hex cap screws torque screws evenly to 90 Ibs Install the drive motor back onto the machine Drive Shaft Assembly 1 Spacer 3 Pinion Gear Key 5 Drive Shaft 2 Pinion Gear 4 42 x25 x 12m Bearing 6 42x20 x 14mm Bearing 3121136 J LG Lift SECTION 3 BASE COMPONENTS 3 6 POT HOLE PROTECTION SYSTEM S T X cath SS 3 Rear Hinge Hardware 1 Actuator Assembly 4 Front Hinge Hardware 2 Actuator Cables Pot Hole Protection Components 5 LeftSide PHP Bar 6 Right Side PHP Bar 7 Machine Front Figure 3 9 Pot Hole Protection System Components Front Assembly Installation 3 Torsion Spring 5 Cotter Pin 4 Flat Washer 1 Flat Head Pin a 2 Limit Switch Cam Notes a Apply White Lithium Grease to shaft Rear Hinge Assembly Installation 3 Torsion Spring 5 Cotter Pin 1 Flat
68. slide pads into slide pad NOTE Always use the an even amount of shim material dia of pd behind slide pads on both sides of the mast rails 2 us ee UNN This will keep mast sections centered in rail chan dp e nels and prevent any distortion of the section f Check mast section for side play If play exists use thicker shims dividing thickness equally a Use two shim pieces per slide pad a thick one between both sides of mast and a thin one When mast slide pads shimmed properly b Start with a total thickness of approximately there should be no side to side movement of 035 and 075 thick shim stock slide pad in rail channel Mast sections should be very snug in channels but still be able to slide in channel by hand Mast Section 5 Bottom End Components Chain Anchor Bracket and Slide Pad Installation 1 Chain Anchor Bracket 3 Slide Pad 5 Slide Pad Bolts Washers a 2 Anchor Bracket Bolts Washers a 4 Long Slide Pad Note a Apply Loctite 242 to threads 5 22 J LG Lift 3121136 SECTION 5 MAST COMPONENTS 4 Slide mast section 5 out even with top of section 4 5 Insert threaded ends of chain assembly attached to top of mast section 3 into the opening between mast section 4 and mast section 5 Slide the threaded ends through the holes in bottom chain anchor plate located on bottom of mast section 5 Loosely thread two 2 3 8 16UNC nuts onto stud thr
69. soil has warmed 1 Remove AdjustScrew Cap 2 Pressure Adjustment Screw Note Machine rear covers mustbe removed to access pump motor Figure 1 1 Hydraulic Pressure Adjustment Screw Machine Rear Covers Removed J LG Lift 1 3 SECTION 1 MACHINE SPECIFICATIONS Hydraulic Pressure Gauge Connection A CAUTION 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 install a t fitting between the pump and the extend line to connect a hydraulic pres sure gauge as shown in Figure 1 2 Typical Hydraulic Pres sure Gauge Installation Hydraulic Filter Removed CHECK and if necessary ADJ UST 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 Pres sure Check following Mnl e 3 T Fitting 4 Return Line 1 Pressure Gauge Assembly 2 Extend Line Figure 1 2 Typical Hydraulic Pressure Gauge Installation Hydraulic Filter Removed After Filter Pressure Check Reinstall the
70. springs To remove the springs press inward on the end of the spring retaining bracket using the tip of a pair of long nose pliers or other appropriate tool The brushes should pop out if not they can be removed by pulling outward on the spring brackets with a pair of long nose pliers after the inside ends are unhooked 4 Now pull the brush out of the brush box by it s wire pig tail NOTE If only inspecting the brushes it is not necessary to remove the pig tail terminal from it s connection to the brush box 5 Loosen the screw securing the pig tail terminal end to the brush box and slide the terminal end out from under the screw completely removing the brush from the drive motor Y u 7 6 Brush Component Installation 1 Roll Spring 4 Brush Box Insulator 2 Roll Spring Hooks 5 Brush 3 Brush Box 6 Pigtail Wire J LG Lift 3 15 SECTION 3 BASE COMPONENTS Brush Reassembly A CAUTION MAKE CERTAIN THAT THE GROUND WIRE IS SECURELY RECON NECTED TO THE GROUND TERMINAL IF REMOVED LEADS INTERNAL TO THE SHIELD MUST BE ROUTED AWAY FROM THE ARMATURE E G BE CLOSE TO THE INSIDE WALL OF THE ALU MINUM SHIELD TO PREVENT A SAFETY HAZARD AND OR DAM AGE TO THE MOTOR 1 Install the brush pig tail terminal end under the screw on the brush box in the same manner as the old brush that was removed and tighten the screw
71. the brakes are ENGAGED brakes on on either side of the friction disk when the brake is RELEASED brakes off Clean and remove debris as necessary 3 With the brakes ENGAGED measure the air gap between the armature plate and the magnetic coil housing The correct setting should be 006 how ever the brakes will operate properly if the measure ment is a minimum of 004 and a maximum of 010 See Gap Setting Illustration this Section 4 If the air gap falls outside the maximum allowable setting of 010 the friction disk has worn To correct this replace the disk with a new one 5 Ifthe airgap is below the minimum allowable setting of 004 recheck the areas between the magnetic coil housing armature plate friction disk and mounting plate for debris Clean as necessary 1 Magnetic Coil Housing 2 Armature Plate 3 Friction Brake Disk 4 Mounting Plate 5 Plate Springs 6 Shim Washers 7 Spacer 8 Mounting Plate Screws Figure 3 7 Brake Assembly Components 3121136 SECTION 3 BASE COMPONENTS 3 4 2 2 T Gap Setting Brake Engaged Gap Setting Brake Disengaged magnet not energized springs engage plate against disk magnet energized plate compresses springs disk rotates freely 1 Magnetic Coil 3 Brake Disk Engaged 5 006 Gap 1 Magnetic Coil 3 Brake Disk Free 5 Plate Engaged 2 Armature Plate 4 Mounting Plate 2 Armature Plate 4 Mounting Plate Springs Comp
72. the lift down valve wiring harness or a damaged lift down valve coil Table 6 19 Code 16 Lift Down Valve Short Circuit STEP ACTION SPEC YES NO 1 AttheGround Control Module P1 connector check the voltage ReplaceGround across pins 10 and 3 to theliftdown valve coil Is reading within 0 2V DC Go to Step 2 Control Modul specification DIMUS 2 Removethe wireterminals atthe lift down valve coil Check resis tance reading of the coil Is coil within specification 24 5 Ohms Go to Step 3 Replace Coil 3 With the terminals still removed from the lift down valve coil check RepairorReplace continuity ofthe wires from pins 10 and 3 onthe P1 connector to the 00 Ohms Wiri p liftdown valve ng Code 17 Ground Control Module In Fold Back Check For These Obvious Conditions First Has machine been operating on a continuous grade or rough terrain for a long period of time Table 6 20 Code 17 Ground Control Module In Fold Back STEP ACTION SPEC YES NO 1 Allow Ground Control Moduleto cool for 30 minutes Does the Replace Ground machine operate OK after cooling Control Module Table 6 3 Amperage Draw for Various Components NOTE If this is a recurring problem compare current draw of your machine with Ground Control Module specifications in Code 18 Alarm Short Circuit Check For These Obvious Conditions First Damaged wiring in the alarm wiri
73. the platform electrical control cables and the sequence cables are seated in their sheave wheel assemblies when extending mast sections for reassembly After assembly readjust the chain at the bottom of mast section 3 and apply Loctite 242 to the lock nuts before final tightening Remove the plastic from under the hydraulic reser voir tank cap SECTION 5 MAST COMPONENTS 5 5 MAST ASSEMBLY INSTALLATION MastRemoval 5 The following components must be removed from the machine before removing the mast assembly Rear Covers Drive Motor Cover Disconnect the Platform Control Console from the Mast mounted junction box Platform Assembly 6 Disconnect the positive battery cable from the left side battery 7 Unplug the platform control cable connector at the ground control module 8 Remove the clamp attaching the platform control cable from inside the mast mounting column 9 Disconnect the spring and clamp attaching the AC receptacle cable inside the mast mounting column 10 Underthe machine disconnect and cap the hydrau lic extend and return lines from the hydraulic cylin der 11 Using an overhead crane or su
74. 0 ft Ibs 10 Piston 11 Wear Ring 12 Piston O Ring 13 Piston Lock Nut a Figure 5 4 Lift Cylinder Component Cross Section 5 10 J LG Lift DVL DVSP 3121136 SECTION 5 MAST COMPONENTS Lift Down Valve and Manual Release Installation DVL DVSP 1 Lift Down Valve a 2 Valve Solenoid b 3 Solenoid Retaining Nut Notes a Coat all o rings with clean hydraulic fluid before assembling b Mount with electrical terminals pointing down 5 O Ring with Backing Rings a 4 Manual Release Assembly 6 Valve O Ring a 7 Solenoid O Ring a 3121136 6 When the rod assembly is ready to be installed into the tube liberally apply an anti seize lubricant to the cylinder head surface which slides into the cylinder tube Next dip the entire rod assembly into hydraulic fluid and stuff this assembly into the tube Watch the seals as they pass over the rod port if visible to be sure they are not nicked or cut Install the head until the retaining ring seats in it s groove Cylinder Installation To install the lift cylinder reverse the Lift Cylinder Removal instructions at the start of this section however perform the following additional steps during re assembly 1 J LG Lift Apply Loctite 222 purple and torque to 85 ft Ibs the cylinder mount shoulder screws securing the lift cylinder mount halves together at the bottom of the mast Check that
75. 00 gt _ 4800 Fault Condition Page6 31 4 4 400 BM USES A OSS Control Module See Table 6 35 X 00000 0 400 4400 Low Internal Supply Page6 27 401 _ 1 4 OSS Control Module See Table 6 35 X 00000 0 401 401 Amplifier Fault Page 6 27 3121136 J LG Lift 6 7 SECTION 6 TROUBLESHOOTING 6 5 TROUBLESHOOTING TABLES INDEX SPECIFICATIONS FOR VARIOUS COMPONENTS PAGE Ohm Ratings for Various 6 10 Amperage Draw for Various 6 10 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS Special Pin Extractor Tools for Electrical Connectors 6 10 FAULT CODE TROUBLESHOOTING TABLES Machine in Drive Speed Cut Back Turtle Mode All The Time 6 11 Obstruction Sensor System 6 12 Battery Voltage Low Warning Level 3 Three 3 LED LCDs 6 12 Code 02 sLeftPHP Bare spate ee cre ee agen SENOS Pe LL DE Dd 6 13 Code 03 RightPHP Bar UP cece teen hh hens 6 13 Code 04 TilECondition ences ERI re ute Er ers ea eniud rd Sure 6 14 Code OSE Resenv d die soin ER M Meese eed 6 14 Code 06 Reserved 45 ced tede ect e ANREDE we ieu uU 6 14 Code 07 Left Drive Motor 5
76. 1 Using the recommended vise jaws clamp the wire rope into a vise with the bottom edge of the black mark made on the wire rope resting just above the vise jaws 1 Cable 2 Mark on Cable 3 Recommended Vise J aws 3121136 SECTION 5 MAST COMPONENTS 2 Twist the sleeve from the clamp kit onto the rope until itis flat against the vise jaws at the mark made made on the wire rope 1 Sleeve Installed on Cable 3 Use a suitable tool and cut the cable as shown in the illustration following For 1 8 in cable the recom mended length is 5 8 in past the end of the sleeve 1 CutTo This Length 2 Sleeve 4 Unlay the cable strands by gently forcing a screw driver between the outer strands to unlay the cable When done properly the outer strands will form a symmetrical basket Do not straighten out the spiral lay of the strands unlay any wires that make up the strand or allow the strands to cross each other inside the sleeve 3121136 J LG Lift 1 Cable Strands Unlayed Install the plug supplied with the kit by placing the plug in the center of the strands starting with the small tapered end of the plug Use a metal tube plug driver and hammer to drive the plug into the sleeve while assuring that the strands are spaced somewhat equally around the plug Drive the plug until it is firmly seated and no more than 1 3 of the plug is visible from above the sleeve
77. 10 Right Brake lt 6 15 Code 11 Left Drive Motor Short Circuit 0 ccc nn 6 16 Code 12 Right Drive Motor Short 6 16 Code 13 Traction Module In Fold 6 16 Code 14 Pump Motor 15 6 17 Code 15 Lift Down Valve 6 17 Code 16 Lift Down Valve ShortCircuit sese nn 6 18 Code 17 Ground Control Module In Fold 6 18 Code 18 Alarm Short 6 18 Code 19 Alarm Disconnected 6 19 Code 20 Beacon Short Circuit sasaaa aaaea 6 19 Code 21 Beacon lt 6 20 Code 22 Horn Short cient 6 20 Code 23 Horn 5 6 21 Code 24 Auxiliary 1 Circuit Short 6 21 Code 25 Auxiliary 1 Circuit 6 22 Code 26 Auxiliary 2 Short amp 6 22 Code 27 Auxiliary 2 Disconnected
78. 18 SERIAL NUMBER LOCATIONS a hh 1 4 SECTION 2 GENERAL 2 1 MACHINE PREPARATION INSPECTION AND MAINTENANCE 2 1 GONE ral c E PE 2 1 Preparation Inspection and 2 1 Pre Start Inspection sese gu teas wane eed eel uk p PR ER EERES EUER 2 1 Pre Delivery Inspection and Frequent 1 5 2 1 Annual Machine 5 2 1 Preventative 2 1 2 2 PREVENTIVE MAINTENANCE AND INSPECTION 5 2 3 Inspection and Maintenance Codes 2 5 5 iis NAN 2 5 2 3 SERVICING AND MAINTENANCE A mnn 2 6 Generala ster e hte mee P a rr wo ies e e wee Sore e es tede 2 6 Safety and Workmanship 2 6 Cleanliness wists toga lan VR IE MEMINI SEA Eu OIM EI P REDE Ra EU UR 2 6 3121136 J LG Lift i TABLE OF CONTENTS Components Removal and 1 5 2 6 Component Disassembly and Reassembly 2 6 Pressure FIEParts oro Se fh oe Ree aO Re ue qd E eie Cold ete dud 2 6 Bearings xev x Mte xcd c Ru
79. 2 LeftSide Battery b 6 Left Drive Motor Harness Reverser a 10 Master Disconnect Switch c 3 175 Amp Fuse 7 Power Cable To Left Drive Motor Brake a 4 Right Side Battery b 8 Power Cable To Right Drive Motor Brake a Ground Control P1 Horn Alarm Beacons Lift Down Valve Harness a P4 Platform J unction Box Harness a Module Plugs P2 PHP Elevation S peed Charger Limit Switch Harness a P5 J oystick Protocol Harness P3 Programmable Security Lock Harness Option a Notes Apply di electric grease J LG Part Number 3020038 to wiring harness terminals to prevent moisture from entering module b Seal NEG and POS 4 posts with battery grease to prevent corrosion c Machines equipped with the UL EE specification option only Figure 6 1 ComponentElectrical Connections 3121136 J LG Lift 6 3 SECTION 6 TROUBLESHOOTING Table 6 1 LCD Display Service Fault Code Conditions PLATFORM FAULT CONSOLE FAULT DESCRIPTION AE LCD SYMBOL SCREEN LCD TEXT SCREEN MACHINE CONDITION TROUBLESHOOTING FLASHING Machine In Drive Speed Exe Cut Back Turtle Mode peu X 00000 0 All TheTime 9 Engage Brakes E m n spin Press Brake Release Button X 00000 0 on Ground Control Station Unplug Charger ChaerACPluggedin ac inputPower Cord X 00000 0 DRIVE Disabled from Machine Obstruction Sens
80. 2 Platform Floor Supports Note a Secure ALL sensor wire cables to platform side frame 3121136 JLG Lift SECTION 4 CONTROL COMPONENTS This page intentionally left blank 4 30 J LG Lift 3121136 SECTION 5 MAST COMPONENTS SECTION 5 MAST COMPONENTS 5 1 MAST COMPONENTS OVERVIEW 1 Mast Section 1 4 MastSection 4 7 Lift Cylinder Mount 10 Lanyard Attach 13 Chain Equalizer 2 Mast Section 2 5 MastSection 5 8 Slide Pads 11 Chain Guard Plate Assemblies 3 Mast Section 3 6 Lift Cylinder 9 Chain Anchor Plates 12 Sheave Assemblies 14 Mast Mini Covers Figure 5 1 Mast Components DVL DVSP 3121136 J LG Lift 5 1 SECTION 5 MAST COMPONENTS 5 2 MAST CHAINS AND SEQUENCING CABLES ADJ USTMENT Mast Chain Cable Adjustment The intention of this procedure is to assure equal load distri bution between the individual chains of a mast section chain sets Also to step each front mast section up approximately 7 16 in 12mm from the section behind itto allow clearan
81. 2 Slide the body of the brush into the brush box be certain that the wire pig tail is aligned with the slot in the base of the brush box so that it can feed into the brush box slot as the brush wears down NOTE The pig tail wire should be formed to rest against the nonmetallic insulator It must be spaced from any metallic surfaces other than the brush box by a mini mum of 125 in 3mm 3 Now install the brush retaining spring bracket Grasp the tip of the spring bracket such that the roll type spring will be on the brush side of the brush box and resting on top of the brush when the brush spring is completely installed 4 Push the spring bracket slowly into it s slot while let ting it s two attaching hooks slide on the wall of the brush box 5 Stop but do not release the spring bracket when it s hooks slip around the edge of the brush box 6 While still grasping the spring bracket with the pliers slowly bring the spring back out of the brush box until the hooks latch around the edge of the brush box 3 16 J LG Lift 7 Now release the spring bracket and check that it is lying flat against the brush box wall If it is cocked it is improperly seated and will have to be reinstalled I 2 Correct Incorrect Brush Installation 1 Correct 2 Incorrect IMPO
82. 2 OUTPUT 24VDC 5 YELLOR RED 7 7 5 SHARED WITH 055 B BAKT Op 24055 BLUE ORANGE 52 3 XI B BLACK 3 879 1879 2 1 5 5 1 B 1 seine i BLACK WHITE ET LEFT MOTOR BRAKE E BLACK M1 PTIONAL LSS CECPTICN CNY 4933184 D 2 Figure 6 4 Electrical Diagram with Load Sensing System DVL DVSP Sheet 2 TRACTION MODULE 6 46 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING ES OUT YELLOW BLACK ES IN YELLOW SHIELD B BLACK RS485B BLUE RS485A ORANGE AUX 1 SIGNAL B RED BLACK AUX 1 RETURN BLUE BLACK 0 5 5 SUPPLY 24V DC RED 0 5 5 DIGITAL RETURN BROWN SPARE ORANGE BLACK SPARE BROWN BLACK SPARE BLACK RED 2 2 lt HHH AJAJIA al
83. Bars UP Table 6 34 Code 33 Both PHP Bars UP STEP ACTION SPEC YES NO 1 Perform steps in Code 2 LeftPHP Bar UP then Code3 Right PHP Bar UP Do either of these steps correctthe problem Done Goto Step 2 2 Perform steps in Table 6 5 Machine In Drive Speed Cut Back Tur tle Mode All The Time of this section Done ConsultFactory Code 38 Battery Voltage Low Warning Level 2 Two 2 LED LCDs lit To maximize battery life it is recommended that the factory supplied batteries be charged continuously for a minimum of 4 hours or until 8 bars are lit on the ground station LCD Display before operating the machine When drained to Warning Level 2 batteries must be charged until 8 bars are lit on the ground station LCD display to clear the fault code Failure to do so will result in a fault code 39 Code 39 Battery Voltage Low Warning Level 3 One 1 LED LCDs lit To maximize battery life it is recommended that the factory supplied batteries be charged continuously for a minimum of 4 hours or until 8 bars are lit on the ground station LCD Display before operating the machine When drained to Warning Level 1 batteries must be charged until 8 bars are lit on the ground station LCD display to clear the fault code 6 26 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING Code 40 Obstruction Sensor System No Communication with Ground Control Module Check For Th
84. Battery Cable 3 Mounting Bracket 7 Cable Nuts 4 Mounting Nut Note See Figure 4 2 for wiring connection instructions 4 5 SECTION 4 CONTROL COMPONENTS a N 4 1 Ground Control Module 5 Traction Control Module a 9 Pump Motor Tank Assembly b 2 Left Side Battery b 6 Left Drive Motor Harness Reverser a 10 Master Disconnect Switch c 3 175 Amp Fuse 7 Power Cable To Left Drive Motor Brake a 4 Right Side Battery b 8 Power Cable To Right Drive Motor Brake a Ground Control P1 Horn Alarm Beacons Lift Down Valve Harness a P4 Platform J unction Box Harness a Module Plugs P2 PHP Elevation Speed Charger Limit Switch Harness a P5 J oystick Protocol Harness a P3 Programmable Security Lock Harness Option a b Seal NEG and POS posts with battery grease to prevent corrosion c Machines equipped with the UL EE specification option only Notes Apply di electric grease J LG Part Number 3020038 to wiring harness terminals to prevent moisture from entering module Figure 4 2 Component Electrical Connections 4 6 J LG Lift 3121136 SECTION 4 CONTROL COMPONENTS 4 4 GROUND CO
85. COMPONENTS 5 4 HYDRAULIC LIFT CYLINDER REMOVAL INSPECTION AND REBUILD WARNING HYDRAULIC CYLINDERS ARE DESIGNED TO HOLD HYDRAULIC FLUID UNDER HIGH PRESSURE ENSURE ALL APPROPRIATE MEA SURES ARE TAKEN TO RELIEVE RESIDUAL PRESSURE IN THE CYL INDER BEFORE DISCONNECTING LINES Lift C ylinder Removal Removal of the hydraulic lift cylinder without removing the mast from the machine requires laying the machine on it s back hood side with the platform end on top 1 Remove the following components from the machine before laying machine on it s back Rear Covers See Section 4 Batteries See Section 4 Drive Motor Cover See Section 3 2 Seal the vented cap on the hydraulic fluid reservoir by removing the cap covering the hole with a few layers of plastic wrap or equivalent Then install and tighten the cap over the plastic wrap to prevent leak age of hydraulic oil from the reservoir while machine is in a layed back position 3 Use a forklift truck or overhead crane and carefully lay the machine on it s back place a support under the mast end keeping mast close to level See Fig ure 5 3 EX ns o S 1 Be Careful of Control Components in this Area 2 Support Mast Here Keep Mast Approximately Level Figure 5 3 Machine Positioned for Cylinder Removal 3121136 J LG Lift 4 At t
