Service & Maintenance Manual

Model(s)
DVL &
DVSP
Series
P/N - 3121136

September 27, 2005

 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
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 INJURY 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 • REMOVE ALL RINGS, WATCHES, AND JEWELRY
to ensure that the machine is safe to operate. WHEN PERFORMING ANY MAINTENANCE.
• DO NOT WEAR LONG HAIR UNRESTRAINED, OR
LOOSE FITTING CLOTHING AND NECKTIES WHICH
MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY ARE APT TO BECOME CAUGHT ON OR ENTANGLED
A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST IN EQUIPMENT.
AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA- • OBSERVE AND OBEY ALL DANGER, WARNING, CAU-
TION. TION AND OTHER INSTRUCTIONS ON MACHINE
AND IN SERVICE MANUAL.
The specific precautions to be observed during machine
maintenance are inserted at the appropriate point in the • KEEP STANDING SURFACES AND HAND HOLDS
manual. These precautions are, for the most part, those FREE OF OIL, GREASE, WATER, ETC.
that apply when servicing hydraulic and larger machine • NEVER WORK UNDER AN ELEVATED PLATFORM
component parts. UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED
Your safety, and that of others, is the first consideration FROM ANY MOVEMENT BY BLOCKING OR OVER-
when engaging in the maintenance of equipment. Always HEAD SLING.
be conscious of component weight and never attempt to • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
move heavy parts without the aid of a mechanical device. PERFORMING ANY OTHER MAINTENANCE, SHUT
Do not allow heavy objects to rest in an unstable position. OFF ALL POWER CONTROLS.
When raising a portion of the equipment, ensure that ade-
quate support is provided. • BATTERY SHOULD ALWAYS BE DISCONNECTED
DURING REPLACEMENT OF ELECTRICAL COMPO-
NENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACH-
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON-
MENTS STOWED IN THEIR PROPER PLACE.
TROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER/ • USE ONLY APPROVED, NONFLAMMABLE CLEANING
OPERATOR. SOLVENTS.

B. HYDRAULIC SYSTEM SAFETY

1. It should be particularly noted that the machines
hydraulic systems operate at extremely high and
potentially dangerous pressures. Every effort should
be made to relieve any system pressure prior to 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 – JLG Lift – a

INTRODUCTION - REVISION LOG

REVISION LOG

October 4, 2001 – Original Issue of Manual

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

b – JLG Lift – 3121136

 TABLE OF CONTENTS

TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.

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

A GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
B HYDRAULIC SYSTEM SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
C MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
REVISION LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

SECTION 1 - MACHINE SPECIFICATIONS

1.1 CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Drive Motor GearBox (gear oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.2 COMPONENT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Hydraulic Pump/Pump Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Rear Wheel Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Batteries/Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.3 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Platform Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Machine Height (platform stowed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Base Footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.4 TORQUE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.5 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.6 HYDRAULIC PRESSURE SETTINGS AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Hydraulic Pressure Gauge Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
After Filter Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.7 CYLINDER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.8 SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
SECTION 2 - GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Pre-Delivery Inspection and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Inspection and Maintenance Codes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Footnotes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.3 SERVICING AND MAINTENANCE GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

3121136 – JLG Lift – i

TABLE OF CONTENTS

Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Pressure-Fit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Mast Chain Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.4 LUBRICATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.5 POSITIONING LIFT FOR ACCESS TO COMPONENTS LOCATED UNDER THE BASE FRAME . . 2-9
SECTION 3 - BASE COMPONENTS
3.1 BASE ASSEMBLY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 BASE FRAME COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Drive Motor Cover - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Battery Charger Cover - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 DRIVE AND CASTER WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Drive Motor Wheel (Std.) - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Caster Wheels - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Wheel Retention for Rough Terrain Drive Wheel (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 DRIVE MOTOR COMPONENT - SERVICING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Torque Limiting Clutch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Visual Inspection and Limiting Torque Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Check Clutch Torque Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Torque Limiting Clutch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Drive Wheel Alignment - (Machines built prior to S/N-0130005271) . . . . . . . . . . . . . . . . . . . 3-5
3.5 DRIVE MOTOR ASSEMBLY - SERVICING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Drive Motor Assembly - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Drive Motor Brake Removal and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Brake Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Brake Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Brush Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Brush Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Brush Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Gear Box Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Gear/Pinion Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Drive Shaft Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Final Gear Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.6 POT HOLE PROTECTION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.7 BATTERY/BATTERY CHARGER - SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Battery Low Voltage Warning Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Battery Condition Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

ii – JLG Lift – 3121136

 TABLE OF CONTENTS

Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
General Component Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Battery Charger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
Printed Circuit Board Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
DC Circuit Breaker/Voltage Select Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
SECTION 4 - CONTROL COMPONENTS
4.1 CONTROL COMPONENTS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 CONTROLS COVER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Battery Cover Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Center, Left and Right Lower Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.3 CONTROL COMPONENTS - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Ground Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Traction Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Platform Control Console Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Horn Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Alarm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Battery Installation (EE Spec Machines Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Fuse Box - (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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Programming Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Activating Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Entering Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Programming Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Selecting Programmable Item to Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Adjusting Programmable Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Service Programming Mode - (Level-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Operator Programming Mode - (Level-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.6 PLATFORM CONTROL CONSOLE - SERVICE PROCEDURES -
(MACHINES S/N - 0130007616 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Remove Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Display/Controller Module Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Mounting Bracket - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Rear Cover - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Display/Controller Module - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
Drive/Lift Mode Switch - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
Horn Button Switch - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