86. EAD SLING BEFORE MAKING ADJ USTMENTS LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPO NENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACH MENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS INTRODUCTION REVISION LOG REVISION LOG October4 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 J anuary 22 2003 Manual Revised Feburary 18 2003 Manual Revised J uly 18 2003 Manual Revised October 1 2003 Manual Revised August 16 2004 Manual Revised September 27 2005 Manual Revised JLG Lift 3121136 TABLE OF CONTENTS TABLE OF CONTENTS SUBJ ECT SECTION PARAGRAPH PAGE NO MAINTENANCE SAFETY PRECAUTIONS eee A GENERALY it tiat sca tatc A B HYDRAULIC SYSTEM SAFETY vote ix ortho be peres A MAINTENANCE tec ROO e REVISION LOG coss ae dex int SECTION 1 MACHINE SPECIFICATIONS 1 CAPACITIES e ette e Ur ERR ord chet gU e OR A INC A 1 2 System Voltage a u ch iau bx Pret Xeno zb decedit MEO OE 1 2 Hydraulic Syst m ra 2 Ede ac Speed ates mier Q
87. Electrical Diagram DVL DVSP 1 6 44 6 4 Electrical Diagram with Load Sensing System DVL DVSP 2 6 46 6 5 Hydraulic Diagram DVL DVSP 0 cece hrs 6 48 3121136 LIST OF TABLES TITLE PAGE NO DVL and DVSP Machine 5 lt 1 1 Hydraulic Oil Operating 1 3 Lubrication Specifications ecco ORC E dacs ee xxu on en xS RU Kiet ce Mina RC 1 3 Cylinder Specifications ors AR Sed 1 4 Lubrication Intervals for Various 1 5 Inspection and 2 2 DVL DVSP Preventive Maintenance amp Inspection 5 2 4 Chain Stretch Tolerante c sz pk deta b Ru EN RE E EL 2 7 Battery Low Voltage Warning 1 5 3 22 DVL DVSP Ground Control Module Field Programmable Settings and Factory Preset 4 13 Obstruction Sensor System Components Platform 4 26 DVL DVSP Mast Component lt 5 13 LCD Display Service Fault Code lt 6 4
88. Ground Control Module P1 connector check the voltage Replace Ground across pins 12 and 5 to the beacon Is reading within specification 0 2VDC Go to Step 2 Control Module 2 Removethe wire terminals atthe beacon check continuity of each ofthe wires from pins 12 and 5 ontheP 1 connectorto the beacon psu R T end eacon eplace Wiring 3121136 JLG Lift 6 19 SECTION 6 TROUBLESHOOTING Code 21 Beacon Disconnected Check For These Obvious Conditions First s machine equipped with flashing amber beacon light Table 6 24 Code 21 Beacon Short Disconnected STEP ACTION SPEC YES NO 1 15 machine equipped with aflashing amber beacon light Go to Step 3 Gotto Step 2 2 AttheGround Control Moduleenterthe programming mode check R ur _ eplace Ground ifthe Beacon light open circuit detection is enabled Disable It Control Module 3 Check voltage atthe P1 connector on the Ground Control Module Replace Ground between pin 12 and pin 5 Is reading within specification 2 4VDC Control Module Goto Step 4 4 Removethe wire terminals atthe beacon check continuity of each ofthe wires from pins 12 and 5 on the P1 connector to the beacon Replace the pepe ar end Beacon Replace Wiring Code 22 Horn Short Circuit Check For These Obvious Conditions First Damaged wiring in the horn wiring harness or a damaged horn unit Table 6 25 Code 22 Horn Short Circuit
89. INTERVAL 0 ITEM COMPONENT LUBE METHOD 3 6 1 2 COMMENTS LUBE POINTS MONTHS MONTHS YEAR YEARS Fill To Line on Check Hyd Oil Check fluid level every day c 1 Hydraulic Oil Reservoir Level v Change hydraulic oil every 2 5Qt Reservoir Change Hyd Oil years Drive Wheel 2 Bearings Permanently Sealed Drive Wheel Change only when serviced 3 Gear Box LAE Gear Oil requires 6 oz 175 cc s to fill 4 Caster Axles 2 Grease Fittings MPG Pressure Gun v 5 SwivelRaceways 2 FrontCasters MPG Pressure Gun v 6 2 PerSection Lube Brush or v Inspect lubricate if dry or rusting Key to Lubricants MPG Multipurpose Grease 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 Notes a Becertainto lubricate like items on each side ofthe machine b Recommended lubricating intervals are based on normal use If machine is subjected to severe operating conditions suchas a high number of cycles location corrosive dirty environment etc user mustadjustlubricating requirements accordingly c Priorto checking hydraulic oil level operate machine through one complete cycle of lift function full up and down Failureto do so will resultin incorrect oil level reading on the hydraulic reservoir 3121136 J LG Lift 1 5 SECTION 1 MACHINE SPECIFICATIONS
90. Installation 1 OSS Control Module 4 Insulating Bushing 2 Mounting Screw a 5 Decal Billboard b 3 Nylon Washer Notes Apply Loctite 222 to threads b Drill out pop rivets to remove 1 3 m 2 E er b OSS Control Module Connections 1 RED LED Detection Indicator 3 J unction Box Harness 2 Sensor Harness moomoo 97 CH2 CH3 5 CH6 Internal View of OSS Control Module 1 Sensor Comm Channels a 3 Wires to Platform J unction Box 2 Sensor Cables 4 LED Indicator Light Notes Channel 1 Sensor 1 Channel 2 Sensor 2 etc 4 28 J LG Lift 3121136 SECTION 4 CONTROL COMPONENTS Transducer Sensor Installation Typical 4 DO NOT Pressure Wash Decal 5 Sensor Side Deflector 1 Mounting Screws a 2 Bushings 3 Transducer Sensor b Notes a Apply Loctite 222 to screw threads and torque to 15 in Ib b Mount sensor with circular membrane facing down Sensor Side Deflectors 1 Sensor Side Deflector a 3 Platform Side Frame 2 Pop Rivet Note a One deflector required on each side of platform Deflector must be even with and not extend inside of the platform side frame Secure Transducer Sensor Wiring 1 Nylon Tie Wraps a
91. JLG Lift 6 47 SECTION 6 TROUBLESHOOTING CYLINDER 2 ie E 10 0 4 6 8 NRI RS PUMP 5 4 1 2792504 1 5 Pressure Adjust Valve 9 Check Valve 2 Filter Screen 6 Extend Line 10 Pressure Compensator Flow Control Valve 3 Pump 7 Hydraulic Filter 11 Manual Decent Valve 4 Pump Motor 8 Return Line 12 LiftCylinder Figure 6 5 Hydraulic Diagram DVL DVSP 6 48 J LG Lift 3121136 CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Batteries also contain other harmful chemicals known to the State of California WASH HANDS AFTER HANDLING Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 Phone 717 485 5161 Fax 717 485 6417 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 2 65 811111 Fax 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Industries Europe Kilmartin Place Tannochside Park Uddin
92. Lift 3121136 SECTION 6 TROUBLESHOOTING SECTION 6 TROUBLESHOOTING 6 1 GENERAL This section contains troubleshooting information to be used for locating and correcting most operating problems If a prob lem should develop which is not presented in this section or which is not corrected by listed corrective actions technically qualified guidance should be obtained before proceeding with any maintenance 6 2 TROUBLESHOOTING INFORMATION Troubleshooting procedures applicable to this machine are listed and defined starting with Section 6 5 TROUBLESHOOT ING TABLES Index in this section of the manual Each malfunction within an individual group or system is followed by a listing of probable causes which will enable determi nation of the applicable remedial action The probable causes and the remedial action should where possible be checked in the order listed in the troubleshooting tables It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electri cal systems For this reason every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment In the remaining machine groups only those problems which are symptomatic of greater problems which have more than one probable cause and remedy are included This
93. NG LOOSE AND FALLING OFF 3121136 3 4 DRIVE MOTOR COMPONENT SERVICING Torque Limiting Clutch Maintenance DVL Series and DVSP machines are equipped with a torque limiting clutch coupling on each drive axle The clutch is mounted in line on a split drive axle between the drive wheel and the drive motor gear box The clutch is designed to slip ata preset torque 220 ft Ib ifthe machines rear wheels are over driven while the machine is being towed pushed or forklifted thus preventing damage to the drive gear box Although factory pre set the clutch assembly torque setting should be checked Annually during Annual Inspection However if the lift is being moved via a fork truck on a regu lar or frequent basis then the torque clutch may be forced into a slipping mode as intended to protect the drive train In that case and if slippage occurs during machine opera tion then the torque setting should be checked Every 3 Months And the torque specification reset per the following instruc tions Diagnostics A torque clutch with INCORRECT torque setting may develop the following symptoms Machine does not drive straight NOTE Machine pulling to one side can also be the result of low battery voltage Be sure and check battery volt age before clutch maintenance begins There is gray dust accumulating around the drive motor s due to excessive clutch wear J LG Lift 3 3 SECTION 3 BASE COM
94. NPUT MAY BE USED FOR HEIGHT LIMITERS AUX 1 INPUT MAY BE USED FOR GATE INTERLOCK 4933184 D 1 Figure 6 3 Electrical Diagram DVL DVSP Sheet 1 3121136 J LG Lift 6 45 SECTION 6 TROUBLESHOOTING BLACK JUNCTION BOX ES QUT YELLOW BLACK MNT eg RED I 1 ES IN YELLOW 1 SHIELD N JOYSTICK MODULE 10 B BLACK 200080 RS485B BLUE 70 RS485A ORANGE 4o 9 AUX 1 SIGNAL B RED BLACK AUX 1 RETURN BLUE BLACK ORANGE O S S SUPPLY 24V DC RED O S S DIGITAL RETURN BROWN C SPARE ORANGE BLACK SHIELD SPARE BROWN BLACK SPARE BLACK RED 9 OPTIONAL 0 5 5 0 5 5 DIGITAL RETURN S SUPPLY 24V DC LSS SWITCH OPEN OVERLOAD i 22 B BLACK ON OFF BLUE COM WHITE GROUND STATION MODULE zii p 2A lC 5 AP MAX 8 BLACK B BLACK PIN 2 ON OFF BLUE PIN 5 Pee e I A COM WHITE PIN 4 OPTIONAL MASTER SWITCH 3 Be 24v0C ALARM 5 8 WHITE HGHT RIGHT e BRAKE 5 AMP LIFT DOW VALVE BLACK 5 RED 155 ALARM o AUX 1 OUTPUT 24VDC 5 AWP MAX y 9 BLACK i Em d 55 ON 25 OFF OVERLOAD i AUX
95. NTROL MODULE SERVICE PROCEDURE IMPORTANT DO NOT ATTEMPT TO DISASSEMBLE THE GROUND CONTROL MOD ULE IF MACHINE IS STILL UNDER WARRANTY OPENING THE GROUND CONTROL MODULE WHILE THE MACHINE IS UNDER WAR RANTY WILL VOID THE WARRANTY IF UNDER WARRANTY REQUEST A REPLACEMENT MODULE FROM THE FACTORY The DVL Series and DVSP Ground Control Module allows for field replacement of two 2 components internal to the module Emergency Stop Switch Power Selector Switch Key IMPORTANT ELECTROSTATIC DISCHARGE CAN DAMAGE COMPONENTS ON THE INTEGRATED CIRCUIT BOARD PLACE THE GROUND CONTROL MODULE ON A NON CONDUCTIVE SURFACE WHEN OPENING 1 Cover LCD Assembly 2 Power Selector Switch Nut 3 Emergency Stop Button 4 Emergency Stop Switch 5 Power Selector Switch 6 Main Board to LCD Ribbon Cable Connector 7 Heat Sink Base Main Board Assembly 8 Cover Attach Screws Figure 4 3 Ground Control Module Components 3121136 JLG Lift 4 7 SECTION 4 CONTROL COMPONENTS Cover Removal Installation IMPORTANT THE MAIN CIRCUIT BOARD AND THE SMALLER LCD CIRCUIT BOARD MOUNTED TO THE COVER ASSEMBLY ARE CONNECTED BY A RIBBON CABLE REMOVE THE COVER CAREFULLY ONCE THE COVER SCREWS ARE REMOVED FROM THE BACK OF THE MODULE Cover Installation 1 Remove the 6 Hex Socket Screws from the Heat Sink Base One screw is under the Warranty Tamper Label Release Ribbon Cable 1 Ribbon Cabl
96. OVAL 3 Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate lower on BOTTOM end of mast section 5 platform mounting section Push threaded ends of chain through anchor plate 4 At the TOP of mast section 5 pull chains out and allow to hang loose Be certain floor surface is clean and free of any metal chips or debris which may stick to lubricated chains OPEN RAIL REFERS TO OPEN RAIL FRONT OF MAST SECTION CLOSED RAIL REFERS TO CLOSED RAIL BACK OF MAST SECTION REFERS TO TOP END OF MAST SECTION WHERE COVER AND SHEAVE WHEELS ARE ATTACHED BOTTOM REFERS TO BOTTOM END OF MAST SECTION WHICH SETS IN MACHINE S BASE FRAME Figure 5 5 Mast Section Assembly Reference 3121136 J LG Lift SECTION 5 MAST COMPONENTS NOTE When sliding mast sections apart be careful not to scratch or score the anodized surface in the slide pad channels Carefully slide mast section 5 out the BOTTOM of mast section 4 rails Disassemble slide pads shims and chain anchor plate from mast section 5 if nec essary MAST SECTION 4 REMOVAL 6 NOTE 10 Remove chain adjust nuts from threaded ends of chains attached to the chain anchor plate lower on BOTTOM end of mast section 4 Push threaded ends of chains through anchor plate At TOP of mast section 4 pull chains out and allow to hang loose Be certain floor surface is clean and f
97. P ACTION SPEC YES NO 1 Checkresistance across positive and negative drive motor Replace Traction leads inM1 connector wiring harness going to the leftdrive 15 1to 3ohms Go to Step 2 reading within spec 2 Repairorreplace leftdrive motor wiring brushes or motor For brush replacement see Section 3 of this Service Manual 6 14 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING Code 08 Right Drive Motor Disconnected Check For These Obvious Conditions First Check right drive motor M2 connector atthe Traction Control Module for secure and proper connection Table 6 11 Code 08 Right Drive Motor Disconnected STEP ACTION SPEC YES NO 1 Check resistance across positive and negative leads in M2 Replace Traction connector wiring harness going to the right drive motor Is reading 1to 3 ohms Module Goto Step 2 within spec 2 Repairorreplacerightdrive motor wiring brushes or motor For brush replacement seeSection 3 ofthis Service Manual Code 09 Left Brake Disconnected Check For These Obvious Conditions First Check left drive motor M1 connector atthe Traction Control Module for secure and proper connection Table 6 12 Code 09 Left Brake Disconnected STEP ACTION SPEC YES NO 1 Check resistance across positive and negative l
98. PONENTS Visual Inspection and Limiting Torque Checking Procedure Special tools required Torque Wrench capable of setting torque in the range of 220 ft Ib Special tool part 0080229 2 3 8 open end wrench Loctite 242 1 2 NOTE NOTE 34 Locate the machine on a firm level surface Before clutch torquing can begin you must remove the wheels using the following procedure Machines equipped with Hough Terrain Wheels make a visible mark on the wheel so the wheel does not get inverted when reinstalled a Using a fork truck raise unit approximately 12 offthe floor and support in a safe manner See Section 3 3 Drive And Caster Wheels illustra tion b Remove the wheel retaining screw 1 from axle assembly Clean threads of screw c Remove retaining washer 2 and shim s 3 d Slide wheel 4 from axle Remove the Drive Motor Cover from under machine see instructions previously outlined in this section of the manual Carefully raise the lift to gain access to the under side of the base frame Refer to Positioning Lift For Access to Components Located Under the Base Frame in Section 2 Locate the clutch assembly on each rear drive axle and check for the following a Checkthe coupling chains for any loose or miss ing parts i e pins links etc replace if neces sary b Check that at least three 3 of the lock tabs on the clutch adjusting nut lock washer are pr
99. RTANT THE SPRING BRACKET MUST BE ALSO LIE COMPLETELY INSIDE THE BRUSH BOX AND NOT OUT OVER THE EDGE THE ROLL END OF THE SPRING MUST BE CENTERED ON THE TOP OF THE BRUSH SEE CORRECT INCORRECT BRUSH INSTALLATION ILLUSTRATION 8 Also apply slight pressure by pulling up on the spring bracket to be certain it is hooked securely around the brush box wall atthe bottom ofthe brush box 9 Screw the brush caps back into the end shield using the largest possible screwdriver 10 Reinstall the drive motor s to the machine and reconnect the power source IMPORTANT NEW BRUSHES MAY BE SEATED BY RUNNING THE DRIVE MOTOR AT NO LOAD PROPER SEATING IS REQUIRED FOR LOWEST BRUSH NOISE LEVEL 3121136 SECTION 3 BASE COMPONENTS 1 Gear Box Cover 2 Cover Screws 3 Wave Washer 4 Bearing 47 x 20 x 14mm 5 Spacer 6 Gear 7 Bearing 47 x 25 x 12mm 9 Drive Shaft 10 Shaft Seal 11 Shaft Key 8 Lip Seal Bearing Retaining Ring 12 Gear amp Pinion 13 Shaft Key 14 Bearing 32 x 12 x 10mm 15 Wave Washer 16 O Ring Figure 3 8 Drive Motor Gear Box Assembly DVL DVSP Gear Box Disassembly Assembly See Figure 3 8 The drive motor gear box is mounted on the rear of each drive motor Transferring power from the electric drive motor to the rear drive wheels the gear box is a right angle worm gear type with a 40 1 reduction drive ratio The internal gears and bearings of the gear box are lubr
100. S Re d ehe rate dix RA MOUSE 1 2 Drive Motor GearBox 1 2 12 gt COMPONENT DATA n son Fac CUP PROC a doa 1 2 Hydraulic Pump Pump Motor 55 lt 1 2 Rear Wheel Drive 5 1 2 Batteries Battery 1 2 1 3 PERFORMANCE xh SLE e DROP Bes NEN 1 2 Platform Capacities piesn end EIE ed Meee lt i e rp E Res e e hub sou Rd E e Sx eR Rea 1 2 Platform S128 ence et ee eA RC UR C t CPI ak D IRR 1 2 Machine Height platform stowed 1 2 Base Footprint ex s sacar ee eb s OS Ra v a acre cae oS 1 2 1 4 TORQUE REQUIREMENTS i23 Ye ore a Eee FUSCE A s SORA Re T qd 1 2 1 5 EUBRIGATION sete och n ER ERU RD CR RD WA eo DRE S 1 3 Hydraulic Oil REN ex Rx halk cae adn eu Res 1 3 Lubrication Hh 1 3 1 6 HYDRAULIC PRESSURE SETTINGS AND ADJ 1 3 Hydraulic Pressure Gauge 1 4 After Filter Pressure 1 4 1 7 CYLINDER SPECIFICATIONS s Rote tt ett qe 1 4
101. Spacer 3 Chain Anchor Plate Assy Note NE NI Chain Anchor Plate Installation Mast Section 1 Shown Cut Away 4 Long Spacer 5 Pin Keeper 6 Keeper Screw a a Apply Loctite 242 to threads 5 16 MAST SECTION 2 ASSEMBLY NOTE When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels 4 Locate mast section 2 carefully slide mast section 2 closed rail into section 1 open rail Slide sections together until ends are even 5 Insert slide pads into the slide pad channels at bot tom end of mast between section 1 and 2 one on each side of the mast with beveled surface facing out towards section 1 0 0 1 Slide Pads 2 Shim Stock 3 Slide Pad Bolts Washers a Note a Apply Loctite 242 to threads Figure 5 7 Mast Bottom End Slide Pad Installation NOTE J LG Lift Typical Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in mast section 2 inside rail into the slide pad inserts Thread in enough to hold pad in place Shim slide pads using the following steps Always use the an even amount of shim material behind slide pads on both sides of the mast rails This will keep mast sections centered in rail chan nels and prevent any distortion of the mast section a Start with a
102. Square or equivalent to Check Note Check with machine resting on a smooth level surface Adding Shims To Correct Alignment 1 Hex Head Screws 3 16Ga 0598 1 5mm Shim s 2 Bearing Mounting Plate 4 Drive Assembly Mount Note Lift Machine Remove Drive Motor Cover and Drive Wheel J LG Lift 3 5 SECTION 3 BASE COMPONENTS 3 5 DRIVE MOTOR ASSEMBLY SERVICING NOTE The following drive motor servicing instructions refer to machines built to both the original design Machines built prior to Serial Number 0130005271 and a new design Machines built since Serial Number 0130005271 The major differ ence between the two designs is the drive motor mounting frame the original is two separate mount ing frames the new design is a one piece frame mount Components on the drive motor assemblies may be ser viced without removing the motor mounting frame assem bly s from the machine if necessary The component parts ofthe left and right drive motor assem blies are identical except for the drive motor mounting frame assembly 3 6 Drive Motor Assembly Removal See Figure 3 2 or Figure 3 3 The DVL DVSP drive motor assemblies are mounted inde pendently of each other on a completely removable drive assembly mounting frame s at the rear of the machine The drive assembly mounting frame is fastened to the base frame at the top and inte
103. TING TABLES Machine in Drive Speed Cut Back Turtle Mode The Time Overview of Procedure Under normal machine operation once the platform is elevated the machine s maximum drive speed is reduced to 1 4 the normal drive speed of when the platform is fully lowered This is detected with a drive speed cut back proximity switch mounted at the base of the mast assembly and a target mounted on the mast assembly When the mast is elevated and the target raised the proximity switch then cuts back the machine drive speed When machine is in the drive speed cut back mode a turtle is displayed on the Ground Control Module LCD display Check For These Obvious Conditions First Mastdrive speed cut back proximity switch and target plate secure and undamaged Both Pot Hole Protection Bar Limit switches secure and undamaged Table 6 5 Machine In Drive Speed Cut Back Turtle Mode All The Time STEP ACTION SPEC YES NO 1 The Pot Hole Protection system bars should be raised when the Check the platform is fully lowered Check if the Pot Hole Protection bars are mechanical Goto Step 2 down when the platform is fully lowered operation of oto Step thePHP System 2 With the platform fully lowered check for continuity on the Cutback Repair orReplace Proximity Switch wires between pins 8 and 18 on the P2 connector Go to Sten 3 Speed Cutback atthe Ground Control Module o to Step Proximity Switch 3
104. The initial lubrication 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 installa tion factory lube must be supplemented by a mainte nance program to provide a film of oil on the chains 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 enn Allowable Stretch Measurement 50 pitch 12 or 24 pitches 24 in 12 in span 625 pitch 15 or24 pitches 30in 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 dis covered replace all chains as seemingly sound plates are on the verge of cracking Fatigue and ultimate strength failures on J LG Lifts are incurred as a result of severe abuse as design specs are well within the rated lift ing capacity of these chains Tight J oints All joints in the leaf chain should flex freely On leaf chain tight join
105. URE RESISTANCE RANGE POSSIBLE Pump Motor 0 2ohm 0 4ohm 77degF 0 120hm 0 490hm Brake Coil 44 7ohm 520hm 68degF 31 40hm 65 30hm Drive Motor Bodine 1 to 30hm Can change depending on the rotation of the armature and temperature N A Table 6 3 Amperage Draw for Various Components COMPONENT AMPERAGE Ground Control M odule 20DVL 95 Amps room temperature with rated load 15DVSP 110 Amps room temperature with rated load Traction Control Module LEVEL SURFACE 15 GRADE 24V RATED LOAD 24V RATED LOAD NOLORD 124 7to 11 Amps 55 to 60 Amps 3 5 to 4 8 Amps per motor per motor 78 to 86 RPM 6 7 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS The following table contains pin extractor tools for DVL Series and DVSP machine electrical connector components Table 6 4 Special Pin Extractor Tools for Electrical Connectors COMPONENT DESCRIPTION J LG PART NUMBER ILLUSTRATION Ground Control Station For removal of electrical connector pins from the Ground Control Station connectors 7016618 Drive Motor Forremoval of electrical connector pins from the Drive Motor main power connectors 7002841 Drive Motor Brake For removal of electrical connector pins from the Drive Motor Brake power connectors 7002842 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING 6 8 FAULT CODE TROUBLESHOO
106. Upper Lower Shell Installation 1 Remove the 4 Phillips Head Screws from the Lower Shell Housing IMPORTANT CAREFULLY SLIDE THE UPPER SHELL HALF FROM THE LOWER SHELL HALF THE COMPONENTS MOUNTED IN THE UPPER SHELL HALF CONNECT TO THE CIRCUIT BOARD IN THE LOWER SHELL HALF Emergency Stop Switch Installation Platform Control Console Circuit Board Connections 1 Connection to Ground Control Module 2 Emergency Stop Wiring Connector 3 External Programming Socket Connector 4 Joystick Ribbon Cable Connector Emergency Stop Switch Installation 1 Emergency Stop Button 2 Seal 3 Square Lock Washer 4 Button Assembly Nut 5 Emergency Stop Switch 6 Switch Release Lock Lever Button Pad Installation Button Pad Installation 1 Button Pad Assembly Attached by adhesive backing 3121136 JLG Lift 4 19 SECTION 4 CONTROL COMPONENTS Joystick Assembly Installation Joystick Calibration Procedure 1 Turn off all power to the platform control module 2 Plug jumper tool J LG Part Number 7024361 into the programming socket under the front of the platform control console This will short pins two 2 and three 3 in the socket S 7 2 1 Programming Socket On Front of Platform Control Module 1 1 2 Pin 2 3 Pin 3 3 Turn the machine power on while holding down the Joystick Installation turtle button on
107. 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 origi nal or one which is equivalent Unless specific torque requirements are given within the text standard torque values should be used on heat treated bolts studs and steel nuts in accordance with recommended shop practices or Torque Chart in Section 1 3121136 SECTION 2 GENERAL Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacles when disconnecting or removing them from the unit This will assure that they are correctly reinstalled Hydraulic System Keep the system clean If evidence of metal or rubber par ticles is found in the hydraulic system drain and flush the entire system Disassemble and reassemble parts on clean work sur face Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assem bly Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart See Sec tion 1 Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricant
108. able 6 27 Code 24 Auxiliary 1 Circuit Short Circuit STEP ACTION SPEC YES NO 1 AttheGround Control Module P1 connector check the voltage Replace Ground across pins 9 and 2 to the horn Is reading within specification 0 2V DC Go to Step 2 Control 2 Removethe wireterminals atthe horn check continuity of each of i Replace the Repair or from pins 9 and 2 onthe P1 connector to the component Component Replace Wiring 3121136 J LG Lift 6 21 SECTION 6 TROUBLESHOOTING Code 25 Auxiliary 1 Circuit Disconnected Check For These Obvious Conditions First 5 machine equipped with a component on the Auxiliary 1 circuit Table 6 28 Code 25 Auxiliary 1 Circuit Disconnected STEP ACTION SPEC YES NO 1 15 machine equipped with acomponenton the Auxiliary 1 circuit Goto Step 3 Gotto Step 2 2 Atthe Ground Control Module enter the programming mode check Replace Ground if the Auxiliary 1 open circuit detection is enabled Default NO Disable It Control Module 3 Check voltage atthe P1 connector on the Ground Control Module Replace Ground between pin 9 and pin 2 Is reading within specification 2 4VDC Control Module Go to Step 4 4 Removethe wire terminals atthe Aux 1 component check conti nuity of each of the wires from pins 9 and 2 onthe P1 connector to Replace the the Aux 1 component Compone
109. acle LE 3121136 SECTION 3 BASE COMPONENTS General Component Installation Notes Cover Installation When removing components make note of the wiring con nections before disconnecting the wiring between the com ponents within the charger assembly Only disconnect enough wiring to remove a component The battery charger manual supplied with the machine con tains a wiring diagram for the charger as well as Figure 3 10 atthe end ofthis section of the manual Battery Charger Installation 1 Disconnect the positive battery cable from the left side battery Carefully raise the lift to gain access to the under side of the base frame Refer to Positioning Lift For Access to Components Located Under the Base Frame in Section 2 Disconnect the wiring connectors from the back of the charger assembly Remove the four 4 capscrews and washers secur ing the charger to the base frame on the front of the charger Swing the front tie down lug up and remove the charger from the machine and place on a suitable work bench for disassembly Battery Charger Remove Install 1 Battery Charger Assembly 2 Charger Capscrews Washers 4 3 Front Tie Down Lug Swing Up 3121136 J LG Lift Battery Charger Cover Remove Install 1 Charger Cover 3 Screws Same on Both Sides 2 Bottom Tray Screws R
110. ains two 2 brushes the brushes are located under the two 2 large round slotted brush caps on the front end of each drive motor Drive Motor Brush Location 3 Protective Rubber Boot shown removed 1 Brush Location 2 Brush Caps A WARNING DISCONNECT THE POWER LEADS FROM THE POWER SOURCE BEFORE INSPECTING OR REPLACING BRUSHES Brush Cleaning and Inspection Brush wear rate varies depending on the individual machine application duty cycle The drive motor brushes should be inspected every 600 hrs or 1 year of operation Brushes should be replaced before they are less than 375 in 9 5mm in length Carbon dust accumulation should be removed periodically If the end shield has been removed from the drive a clean dry non linting cloth can be used for cleaning DO NOT use solvents as they my damage non metallic parts and adversely affect subsequent brush com mutation 3121136 Removal of the brushes also requires the removal of the drive motor s from the machine see procedure described earlier in this section for instructions to remove the drive motors If not already done disconnectthe positive bat tery cable from the left side battery before proceding 1 Remove the clamp and protective rubber boot from the drive motor 2 Unscrew the large round brush caps from each side of the drive motor use as large a screw driver as possible 3 The brushes are retained by constant force roll type
111. and check if the BLACK wire is connected to the posi tive terminal and the WHITE wire is connected to the negative _ Consult Rewire as terminal The Left Motor Power lead is reversed from the Right Factory Necessary Motor lead dueto the reverser harness Reference Figure 6 3 Electrical Diagram DVL DVSP Sheet 1 3121136 J LG Lift 6 39 SECTION 6 TROUBLESHOOTING Machine Won t Drive Straight Overview Of Procedure The following procedure examines the drive motor assembly weldments attaching the drive motors to the base frame Also internal components of the drive motors gear box and a check of the components between the gear box and the drive wheels Check For These Obvious Conditions First Battery voltage 24 volts Fully charge batteries Nothing is lodged between one ofthe wheels and the base frame A caster wheel on the front of the machine is seized up creating resistance Table 6 51 Machine Won t Drive Straight STEP ACTION SPEC YES NO 1 Check for the following onthe drive assembly drive attachment _ Repair Replace Goto Step 2 weldments is bent has broken welds or loose hardware Tighten weldment 2 Checkforthefollowing on the drive assembly drive motor mounting Repair Replace Ta are bent are square with drive weldments oris hardware Tighten weldment Goto Step 3 3 Checkforthefollowing onthe drive a
112. and coated with hydraulic fluid to prevent surface corrosion JLG recommends replacing all seals and o rings when disassembling and reassembling the pump motor unit The motor and motor brushes can be serviced without removing the complete pump motor unit However compo nents on the bottom end of the unit will require removal of the complete pump motor unit See Pump Motor Tank Installation instructions following Inline Hydraulic Filter Installation Pump Motor Tank Assembly Installation 1 Valve Body Extend Line Fitting 3 Extend Line to Lift Cylinder 2 Inline Hydraulic Filter 3121136 Pump Motor Tank Installation IMPORTANT BE CERTAIN THE MAST IS FULLY LOWERED BEFORE REMOVING ANY HYDRAULIC LINES FROM THE PUMP UNIT WEAR PROTECTIVE GEAR WHEN WORKING AROUND PRESSURIZED HYDRAULIC LINES REMOVE CONNECTIONS CAREFULLY AND CAP ALL LINES me re Pump Motor Tank Assembly Installation 1 Pump Motor Tank Assembly 3 Detach and Cap Extend 2 Attach Screws Washers and Return Lines Note See Figure 4 2 for wiring connection instructions JLG Lift 4 21 SECTION 4 CONTROL COMPONENTS Motor Cap Motor Installation Motor Brush Installation o Motor Cap Installation 1 Cap Assembly Screws 2 Cap Assembly Brush Housing Installation 1 Brush Housing 2 Brush Housing Screws 3 Mark Front of Mot
113. and pump internal valves be checked to see if any are stuck open it also examines the lift down and dump valve circuits Also suggests that the lift cylinder packing could be leaking internally Check For These Obvious Conditions First Manual descent valve is closed tight Table 6 44 Platform Mast Won t Stay Elevated STEP ACTION SPEC YES NO 7 i 1 stheliftdown valve stuck open _ Repair or Clean Goto Step2 Valve 2 Liftdown valves could be open due to incorrectelectrical signal Check Pump Valve Electrical Goto Step 3 Circuit 3 Oilcould be passing around the lift cylinder bore packing Replace or Rebuild the Lift Cylinder Platform Mast Descends Too Slowly Overview Of Procedure The following procedure examines the mast some hydraulic components for obstructions and defects Table 6 45 Platform Mast Descends Too Slowly STEP ACTION SPEC YES NO 1 Check mastslide pads shimmed to tight Reshim Mast Go to Step2 ioni 2 15 there an obstruction in the mast _ Remove Goto Step3 Obstruction 3 Theliftcylinder packing could be too tightin the bore of the cylinder Rebuild or Goto Sten 4 barrel Replace Cylinder 4 Checkiftheliftdown valve is opening completely _ Clean or Replace Goto Step5 Valve ET 5 Istherearestricted hydraulic line smashed _ Replace Hydrau Go to Step6 lic Line 6 Check the flow valve in the cyl
114. ation Battery Installation Alarm Installation 1 Battery 4 J Hook Hold Down Rod 2 Wing Nut Washer 5 Battery Tray 1 Alarm Assembly 2 Attach Screws Washers 3 Cross Bar Note See Figure 4 2 for wiring connection instructions Note See Figure 4 2 for wiring connection instructions Installation same for either side battery Horn Installation he Horn Installation 1 Horn Assembly 2 Attach Screws Washers Note See Figure 4 2 for wiring connection instructions 4 4 J LG Lift 3121136 SECTION 4 CONTROL COMPONENTS Battery Installation EE Spec Machines Only Battery Installation UL EE Only 4 Hold Down Bolt Washer Nut 5 Hold Down Bar 1 Box Cover 2 Battery 3 Box Assembly Note See Figure 4 2 for wiring connection instructions Master Disconnect Switch EE Spec Machines Only Installation same for either side battery Fuse Box EE Spec Machines Only Hn Fuse Box Installation UL EE Only 3 Fuse Box Cover 4 Cover Mounting Screws 1 Fuse Box 2 Fuse Note See Figure 4 2 for wiring connection instructions 3121136 JLG Lift Master Disconnect Switch Installation UL EE Only 1 Switch Lever 5 Switch 2 Mounting Nut 6 Pos
115. avy 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 ade quate supportis provided A WARNING SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON TROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER OPERATOR 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 dis connecting 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 compo nents can then be disconnected with minimal fluid loss 3121136 J LG Lift 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 CAU TION 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 OVER H
116. base assembly allowing the top of mast section 2 to t JI be completely exposed Fa W NO AR mW m LJ Cylinder Rod Pin Installation 1 Cylinder Rod Pin 3 Cyl Chain Anchor Block 2 Cylinder Rod Exposing Top of Mast Section 2 1 Sections 3 4 and 5 Pushed Back 2 Top of Mast Section 2 Exposed JLG Lift 3121136 SECTION 5 MAST COMPONENTS 11 Atthe bottom of mast section 1 remove the cylinder mount bolts and mount reinforcement plates Lift Cylinder Mount Installation 1 Cylinder Mount Assembly 3 Washers 2 Reinforcement Plate 4 Mount Mounting Screws a Notes a Apply Loctite 242 to threads at final assembly 12 Slide the cylinder and mount assembly out of the bottom of mast section 1 and 2 and place on a suit able work surface Cylinder Installation 1 Lift Cylinder and Cylinder Mount Assembly 2 Mount Shims Mark Shim Packs for Reinstallation 3121136 Cylinder Disassembly See Figure 5 4 1 Before disassembling the cylinder clean away all dirt and foreign substances from openings particu larly the head area NOTE Always protect the chrome surface of the cylinder rod during assembly and disassembly Any damage to this surface will require replacement of the rod 2 Extend the rod until the piston bottoms out against the cylinder head
117. ble 6 3 lthru5 RO SUE 6 Checkthedrive motor brushes do they need replaced Replace per procedureinthis Goto Step 7 Service Manual 7 Inside the drive motor gear box check if the drive shaftis exces Repair Replace gear box sively loose amp condition of drive shaft bearings components per procedure in this Are any gears broken or gear teeth excessively worn Service Manual 3121136 J LG Lift 6 41 SECTION 6 TROUBLESHOOTING PROGRAMMABLE _ GROSND SECURITY PUMP C 2 CONTROL LOCK MOTOR Sf STATION OPTION MASTER SWITCH UL EE OPTION BATTERIES AUX1 2597 OUTPUT amp gt POWER AUX 2 LEFT DRIVE MOTOR HARNESS REVERSER BEACON LIGHT MAST OPTION BEACON LIGHT BASE DVSP Figure 6 2 Overview of Electrical System Components DVL DVSP Sheet 1 of 2 6 42 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING BATTERY S BATTERY L E D LIGHT BATTERY CHARGER RECEPTACLE SPARE 94 ANALOGUE PLATFORM INHIBITS LIFT DRIVE ACCESSORY RECEPTACLE JUNCTION BOX S SPEED T ET CUTOUT Lu SWITCH SWITCH 22 OPTION PLATFORM OX CONSOLE S OBSTRUCTION ELECTRONICS BOX OPTION OBSTRUCTION SENSORS Figure 6 2 Overview of Electrical System Components DVL DVSP Sheet 2 of 2 3121136 J LG Lift SECTION 6 TROUBLESHOOTING BLACK
118. c 08 0010 Orc ooz 09c OOELZ 0 OL Occ 009ScC 99 081 Orc 000 c 06L OEL 0 1 00891 09920 08290 8L oLz 009 Orc 08L 011 Occ 0S 0c GOL GEL OSL 09 0 LL GOL 00 0c 06L YSL OEL 04L 09581 GEL 601 06 OcL 09651 0 0c 0 Gz960 8L 91 6 GGL 00681 GOL 6 L OSL 00791 OcL 96 08 OLL 009 02810 SL 06691 GEL 80 06 0 OOL 08 99 06 00101 66S1 0 00080 0 2 OLL 06LvL OcL 96 08 OLL 09451 98 89 GS GL 0906 6LvLO L GL 0 8LL 06 OL 09 08 OOZOL 09 0S Or SG OSSZ 48170 5 60 0 OL 0 901 08 9 GS OL 0996 99 Gv Ge 0S 0089 90L 0 vL 05 08 8 SG Sp SE 05 0062 OF ze Gz St 0095 8 800 oseo ge Gv 09 4 0S Ov 9 Sv 0004 Ge 8c ec 0 Or6v 92200 9L 1 0089 0 9 0 9 0 9 LZ ZL vL 6L 007 08900 SZLe0 vc 91 9 GZ Oves 0 cc SZ Ozzy 6 9L L X 0755 00 14 91 13 91 13 91 13 81 14 91 13 81 14 91 1491 vL 079 981 0 891 086 GEL 98 0655 7950 0 00520 8c vl L 0815 091 801 vvL 0982 SOL SZ 96 0 0 81800 0 LG 89 008 9 6v sez 000800 7 Sp 09 0891 ce ev OcLL 09 100 ce ev OZEL LE 076 7197100 OP9L O 9 g Le LY 091 0 006 oor LOO ce 6L Sc 026 L SL 0 9 SLOLOO 080 Or 9 LL ec 08 OL 08S 606000 ce mE mE OL L 009 Z 6 ocr 19900 0 8r b E 6
119. ce for the individual mast section covers Adjust using the following procedure 1 With mast retracted step into the platform and bounce your weight up and down a few times to be certain platform is at the bottom of travel Be certain all chain cable sets are seated in their sheaves prop erly at the top of each mast section Then with no load in the platform check the side pro file of the top of the mast for the amount of adjust ment necessary to obtain the 7 16 in 12mm step for mastsections 3 and up See Illustration Mast section 1 is fixed to the base and mast section 2 is attached to the lift cylinder these sections require no adjustment Adjust one mast section at a time starting from the back section 3 section 4 etc of the mast and work forward i e if three is OK then jump to four etc To adjust elevate the platform until the chain cable anchor adjust nuts are accessible at the front and bottom of each mast section WARNING NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCK ING OR OVERHEAD SLING 5 5 2 Start with the mast section which needs adjustment and loosen the bottom jam nut on each chain cable NOTE 10 Tighten to raise mast section or loosen to lower mast section the adjusting nut against the anchor plate on each chain cable Adjust the nut the amount required to raise or lower the top of
120. cedure The following procedure examines the drive motor assembly weldments attaching the drive motors to the base frame Also internal components of the drive motors gear box and a check of the components between the gear box and the drive wheels Check For These Obvious Conditions First Battery voltage 24 volts Fully charge batteries Nothing is lodged between one ofthe wheels and the base frame A caster wheel on the front of the machine is seized up creating resistance Table 6 52 Noise from Drive Assembly STEP ACTION SPEC YES NO 1 Check for the following onthe drive assembly drive attachment _ Repair Replace Go to Step 2 weldment is bent has broken welds or loose hardware Tighten weldment 2 Checkforthefollowing onthedrive assembly drive motor mounting Repai mdr _ pair Replace ds are bent are square with drive weldments oris hardware Tighten weldment Go to Step 3 3 Check forthe following onthe drive assembly drive motor hard Repair Replace ware is hardware loose flange bearing bad loose slip clutch Tighten Go to Step 4 check torque settings or adjustment Component 4 Checkthe left and right drive motor brakes for loose hardware amp not Tighten orAdjust releasing properly _ GotoStep5 inthis Service Manual 5 15 theelectrical signal and amperage draw to the drive motors Recheck Steps equal Check with machine on level surface See Ta
121. ch 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 conditions and depend ing on the location and use ofthe machine 3121136 J LG Lift 2 3 SECTION 2 GENERAL Table 2 2 DVL DVSP Preventive Maintenance amp Inspection Schedule INTERVAL AREA ON MACHINE PRE START a 3 MONTH 6 MONTH PRE DELIVERY b ANNUAL d INSPECTION PREVENTATIVE PREVENTATIVE OR FREQUENT c YEARLY MAINTENANCE MAINTENANCE INSPECTION INSPECTION MAST ASSEMBLY 7 MastSections 2 5 2 5 Chain Systems 14 3 14 14 25 Sequence Cable Systems 3 1 2 3 Covers or Shields 1 Sheave Systems 1 2 12 Bearings 1 2 Slide Pads 1 2 PLATFORM ASSEMBLY 7 Platform 1 1 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 Anchorage Point 1 4 1 4 CHASSIS ASSEMBLY 7 PotHole Protection System 5 5 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 2 2 Gear BoxAssembly Drive Motor Brushes 2 20 Torque Limit Clutch 1 7 3 Brake Release 5 5 FUNCTIONS CONTROLS 7 Platform Contr
122. ck from sequencing cable The springs should not be compressed more than 25 after adjusting Run mast through several cycles to verify cable chain adjustments and ensure no interference exists between chain anchor brackets and mast 3121136 SECTION 5 MAST COMPONENTS Ue 7 ere B m 7 Check Mast Stowed Height 10 Chain Lock Nut 11 Threaded Chain End 1 Sequence Cable Adjust Nut 4 Mast Section 3 2 MastSection 1 5 MastSection 4 6 MastSection 5 8 Chain Anchor Plate 9 Chain Adjust Nut 3 Mast Section 2 Figure 5 2 DVL DVSP Mast Chain and Sequence Cable Adjustment Components J LG Lift 3121136 5 3 SECTION 5 MAST COMPONENTS 5 3 SEQUENCE CABLE REPLACEMENT KIT A sequence cable replacement