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TABLE OF CONTENTS

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

E-Stop/ShutDown Switch - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Joystick Assembly - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.7 PLATFORM CONTROL CONSOLE - SERVICE PROCEDURES -
(MACHINES PRIOR TO S/N - 0130007616) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Remove Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Upper/Lower Shell Attach Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Emergency Stop Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Upper/Lower Shell Component Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Button Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Joystick Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Joystick Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.8 PUMP-MOTOR ASSEMBLY - SERVICE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Inline Hydraulic Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Pump/Motor/Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Motor Cap/Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Motor Brush Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Brush Housing Final Assembly Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 - OPTION) . . . . . . . . . . . . 4-26
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Transducer Sensor Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
OSS Component Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
SECTION 5 - MAST COMPONENTS
5.1 MAST COMPONENTS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Mast Chain/Cable Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Sequencing Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 SEQUENCE CABLE REPLACEMENT KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Remove Old Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Replacement Cable Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Clamp Installation (Drum/Socket Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILD . . . . . . . . . . . . . . . . . . . 5-7
Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Lift Cylinder Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.5 MAST ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Mast Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.6 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Mast Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Mast Assembly - DVL/DVSP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.7 DVSP - STOCKPICKER PLATFORM - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5.8 DVSP - STOCKPICKER PLATFORM - MID-GATE INTERLOCK INSTALLATION. . . . . . . . . . . . . . 5-25
5.9 MAST BEACON - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

iv – JLG Lift – 3121136

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SECTION 6 - TROUBLESHOOTING
6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 TROUBLESHOOTING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.3 HYDRAULIC CIRCUIT CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.4 ELECTRICAL CIRCUIT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Ground Control Module LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6.5 TROUBLESHOOTING TABLES INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Specifications For Various Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
Special Pin Extractor Tools For Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
Fault Code Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
Main Power Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Mast Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Hydraulic Leak Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Base Frame Components Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Drive System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
6.6 SPECIFICATIONS FOR VARIOUS COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
6.7 SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS . . . . . . . . . . . . . . . . . . .6-10
6.8 FAULT CODE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 Bar - UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
Code 03 - Right PHP Bar - UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
Code 04 - Tilt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
Code 05 - Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
Code 06 - Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
Code 07- Left Drive Motor - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
Code 08 - Right Drive Motor - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Code 09 - Left Brake - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Code 10 - Right Brake - Disconnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Code 11 - Left Drive Motor - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
Code 12 - Right Drive Motor - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
Code 13 - Traction Module - In Fold Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
Code 14 - Pump Motor - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
Code 15 - Lift Down Valve - Disconnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
Code 16 - Lift Down Valve - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
Code 17 - Ground Control Module - In Fold Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
Code 18 - Alarm - Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
Code 19 - Alarm - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19
Code 20 - Beacon - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19
Code 21 - Beacon - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
Code 22 - Horn - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
Code 23 - Horn - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
Code 24 - Auxiliary #1 Circuit - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
Code 25 - Auxiliary #1 Circuit - Disconnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
Code 26 - Auxiliary #2 - Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
Code 27 - Auxiliary #2 - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
Code 28 - Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
Code 29 - Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25
Code 33 - Both PHP Bars - UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
Code 38 - Battery Voltage Low - Warning Level 2 - Two (2) LED/LCDs lit . . . . . . . . . . . . .6-26

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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 Condition . . . . . . . . . . . . . . . . . . . . . 6-28
Codes (100 - 199) Ground Control Module - Fault Condition . . . . . . . . . . . . . . . . . . . . . . . 6-29
Codes (200 - 299) Platform Control Console - Fault Condition . . . . . . . . . . . . . . . . . . . . . . 6-30
Codes (300 - 399) Traction Control Module - Fault Condition. . . . . . . . . . . . . . . . . . . . . . . 6-31
6.9 MAIN POWER CIRCUIT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Machine Will Not Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6.10 MAST TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Platform Will Not Lower Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Platform Lift Up And Down Jerky . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Mast Noisy When Lifting And Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Platform (Mast) Won’t Stay Elevated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Platform (Mast) Descends Too Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
6.11 HYDRAULIC LEAK TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Miscellaneous Hydraulic Leak Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6.12 BASE FRAME COMPONENTS TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Caster Wheels Not Operating Freely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Pot Hole Protection (PHP) Bars will not Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
6.13 DRIVE SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Won’t Climb Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Machine Drives in Opposite Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Machine Won’t Drive Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Noise From Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

vi – JLG Lift – 3121136

 TABLE OF CONTENTS

LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. Hydraulic Pressure Adjustment Screw. (Machine Rear Covers Removed) . . . . . . . . . . . . . . . . . .1-3
1-2. Typical Hydraulic Pressure Gauge Installation (Hydraulic Filter Removed). . . . . . . . . . . . . . . . . .1-4
1-3. Typical Hydraulic Pressure Gauge Installation (After Hydraulic Filter). . . . . . . . . . . . . . . . . . . . . .1-4
1-4. Torque Chart. (ANSI Spec.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-5. Torque Chart. (ANSI to METRIC Conversion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1-6. Torque Chart (Metric Class Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
2-1. Accessing Machine Underside Components by Lifting with a Fork Truck. . . . . . . . . . . . . . . . . . .2-9
3-1. Base Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 S/N-0130005271) . . . . . . . . . . . . . . . .3-10
3-6. Torque Limiting Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
3-7. Brake Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
3-8. Drive Motor Gear Box Assembly - DVL/DVSP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
3-9. Pot-Hole-Protection System Components.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
3-10. DVL/DVSP - SCR Dual Voltage - Battery Charger Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . .3-28
4-1. Control Components Location - DVL/DVSP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4-2. Component Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4-3. Ground Control Module Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4-4. Platform Control Console Components.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
4-5. Platform Control Console Components.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
5-1. Mast Components. (DVL/DVSP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5-2. DVL/DVSP - Mast Chain and Sequence Cable Adjustment Components. . . . . . . . . . . . . . . . . . .5-3
5-3. Machine Positioned for Cylinder Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5-4. Lift Cylinder Component Cross-Section (DVL/DVSP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5-5. Mast Section - Assembly Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
5-6. Mast Chain Routing Diagram. - DVL/DVSP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
6-1. Component Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6-2. Overview of Electrical System Components. (DVL/DVSP) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . .6-42
6-3. Electrical Diagram. (DVL/DVSP) (Sheet 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44
6-4. Electrical Diagram - (with Load Sensing System) (DVL/DVSP) (Sheet 2) . . . . . . . . . . . . . . . . . . .6-46
6-5. Hydraulic Diagram. (DVL/DVSP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48

LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 DVL and DVSP - Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-2 Hydraulic Oil Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-3. Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-4. Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-5 Lubrication Intervals for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-2 DVL/DVSP - Preventive Maintenance & Inspection Schedule.. . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2-3 Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
3-1 Battery Low Voltage Warning Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
4-1 DVL/DVSP Ground Control Module - Field Programmable Settings and Factory Preset.. . . . . . .4-13
4-2 Obstruction Sensor System Components (Platform Cutaway) . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
5-1 DVL/DVSP Mast Component Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
6-1 LCD Display - Service Fault Code Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

3121136 – JLG Lift – vii

TABLE OF CONTENTS

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

6-3 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 - Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
6-7 Code 02 - Left PHP Bar - UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
6-8 Code 03 - Right PHP Bar - UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
6-9 Code 04 - Tilt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
6-14 Code 11 - Left Drive Motor - Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
6-15 Code 12 - Right Drive Motor - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
6-16 Code 13 - Traction Module - In Fold Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
6-17 Code 14 - Pump Motor - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
6-18 Code 15 - Lift Down Valve - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
6-19 Code 16 - Lift Down Valve - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
6-20 Code 17 - Ground Control Module - In Fold Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
6-21 Code 18 - Alarm - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
6-22 Code 19 - Alarm - Disconnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19
6-23 Code 20 - Beacon - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19
6-24 Code 21 - Beacon - Short Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
6-25 Code 22 - Horn - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
6-26 Code 23 - Horn - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
6-27 Code 24 - Auxiliary #1 Circuit - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
6-28 Code 25 - Auxiliary #1 Circuit - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
6-29 Code 26 - Auxiliary #2 - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
6-30 Code 27 - Auxiliary #2 - Disconnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
6-31 Code 30 - Traction Module - No Communication with Ground Control Module . . . . . . . . . . . . . .6-24
6-32 Code 31 - Platform Control Console - No Communication with Ground Control Module. . . . . . .6-25
6-33 Code 32 - Pump Motor - Over Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25
6-34 Code 33 - Both PHP Bars - UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
6-35 Code 40 - OSS - No Communication with Ground Control Module . . . . . . . . . . . . . . . . . . . . . . .6-27
6-36 Codes 41 thru 46 - OSS - Sensor 1 through 6 - Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . .6-28
6-37 Codes (100 - 199) Ground Control Module - Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29
6-38 Code (200 - 299) Platform Control Console - Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30
6-39 Codes (300 - 399) Traction Control Module - Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31
6-40 Machine Will Not Power UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32
6-41 Platform Will Not Lower Manually. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33
6-42 Platform Lift Up and Down Jerky . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33
6-43 Mast Noisy when Lifting and Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34
6-44 Platform (Mast) Won’t Stay Elevated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35
6-45 Platform (Mast) Descends Too Slowly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35
6-46 Hydraulic Leak Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36
6-47 Caster Wheels Not Operating Freely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37
6-48 Pot Hole Protection (PHP) Bars will not Lower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37
6-49 Won’t Climb Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38
6-50 Machine Drive in Opposite Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39
6-51 Machine Won’t Drive Straight.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40
6-52 Noise from Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41

viii – JLG 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 lb. 350 lb. 500 lb. 400 lb.
(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)
15 ft. 19.5 ft. 15 ft. 19.5 ft.
Maximum Vertical Platform Height:
(4.57 m) (5.94 m) (4.57 m) (5.94m)
Maximum Wheel Load (Per Wheel): 800 lb. (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. 20 sec. 22.5 sec.
Platform Down: 15 - 21 sec. 21 - 26 sec. 15 - 21 sec. 21 - 26 sec.
2,105 lb. 2,105 lb. 2,150 lb. 2,150 lb.
Gross Machine Weight (Platform Empty):
(955 kg) (955 kg) (975 kg) (975kg)