123. ction Rebuild Hydraulic oil level in reservoir tank at full level Hydraulic oil is not milky presence of water or foamy full of air Table 6 42 Platform Lift Up and Down J erky STEP ACTION SPEC YES NO CONTROLS ELECTRICAL 1 15 platform control console platform enable up or down pad defec _ Replace pad Go to Step2 2 Looseconnections ground and power _ Repair Goto Step 3 connection 3 Valvesolenoid keeps opening and closing Repair Connec tion or Replace Goto Step 4 Valve 4 Problem internal to the Ground Control Module Replace Module Goto Step5 HYDRAULIC 5 Isthehydraulic valve working properly Go to Step 6 Replace Valve Pump drive cavatating Replace Pump Goto Step 7 7 Liftcylinder _ Rebuild or Replace Cylinder 3121136 J LG Lift 6 33 SECTION 6 TROUBLESHOOTING Mast Noisy When Lifting And Lowering Overview Of Procedure This procedure examines components of the mast itself and as well as it s lifting components for dirt debris proper lubrica tion and operation Table 6 43 Mast Noisy when Lifting and Lowering STEP ACTION SPEC YES NO 1 Doslidepads and slide pad channels needto be cleaned of dust _ Clean Pads and Goto Step 2 dirt orother debris Channels 2 Domastchains need to belubricated LG specification in the Lubricate as Got
124. dL Service amp Maintenance Manual Model s DVL amp DVSP Series P N 3121136 September 27 2005 JG INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS MAINTENANCE SAFETY PRECAUTIONS A GENERAL C MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial WARNING platform It is of utmost importance that maintenance per FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN sonnel pay strict attention to these warnings and precau THIS SECTION COULD RESULT IN MACHINE DAMAGE PERSON tions to avoid possible injury to themselves or others or NEL INJ URY OR DEATH AND IS A SAFETY VIOLATION 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 WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA TION 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 he
125. disconnected at both ends check for RepairorReplace continuity between Pins 2 3 and 4 ofthe P5 connector end a tea Goto Step 4 4 Plug the communications cable on the Traction Control Module to the round socketon the opposite end of the module Does this fix Done ea Peya problem 5 Unplug the P5 connector atthe Ground Control Module Check volt Replace Ground age between pins 2 lead in and 5 lead in Is voltage within 4 5vDC Done Control Module spec 6 24 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING Code 31 Platform Control Console No Communication with Ground Control Module Check For These Obvious Conditions First Check the harness connection at the P4 connector on the Ground Control Module and the harness connection at the other end on the Platform J unction Box Table 6 32 Code 31 Platform Control Console No Communication with Ground Control Module STEP ACTION SPEC YES NO 1 CheckifLEDs are illuminated on the Platform Control Console Go To Step 2 Go to Step 3 2 Removethe 9 pin Platform Control Console connector from the side RepairorReplace ofthe Platform J unction Box and the P4 connector atthe Ground _ Platform Control RepairorReplace Control Module Check continuity from the P4 connector pin 5 to C Wiring J unction Box pin 3 and P4 pin 9 to J unction Box pin 4 anaes 3 Removethe9 pin Platform Control Console connector from the side Repa
126. e Battery Charger Cover Installation item 4 with retaining screw torqued Caster Wheels Installation 4 DN ES L d 1 Caster Wheel Assembly 3 Caster Shim b 2 Hex Head Screw Flat Washer a Note a On assembly apply Loctite 242 to threads b As required Place unit on a flat surface shim a caster Note a Standard on DVSP Option on DVL Series wheel that is more than 015 off of flat surface 1 Battery Charger Cover 3 Hex Head Screws Washers 2 CapScrews Washers 4 Base Mounted Beacon 3 2 J LG Lift 3121136 SECTION 3 BASE COMPONENTS Wheel Retention for Rough Terrain Drive Wheel Option 1 The rought terrain drive wheel is installed same as the regular drive wheel except place the wheel onto drive motor shaft ensuring that the deepest point of the rim 5 8 as shown below is facing out Failure to do so will result in the drive wheel rubbing the drive motor cover Note Do not forget to replace shim s 005 min Gap is critical between retaining washer and wheel hub 2 Replace shims and the retaining washer 3 Apply Loctite 242 onto retaining screw and install with a torque rating of 35 ft Ib IMPORTANT FAILURE TO APPLY LOCTITE 242 TO THE RETAINING SCREW AND TORQUING THE RETAINING SCREW TO 35 FT LB MAY RESULT IN THE WHEEL COMI
127. e Connector Tabs Push tabs away from connector to release cable then slide cable out of connector Note Connector works same at both ends of the ribbon cable Wy 27 Disconnect the Ribbon Cable 1 Ribbon Cable Connector 3 Support for Cover Reconnecting Ribbon Cable 1 Ribbon Cable Connector Release Tabs Slide cable into connector then push tabs back into connector Note Connector same at both ends of the ribbon cable 2 Ribbon Cable 4 8 JLG Lift 3121136 SECTION 4 CONTROL COMPONENTS Power Selector EStop Switch Installation Emergency Stop Switch Installation 1 Emergency Stop Button 4 Nut 2 Button Seal 5 Emergency Stop Switch 3 Square Lock Washer 6 Switch Lock Release Lever Note Tighten nut enough to keep button from turning Reattach wires to same terminals on new switch Note To release switch connectors push tab on top of connector Power Selector EStop Switch Connectors Location 1 LCD and Button Circuit Board 2 Emergency Stop Switch Connector 3 Main Power Selector Switch Connector Power Selector Switch Installation 1 Nut 2 Power Selector Switch 3 Align and inserttab on switch into slot on cover Note Reattach wires to the same terminals on new switch
128. e Motor Brake Removal and Adjustment A brake assembly is mounted to the front of each drive motor housing The brakes are ENGAGED brakes on when the machine is parked and are RELEASED electrically brakes off when the joystick is enabled and pushed in any direction The brakes can also be RELEASED electrically using the manual brake release button on the ground con trol station NOTE The brakes are intended only as parking brakes to keep the machine from moving while at rest The brakes are not used to stop the machine during driv ing operations this braking is controlled by the drive motors themselves Under normal driving conditions once released the brakes are not engaged again until the machine comes to a complete stop Drive Motor Brake Location 1 Drive Motor Brake 3 Boot Assembly Shown Cutaway 2 Motor Brake Power Cable from Traction Control Module 3121136 J LG Lift 3 11 SECTION 3 BASE COMPONENTS Brake Operation See Figure 3 7 When the magnetic coil is not energized brake on the armature plate is pushed away from the magnetic coil sur face by heavy springs internally mounted in the magnetic coil housing This pressure forces the armature plate against the friction brake disk holding it tight between the armature plate and the mounting plate The friction brake pad is mated to the drive motor armature shaft The brake is not released until the magnetic coil is energized pulli
129. eads in M1 Replace Traction connector wiring harness going to the leftdrive motor brakeassem SeeTable6 2 Go to Step 2 bly Is reading within spec 2 Repairorreplace left brake wiring or left brake assembly Code 10 Right Brake Disconnected Check For These Obvious Conditions First Check right drive motor M2 connector atthe Traction Control Module for secure and proper connection Table 6 13 Code 10 Right Brake Disconnected STEP ACTION SPEC YES NO 1 Check resistance across positive and negative leads in M2 Replace Traction connector wiring harness going to the right drive motor brake See Table6 2 Go to Step 2 assembly Is reading within spec 2 Repair orreplace right brake wiring or right brake assembly 3121136 J LG Lift 6 15 SECTION 6 TROUBLESHOOTING p Code 11 Left Drive Motor Short Circuit Check For These Obvious Conditions First Wiring harness from M1 connector on Traction Control Module to Left Drive Motor for damage Table 6 14 Code 11 Left Drive Motor Short Circuit STEP ACTION SPEC YES NO 1 RemovetheM1 connector from the Traction Control Module and This circuit check both the pins to the drive motor for any voltage No Voltage shouldbe Go to Step 2 Ground the meter to the Ground Control Module Negative lug isolated Repair 2 Check for continuity of both the pins to ground orReplace Replace No Ground Comp
130. eads on each chain Chains will be adjusted later in assembly 6 Slide mast section 5 back into mast section 4 until bottom ends of masts are even Check to make sure chain set attached to top of section 3 is seating properly in cable sheave wheels attached to top of mast section 4 Mast section 3 may need to be restrained to keep it s slide pads from pushing out the bottom of mast sections 2 7 Atbottom of mast assembly thread all chain adjust ing nuts on threaded ends until they are snug against the bottom anchor plates and all slack is removed from chains Check that chains are seated in their sheave wheels at top of mast assembly 8 Do notassemble the mini covers to the top of mast sections until the mast chains have been adjusted properly 9 Attach the lanyard attach assembly to the side of mast section 5 10 Attach the sequencing cables and hardware to the sides of the mast assembly 11 Install the mast chain guard to the top mast section 5 The mast assembly is now ready to install on the machines base frame Sequence Cable Bracket Installation Bottom End 3121136 J LG Lift 5 23 SECTION 5 MAST COMPONENTS 5 7 DVSP STOCKPICKER PLATFORM INSTALLATION 1 MastPlatform Header Section 3 Washers
131. ear set into the gear box Install the seal so it is even with the bottom of 6 the chamfer in the drive shaft hole on the outside of the housing and flush with the bearing seat on the inside of the housing 2 Lube the drive shaft seal with a thin film of oil before sliding the drive shaft over the seal 7 3 Position the gear box with open cover side up allow space under the gear box for the drive shaft to extend through without obstruction 4 Hold the gear and pinion and drive shaft assemblies 8 together with the pinion gear and the ring gear on the drive shaft meshing Now carefully slide these assemblies into the gear box housing sliding the drive shaft through the drive shaft lip seal 9 NOTE While assembling the gear assemblies into the gear 10 box housing be careful with the drive shaft seal and the softer brass worm gear and brass drive worm 11 gear from the drive motor 5 Continue to drop the gear assemblies into the gear 12 box align the bearings with the bearing seats in the housing on both assemblies Drop the gear and pin ion smaller bearing into it s seat first while wiggling that gear set align the drive shaft bearing and wiggle it into it s seat When both are seated continue to next step With the gear box still positioned with the open cover side up fill the gear box with six 6 ounces U S 175cc s of good quality worm gear oil Spec ification SAE 90 weight AGMA 5 EP Com pounded When
132. ected RIGHT BRAKE s 10 6 gt k gt DISCONNECTED 4 DRIVE Lift UP DOWN x e ne X 00000 0 410 410 Disabled er Left Drive Motor LEFT MOTOR m 11 6 numm lt gt lt gt SHORTED Short Circuit ons pu X 00000 0 11 11 DRIVE Disabled d RightDrive Motor RIGHT MOTOR 12 6 E lt gt lt gt SHORTED mos Short Circuit a X 00000 0 1 12 DRIVE Disabled oe m zy Traction Module See Table 6 16 13 6 gt IN FOLD BACK In Fold Back Page6 16 X 00000 0 413 413 DRIVE Disabled age PUMP MOTOR Pump Motor Disconnect Table 6 17 14 7 a lt gt DISCONNECTED a TUR nested P S an X 00000 0 14 14 LiftDown Valve 4 DOUN VALVE 4 SeeTable 6 18 15 7 24 lt gt DISCONNECTED 4 Disconnected Page6 17 X 00000 0 15 15 LiftUP DOWN Disabled p Down Valve or Down Valve See Table 6 19 16 7 SHORT 4 CircuitShort Page 6 18 X 000000 16 16 LiftUP DOWN Disabled 9 Ground Control Module GROUND MODULE E 17 7 Ei lt gt IN FOLD BACK In Fold Back X 00000 0 17 e Machine Stopped 9 ALARM SHORT Alarm or See Table 6 21 18 25 sae X 000000 418 418 Alarm Circuit Short 6 18 ALARM DISCONNECTED x 19 E gt Alarm Disconnected Ee Ti X 00000 0 419 419 age 6 BERCON SHORT Beaconor SeeTable 6 23 20 E re Beacon CircuitShort 6 19 X 00000 0 20 420 BEACON DISCONNECTED a 21 Beacon Disconnected X 00000 0 21 21 Agee 22 BE Horn orHorn Circui
133. ection 2 until ends are even Check to make sure chain assembly wide chains are seating properly in chain anchor block chain sheave wheels attached to mast section 2 5 20 MAST SECTION 4 ASSEMBLY NOTE 39 40 NOTE 41 42 43 44 45 46 47 J LG Lift When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 4 into section 3 until ends are even Insert slide pads into the top end mast rails between section 2 and 3 one on each side of the mast with beveled surface facing inward towards section 3 Same as Figure 5 8 Before fastening and shimming the slide pad on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in outside rail on top of mast section 2 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Insert slide pads into the bottom end mast rails between section 2 and 3 one on each side of the mast with beveled surface facing out towards sec tion 2 Same as Figure 5 7 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes
134. emoval Optional AC Line Fuse Installation AC Line Fuse Remove Install 1 Fuse 3 Back of Charger 2 Cap Screw Lock Washer Nut SECTION 3 BASE COMPONENTS Interlock Relay Installation Shunt Assembly Installation Interlock Relay Remove Install 1 Interlock Relay 3 Back of Charger 2 Attach Screws 2 Shunt Assembly Remove Install 1 Shunt Assembly 3 Spacers 2 2 Cap Screws 2 Wet VRLA Switch Installation SCR Rectifier Installation Either Side Wet VRLA Switch Remove Install 1 Wet VRLA Switch 2 Back of Charger SCR Rectifier Remove Install Same Mounting on Both Sides 1 SCR Rectifier 3 Aluminum Mount Plate 2 Nut Lock Washer J LG Lift 3121136 SECTION 3 BASE COMPONENTS Transformer Installation DC Circuit Breaker Voltage Select Switch Installation 1 p TS K 240 uL 1 im D fm eu Teu D REN F CD 7 1 p j DLO C Bde N o 1 DC Circuit Breaker Voltage Select Switch Remove Install ll 1 DC Circuit Breaker 3 DC Circuit Breaker 2 a 2 120 240 Voltage Selector Switch Transformer Remove Install 1 Transformer 2 Capscrews Nuts Washers 4
135. ensor check see Section 4 9 9 SSS J 555 22220 00000 00000 00000 00000 f 00007 266 M n ul 00000 00000 00000 C0000 00000 00000 t NNN SOSS NS S9900 Transducer Sensor Locations 1 Transducer Sensors 1 through 6 2 Underside of DVSP Platform 3121136 JLG Lift 4 27 SECTION 4 CONTROL COMPONENTS OSS Component Installation IMPORTANT THE FOLLOWING ILLUSTRATIONS PROVIDE KEY INSTALLATION INSTRUCTIONS FOR THE OSS TO OPERATE PROPERLY The OSS Control Module must be electrically isolated from the mast see installation instructions The sensor shield tubes attached to the platform s under sides must be properly installed and undam aged to prevent sensor detection of objects outside the platform parameter The area under the platform floor must be free of any objects or debris dangling from beneath the platform to avoid false detection by the sensors DO NOT allow high pressure spray to directly contact the transducer sensor circular membrane this will damage the sensor OSS Control Module
136. ese Obvious Conditions First s machine equipped with an Obstruction Sensor System Are the electrical harness connectors from the OSS Module through the Platform J unction Box to the Ground Control Module tight and undamaged Table 6 35 Code 40 OSS No Communication with Ground Control Module STEP ACTION SPEC YES NO 1 15 machine equipped with an OSS system Gotto Step 4 Goto Step2 2 AttheGround Control Module enter programming mode and view if OSS is enabled Is OSS enabled X No Go to Step 3 NAE 3 In Service Level Programming mode Disable Obstruction Senor System X No 4 With machine powered up check ifthe RED LED is liton the frontof the OSS Module Go to Step 5 Goto Step 10 5 Checkcontinuity from pin 9 onthe OSS module 9 pin connector Inspect Wiring tothe platform junction box pin 2 4 pin connector Go To Step 6 and Harness Connectors 6 Check continuity from platform junction box pin 2 4 pin connec Inspect Wiring tor to the Ground Control Module P 4 connector pin 7 Go to Step 7 and Harness Connectors 7 Check continuity from pin 9 on OSS module 9 pin connector to Inspect the Ground Control Module P 4 connector 7 Connection atthe Go to Step 8 PI atform J unc tion Box 8 Program the Ground Control Module to Disable the OSS System Replace the Does faultcondition still appear Ground Control Go to Step 9 Modu
137. eters of various machine components This Level can adjust all programmable settings Level 2 Service and Maintenance Settings allow modifi cation to machine personality settings such as lift speeds drive speeds as well as various switch polarity settings also enable various optional equipment if installed This level can also adjust Level 3 settings Level 3 Operator Settings allow the direct user to modify a few settings such as the language setting of text output to the Ground Control Module LCD screen setting machine Sleep time and enabling the detection of the horn and bea con components 4 10 J LG Lift Activating Programming Mode Joe ques Activating Programming Mode 1 With machine power off press and hold the Brake Release Button 1 on the Ground Control Module 2 While holding the Brake Release Button in power machine up by turning the Main Power Selector Switch 2 to either the Ground Control or Platform Control Mode 3 Release the Brake Release Button 1 after machine is powered up The LCD display should now display five zeros one with a box around Continue to next step Entering Password NOTE If machine did not power up check that both the Ground Control Module Emergency Stop Button and the Platform Control Console Emergency Stop Button are in the RESET position Also if machine is equipped with the PSL Program mable Security Lock option
138. f machine is on a tilt of more than 1 5 in either or both the X or Y direction this is normal operation DRIVE and LIFT UP are disabled when tilt is detected Check if Ground Control Module is mounted securely to the mast support column Table 6 9 Code 04 Tilt Condition STEP ACTION SPEC YES NO 1 Using a digital level check the actual level of the machines resting 15 Dri E uri rive Machine to surfacein both the Xandthe Y directions Does surface check within Xand Y Direction Go to Step 2 Level Surface machine specification 2 AttheGround Control Module enter the programming mode See Ground Control Programming Section 3 of Service Manual and l5 Replace Ground Goto Step3 checkthetiltsensor X and Y readings Are readings within machine Xand Y Direction Control Module specification 3 ZeroTiltSensorona surface checked to within 0 0 degrees with a digital level in both the X and Y directions See Ground Control Pro gramming Section 3 of Service Manual NOTE If frequent calibration of the internal Tilt Sensor is required replace the Ground Control Module Code 05 Reserved d Code 06 Reserved Code 07 Left Drive Motor Disconnected Check For These Obvious Conditions First Check left drive motor M1 connector atthe Traction Control Module for secure and proper connection Table 6 10 Code 07 Left Drive Motor Disconnected STE
139. fety Publications Incorporated 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 Testof All Systems 22 22 Paintand Appearance 7 7 Stamp Inspection Date on Frame 22 22 Change only when serviced requires 6 oz 175cc s to fill Ifthe liftis moved via fork truck regular orfrequentbasis then the torque setting 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 Inspection and Maintenance Codes 16 1 Check for proper and secure installation 2 Visual inspection for damage cracks distortion or 18 19 Fully charged 3 Check for proper adjustment 20 4 Check for cracked or broken welds 21 Verify 5 Operates properly 22 Perform 6 Returns to neutral or off position when released 23 Sealed properly 7 Clean and free of debris 24 8 Interlocks function properly 25 9 Check for signs of leakage 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 3121136 17 No gouges excessive wear or cords showing Properly inflated and seated around rim Proper and authorized compone
140. gston G71 5PH Scotland Phone 44 1 698 811005 Fax 44 1 698 811055 JLG Industries UK Unit 12 Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 25 England Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industries Pty Ltd Unit 1 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone 27 11 453 1334 Fax 27 11 453 1342 JLG Deutschland GmbH Max Planck Strasse 21 D 27721 Ritterhude Ihlpohl Bei Bremen Germany Phone 49 421 693 500 Fax 49 421 693 5035 JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47 6682 2001 Plataformas Elevadoras JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755Castellbisbal Spain Phone 34 93 77 24700 Fax 34 93 77 11762 JLG Industries Italia Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 02 9359 5210 Fax 39 02 9359 5845 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 200 JLG Industries Sweden Enkopingsvagen 150 Box 704 SE 175 27 Jarfalla Sweden Phone 46 8 506 59500 Fax 46 8 506 59534