3121136 – JLG Lift – 1-1

 SECTION 1 - MACHINE SPECIFICATIONS

1.1 CAPACITIES 1.3 PERFORMANCE DATA

System Voltage Platform Capacities
All Models – 24 Volt DC Standard - 15DVL - 500 lb. (230kg)
Hydraulic System 20DVL - 350 lb. (160kg)
StockPicker - 15DVSP - 500 lb. (230kg)
All Models – 5 qts. U.S. (4.7 L)
20DVSP - 400 lb. (180kg)
Drive Motor GearBox (gear oil)
Extendible - 15DVL/ 15DVSP - 500 lb. (230kg)
All Models – 6 oz. (175cc) 20DVL Series - 350 lb. (160kg)
Molded - 15DVL/15DVSP - 500 lb. (230kg)

1.2 COMPONENT DATA 20DVL Series - 350 lb. (160kg)

Hydraulic Pump/Pump Motor Assembly NOTE: Distribute weight evenly in platform when loading.
Reference the capacity decal on the machines’ decal
Pump Motor - 24 Volt DC motor, Standard Duty billboard mounted on mast.
Pump Displacement –
DVL/DVSP – .098 cu. in./rev. (1.6cc/rev.) Platform Size
Pump Output (Max.) – Standard - 26in.-W x 26 in.-L (66cm) x (66cm)
DVL/DVSP - 1.20 gpm @ 2200 psi @ 23.5 volts and 105 Stockpicker - 28in.-W x 48in.-L (71cm x 122cm)
amps @ 45 centistrokes (200 SSU) Extendible - 26in.-W x 49in.-L (66cm x 124cm)
Reservoir Capacity – Moulded - 25in.-W x 26in.-L (64cm x 66cm)
DVL/DVSP - 1 Gallon (3.78 L)
Machine Height (platform stowed)
Rear Wheel Drive Motors
DVL/DVSP - 78 in. (198cm) height
Drive Motors -
Base Footprint
1/2 HP, 24 Volt DC, Variable
Right Angle, Sealed Gear Box, 40:1 ratio DVL/DVSP - 29.25in.-W x 52in.-L (74cm) x (132cm)
Brake Shaft and Drive Shaft - Integral to Motor
Parking Brake (must be released for pushing)
1.4 TORQUE REQUIREMENTS
Batteries/Battery Charger
When maintenance becomes necessary or a fastener has
Batteries (2) – 12 Volt / 100 Amp Hour – loosened, refer to the applicable Torque Chart in this section
of the manual, to determine proper torque values.
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 on DVL/DVSP machines require

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

1-2 – JLG Lift – 3121136

 SECTION 1 - MACHINE SPECIFICATIONS

1.5 LUBRICATION 1.6 HYDRAULIC PRESSURE SETTINGS AND

ADJUSTMENT
Hydraulic Oil Adjust system pressure so that platform will raise with maxi-
Hydraulic oils must have anti-wear qualities at least to API mum rated capacity in platform.
Service Classification GL-3, and sufficient chemical stabil- The following pressure setting are factory recommended
ity for mobile hydraulic system service. JLG Industries, (initial) settings;
recommends Mobilfluid 424 hydraulic oil, which has an
SAE viscosity of 10W-30 and a viscosity index of 152.
MODEL PRESSURE SETTING
For cold weather applications, i.e. when temperatures
15DVL/15DVSP 2600 PSI
remain consistently below +20°F (–7°C) JLG recom-
mends using Mobil DTE 13 hydraulic oil. 20DVL 1800 PSI
20DVSP 2800 PSI
Aside from JLG recommendations, it is not advisable to
mix oils of different brands or types, as they may not con-
tain the same required additives or be of comparable vis- Turning adjustment screw clockwise increases system
cosities. If use of hydraulic oil other than Mobilfluid 424 is pressure, turning screw counterclockwise decreases sys-
desired, contact JLG Industries for proper recommenda- tem pressure. (See Figure 1-1., Hydraulic Pressure Adjust-
tions. ment Screw. (Machine Rear Covers Removed))
Perform pressure adjustment with oil at normal operating
Table 1-2. Hydraulic Oil Operating Range temperature. If pressure is set when oil is cold, platform may
not raise rated load after soil has warmed.
HYDRAULIC SYSTEM OPERATING SAE VISCOSITY
TEMPERATURE RANGE GRADE
+0˚ F to +180˚ F 10W
(-18˚ C to +83˚ C)
+0˚ F to +210˚ F 10W-20, 10W-30
(-18˚ C to +99˚ C)
+50˚ F to +210˚ F 20W-20
(+10˚ C to +99˚ C)

2
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 1
classification GL-5 or MIL-Spec MIL-L-2105.
HO - Hydraulic Oil. ISO-Vg grade 32, 46.
CL - Chain Lube. Use a good quality chain lubricant. 1. Remove Adjust Screw Cap 2. Pressure Adjustment Screw
Note: Machine rear covers must be removed to access pump motor.

Figure 1-1. Hydraulic Pressure Adjustment Screw.