141. he Positive Negative cables from the Ground Control Module to the Pump Motor studs for loose or cor roded connections Table 6 17 Code 14 Pump Motor Disconnected STEP ACTION SPEC YES NO 1 Check resistance across the positive and negative studs on RepairorReplace the pump motor SeeTable 6 2 Pump Motoror Control Module Motor Brushes Code 15 Lift Down Valve Disconnected Check For These Obvious Conditions First Inspect wire terminals on the lift down valve at the base of the lift cylinder for tight and secure connection Table 6 18 Code 15 Lift Down Valve Disconnected STEP ACTION SPEC YES NO 1 Check voltage atthe P1 connector on the Ground Control Module Replace Ground between pin 10 and pin 3 Is reading within spec 2 4VDC Control Module Go to Step 2 2 Check resistance between the terminals on the lift down valve RepairorReplace Replacethe located atthe base ofthe liftcylinder Is reading within spec Wiring Harness 24 5 Ohms LiftDown Valve from Ground Solenoid Control M odule 3 With the terminals still removed from the lift down valve coil check continuity ofthe wires from pins 10 and 3 1 connector to the 00 Ohms E E liftdown valve 9 3121136 JLG Lift 6 17 SECTION 6 TROUBLESHOOTING Code 16 Lift Down Valve Short Circuit Check For These Obvious Conditions First Damaged wiring in
142. he base end remove and cap the extend and return hydraulic lines Hydraulic Extend and Return Lines 1 Cylinder Return Line 3 Cylinder Valve Block 2 Cylinder Extend Line 4 Drive Motor Assemblies Remove the mini covers from the tops of the mast sections Manually extend the mast assembly until the top of mast section 2 is extended approximately one 1 foot 31cm to allow access to the sheave wheel anchor block atthe top of mast section 2 and the lift cylinder Extending Mast Sections 1 Mast Section 2 2 1ft 31cm Extended 5 7 SECTION 5 MAST COMPONENTS 7 Remove the adjust and lock nuts from the chain 9 Remove the cylinder anchor block attach pin snap studs at the bottom of mast section 3 ring from the back of the top of mast section 2 EST Aaw NH Snap Ring Installation 1 Back of Mast Section 2 3 Pin and Snap Ring Chain Assembly Bottom of Mast Section 3 2 Cyl Chain Anchor Block 4 Cylinder Rod 1 MastSection 4 4 Adjust Nut 2 Mast Section 3 5 Lock Nut b 10 Remove the cylinder rod pin from the cylinder chain 3 Chain Assembly Stud a anchor block Note a Remove nuts and push studs through anchor plate 8 Push mast sections 3 4 and 5 back towards the W U4 Jj
143. he prior Annual Machine Inspection J LG Industries Inc recog nizes a qualified J LG equipment mechanic as a person who has successfully completed the J LG Service Training School for the subject J LG product model Reference the machine Service and Maintenance Manual and appropri ate J LG inspection form for performance of this inspec tion Reference the J LG 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 man ual for servicing and maintenance procedures For the purpose of receiving safety related bulletins it is importantthat J LG Industries Inc has updated ownership information for each machine When performing each Annual Machine Inspection notify J LG Industries Inc of the current machine ownership Preventative Maintenance The Pre Delivery Inspection and Frequent Inspection shall be performed by a qualified J LG equipment mechanic J LG Industries Inc recognizes a qualified J LG equipment mechanic as a person who by possession of a recog nized degree certificate extensive knowledge training or experience has successfully demonstrated the ability and proficiency to service repair and maintain the subject J LG product model The Pre Delivery Inspection and Frequent Inspection pro cedures are performed in the same manner but at differ ent t
144. housing is installed look into the motor housing from the opposite end to check that the positive post wires and static winding wires are positioned not to block the holes for the motor mounting bolts and are properly posi tioned around the motor housing After final assembly of the brush housing check that all brush terminal screws are tight and the brush springs are positioned properly before mounting the motor to the pump motor end head Brush Final Positioning IMPORTANT ONCE THE ROTOR ASSEMBLY IS IN PLACE REMEMBER TO PUSH EACH BRUSH DOWN UNTIL THE BRUSH FACE IS IN CON TACT WITH THE COMMUTATOR ON THE ROTOR SHAFT AND THE BRUSH SPRING IS PUSHING DOWN ON TOP OF THE BRUSH 3121136 JLG Lift 4 23 SECTION 4 CONTROL COMPONENTS Tank Installation Tank Installation 1 Tank Assembly 3 O Ring Seal 2 Tank Screws 4 4 Use Screwdriver to pry tank Pump O Ring Installation away from pump head 1 Pump Assembly 2 O Ring Seal 3 O Ring Seal Pump Installation Filter Screen Installation Filter Screen Installation Pump Installation 1 Filter Screen 2 Pump Pick Up Tube 1 Pump Assembly 3 Pump Shaft Seal 2 Pump Assembly Screws 4 Pump End Head 4 24 J LG Lift 3121136 SECTION 4 CONTROL COMPONENTS Pressure Adjust Valve Installation Pressure Check Valve Installation
145. hydraulic oil filler and install the t fitting between the hydraulic filter and the extend line to the cylin der Recheck the hydraulic pressure and compare with the previous readings when filter was removed If a significant drop in pressure reading has occurred replace the hydrau lic filter and recheck the after filter pressure reading 1 4 J LG Lift o la fm IL 1 Hydraulic Oil Filter 2 T Fitting 3 Pressure Gauge Assembly 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 parenthe ses Table 1 4 Cylinder Specifications DESCRIBTION BORE STROKE ROD DIA in cm in cm in cm 15DVL 15DVSP 1 63 41 50 1 375 Lift Cylinder 4 10 105 4 3 49 20DVL 20DVSP 1 63 54 0 1 375 Lift Cylinder 4 10 137 1 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 3121136 SECTION 1 MACHINE SPECIFICATIONS Table 1 5 Lubrication Intervals for Various Components
146. icated by 6 oz 176cc of gear oil in an unvented aluminum alloy housing The fol lowing procedures disassemble and assemble the gear box housing internal components Gear Box Disassembly 1 Remove the drive motor gear box brake assembly from the machine using the procedure outlined pre viously in this section of the manual 3121136 NOTE The gear oil can be drained out when the side cover is removed in the next step Remove the side cover from the gear box with the drive shaft side pointing down then tilt drive motor gear box assembly to drain the oil into a suitable container 2 Remove the four 4 hex cap screws securing the side cover to the gear box housing and remove the side cover and rubber seal ring Note Early model machines did not have the rubber seal ring and were sealed with sealant only Be careful notto scratch or gouge the mating surfaces between the cover and the gear box housing This area is sealed by the rub ber ring sealant and may leak oil if damaged 3 Remove the wave washers from atop the large and small bearings and lay inside their respective holes in the side cover JLG Lift 3 17 SECTION 3 BASE COMPONENTS 10 Using a suitable catch container drain the gear oil from the gear box housing Remove the drive shaft assembly from the housing Place the drive motor gear box assembly on a hydraulic press with the open side of the gear box housing facing down Support the gear box hou
147. ightened turned clockwise to increase the torque setting or loosened counter clockwise to decrease the torque setting 1 Bend lock tabs away from the adjusting nut 2 Hold the drive axle steady using service tool P N 0080229 and the torque wrench used to check the torque setting 3 Depending on how far off the original torque setting was see note at beginning of this procedure tighten or loosen the adjusting nut accordingly then recheck the slip torque setting Repeat this until the proper slip torque setting is achieved 4 When proper torque setting is achieved bend three 3 of the lock washer lock tabs down against the adjust nut 5 Re install the drive wheels per instructions Section 3 3 Drive And Caster Wheels EN i ANA ju WEN Torque Clutch Adjust Nut and Nut Lock Tabs 1 Clutch Adjust Nut 2 Lock Tab Washer Bend 3 Tabs Over 3121136 Drive Wheel Alignment Machines built prior to S N 0130005271 The following procedure corrects DVL DVSP machine drive wheel alignment if required A drive wheel must be aligned if the wheel is more than 1 16 2mm off of vertical alignment with machine resting on a level surface Checking Drive Wheel Alignment 1 Drive Wheel Vertical Alignment Maximum 1 16 2mm Gap Between Top and Bottom Edge of Wheel 2 Use a Steel Carpenter s
148. imes 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 ser vice 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 3121136 In conjunction with the specified inspections mainte nance shall be performed by a qualified J LG equipment mechanic J LG Industries Inc recognizes a qualified J LG equipment mechanic as a person who by possession of a recognized degree certificate extensive knowledge train ing or experience has successfully demonstrated the ability and proficiency to service repair and maintain the subject LG product model Reference Table 2 2 DVL DVSP Preventive Maintenance amp Inspection Schedule and the appropriate 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 J LG Lift 2 1 SECTION 2 GENERAL Table 2 1 Inspection and Maintenance Type Frequenc PU Seve Reference Responsibility Qualification Pre Start Priorto use each day or User or Operator User or Operator Operator and Safety M anual Inspection Ateach Operator change Pre Delivery Priorto each sale lease or Owner Dealer or
149. inder valve block fora restriction i e Clean or Replace _ dirt Flow Valve 3121136 JLG Lift 6 35 SECTION 6 TROUBLESHOOTING 6 11 HYDRAULIC LEAK TROUBLESHOOTING Miscellaneous Hydraulic Leak Troubleshooting Overview Of Procedure This series of steps gives remedies for various areas of the machine where leaks could occur Table 6 46 Hydraulic Leak Troubleshooting STEP ACTION SPEC YES NO 1 Oilleaking around the lift cylinder rod Replace the Seal atthe end ofthe Piston and Cylinder Barrel 2 Oilleaking around the cylinder extend or return line fittings _ Tighten or _ Replace Fittings 3 Oilleaking around the hydraulic lines Tighten or Replace Hydraulic Lines 4 Oilleaking around the liftdown valve _ Tighten Cartridge 5 Oilleaking aroundthe Red manual descentvalve _ Replace Lift _ Down Valve Note Do not overtighten the nut on the solenoid in step 5 6 36 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING 6 12 BASE FRAME COMPONENTS TROUBLESHOOTING Caster Wheels Not Operating Freely Check For These Obvious Conditions First s machine operating on a smooth level surface Table 6 47 Caster Wheels Not Operating Freely STEP ACTION SPEC YES NO 1 sthecasterrotating freely Lubricate or Go to Step 2 Replace Caster Housing a 5 2 Is the wheel spinning freely _ Go t
150. ing thoroughly dry batteries and coat battery terminals with an anti corrosion compound JLG Lift Before testing for battery condition the open circuit voltage should be taken from each battery If the voltage of the bat teries differs by 0 3 volts or more the lower voltage battery should be replaced 3121136 SECTION 3 BASE COMPONENTS Battery Testing Can Be Performed In Two Ways 1 The batteries can be tested using a battery tester capable of testing 12V 100Ah AGM VRLA Valve Regulated Lead Acid batteries using the instruc tions of the battery tester manufacturer 2 If an appropriate battery tester is unavailable the batteries can be tested by fully charging them with the charger that is installed in the machine Then check the battery voltage of each battery 4 hours after charging is complete Batteries less than 12 72 volts should be replaced NOTE If a faulty charger is suspected the batteries can be charged using a charger that supplies 2 45 volts cell Charging should be terminated when the charge current drops below 1 amp Battery Replacement Replacement battery s must be of equivalent voltage and amperage output as the OEM battery s in order for the machine to operate to as manufactured specifications Battery replacement part weight must also be 65 Ib 30Kg in order to maintain machine stability as manufac tured A WARNING DO NOT REPLACE ITEMS CRITICAL TO STABILITY SUCH AS BAT
151. irorReplace ofthe Platform unction Box Check the voltage across 1 and 5 24V DC Platform Control Goto Step 4 inthe unction Box connector Console 4 Check voltageacross 10 and 2 on connector P4 atthe Ground Control Module 24V DC Go to Step5 ae 5 Check continuity of P4 connector pin 10 to Platform unction Box pin 1 Also P4 connector pin 2 to Platform unction Box pin 5 Repair or Replace Wires Code 32 Pump Motor Over Current Check For These Obvious Conditions First Platform overload condition e Obstruction in mast system Pump Positive and Negative connections are secure and undamaged Crushed or kinked hydraulic lines Hydraulic leaks Table 6 33 Code 32 Pump Motor Over Current STEP ACTION SPEC YES NO 1 Check current draw of pump motor by elevating the platform to full Less than heightand load pump by continuing to press the UP button 145A Go to Step 2 Goto Step 3 Is reading within spec mps 2 Didunitgivea 32 Fault Code while performing Step 1 Replace Ground 7 Control Module B 3 lsthepump hydraulic pressure setting within specification as show Adjustto in Section 1 6 of this Service Manual SeeSection 1 6 Goto Step 4 Specification 4 Check pump motor brushes and rotor commutator for abnormal Replaceas Replace Wear Required Pump Motor 3121136 JLG Lift 6 25 SECTION 6 TROUBLESHOOTING Code 33 Both PHP
152. itable lifting device capable of supporting the weight of the mast assem bly attach a sling strap to the mast If installed use the optional crane lifting lug on the back of the mast 12 Remove the six 6 mast attach bolts with washers and nuts securing the mastto the mounting column 13 Lift the mast off the base frame and place on a suit rae able work surface f Jn n Mast Installation E ub PM To install the mast assembly reverse the Mast Assembly Removal instructions however perform the following addi tional steps during re assembly Mast Assembly Installation 1 Install machine covers per instructions Section 3 1 Mast Mounting Column 2 Once assembly is complete cycle the mast up and 2 Mounting Bolt Washer Nut Locations a down several times then check the oil level in the Notes a Apply Loctite 271 to bolt threads on final assembly hydraulic reservoir 5 12 J LG Lift 3121136 SECTION 5 MAST COMPONENTS 5 6 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES The DVL DVSP lift mast sections are constructed of extruded aluminum protected with an anodized surface finish The mast sections are interlocked into each
153. kit is available from the J LG Parts Department to service broken or worn sequence cables This kit consists of a replacement sequence cable with the threaded top end attached same as the top end of the factory cable Also included is a clamp drum socket type to secure the bottom end of the cable Use the follow ing procedure to install the replacement cable and clamp kit Remove Old Cable 1 Remove the locking nut from the threaded end of the cable atthe top of the mastand then remove the spring cap spring and spacer washers if installed 2 Slide the threaded top end out of the upper anchor bracket then at the bottom end pull the cable out though the sheave pulley anchor bracket until it is completely clear of the machine Replacement Cable Installation 1 Be certain the mast is completely retracted and at the bottom of travel Check the mast Side Profile at the top of the mast as shown in Figure 5 2 adjust mast sections to proper height if necessary 2 To determine where the clamp will be installed atthe bottom of the replacement cable temporarily assemble the new replacement cable to the top cable anchor bracket on the mast using the wash ers spring spring cap and lock nut previously dis assembled Thread the lock nut on until approximately 1 8 in 3mm of threads are exposed 3 Atthe bottom of the mast thread the loose end of the replacement cable through the proper sheave pulley and through the hole i
154. l steps in sequence Do not partially disassemble or assemble one part then start on another 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 sol vent 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 pit ted 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 instal lation 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 fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usage and Torque Application J LG Lift
155. le Power Selector Switch Key is set to PLATFORM CONTROL MODE When the Power Selector Switch Key is set to GROUND CONTROL MODE the OSS will detect an obstruction but will not stop platform downward movement or sound the horn However the OSS Control Module LED will flash if a sensor detects the presence of an object An OSS Sensor replacement kit is available from the J LG Parts Department for individual sensors The kit provides instructions and everything necessary to connect the new sensor to the existing soldered wire ends If the OSS Control Module has failed it is recommended to replace the complete OSS system See Section 6 of this manual for further OSS Troubleshooting instructions 1 Mast Platform Header Section 2 Platform Electrical J unction Box 3 Obstruction Sensor Control Module 4 Transducer Sensor Arrangement Table 4 2 Obstruction Sensor System Components Platform Cutaway 4 26 J LG Lift 3121136 SECTION 4 CONTROL COMPONENTS Transducer Sensor Check Perform the following daily Pre Start Inspection to check if each transducer sensor is working properly 1 Power up machine by setting the Power Selector Key Switch to Ground Control Mode 2 Raise the platform approximately four 4 to five 5 feet 3 Hold an object about the size of 8 1 2 x 11 inches directly under one of the sensors The OSS Control Modu
156. le 9 Replacethe Obstruction Sensor System and check for fault Replace the Ground Control Module 10 Disconnect9 pin connector atthe OSS Module Place a positive Replace the OSS lead on Pin 1 and a negative lead on pin 5 Check for 24v 24V DC d Goto Step 11 DC odule 11 Checkthewiring harness from the Platform unction Box connector Repair or to the Ground Control Module positive lead on pin 1 to negative Replace OSS to lead on pin 4 Check for 24v DC 24V DC Junction Box Go to Step 12 Wire Harness 3121136 J LG Lift 6 27 SECTION 6 TROUBLESHOOTING Table 6 35 Code 40 OSS No Communication with Ground Control Module Continued Wire Harness STEP ACTION SPEC YES NO 12 Atthe Ground Control Module P 4 connector check voltage Repair or between pin 8 and pin 2 place positive lead on pin 8 Replace J unc tion Boxto Replace Ground AADC Ground Control Control Module Module Codes 41 thru 46 OSS Sensor 1 through 6 Fault Condition Check For These Obvious Conditions First s there an obstruction under the sensor showing the fault s the faulted sensor mounted properly and securely to the platform base frame Table 6 36 Codes 41 thru 46 OSS Sensor 1 through 6 Fault Condition STEP ACTION SPEC YES NO 1 15 machine equipped with an OSS system ES Gotto Step 4 Goto Step2 2 AttheGround Co
157. le Console 4 Check continuity of the wires running from the P4 connector on Ground Control Moduleto the Platform J unction Box _ ReplacePlatform RepairorReplace P4 connector Pin 1 to unction BoxPin 2 and Control Console Wiring P4 connector Pin 10 to unction BoxPin 1 6 32 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING 6 10 MAST TROUBLESHOOTING Platform Will Not Lower Manually Check For These Obvious Conditions First s there an obstruction in the mast assembly s there a restricted hydraulic line smashed Are the mast slide pads shimmed properly nottoo tight per Mast Assembly procedure in Service Manual Table 6 41 Platform Will Not Lower Manually STEP ACTION SPEC YES NO 1 Check to see of the platform will lowerfrom the Ground Control Sta RepairorReplace tion in Ground Control Mode the Manual Go to Step 2 Descent Control Valve 2 Check to seeif the liftdown valve is opening completely _ Go to Step3 Replacethe Lift Down Valve 3 Checktheflow valve in the liftcylinderfor a restriction _ Clean or Replace ConsultFactory Flow Valve Platform Lift Up And Down J erky Overview Of Procedure The following procedure suggests areas on the machine which might attribute to erratic movement of the platform during lift up and down Check For These Obvious Conditions First If mastis not running smooth or has tight and rough spots refer to the Mast Se