(Machine Rear Covers Removed)

3121136 – JLG Lift – 1-3

 SECTION 1 - MACHINE SPECIFICATIONS

Hydraulic Pressure Gauge Connection

ONLY OPEN HYDRAULIC SYSTEM LINES WITH THE MAST FULLY

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

Remove the hydraulic oil filter and 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- 1
sure Gauge Installation (Hydraulic Filter Removed).
2
CHECK, and if necessary, ADJUST the hydraulic pressure to
initial settings shown in table at the beginning of this section.
Cycle the hydraulic system several times with the maximum
3
load capacity in the platform, then recheck pressure setting.
4
When pressure has stabilized continue to "After Filter Pres-
sure Check" following.

1. Hydraulic Oil Filter 3. Pressure Gauge Assembly

2. T- Fitting 4. Extend Line

Figure 1-3. Typical Hydraulic Pressure Gauge

4 Installation (After Hydraulic Filter).
1

3
1.7 CYLINDER SPECIFICATIONS
NOTE: All dimensions are given in inches (in), with the met-
2 ric equivalent, centimeters (cm), given in parenthe-
ses.

Table 1-4. Cylinder Specifications

BORE STROKE ROD DIA.

DESCRIPTION
in./(cm) in./(cm) in./(cm)
15DVL/15DVSP - 1.63 41.50 1.375
1. Pressure Gauge Assembly 3. T- Fitting Lift Cylinder (4.10) (105.4) (3.49)
2. Extend Line 4. Return Line 20DVL/20DVSP - 1.63 54.0 1.375
Lift Cylinder (4.10) (137.1) (3.49)
Figure 1-2. Typical Hydraulic Pressure Gauge
Installation (Hydraulic Filter Removed).

1.8 SERIAL NUMBER LOCATIONS

After Filter Pressure Check
For machine identification, a serial number plate is affixed to
Reinstall the hydraulic oil filter and install the t-fitting the machine. The plate is located on the back of the mast,
between the hydraulic filter and the extend line to the cylin- just above the mast support column.
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 – JLG Lift – 3121136

 SECTION 1 - MACHINE SPECIFICATIONS

1
4

Table 1-5.Lubrication Intervals for Various Components

INTERVAL (b)
NO/TYPE (a)
ITEM COMPONENT LUBE/METHOD COMMENTS
LUBE POINTS 3 6 1 2
MONTHS MONTHS YEAR YEARS

Fill To Line on HO - Check Hyd. Oil Check fluid level every day. (c)
1 Hydraulic Oil Reservoir Level ✔ Change hydraulic oil every 2
5 Qt. Reservoir HO - Change Hyd. Oil years.
Drive Wheel
2 — — Permanently Sealed.
Bearings
Drive Wheel Change only when serviced
3 2 - Gear Boxes Gear Oil
Gear Box requires 6 oz. (175 cc’s) to fill.
4 Caster Axles 2 - Grease Fittings MPG - Pressure Gun ✔
5 Swivel Raceways 2 - Front Casters MPG - Pressure Gun ✔
Chain Lube - Brush or
6 Mast Chains 2 - Per Section
Spray ✔ Inspect, lubricate if dry or rusting.

Key to Lubricants: MPG - Multipurpose Grease

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

Notes: (a) Be certain to lubricate like items on each side of the machine.
(b) Recommended lubricating intervals are based on normal use. If machine is subjected to severe operating conditions,
such as a high number of cycles, location, corrosive/dirty environment, etc., user must adjust lubricating requirements accordingly.
(c) Prior to checking hydraulic oil level, operate machine through one complete cycle of lift function (full up and down). Failure to do so
will result in incorrect oil level reading on the hydraulic reservoir.

3121136 – JLG Lift – 1-5

 SECTION 1 - MACHINE SPECIFICATIONS

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

1-6 – JLG Lift – 3121136

 UNPLATED
VALUES FOR ZINC PLATED BOLTS ONLY CAP SCREWS

3121136
– JLG Lift –
Figure 1-5. Torque Chart. (ANSI to METRIC Conversion)
Note: These torque values do not apply to cadium plated fasteners.

SAE GRADE 5 SAE GRADE 8

SECTION 1 - MACHINE SPECIFICATIONS

1-7
 SECTION 1 - MACHINE SPECIFICATIONS

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY

CLASS 8.8 METRIC BOLTS & CLASS 10.9 METRIC BOLTS &
CLASS 8 METRIC NUTS CLASS 10 METRIC NUTS
TORQUE TORQUE
TENSILE
CLAMP DRY OR LOCTITE CLAMP DRY OR LOCTITE
STRESS LOCTITE LOCTITE
SIZE PITCH LOAD LOCTITE LUB 242 OR LOAD LOCTITE LUB 242 OR
AREA 262 262
263 271 263 271
sq. mm KN N, m N, m N, m N, m KN N, m N, m N, m N, m
3 .5 5.03 2.19 1.3 1.0 1.2 1.4 3.13 1.9 1.4 1.5 2.1
3.5 .6 6.78 2.95 2.1 1.6 1.9 2.3 4.22 3.0 2.2 2.4 3.3
4 .7 8.78 3.82 3.1 2.3 2.8 3.4 5.47 4.4 3.3 3.5 4.8
5 .8 14.2 6.18 6.2 4.6 5.6 6.8 8.85 8.9 6.6 7.1 9.7
6 1 20.1 8.74 11 7.9 9.4 12 12.5 15 11 12 17
7 1 28.9 12.6 18 13 16 19 18 25 19 20 28
8 1.25 36.6 15.9 25 19 23 28 22.8 37 27 29 40
10 1.5 58.0 25.2 50 38 45 55 36.1 72 54 58 79
12 1.75 84.3 36.7 88 66 79 97 52.5 126 95 101 139
14 2 115 50.0 140 105 126 154 71.6 200 150 160 220
16 2 157 68.3 219 164 197 241 97.8 313 235 250 344
18 2.5 192 83.5 301 226 271 331 119.5 430 323 344 473
20 2.5 245 106.5 426 320 383 469 152.5 610 458 488 671
22 2.5 303 132.0 581 436 523 639 189.0 832 624 665 915
24 3 353 153.5 737 553 663 811 220.0 1060 792 845 1170
27 3 459 199.5 1080 810 970 1130 286.0 1540 1160 1240 1690
30 3.5 561 244.0 1460 1100 1320 1530 349.5 2100 1570 1680 2310
33 3.5 694 302.0 1990 1490 1790 2090 432.5 2600 2140 2280 2860
36 4 817 355.0 2560 1920 2300 2690 509.0 3660 2750 2930 4020
42 4.5 1120 487.0 4090 3070 3680 4290 698.0 5860 4400 4690 6440

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

METRIC CLASS 8.8 METRIC CLASS 10.9

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

1-8 – JLG Lift – 3121136

 SECTION 2 - GENERAL

SECTION 2. GENERAL

Reference the JLG Pre-Delivery and Frequent Inspection

2.1 MACHINE PREPARATION, INSPECTION, Form and the Inspection and Preventative Maintenance
AND MAINTENANCE Schedule for items requiring inspection during the perfor-
mance of these inspections. Reference the appropriate
General areas of this manual for servicing and maintenance proce-
dures.
This section provides the necessary information needed
by those personnel that are responsible to place the Annual Machine Inspection
machine in operation readiness and maintain its safe
operating condition. For maximum service life and safe The Annual Machine Inspection must be performed by a
operation, ensure that all the necessary inspections and qualified JLG equipment mechanic on an annual basis, no
maintenance have been completed before placing the later than thirteen (13) months from the date of the prior
machine into service. Annual Machine Inspection. JLG Industries, Inc. recog-
nizes a qualified JLG equipment mechanic as a person
Preparation, Inspection, and Maintenance who has successfully completed the JLG Service Training
School for the subject JLG product model. Reference the
It is important to establish and conform to a comprehen- machine Service and Maintenance Manual and appropri-
sive inspection and preventive maintenance program. The ate JLG inspection form for performance of this inspec-
following table outlines the periodic machine inspections tion.
and maintenance recommended by JLG Industries, Inc.
Consult your national, regional, or local regulations for fur- Reference the JLG Annual Machine Inspection Form and
ther requirements for aerial work platforms. The frequency the Inspection and Preventative Maintenance Schedule for
of inspections and maintenance must be increased as items requiring inspection during the performance of this
environment, severity and frequency of usage requires. inspection. Reference the appropriate areas of this man-
ual for servicing and maintenance procedures.
Pre-Start Inspection For the purpose of receiving safety-related bulletins, it is
important that JLG Industries, Inc. has updated ownership
It is the User’s or Operator’s primary responsibility to per- information for each machine. When performing each
form a Pre-Start Inspection of the machine prior to use Annual Machine Inspection, notify JLG Industries, Inc. of
daily or at each change of operator. Reference the Opera- the current machine ownership.
tor’s and Safety Manual for completion procedures for the
Pre-Start Inspection. The Operator and Safety Manual Preventative Maintenance
must be read in its entirety and understood prior to per-
forming the Pre-Start Inspection. In conjunction with the specified inspections, mainte-
nance shall be performed by a qualified JLG equipment
Pre-Delivery Inspection and Frequent mechanic. JLG Industries, Inc. recognizes a qualified JLG
Inspection equipment mechanic as a person who, by possession of a
recognized degree, certificate, extensive knowledge, train-
The Pre-Delivery Inspection and Frequent Inspection shall ing, or experience, has successfully demonstrated the
be performed by a qualified JLG equipment mechanic. ability and proficiency to service, repair, and maintain the
JLG Industries, Inc. recognizes a qualified JLG equipment subject JLG product model.
mechanic as a person who, by possession of a recog- Reference Table 2-2, DVL/DVSP - Preventive Maintenance
nized degree, certificate, extensive knowledge, training, or & Inspection Schedule., and the appropriate areas of this
experience, has successfully demonstrated the ability and manual for servicing and maintenance procedures. The
proficiency to service, repair, and maintain the subject frequency of service and maintenance must be increased
JLG product model. as environment, severity and frequency of usage requires.
The Pre-Delivery Inspection and Frequent Inspection pro-
cedures are performed in the same manner, but at differ-
ent times. The Pre-Delivery Inspection shall be performed
prior to each sale, lease, or rental delivery. The Frequent
Inspection shall be accomplished for each machine in 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 – JLG Lift – 2-1

 SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Primary Service
Type Frequency Reference
Responsibility Qualification

Pre-Start Prior to use each day; or User or Operator User or Operator Operator and Safety Manual
Inspection At each Operator change.