158. le RED LED will flash if the sensor is working properly 4 Remove object allow the LED to stop flashing and check the next sensor repeat this for all six 6 sen sors Transducer Sensor Check 1 Electronic Module LED Indicator a 2 Detection Zone 3 Place a pad of paper or similar size object 6 to 12 in 15 to 30cm individually beneath each transducer to check detection Note a The LED Indicator will flash when an object is detected at each sensor Remove object and allow the LED to stop flashing before testing next sensor The Ground Control Module can also display the following sensor detection information when in Level 2 password Ser vice and Maintenance Settings mode OSS Sensor Displays current Obstruction Sensor System status Detec tion YES NO Also if an object is detected the sensor s detecting the object and distance the object is from the sen sor is displayed oe NO 2 1 Bin O 4 en 2 O 5 Qin 4 3 8 Bin 0 OSS Sensor LCD Display Mode 1 Detection Indicator Yes No 2 Sensor numbers 3 Object distance from sensor 4 Signal strength Note This screen can be viewed while another person performs the transducer s
159. m x N E3 mmm g 00000 0 400 d 4 X00000000X XOX V 00 LCD Display Symbols Battery Charge Indicator Function Display or Function Disable Indicators Hour Meter Display Fault Code Indicator Fault Code Text Message Display a Note a When an Fault code is indicated the LCD screen will alternate between the text and symbol display modes In the LCD Display Symbols illustration item 2 above the Function Display or Function Disable Indicators will vary as shown following DRIVE Disabled gt Both LIFT UP and LIFT DOWN Disabled LIFT UP Disabled Drive Speed Cut Back Turtle Mode Engaged 4 LIFT DOWN Disabled 4 4 c Battery Charger Plugged In J LG Lift 3121136 SECTION 6 TROUBLESHOOTING 10 me TP T X 11 ENS mg HEH EN 2 a 8 EN 7 dy 9 1 Ground Control Module 5 Traction Control Module a 9 Pump Motor Tank Assembly b
160. m lo eoim o 293 sl o gt Q gt gt gt wo o z gt 2 al 5 8 lt 55 Pe 812152 Je 8 lt 2 IE E e S 50 2 8 25 3 8 als 5 3 ug a x S wl AS gt 9 i PLATFORM 5 g amp AUX 2 8 8 8 s PLATFORM i 8 dolo 1 979 AUX INPUT 1 B BLACK B BLACK ON OFF BLUE ON OFF BLUE ied COM WHITE COM WHITE a 1 L ZIS P4 ri P5 BE ale A a 5 QA AAR eo Jn QQ O g 4 2 1 R 8 2 Ll L1 Q QQ y 1 5252 i SIGNAL OUT Ecc ry Lock OPTIONAL LF IS SIGNAL IN I5 S Fy VOLTAGE LOW REF AUX ANALOGUE INPUT lm SPARE ANALOGUE INPUT RIJEI B VOLTAGE HIGH REF e E E B E TILT SWITCH RETURN INHIBITS LIFT DRIVE 7 B Il B TILT SWITCH 8 B POWER 7 JH s E B AUX 2 SIGNAL SPARE DIGITAL INPUT 2 zle AUX 2 RETURN INHIBITS LIFT B AUX 1 SIGNAL INHIBITS DRIVE RS AUX 1 RETURN B FTO PLUGGED IN OPEN n Lio NOTE E a 4 ELEVATION 4 SPEED AUX 2 INPUT MAY BE USED FOR HEIGHT LIMITERS lt E AUX 1 INPUT MAY BE USED FOR INTERLOCK d 22 oM mor LEFT PI IM LT ii OPTIONAL LSS CECPIION ONY 4933184 D 2 Figure 6 4 Electrical Diagram with Load Sensing System DVL DVSP Sheet 2 3121136
161. n place SECTION 5 MAST COMPONENTS 16 Assemble one ofthe narrow chains sets 444 and to the small chain equalizer anchor plate using the pins washers and cotter keys Set aside 17 Locate the chain anchor block and slide it onto the hydraulic cylinder rod end sticking out the top of mast section 2 18 Lay out the chain 444 anchor plate assembly with anchor plate end towards mast be certain floor sur face is clean and free of any metal chip or debris which may stick to lubricated chains or lay chains in a clean bucket 19 Assemble the chain anchor plate assembly and the chain anchor block to the cylinder rod end using the anchor plate block attach pin and snap ring Install Chain Anchor Block to Top of Lift Cylinder 1 Attach Pin 4 Attach Pin Snap Ring 2 Chain Equalizer Assembly 5 Cylinder Rod Extended 3 Chain Anchor Block 5 18 20 Assemble chain sheaves on chain assembly anchor block attached to cylinder rod end and attach to mast section 2 using following steps a Insert sheave pin through anchor block and cyl inder rod on cylinder rod end b Load three 1 flat washers onto the sheave pin on each side of the anchor block c Place sheave wheels for wide 544 chain on sheave pin one each side of anchor block d On the outside of each sheave wheel place another 1 flatwasher a roll pin into the slot in each end of the pin and then place a sheave pin su
162. n the sheave pulley anchor bracket on the mast section ahead of the sheave pulley 4 Grasp the cable and pull on the cable until the spring at the top of the cable is slightly compressed Use a black marker to mark the cable on the top side of the sheave pulley anchor bracket This will determine where the clamp drum socket sleeve will be positioned on the cable IMPORTANT DO NOT CUT THE CABLE AT THE MARKED POINT ON THE CABLE THIS IS ONLY USED AS A REFERENCE FOR POSITIONING THE CABLE SLEEVE WHICH WILL REST AGAINST THE ANCHOR BRACKET ONCE INSTALLED 5 4 J LG Lift Clamp Installation Drum Socket Type IMPORTANT THE MANUFACTURER OF THE DRUM SOCKET CLAMP RECOM MENDS THE USE OF THEIR CABLE CLAMP ASSEMBLY KIT J LG P N 7023275 TO ASSEMBLE THE CLAMP TO THE WIRE ROPE THE KIT CONSISTS OF VISE JAWS TO HOLD THE WIRE ROPE IN A VISE PROPERLY WITHOUT DAMAGING ANY ROPE STRANDS AND A PLUG DRIVER TO DRIVE THE PLUG INTO THE CENTER OF THE WIRE ROPE AND IS ALSO USED TO FORM THE STRANDS OF THE ROPE DURING ASSEMBLY NOTE The tools in the clamp assembly kit may be frabra cated if necessary The vise clamp consists of vise jaws with a hole drilled 1 32 in smaller than the diameter of the wire rope you are working with i e 1 8 in rope 3 32 in hole The plug driver is a metal tube with a hole in the bot tom to allow the strands of the wire rope to be shaped after the plug has been tapped into the cen ter of the wire rope
163. nds are even 25 Insert slide pads into the top end mast rails between section 2 and 3 one on each side of the mast with beveled surface facing inward towards section 3 Same as Figure 5 8 NOTE Before fastening and shimming the slide pad on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher 3121136 SECTION 5 MAST COMPONENTS 26 27 28 29 30 31 32 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in outside rail on top of mast section 2 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Insert slide pads into the bottom end mast rails between section 2 and 3 one on each side of the mast with beveled surface facing out towards sec tion 2 Same as Figure 5 7 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes on inside rail on bottom end of mast section 3 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Slide section 3 out the bottom of section 2 approxi mately one 1 foot Locate one 1 ofthe chain bottom anchor brackets one with threaded holes horizontally aligned to out side
164. ne is operating are recommended for use NOTE Metal particles may appear in the oil of new machines due to the wearin of meshing compo nents 2 8 Hydraulic Oil For best performance J LG recommends the use of ISO Vg 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 Manual 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 itis nec essary to change the oil use only those oils meeting or exceeding the specifications appearing in this manual 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 syn thetic base oils J LG Industries recommends changing the hydraulic oil annually Use every precaution to keep the hydraulic oil clean If the oil must be poured from the original container into another be sure to clean all possible contaminants from the service container While the unit is shut down a good preventive mainte nance 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 J LG Lift Specified lubricants as recommended by the compo
165. nent manufacturers are always the best choice however multi purpose greases usually have the qualities which meet a variety of single purpose grease requirements Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion Referto Section 1 in this Service Manual for an expla nation of the lubricant key designations appearing in the Lubrication Chart 3121136 SECTION 2 GENERAL 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 1 3 When lifting with a fork truck lift only using the fork a lift truck pockets running the length of the machine s base frame from rear to front n AK 4 After lifting machine to desired work height place 1 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 2 Locate work area on a firm level surface WARNING KEEP MACHINE LEVEL OR SLIGHTLY TILTED TOWARD FORK LIFT TRUCK WHEN LIFTING TO PREVENT MACHINE FROM SLID ING OFF LIFTING TINES
166. ness If out of roundness exceed 0 007 this is unacceptable Check the condition of the dynamic seals wiper rod seals looking particularly for metallic particles embedded in the seal surface It is normal to cut the static seal on the retaining ring groove upon disas sembly Remove the rod seal static o ring and backup and J LG Lift 5 9 SECTION 5 MAST COMPONENTS rod wiper Damage to the seal grooves particularly on the sealing surfaces is unacceptable In the event that an unac ceptable condition occurs the head should be replaced Piston Visually inspect the outside surface for scratches or polish ing Deep scratches are unacceptable Polishing indicates uneven loading and when this occurs the diameter should be checked for outofroundness outof roundness exceeds 0 007 this is unacceptable Check the condition of the dynamic seals and bearings looking particularly for metallic particles embedded in the bearing and in the piston seal surface Remove the seals and bearings Damage to the seal grooves particularly on the sealing surfaces is unacceptable In the event that an unacceptable condition occurs the piston should be replaced Tube Assembly Visually inspect the inside bore for scratches and pits There should be no scratches or pits deep enough to catch the fin gernail Scratches that catch the fingernail but are less than 0 5 inch long and primarily in the circumferential direction are acceptable
167. ng harness or a damaged alarm Table 6 21 Code 18 Alarm Short Circuit STEP ACTION SPEC YES NO 1 AttheGround Control Module P1 connector check the voltage Replace Ground across pins 13 and 6 to the alarm Is reading within specification 0 2V DC Go to Step 2 Control Module 2 Removethe wire terminals atthe alarm check continuity of each of Re placethe Repairor the wires from pins 13 and 6 onthe P1 connector to the alarm end Alarm Replace Wiring 6 18 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING Code 19 Alarm Disconnected Check For These Obvious Conditions First Damaged wiring in the alarm wiring harness or a damaged alarm Activate a function to check if alarm beeps Table 6 22 Code 19 Alarm Disconnected STEP ACTION SPEC YES NO 1 Check voltage atthe P1 connector on the Ground Control Module Replace Ground between 13 and pin 6 Is reading within specification 2 4V DC Control Module Goto Step 2 2 Removethe wireterminals atthealarm check continuity of each of Replace th the wires from pins 13 and 6 onthe P1 connector to the alarm end prs e Replace Wiring Code 20 Beacon Short Circuit Check For These Obvious Conditions First Damaged wiring in the beacon wiring harness or a damaged beacon unit Table 6 23 Code 20 Beacon Short Circuit STEP ACTION SPEC YES NO 1
168. ng the armature plate away from the friction brake disk A correctly adjusted brake will ideally have a measurement of approximately 006 but will operate normally at 004 to 010 between the armature plate and magnetic coil hous ing surface when the brakes are ENGAGED brakes on Never allow any type of lubricant oil grease hydraulic fluid etc to come in contact with the brake friction disk or it s contacting surfaces Also if brake becomes clogged with debris or dirt the brake may not release properly Brake Assembly Removal 1 Lift the machine to gain access to the underside See Section 2 5 2 Remove the drive motor cover See Section 3 2 3 Disconnect the drive motor power connector from 5 wiring harness connector 4 Loosen the boot clamp and slide the protective rub ber boot off the end of the drive motor housing exposing the brake assembly 5 Remove the four 4 hex cap screws securing the brake assembly to the end of the drive motor hous ing and remove the brake assembly from the end of the drive motor Boot and Brake Removal 1 Protective Rubber Boot 2 BootClamp 3 Brake Assembly 3 12 J LG Lift Checking Adjusting Armature Plate Gap Setting 1 First inspect that all parts of the brake assembly are tight and secure Tighten as necessary 2 Inspect the brake for any debris which may be lodged in the air gap between the armature plate and magnetic coil when
169. nt Replace Wiring Code 26 Auxiliary 2 Short Circuit Check For These Obvious Conditions First Damaged wiring in the Auxiliary 2 Component wiring harness or a damaged Component Table 6 29 Code 26 Auxiliary 2 Short Circuit STEP ACTION SPEC YES NO 1 AttheGround Control Module P1 connector check the voltage Replace Ground across pins 8 and 1 to the Aux 2 component Is reading within 0 2V DC Go to Step 2 C ai IModul specification Sn MUR 2 Removethe wire terminals atthe Aux 2 component check conti of each of the wires from pins 8 and 1 on theP1 connector to d R d the Aux 2 componentend omponen J LG Lift 3121136 SECTION 6 TROUBLESHOOTING Code 27 Auxiliary 2 Disconnected Check For These Obvious Conditions First s machine equipped with a componenton the Auxiliary 2 circuit Table 6 30 Code 27 Auxiliary 2 Disconnected STEP ACTION SPEC YES NO 1 smachineequipped with a componenton the Auxiliary 2 circuit Goto Step 3 Gotto Step 2 2 Atthe Ground Control Module enter the programming mode check Replace Ground if the Auxiliary 2 open circuit detection is enabled Default NO Disable It Control Module 3 Check voltage atthe P1 connector on the Ground Control Module Replace Ground between pin 8 and pin 1 Is reading within specification 2 4VDC Control Module Goto Step 4 4 Removethe
170. nto service Preparation Inspection and Maintenance Reference the J LG Pre Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the perfor mance of these inspections Reference the appropriate areas ofthis manual for servicing and maintenance proce dures Annual Machine Inspection It is important to establish and conform to a comprehen sive inspection and preventive maintenance program The following table outlines the periodic machine inspections and maintenance recommended by J LG Industries Inc Consult your national regional or local regulations for fur ther requirements for aerial work platforms The frequency of inspections and maintenance must be increased as environment severity and frequency of usage requires Pre Start Inspection Itis the User s or Operator s primary responsibility to per form a Pre Start Inspection of the machine prior to use daily or at each change of operator Reference the Opera tor 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 per forming the Pre Start Inspection Pre Delivery Inspection and Frequent Inspection The Annual Machine Inspection must be performed by a qualified J LG equipment mechanic on an annual basis no later than thirteen 13 months from the date of t
171. ntrol Module enter programming mode and view if Re _ place Ground 055 is enabled 15 055 enabled X Goto Step 3 Control Module 3 InServiceLevel Programming mode Disable Obstruction Senor System No Goto Step 4 4 Replacethe sensor showing the fault Does this correctthe prob lem Done Go to Step 5 5 Replacethecomplete OSS system module and sensors 6 28 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING Codes 100 199 Ground Control Module Fault Condition Check For These Obvious Conditions First That all battery and harness connectors secure and undamaged on Ground Control Module Batteries have sufficient charge Confirm that the static ground strap attached under base frame is secure and undamaged Table 6 37 Codes 100 199 Ground Control Module Fault Condition STEP ACTION SPEC YES NO 1 Recycle machine power5 times allowing a 10 second interval between each power recycle Does fault clear Done Goto Step 2 2 Which codenumberis displaying Code 103 Go to Step 3 Replace Ground Control Code 119 Go to Step 5 Module 3 Confirm that both installed batteries are 12 Volt DC 12VDC GotoStep4 _Replacewith proper Batteries 4 operating Is voltage within Maxim mof Replace Repairor Replace specification Ground Control 31 Volts DC Battery Charger Module 5 Remove the communications cable P5 connector atthe Ground Control M
172. nts No loose connections corrosion or abrasions Overrides Platform controls Inspected per Service and Maintenance Manual a Priorto use each day or at each Operator change b Prior to each sale lease or delivery 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 ofthe prior inspection J LG Lift 2 5 SECTION 2 GENERAL 2 3 SERVICING AND MAINTENANCE GUIDELINES General The following information is provided to assist you in the use and application of servicing and maintenance proce dures 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 ade quate support is provided WARNING NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING Cleanliness The most important single item in preserving the long ser vice 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 fil ters are p
173. o Step3 Service Manual Required 3 Arethechain cable sheave wheels dry and need lubrication Lubricate or Note Plastic wheels will howl on the sheave pin when they are dry _ ReplaceSheave Sheave wheels may seize to the sheave pin and the pin may turn in Pi d Wheel the pin retainer blocks Lu 4 Arethesequencecables located onthe side of mast chattering whenthe springs are compressed Clean Slide Pads Note This noiseis normal atthe sequence cable sheave wheels Channels iio when the mastis completely lowered However if sequence shimMastbar Go to Step 5 cable chattering is happening no matter what position the mastis in itcould be a result of the mast being shimmed to tight or dirt and Service Manua debris in the slide pad channels causing the mastto be tight 5 15 the bore of thelift cylinder dry Replace Packing Goto Step 6 or LiftCylinder 6 Arethebearings intheliftpump motorand pump drive worn _ RepairorReplace Goto Step 7 Pump 7 Arethe hydraulic lines vibrating together _ Adjustthe Posi Goto Step 8 tion of the Lines 8 Checkifthe pump motoris looseto it s mounting plate Tighten pump mounting Goto Step 9 fasteners 9 Hydraulic oil could be cavatating insidethe pump _ Repair or Replace _ 6 34 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING Platform Mast Won t Stay Elevated Overview Of Procedure The following procedure requests that the lift down dump
174. o Step3 Lubricate or Replace Wheel 3 1 debris stuck in the rubber wheel _ RemoveDebris or _ Replace Wheel Pot Hole Protection PHP Bars will not Lower Check For These Obvious Conditions First Obstruction under pot hole baron either side of machine Obstruction around the actuator assembly at the base of the mast Table 6 48 Pot Hole Protection PHP Bars will not Lower STEP ACTION SPEC YES NO 1 Checktheactuatorassembly and cables for adjustmentor damage _ AdjustorReplace ConsultFactory 3121136 J LG Lift SECTION 6 TROUBLESHOOTING 6 13 DRIVE SYSTEM TROUBLESHOOTING Won t Climb Grade Overview Of Procedure The following procedure checks the drive motor and attached components for component failure misadjustment due to wear Check For These Obvious Conditions First Batteries are Fully Charged 24 Volts Speed Control is Set to Maximum s Grade within the Maximum Allowable Specification of 2096 Grade Does the Travel Surface allow for Proper Drive Wheel Traction s Platform Load within the Maximum Rated Capacity Table 6 49 Won t Climb Grade STEP ACTION SPEC YES NO 1 Does machine drive straightona level surface Referto Machine Won tDrive Go to Step 2 Straight Table 6 51 2 Areboththeleftand rightdrive motor slip clutches located Repair Replace between the drive motor and the drive wheels working properly Go to Step 3
175. oading Reference the capacity decal on the machines decal billboard mounted on mast Platform Size Standard 26in W x26 in L 66cm x 66cm Stockpicker 28in W 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 Footprint DVL DVSP 29 25in W x52in L 74cm x 132cm 14 TORQUE REQUIREMENTS When maintenance becomes necessary or a fastener has loosened refer to the applicable Torque Chart in this section ofthe manual to determine proper torque values 3121136 SECTION 1 MACHINE SPECIFICATIONS 15 LUBRICATION Hydraulic Oil Hydraulic oils must have anti wear qualities at least to API Service Classification GL 3 and sufficient chemical stabil ity for mobile hydraulic system service J LG Industries recommends Mobilfluid 424 hydraulic 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 7 C JLG recom mends using Mobil DTE 13 hydraulic oil Aside from J LG recommendations it is not advisable to mix oils of different brands ortypes as they may not con tain the same required additives or be of comparable vis cosities If use of hydraulic oil other than Mobilfluid 424 is desired contact J LG Industries for proper recommenda tions Table 1 2 Hydraulic Oil