Pre-Delivery Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Service and Maintenance Man-
Inspection rental delivery. Mechanic ual and applicable JLG inspec-
tion form.

Frequent In service for 3 months; or Out of service Owner, Dealer, or User Qualified JLG Service and Maintenance Man-
Inspection for a period of more than 3 months; or Pur- Mechanic ual and applicable JLG inspec-
chased used. tion form.

Annual Annually, no later than 13 months from the Owner, Dealer, or User Qualified JLG Service and Maintenance Man-
Machine date of the prior inspection. Mechanic ual and applicable JLG inspec-
Inspection tion form.

Preventative At intervals as specified in the Service and Owner, Dealer, or User Qualified JLG Service and Maintenance Man-
Maintenance Maintenance Manual. Mechanic ual

2-2 – JLG 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
which that component is to be checked.
The checks and services listed in this schedule are not
intended to replace any local or regional regulations that
may pertain to this type of equipment nor should the lists
be considered as all inclusive. Variances in interval times
may occur due to climate and/or conditions and depend-
ing on the location and use of the machine.

3121136 – JLG Lift – 2-3

 SECTION 2 - GENERAL

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

INTERVAL
AREA ON MACHINE 3 MONTH 6 MONTH PRE-DELIVERY (b) ANNUAL (d)
PRE-START (a)
PREVENTATIVE PREVENTATIVE OR FREQUENT (c) (YEARLY)
INSPECTION
MAINTENANCE MAINTENANCE INSPECTION INSPECTION
MAST ASSEMBLY 7
Mast Sections 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 1, 2
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
Pot Hole 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 Box Assembly *
Drive Motor Brushes 2, 20
Torque Limit Clutch ** 1, 7 3
Brake Release 5 5
FUNCTIONS/CONTROLS 7
Platform Controls 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 & Platform) 5
Function Limit or Cutout Switch Systems 5
Drive Brakes 5
Manual Descent or 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 1, 2 1, 2
Hydraulic Hoses, Lines, and Fittings 1, 9 1, 9
Hydraulic Reservoir, Cap, and Breather 5, 7 5, 7

2-4 – JLG Lift – 3121136

 SECTION 2 - GENERAL

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

INTERVAL
AREA ON MACHINE 3 MONTH 6 MONTH PRE-DELIVERY (b) ANNUAL (d)
PRE-START (a)
PREVENTATIVE PREVENTATIVE OR FREQUENT (c) (YEARLY)
INSPECTION
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 Safety 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 Test of All Systems 22 22
Paint and Appearance 7 7
Stamp Inspection Date on Frame 22
Notify JLG of Machine Ownership 22
* Change only when serviced, requires 6 oz. (175cc’s) to fill.
** If the lift is moved via fork truck on a regular or frequent basis, then the torque 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. No gouges, excessive wear, or cords showing.
17. Properly inflated and seated around rim.
1. Check for proper and secure installation.
18. Proper and authorized components.
2. Visual inspection for damage, cracks, distortion, or
excessive wear. 19. Fully charged.
3. Check for proper adjustment. 20. No loose connections, corrosion, or abrasions.
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. Overrides Platform controls.
8. Interlocks function properly. 25. Inspected per Service and Maintenance Manual.
9. Check for signs of leakage.
Footnotes:
10. Decals installed and legible.
(a) Prior to use each day; or at each Operator change
11. Check for proper fluid level.
(b) Prior to each sale, lease, or delivery
12. Check for chafing and proper routing.
(c) In service for 3 months; or Out of service for 3 months
13. Check for proper tolerances. or more; or Purchased used
14. Properly lubricated. (d) Annually, no later than 13 months from the date of the
15. Torqued to proper specification. prior inspection

3121136 – JLG Lift – 2-5

 SECTION 2 - GENERAL

If a part resists removal, check to see whether all nuts,

2.3 SERVICING AND MAINTENANCE bolts, cables, brackets, wiring, etc., have been removed
GUIDELINES and that no adjacent parts are interfering.