176. of bracket Attach using outer set of holes in bottom of mast section 3 with two 2 1 4 20UNC x 3 4 long bolts place a flatwasher under head of each bolt 1 Chain Anchor Bracket 2 Mast Section 3 Note Mast Section 3 Chain Anchor Bracket Bottom of Mast 3 Anchor Bolts Washers a a Apply Loctite 242 to threads 3121136 33 34 Slide section 3 out the top of section 2 approxi mately one 1 foot Locate the remaining narrow chain set 444 and attach them to the remaining triangular shaped anchor plate using the attach pins flat washers and cotter keys Note 1 Chain Anchor Plate Assy 4 Pin Keeper 2 Anchor Pin 5 Keeper Screw a 3 Spacer a Apply Loctite 242 to threads Mast Section 3 Chain Anchor Plate Installation Mast Section 3 Shown Cut away 35 36 J LG Lift Install the chain anchor plate assembly into the top of mast section 3 using the remaining large pin and pin keeper Allow to hang out the top of mast sec tion 3 for later assembly Insert the threaded the ends of chain assembly attached to top of mast section 1 into the opening between mast section 2 and mast section 3 Slide the threaded ends through the holes in chain anchor bracket attached at the bottom of mast section 3 Loosely thread two 2 3 8 16UNC nuts onto stud threads on each chain and remove any
177. ols 5 6 7 5 6 7 Ground Controls 5 6 5 6 14 Function Control Locks Guards or Detents 5 5 Function Enable System Emergency Stop Switches Ground amp Platform 5 Function Limitor Cutout Switch Systems 5 Drive Brakes 5 Manual Descentor Auxiliary Power 5 5 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 12 12 Hydraulic Hoses Lines and Fittings 1 9 1 9 Hydraulic Reservoir Cap and Breather 5 7 5 7 2 4 J LG Lift 3121136 SECTION 2 GENERAL Table 2 2 DVL DVSP Preventive Maintenance amp Inspection Schedule Continued Notify J LG of Machine Ownership INTERVAL AREA ON MACHINE PRE START a 3 MONTH 6 MONTH PRE DELIVERY b ANNUAL d INSPECTION PREVENTATIVE PREVENTATIVE OR FREQUENT c YEARLY MAINTENANCE MAINTENANCE INSPECTION INSPECTION Hydraulic Filter Hydraulic Fluid 11 11 11 Electrical Connections 20 20 Instruments Gauges Switches Lights Horn 5 GENERAL Operator and Safety Manuals in Storage Box 21 21 21 ANSI and EMI Manuals Handbooks Installed 21 21 21 Capacity Decals Installed Secure Legible 21 21 21 All Decals Placards Installed Secure Legible 21 21 21 Walk Around Inspection Performed 22 Annual Machine Inspection Due 21 No Unauthorized Modifications or Additions 21 21 All Relevant Sa
178. onents as Traction Required Control Module Code 12 Right Drive Motor Short Circuit Check For These Obvious Conditions First Wiring harness from M2 connector on Traction Control Module to Left Drive Motor for damage Table 6 15 Code 12 Right Drive Motor Short Circuit STEP ACTION SPEC YES NO 1 RemovetheM2 connectorfrom the Traction Control Module and This circuit check both the pins to the drive motor for any voltage No Voltage should be Goto Step 2 Ground the meterto the Ground Control Module Negative lug isolated Repair 2 Checkforcontinuity of both the pins to the drive motorto ground orReplace Replace No Ground Components as Traction Required Control Module Code 13 Traction Module In Fold Back Check For These Obvious Conditions First Machine is operating on a continuous grade or rough terrain Table 6 16 Code 13 Traction Module In Fold Back STEP ACTION SPEC YES NO 1 Allow machine to cool the traction module for 30 minutes Does the Replace Traction machine operate OK after cooling Module Table 6 3 Amperage Draw for Various Components NOTE If this is a recurring problem compare current draw of your machine with Traction Control Module specifications in J LG Lift 3121136 SECTION 6 TROUBLESHOOTING Code 14 Pump Motor Disconnected Check For These Obvious Conditions First Check t
179. op erly bentand the nut is secure c Check for any debris wedged in or wrapped around the clutch coupling chains and axle shafts Remove debris and clean area if neces sary J LG Lift Check Clutch Torque Setting 1 Select a torque wrench capable of setting a torque of 220 ft Ib Insert special tool P N 0080229 into a 1 3 4 socket on the torque wrench Slide the tool onto the end of the drive axle aligning the key on the axle shaft install key on axle if nec essary with key slot in the tool Notes a DO NOT lubricate chain lubricant could drip onto the Checking Clutch Torque Setting 1 Torque Limiting Clutch a 3 Clutch Torque Setting 2 Socket Tool Insert 220 ft Ib torque clutch friction disk surfaces and cause the clutch to slip Set the torque wrench to the proper torque setting 220 ft Ib Turn the torque wrench and note the torque setting when the torque limiting clutch slips Check both rear drive axles If torque setting is OK re install the drive motor cover and drive motor wheels and lower machine IF NOT continue with Torque Limiting Clutch Adjust ment following 3121136 SECTION 3 BASE COMPONENTS Torque Limiting Clutch Adjustment NOTE The large adjusting nut on the side of the clutch assembly is a standard type thread If the torque slip setting of the clutch assembly is off spec 220 ft Ib the large adjusting nut must be t
180. or Adjust Slip Clutch 3 Dotheleftand right drive motor brakes release properly and allow Dragging the drive wheels to rotate freely Go to Step 4 Repair Replace or Adjust Brakes 4 Checkthe amperage output of the on the drive motor leads They Controller will should notexceed 100 amps while pulling a grade Shut Drive Down Go to Step 5 and will flash a7 LED Code 5 Check thecondition of the drive motor brushes Worn down OK goto Step6 replace brushes or drive motor 6 Ifallaboveis OK Drive motors are working properly Consult Fac _ _ _ 6 38 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING Machine Drives in Opposite Direction Table 6 50 Machine Drive in Opposite Direction STEP ACTION SPEC YES NO 1 AttheTraction Control Module check if the left drive motor power Switch the Left lead is plugged into the M 1 socket and RightDrive NOTE The left drive motor power lead uses a reverser har Go to Step 2 Motor Power ness between the module and the power lead to the Leads at the motor Traction Module 2 Remove the Right Drive Motor power lead at the Traction Control Module M2 and check if the WHITE wire is connected to the posi tive terminal and the BLACK wire is connected to the negative Go to Step 3 terminal ReferenceFigure 6 3 Electrical Diagram DVL DVSP Sheet 1 3 Removethe LeftDrive Motor power lead atthe Traction Control Module 1
181. or System oo OBSTRUCTION BELOU E 4 gt PLATFORM 4 Platform Elevated p X 000000 LIFT DOWN Disabled 9 ENTER SECURITY Programmable Security ni PSL key Pad E lt gt CODE See Operators Manual for X 00000 0 Proper Operation 1 emus Bog Low Battery Voltage See Page6 12 X 00000 0 Left PHP BarUP LEFT PHP gt 02 2 CA pamm p lt gt BAR UP ME Platform Elevated X 00000 0 02 402 DRIVE and LiftUP Disabled 9 Right PHP Bar UP 2 E3mmmmmpee 0007 5 5068 X 000000 403 03 LiftUP Disabled ET THE ZU TiltCondition See Table 6 9 04 3 2 Platform Elevated Paoe6 14 X 000000 204 204 DRIVE and LiftUP Disabled 9 05 RESERVED RESERVED 06 RESERVED RESERVED Left Drive Motor E3mmmhee 9 Disconnected goo cou X 00000 0 07 07 DRIVE Disabled RightDrive Motor RIGHT MOTOR 08 6 E mum nnm 4e gt DISCONNECTED Disconnected X 00000 0 08 08 DRIVE Disabled 9 Left Brake Disconnected LEFT BRAKE 09 6 mmn 4 lt gt DISCONNECTED v DRIVE Lift UP DOWN ed X 00000 0 209 209 Disabled Wr 6 4 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING Table 6 1 LCD Display Service Fault Code Conditions PLATFORM FAULT CONSOLE FAULT DESCRIPTION FOR TROUBLESHOOTING CODE LEDs LCD SYMBOL SCREEN LCD TEXT SCREEN MACHINE CONDITION REFER TO FLASHING Right Brake Disconn
182. or and Brush Housing For Reference when reassembling Motor Installation 1 Motor Assembly 3 Pump End Head 2 Motor Assembly Screws 4 Motor to Pump Coupler Brush Assembly Connections 1 Negative Post 3 Brush Assemblies 2 Positive Post 4 Spring Washer Note Length of wires to brush assemblies shown exaggerated for illustrative purposes 4 22 J LG Lift 3121136 SECTION 4 CONTROL COMPONENTS Once brush housing has been removed inspect the rotor commutator for excessive wear before installing a new brush set The rotor commutator surface when new is approximately 1 8 in 3mm in thickness 0 Vi f New Brush Installation 1 Brush Terminal Screw 4 Brush Spring 2 Brush 5 See Installation Note Below 3 Brush Holder Installation the same for all four 4 brush assemblies Note Using a clean towel push each brush 2 up into it s holder 3 slide the spring 4 over the side of the brush This will hold each brush in place and allow them to clear the rotor commutator during reassembly Clean the rotor commutator with a non conductive electrical cleaner before assembling the brush housing to the motor hous ing Brush Housing Final Assembly Tips It is easier to install the brush housing assembly by sliding the rotor assembly completely out of the other end of the motor housing then attach the brush housing first After the brush
183. or block to mast section 1 Remove chain anchor block assemblies from mast and lay aside Remove slide pads and shims from mast section 1 Mast disassembly should now be complete J LG Lift 3121136 SECTION 5 MAST COMPONENTS MAST SECTION 5 MAST SECTION 4 MAST SECTION 3 MAST SECTION 2 MAST SECTION 1 CHAIN ASSEMBLYS numi mm CHAIN ANCHOR BRACKETS Figure 5 6 Mast Chain Routing Diagram DVL DVSP 5 15 J LG Lift 3121136 SECTION 5 MAST COMPONENTS Mast Assembly DVL DVSP See Figure 2 2 MAST SECTION 1 ASSEMBLY 1 Place mast section 1 rail open side up See Figure 2 1 on a clean flat surface preferably a table or work bench capable of supporting the weight of the entire mast assembly Slide mast out over end of work surface far enough to allow access to the chain anchor attach hole nearthe top of the mast Locate the two 2 single wide chain assemblies and attach to the large equalizer anchor plate if not already attached Lay out the chain anchor plate assembly with the anchor plate end towards top of the mast Be certain floor surface is clean and free of any metal chips or debris which may stick to lubri cated chains Insert the chain anchor plate assembly end into the top of mast section 1 and secure using the large anchor plate attach pin spacers and pin keeper 1 Anchor Plate Pin 2 Short
184. orm Console Circuit Board Connections Horn Switch C5 4 E Stop ShutDown Switch Communications Cable to C4 Platform J unction Box 5 Drive Lift ModeSelect C6 Switch C7 ON OFF Key Switch C3 6 Joystick C8 Note The C numbers shown after the description above repre 3121136 sent the corresponding identification of the plug on the module s circuit board Mounting Bracket Install Remove Platform Console Mounting Bracket 1 Mounting Bracket 2 Bracket Screws a Note a Apply Loctite 242 to screw threads on final assembly Rear Cover Install Remove Platform Console Rear Cover Installation 1 Rear Cover JLG Lift 2 Cover Mounting Screws SECTION 4 CONTROL COMPONENTS Display Controller Module Install Remove Horn Button Switch Install Remove Platform Console Display Module 1 Display Controller Module a 2 Mounting Screws Note a Unplug all connections on the back of the module before removing from console Drive Lift Mode Switch Install Remove Platform Console Drive Lift Mode Select Switch 1 Switch Assembly a 2 Locking Tabs Note a Remove rear cover unplug switch wire press tabs to remove 4 16 JLG Lift a Platform Console Horn Switch Installation 1 Horn Button Switch a 3 Nut 2 Lock Washer Note
185. pport bar rectangular plate with threaded holes on each side of pin bore hole e Slide the whole anchor block cylinder assembly with sheave pin wheels and pin support bars into top of mastsection 2 f Align the threaded holes in the attach bars on each side of the mast and attach to top of mast section 2 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten Mast Section 2 Chain Anchor Block Sheave Wheel Assembly 1 Support Bar Screws a 4 Sheave Wheel Assy 2 Pin Support Bars 5 Sheave Pin 3 Narrow Washer 6 Square Keys Note a Apply Loctite 242 to threads J LG Lift 21 Remove the cylinder mount cap shoulder screws and apply Loctite 242 to the threads Install the screws and torque to 85 ft Ibs 22 Tighten the center lift cylinder mount screw this screw keeps the cylinder assembly from rotating in the mount 23 Slide mast section 2 back into section 1 until top and bottom ends are even MAST SECTION 3 ASSEMBLY NOTE When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels 24 Carefully slide mast section 3 into section 2 until e
186. provided they cannot cut the piston seal The roughness of the bore should be between 10 and 20 u inches RMS Significant variation greater than 8 inches difference are unacceptable In the event that an unaccept able condition occurs the tube assembly should be repaired or replaced Cylinder Assembly See Figure 5 4 1 Rinse the inside of the tube with hydraulic fluid and allow to drain A high pressure rinse followed by a wipe with a lint free rag is preferable Clean all inter nal components of any foreign material 2 Lubricate the head and all seals with hydraulic fluid prior to installation Install the seal wiper o ring back up ring and retraining ring to the cylinder head 3 Lubricate the piston and all components with hydraulic fluid Install the seal and wear ring to the piston NOTE He check that seals are not twisted or pinched and are properly seated 4 Place the rod on a clean table Install the static pis ton o ring seal into the groove on the piston end of the rod 5 Install the head followed by the piston onto the rod noting the proper orientation of each component Torque the piston nut to 100 120 ft Ibs 13 Cylinder Rod Cylinder Head Rod Wiper Rod Seal 5 O Ring PWN HB 12 6 Apply Anti Seize 7 Cylinder Tube 8 Spacer 9 Piston Seal Note a Torque 100 12
187. r Programming Mode Level 3 4 12 4 6 PLATFORM CONTROL CONSOLE SERVICE PROCEDURES MACHINES S N 0130007616 TO PRESENT 4 14 Generals PLC LIES 4 14 Remove Platform Control 5 4 14 Display Controller Module Electrical lt 4 15 Mounting Bracket InstallRemove _ 4 15 Rear Cover InstalllRemove _ 4 15 Display Controller Module InstallRemove 4 16 Drive Lift Mode Switch InstallRemove 4 16 Horn Button Switch InstalllRemove 4 16 3121136 J LG Lift TABLE OF CONTENTS Key Switch InstalllRemove 4 16 E Stop ShutDown Switch InstalllRemove _ 4 17 Joystick Assembly InstalllRemove 4 17 4 7 PLATFORM CONTROL CONSOLE SERVICE PROCEDURES MACHINES PRIOR TO S N 0130007616 isses mmm 4 18 General E ecrit Rod eot ban Ea did tom dui 4 18 Remove Platform Control lt 4 18 Upper Lower Shell Attach Screws
188. ree of any metal chips or debris which may stick to lubricated chains Slide mast section 4 out the TOP of mast section 3 far enough to allow access to the chain sheave wheel assembly Remove countersunk flathead screws securing chain sheave wheel assembly attach bars on both side rails at TOP of mast section 4 and remove sheave wheel assembly When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 4 out BOTTOM of sec tion 3 Remove slide pads shims and cable anchor plate if necessary MAST SECTION 3 REMOVAL 11 12 13 14 15 5 14 Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate on BOT TOM end of mast section 3 Push threaded ends of chain through the anchor plate At TOP of mast section 3 pull chains out and allow to hang loose be certain floor surface is clean and free of any metal chips or debris which may stick to lubricated chains Slide mast section 3 out TOP of mast section 2 far enough to allow access to the chain sheave wheel assembly Remove countersunk flathead screws securing chain sheave wheel assembly attach bars on both side rails at TOP of mast section 3 and remove the sheave wheel assembly While mast section 3 is still extended from section 2 remove the pin attaching the chain anchor plate to the TOP of mast section 3 Remove chains NOTE 16
189. ressed Brake Assembly Installation 1 Secure the brake assembly to the drive motor hous ing using four 4 hex cap screws with washers Torque evenly to 44 in Ibs 2 Reinstall the protective rubber boot over the drive motor housing secure the boot with the boot clamp 3 Reconnect the drive motor brake power wiring con nector to wiring harness connector 4 Install the drive motor cover 3121136 J LG Lift 3 13 SECTION 3 BASE COMPONENTS Drive Motor Boot Assembly Installation ae D 2 Drive Motor Boot Assembly Installation 1 Boot Assembly Left Drive Motor Boot Shown Cutaway 2 Drain Hole Always Locate on Bottom of Boot a 3 Wiring Harness Nipple 4 Boot Clamp Note a If replacing the boot assembly cut a hole approximately 3 16 inch 4mm size on the BOTTOM of the new boot This will allow any accumulated condensation to drain out The Left and Right Drive Motor use the same replacement boot however the wiring harness nip ple on the boot always points towards the outside of the machine The drain hole must always be located on the BOTTOM of the boot see illustration below BOOT ASSEMBLY pa WIRING HARNESS WIRING HARNESS NIPPLE NIPPLE DRAIN HOLE RIGHT DRIVE MOTOR BOOT LEFT DRIVE MOTOR BOOT 3 14 J LG Lift 3121136 SECTION 3 BASE COMPONENTS Drive Motor Brush Replacement Brush Removal Each drive motor cont
190. rlocks with slots in the drive motor cover at the bottom 1 J LG Lift Disconnect the positive battery terminal from the left side battery Remove the drive motor assembly cover and set aside see Section 3 2 Base Frame Covers Disconnect the drive motor harness connector s from the traction module mounted just above the hydraulic pump motor located under the rear machine covers Guide motor harness down through base frame Carefully raise the lift to gain access to the under side of the base frame Refer to Section 2 5 Posi tioning Lift For Access to Components Located Under the Base Frame Remove the hex head cap screw and washer from the front of the drive assembly mounting frame While holding the drive motor assembly in place remove the nut and washer from the remaining hex head cap screw holding the drive assembly mount ing frame to the base frame Lower the drive motor assembly from the machine and place on a Suitable work bench for disassembly 3121136 SECTION 3 BASE COMPONENTS 1 Left Drive Motor Assembly 2 Right Drive Motor Assembly 3 Drive Motor Cover Figure 3 2 Drive Motor Assembly Components Machines built prior to S N 0130005271 1 Left and Right Drive Motor Assemblies 2 Drive Motor Mounting Frame Assembly 3 Drive Motor Cover Figure 3 3 Drive Motor Assembly Components Machines built since S N 0130005271 3121136 J LG Lift 3 7 SECTION 3
191. rovided to keep the wheel bearings mast sec tions 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 adja cent areas as well as the openings and fittings them selves As soon as a line or component is disconnected cap or cover all openings to prevent entry of foreign mat ter Clean and inspect all parts during servicing or mainte nance 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 until 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 perpendicular as possible 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 sim ilar bracket lessens as the angle between the supporting structure and the component becomes less than 90 degrees 2 6 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 com plete the procedura
192. s are not available consult your local supplier for an equiva lent 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 3121136 Inspect mast chains for the following conditions 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 sheave 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 crack ing
193. s are lit on the ground station LCD Display before operating the machine When drained to Warning Level 2 or 3 batteries must be charged until 8 bars are lit on the ground station LCD display to clear the fault code Diagnostics Continued operation of the machine in a low voltage state will damage sulfate the batteries Eventually this will cause Shorter cycle times before recharge is needed as well as progressively shorter charging time before 100 charge complete light illuminates 1 If the cycle time of your machine becomes drasti supplies a constant high current This should overcome any sulfated batteries NOTE When battery voltage becomes too low the machine will begin to pull to the left when driven Battery Condition Testing cally reduced try the following solutions a Remove the batteries and place them individu Cycling the battery charger several times after the green light comes on will break through most sulfated batteries Do this by plugging the charger into the proper receptacle and charging until a full charge is indicated After a full charge is indicated unplug the battery charger and plug itin again Repeat this procedure several times ally on a 12 volt automotive type charger that higher NOTE Batteries in storage should be kept at 12 5V or Clean batteries terminals using a non metallic brush and a solution of baking soda and water RInse with clean water After clean
194. s to both sides of mast section 5 using five 5 1 4 20UNC x 1 l Locate the remaining mast section 5 platform u 1 4 long hex head cap screws per side with mounting mast section Lay mast section on flat under a Assemble stable surface shim stock and slide pad to mastsection rail with 2 Attach the remaining chain bottom anchor plate shim stock against rail and slide pad with bev one with threaded holes aligned at the outside of eled side out bracket Attach through set of holes in bottom of d Carefully thread the slide pad mounting bolts mast section 5 with four 4 1 4 20UNC x 3 4 long with flat washers through slide pads and shim bolts place a flatwasher under head of each bolt stock into threads in mast section 5 Be certain NOTE The platform mounting section slide pads are T n x and assembled differently than the slide pads for the UO De other mast sections Mast section 5 slide pads NOTE Mast section 5 into section 4 fit should be very snug need to be assembled disassembled several times in but still be able to be pushed together by hand If too order to determine the correct shim stock required tight remove section 5 disassemble slide pad and for proper fit reduce thickness of shim stock 3 Complete the following steps to determine shim e Begin sliding top of mast section 5 with closed stock thickness required for section 5 rail down engaging the
195. sing surface but do not block the free travel of the drive gear and bearings on the drive shaft or the pinion gear assembly With the open surface of the housing properly sup ported carefully press the drive shaft down through until it is free of the housing When the drive shaft assembly is free slide it completely out of the hous ing To remove the large 47mm cover side bearing and housing side bearing from the drive shaft use a suitable hydraulic press and press the bearing s off the shaft Keep the spacer from between the cover side bearing and the drive shaft gear for reuse during assembly To remove the small 32mm bearing s from the gear brass and pinion assembly use a suitable hydraulic press and press the bearing s off the gear and pinion shaft To remove the brass worm gear from the pinion assembly use a suitable hydraulic press and press the gear off the pinion shaft Keep the brass gear key for reuse during assembly Inspect the drive shaft seal for cuts cracks and wear or if showing signs of leakage Replace if nec essary Gear Pinion Shaft Assembly 11 12 NOTE Locate the pinion gear shaft place the key for the brass worm gear into the sloton the gear shaft Press the brass worm gear onto the pinion shaft and align the keyway in the brass worm gear with the key on the pinion shaft Press the brass worm gear onto the shaft until it bottoms out against the pinion gear
196. slack in the chains Chains will be adjusted later in assembly 5 19 SEC TION 5 MAST COMPONENTS 37 Assemble chain sheaves for narrow chain assem bly to top of mast section 3 as follows a Place four 4 of the 1 flat washers onto one of the remaining sheave pins Locate two 2 nar row chain sheave wheels and slide onto sheave pin on each side of the flat washers b Slide two 2 short spacer tubes onto sheave pin one each end of sheave pin to outside of sheave wheels c Place two 2 sheave pin support bars one each end of sheave pin onto outside of spacer tubes Place a roll pin in the slots at each end of the sheave pins and align with the cutouts in the pin support bars d Holding complete sheave wheel assembly slide assembly into top of mast section 3 and align threaded holes in sheave pin support bars with holes in mast rails e Attach to top of mast section 3 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten pr a I A Bi Mast Section 3 Sheave Wheel Assembly 5 Narrow Washer 6 Sheave Pin 7 Square Keys 1 Support Bar Screws a 2 Pin Support Bars 3 Wide Spacers 4 Sheave Wheel Assys Note a Apply Loctite 242 to threads 38 Slide mast section 3 back into s
197. ssembly drive motor hard Repair Replace ware is hardware loose flange bearing bad loose slip clutch Tighten compo Goto Step 4 check torque settings or adjustment nent 4 Check theleftand right drive motor brakes for loose hardware amp not Tighten or Adjust ly releasing properly _ per procedure Goto Step5 inthis Service Manual 5 Istheelectrical signal and amperage draw to the drive motors Recheck Steps equal Check with machineon level surface See Table 6 3 lthru5 6 Checkthedrive motor brushes do they need replaced Replace per procedureinthis Step 7 Service Manual 7 Calibrate joystick on Platform Control Console perprocedure in _ Section 4 ofthis Service Manual Does this fixthe problem Done Goto Step8 8 15 joystick control defective Repair Replace Goto Step 9 If possible swap out with another platform control Platform control 9 15 the Traction Control Module defective or connections nottight Tighten Connec If possible swap out with another Traction Control Module tions orReplace Go to Step 10 Traction Control Module 10 Inside the drive motor gear box check if the drive shaftis exces Repair Replace gear box sively loose amp condition of drive shaft bearings components per procedure in this Are any gears broken or gear teeth excessively worn Service Manual 6 40 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING Noise From Drive Assembly Overview Of Pro
198. tShort pen X 00000 0 22 22 age 3121136 J LG Lift 6 5 SECTION 6 TROUBLESHOOTING Table 6 1 LCD Display Service Fault Code Conditions PLATFORM FAULT CONSOLE FAULT DESCRIPTION FOR TROUBLESHOOTING CODE LEDs LCD SYMBOL SCREEN LCD TEXT SCREEN MACHINE CONDITION REFER TO FLASHING 23 _ ES HORN DISCONNECTED Horn Disconnected xen X 00000 0 23 23 9 AUX 1 SHORT ae See Table 6 27 24 Auxiliary 1 CircuitShort Page6 21 X 00000 0 24 24 g RUX 1 Auxiliary 1 Circuit SeeTable 6 28 25 lt gt DISCONNECTED NE Page6 22 X 00000 0 25 25 RUX 8 SHORT 26 E Auxiliary 2 CircuitS hort E X 00000 0 26 26 RUX 2 ili 27 DISCONNECTED a qa d X 00000 0 27 427 9 28 RESERVED RESERVED 29 RESERVED RESERVED Traction Module e Em No Communication X 00000 0 30 mo conns 30 with Ground Control Module 9 Platform Control Console JOYSTICK o 31 E lt gt NODULE No Communication with Eden X 00000 0 31 0 conns 31 Ground Control Module 9 _ PUMP MOTOR 2 2 1 7 Popes X 00000 0 32 32 9 E3mmmmpee ri Ded iria X 00000 0 433 433 2 LEDs BARS Flashing with 38 A 5 BarteRs anaudiblebeep See Page 6 26 X 00000 0 38 38 Platform Lift UP Function is Locked Out 1 LED BAR Flashing with an 39 1 73 800000000 D lt gt audible beep See Page 6
199. tatus after diagnostic test is complete NOTE Be sure batteries are fully charged before discon necting the battery charger Failure to do so will result in reduced battery life er 100 CHARGE COMPLETE W GREEN TOP LED ON lt 100 Complete N Z e CHARGING A AMBER MIDDLE LED ON 5 Charge Incomplete i CHARGING PROBLEM e imp 100 RED BOTTOM LED ON e s Consult Troubleshooting Section A lt of the Service Manual or the Charger SCR Manual in Manual Storage Box 3 24 J LG Lift Wet VRLA Battery Charging Profile Switch The DVL and DVSP battery charger is equipped with a man ually selectable charge profile switch located on the rear panel This switch must be set properly to select the charg ing profile required for either WET gassing lead acid batter ies or VRLA Valve Regulated Lead Acid gelled agm type lead acid batteries The machine is equipped from the factory with VRLA valve regulated lead acid batteries and the switch is set from the factory to VRLA Ifthe factory batteries are replaced with wet gassing batteries set this switch to WET IMPORTANT AN IMPROPER PROFILE SETTING MAY DAMAGE THE BATTERIES AND SHORTEN THE BATTERY S LIFE T vRLA whem Ex WET VRLA Battery Selector Switch Location 1 WET VRLA Battery Selector Switch 2 Battery Charger Rear Panel 3 AC Voltage Input Recept
200. teeth Press bearings onto the shaft pressing only against the bearing inner race Do not press against the outer race or damage could occur to the bearing 13 Press the small 32mm bearings onto the ends of the pinion shaft The inner race ofthe bearing on the pinion gear side can be bottomed out against the pinion gear Do not press the bearing on the brass worm gear side of the shaft in tight against the brass worm gear This bearing must be flush with the end of the shaft on the outside yet have clear ance from the brass worm gear on the inside so it can rotate freely Gear Pinion Shaft Assembly 4 Gap 5 32mm Bearing 6 Worm Gear Key 1 32mm Bearing 2 Pinion Gear Shaft 3 Worm Gear brass Drive Shaft Assembly 1 J LG Lift Slide the housing side 42mm x 25mm x 12mm thinner bearing onto the long end of the drive shaft Press the bearing inner race until it bottoms against the shaft shoulder between the drive gear and the bearing Slide the narrow spacer onto the drive gear end of the shaft and press the cover side 42mm x 20mm x 14mm wider bearing onto the drive shaft until it bottoms against the spacer This bearing should be flush with the end of the drive shaft 3121136 SECTION 3 BASE COMPONENTS Final Gear Box Assembly Ifnecessary install a new drive shaft lip seal into the drive shaft hole in the gear box housing before assembling the drive shaft g
201. the P4 connector at Replace Repalror Ground Control Module Check continuity from the P4 connector Platform Repl Wir pin 5 to J unction Box pin 3 and P4 pin 9 to J unction Box pin 4 Control Module amp P ace 1110 Is there continuity on these wires 4 Performthe oystick Calibration Procedure in Section 4 5 of this Replace Service Manual Does this clearthefaultcode Done Platform Control Module 6 30 J LG Lift 3121136 SECTION 6 TROUBLESHOOTING Codes 300 399 Traction Control Module Fault Condition Check For These Obvious Conditions First Damage to Traction Control Module wiring harness Confirm that the static ground strap attached under base frame is secure and undamaged Table 6 39 Codes 300 399 Traction Control Module Fault Condition STEP ACTION SPEC YES NO 1 Recycle machine power5 times allowing a 10 second interval between each power recycle Does fault clear Done Goto Step 2 2 lsacodenumber displaying on the Ground Control Station Replace Code 316 Goto Step 3 Traction Control Module Code 325 Goto Step 5 3 Confirm that both installed batteries are 12 Volt DC 12VDC GotoStep4 Replacewith proper Batteries 4 voltage while chargeris operating Is voltage within Missa E RepairorReplace 31 Volts DC Battery Charger Module 5 Check for shortin harness wires from Ground Control Station con nector P5 to Traction Module
202. the mast section to match the side profile shown in Figure 5 2 when the mast is retracted It is more important that the threaded ends studs protruding on the adjustments are equal side to side on a mast section than it is that the tension in the chains is equal The chain equalizers will always assure equal tension but if the adjustment isn t equal as described the chains may tend to pull to one side or the other The threaded end of the chain cable may need to be restrained while tightening the adjust nut to keep the chain cable from twisting Retract the mast all the way and check if the top of the mast sections appear as shown in Figure 5 2 Repeat steps 1 through 7 for remaining mast sec tions Once mast section adjustment is completed apply loctite 242 to the threads under the jam nuts that were loosened Then re tighten the loosened jam nuts until tight against the top adjust nut Chain cable should have slight tension but should not be taut DVSP Only After all mast adjustments are com plete if necessary adjustthe bumpers on the under side of the stock picker platform so the platform rests slightly above the base frame when it is low ered and empty Sequencing Cable Adjustment 1 J LG Lift Retract mast completely and check each sequenc ing cable on outside of masts for excessive slack Adjust only to remove slack from cable Tighten nylock nut just enough to remove excessive sla
203. the platform control module button 1 Knob Set Screw a 3 J oystick Attach Screws pad 2 Emergency Stop Switch Release Lock Lever 4 The platform control LED s will indicate calibration Notes a Apply Loctite 222 to threads on final assembly mode selected 10 ALL LED s flashing J oystick replacement requires J oystick Calibration 5 Release the turtle button when complete 6 Run the joystick shaft around the gate of the of the joystick two 2 to three 3 times Release the joy Stick to center roseo Bh oystick Shaft Around J oystick Gate 2 to 3 Times Before Returning It To Center 7 Disconnect the jumper tool from the socket under the front of the platform control module 8 Turn off system power The joystick calibration is now complete 4 20 J LG Lift 3121136 SECTION 4 CONTROL COMPONENTS 4 8 PUMP MOTOR ASSEMBLY SERVICE PROCEDURE General The following is a complete disassembly assembly of the DVL DVSP machines pump motor assembly No internal parts to the hydraulic pump are serviced by J LG exceptfor a pump installation seal kit Also the only parts serviceable internal to the pump electric motor is the motor brush kit NOTE During reassembly of the pump motor assembly apply a liberal coat of J LG recommended hydraulic fluid to all seals and o rings Also keep all internal metal parts clean
204. tion 1 outside rail top of mast and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly 11 Install the lift cylinder mount into the bottom of Mast Section 1 Note 1 Cylinder Mount 2 Shim Stock Lift Cylinder Mount Installation 3 Mount Reinforcement Plate 4 Mount Bolts Washers a a Apply Loctite 242 to threads 12 NOTE 13 14 15 J LG Lift Slide the mount into mast section 1 and check for side to side clearance Use mounting shims of equal thickness on each side to center the mount in the closed rail portion if necessary If hydraulic cylinder needs to be extended the pro tective caps on the extend and return ports will need to be temporarily removed Be careful not to nick or scour rod surface when extending also catch any oil draining out of cylinder to avoid spillage onto work area Slide mast section 2 out of mast section 1 approxi mately one foot Slide the lift cylinder into the closed rail side of mast section 2 with rod end to top and port end to bottom of mast Cylinder should extend out of mast on both ends of the mast with the port end resting in the cyl inder mount at the bottom of the mount The manual descent valve should be pointing down towards the back ofthe mast assembly Loosely assemble the cylinder mount cap onto the lift cylinder mount to hold the cylinder assembly i
205. ts are usually caused by rust corro sion or the inside plates walking offthe 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 lubrica tion 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 replace chains with bent or peened chain components Keep chains lubricated Protruding or Turned Pins Chains operating with inade quate lube generate tremendous friction between the pin and plates pin and bushing on leaf chain In extreme cases this frictional torque can 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 chain 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 JLG Lift 2 7 SECTION 2 GENERAL be replaced They should also be adjusted to eliminate twisting the chain for an e
206. utch 12 Drive Motor Assembly nipple towards the outboard side of the base frame Notes Tighten bearing collar set screws on bearing into the drive shaft when assembling Install with item 6 inside of item 5 before driving into shaft Apply Loctite 242 to the threads of item 8 and to the threads of the countersunk screws mounting the drive motor to item 9 b C d Installation shown applies to both left or right drive motor left side shown above Drive motors are mounted with the power cable outlet Required only if drive wheel vertical alignment is not within specification See Drive Wheel Alignment this section of manual Figure 3 4 Drive Motor Component Assembly Machines built prior to S N 0130005271 3121136 J LG Lift 3 9 SECTION 3 BASE COMPONENTS 9 9 5 1 2 56 7 8 9 10 1 Wheel Drive Shaft 5 Roll Pin 9 Drive Motor Attach Screws d 13 Motor Mount Plate Screws 2 Drive Shaft Bearings a 6 Drive Shaft Clutch Key 10 Drive Motor Assembly 3 Bearing Collar Set Screws 7 Torque Limiting Clutch b 11 Clutch Motor Shaft Set Screws c d 4 Drive Motor MountFrame 8 Clutch Motor Shaft Key 12 Motor Mount Plate Installation shown applies to both left or right drive motor left side shown above Drive motors are mounted with the power cable outlet nipple towards the outboard side of the base frame Notes a
207. ven 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 Sheave bearings pin bad c Bent misaligned chains 2 4 LUBRICATION INFORMATION Hydraulic System The primary enemy of a hydraulic system is contamina tion Contaminants enter the system by various means e g using inadequate hydraulic oil allowing moisture grease filings sealing components sand etc to enter when performing maintenance or by permitting the pump to cavitate due to insufficient system warm up or leaks in the pump supply The design and manufacturing tolerances of the compo nent 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 gener ally 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 per mits organic growth resulting in oxidation or corrosion If this condition occurs the system must be drained flushed and refilled with clean oil Itis not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities Good grade mineral oils with viscosities suited to the ambient temperatures in which the machi
208. wered 45 1 100 2 Turn Acceleration Platform Lowered 30 1 100 2 Turn Deceleration Platform Lowered 30 1 100 2 Maximum Forward Speed Platform Lowered 100 1 100 2 Minimum Forward Speed Platform Lowered 30 1 100 2 Maximum Reverse Speed Platform Lowered 100 1 100 2 Minimum Reverse Speed Platform Lowered 20 1 100 2 Maximum Turn Speed Platform Lowered 30 1 100 2 Minimum Turn Speed Platform Lowered 10 1 100 2 Minimum Forward Speed Platform Elevated 20 1 100 2 Minimum Reverse Speed Platform Elevated 20 1 100 2 Maximum Turn Speed Platform Elevated 5 1 100 2 Motor Compensation 90 mOhms 0 500 mOhms 3 Forward Alarm Disable NO YES NO 3 OSS Diagnostic NO YES NO 2 Mode Select Delay Drive Lift M ode active before timeout 5 Sec 0 60 Seconds 2 Invert Lift Direction X YES NO 2 Lift Lock Delay 5 Sec 0 60 Seconds Notes a DVSP Models equipped with stock picker platform and mid gate interlock drive inhibit switch are factory presetto HIGH b DVSP Models equipped with 12 ft lift limit switch option are factory preset to HIGH c DVSP Models this feature is standard equipmentand are factory presetto YES d This circuitis currently unused on both DVL DVSP Models 3121136 J LG Lift SECTION 4 CONTROL COMPONENTS 4 6 PLATFORM CONTROL CONSOLE SERVICE PROCEDURES MACHINES S N 0130007616 TO PRESENT General IMPORTANT DO NOT ATTEMPT TO DISASSEMBLE THE PLATFORM CONTROL BOX IF MACHINE IS STILL UNDER WARRANTY
209. wheels onto the sheave pin on each side of the wide spacer c Slide two 2 1 flat washers onto each end of sheave pin to outside of sheave wheels d Place two 2 sheave pin support bars one each end of sheave pin to outside of space tubes Place a roll pin in the slots at each end of the sheave pins and align with the cutouts in the pin support bars e Holding complete sheave wheel assembly slide assembly into top of mast section 4 and align threaded holes in sheave pin support bars with holes in mast rails f Attach to top of mast section 4 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten 3 3 i 5 le NO LN 1 1 N 7 I d Mast Section 4 Sheave Wheel Assembly 5 Wide Spacer 6 Sheave Pin 7 Square Keys 1 Support Bar Screws a 2 Pin Support Bars 3 Narrow Washers 4 Sheave Wheel Assys Note a Apply Loctite 242 to threads 51 Carefully slide mast section 4 into section 3 until ends are even Check to make sure chain assembly narrow chains are seating properly in chain anchor block chain sheave wheels attached to mast sec tion 3 JLG Lift 5 21 SECTION 5 MAST COMPONENTS MAST SECTION 5 ASSEMBLY c Attach shim stock and slide pad
210. wireterminals atthe Aux 2 component check conti Replacethe Repairor of each of the wires from pins 8 and 1 on theP 1 connector to the Aux 2 component Component Replace Wiring Code 28 Reserved Code 29 Reserved 3121136 J LG Lift 6 23 SECTION 6 TROUBLESHOOTING p Code 30 Traction Module No Communication with Ground Control Module Check For These Obvious Conditions First Check if the communications cable connections P5 connector on the Ground Control Module and round plug on the Traction Control Module are seated properly in their sockets at each end Check the Positive RED and Negative BLACK power cable connections from the Ground Control Module to the Traction Control Module are tight and secure at both ends Table 6 31 Code 30 Traction Module No Communication with Ground Control Module STEP ACTION SPEC YES NO 1 Check the voltage reading atthe main power Positive Negative Repair orReplace j j le iti cable connection on the Traction Control Module 24v DC Goto Step2 usn Cable 2 Removethe communications cable P5 connector atthe Ground Control Moduleand round connectoratthe Traction Control Module _ 5 3 RepairorReplace Check continuity of all three 3 wires inthe communications cable Wire s from end to end P5 Pins 2 3 and 4 3 With communications cable

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