General Component Disassembly and Reassembly

The following information is provided to assist you in the When disassembling or reassembling a component, com-
use and application of servicing and maintenance proce- plete the procedural steps in sequence. Do not partially
dures contained in this chapter. disassemble or assemble one part, then start on another.
Always recheck your work to assure that nothing has been
Safety and Workmanship overlooked. Do not make any adjustments, other than
those recommended, without obtaining proper approval.
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always Pressure-Fit Parts
be conscious of component weight. Never attempt to
move heavy parts without the aid of a mechanical device. When assembling pressure-fit parts, use an “anti-seize” or
Do not allow heavy objects to rest in an unstable position. molybdenum disulfide base compound to lubricate the
When raising a portion of the equipment, ensure that ade- mating surface.
quate support is provided.
Bearings
When a bearing is removed, cover it to keep out dirt and
NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT-
abrasives. Clean bearings in nonflammable cleaning sol-
FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT
vent and allow to drip dry. Compressed air can be used
BY BLOCKING OR OVERHEAD SLING.
but do not spin the bearing.
Cleanliness Discard bearings if the races and balls (or rollers) are pit-
ted, scored, or burned.
The most important single item in preserving the long ser- If bearing is found to be serviceable, apply a light coat of
vice life of a machine is to keep dirt and foreign materials oil and wrap it in clean (waxed) paper. Do not unwrap
out of the vital components. Precautions have been taken reusable or new bearings until they are ready to install.
to safeguard against this. Shields, covers, seals, and fil-
Lubricate new or used serviceable bearings before instal-
ters are provided to keep the wheel bearings, mast sec-
lation. When pressing a bearing into a retainer or bore,
tions and oil supply clean; however, these items must be
apply pressure to the outer race. If the bearing is to be
maintained on a scheduled basis in order to function
installed on a shaft, apply pressure to the inner race.
properly.
At any time when oil lines are disconnected, clear adja- Gaskets
cent areas as well as the openings and fittings them-
selves. As soon as a line or component is disconnected, Check that holes in gaskets align with openings in the
cap or cover all openings to prevent entry of foreign mat- mating parts. If it becomes necessary to hand-fabricate a
ter. gasket, use gasket material or stock of equivalent material
Clean and inspect all parts during servicing or mainte- and thickness. Be sure to cut holes in the right location, as
nance, and assure that all passages and openings are blank gaskets can cause serious system damage.
unobstructed. Cover all parts to keep them clean. Be sure
all parts are clean before they are installed. New parts Bolt Usage and Torque Application
should remain in their containers until they are ready to be
Use bolts of proper length. A bolt which is too long will
used.
bottom before the head is tight against its related part. If a
bolt is too short, there will not be enough thread area to
Components Removal and Installation engage and hold the part properly. When replacing bolts,
Use adjustable lifting devices, whenever possible, if use only those having the same specifications of the origi-
mechanical assistance is required. All slings (chains, nal, or one which is equivalent.
cables, etc.) should be parallel to each other and as near Unless specific torque requirements are given within the
perpendicular as possible to top of part being lifted. text, standard torque values should be used on heat-
Should it be necessary to remove a component on an treated bolts, studs, and steel nuts, in accordance with
angle, keep in mind that the capacity of an eyebolt or sim- recommended shop practices or Torque Chart in Section
ilar bracket lessens, as the angle between the supporting 1.
structure and the component becomes less than 90
degrees.

2-6 – JLG Lift – 3121136

 SECTION 2 - GENERAL

Hydraulic Lines and Electrical Wiring steam clean or degrease chains. At time of chain installa-
tion, factory lube must be supplemented by a mainte-
Clearly mark or tag hydraulic lines and electrical wiring, as nance program to provide a film of oil on the chains at all
well as their receptacles, when disconnecting or removing times. If chains are corroded, they must be inspected,
them from the unit. This will assure that they are correctly especially the outside plates, for cracks in-line with the
reinstalled. pins. If cracks are found, replace the chain; if no cracks
are discovered, lubricate the chains by dipping in heated
Hydraulic System oil, and reinstall on the machine. Keep chains lubricated.
Keep the system clean. If evidence of metal or rubber par- Table 2-3. Chain Stretch Tolerance
ticles is found in the hydraulic system, drain and flush the
entire system. Pin to Pin
Chain Size Allowable Stretch
Disassemble and reassemble parts on clean work sur- Measurement
face. Clean all metal parts with non-flammable cleaning .50" pitch 12" or 24 pitches .24 in./12 in. span
solvent. Lubricate components, as required, to aid assem-
.625 pitch 15" or 24 pitches .30 in./15 in. span
bly.

Lubrication and Servicing Fatigue Cracks: Fatigue is a phenomenon that affects

most metals, and is the most common cause of chain
Components and assemblies requiring lubrication and plate failures. Fatigue cracks are found through the link
servicing are shown in the Lubrication Chart, (See Sec- holes, perpendicular (90 degrees) from the pin in-line
tion-1). Service applicable components with the amount, position. Inspect chains carefully after long time use and
type, and grade of lubricant recommended in this manual, heavy loading for this type of crack. If any cracks are dis-
at the specified intervals. When recommended lubricants covered, replace all chains, as seemingly sound plates
are not available, consult your local supplier for an equiva- are on the verge of cracking. Fatigue and ultimate
lent that meets or exceeds the specifications listed. strength failures on JLG Lifts are incurred as a result of
severe abuse as design specs are well within the rated lift-
Batteries ing capacity of these chains.
Tight Joints: All joints in the leaf chain should flex freely.
Clean batteries, using a non-metallic brush and a solution
On leaf chain, tight joints are usually caused by rust/corro-
of baking soda and water. Rinse with clean water. After
sion, or the inside plates “walking” off the bushing. Limber
cleaning, thoroughly dry batteries and coat terminals with
up rusty/corroded chains (after inspecting care fully) with
an anti-corrosion compound.
a heavy application of oil (preferably a hot oil dip). Tap
inside “walking” plates inward; if “walking” persists,
Mast Chain Inspection Procedure replace the chain. This type of problem is accelerated by
Inspect mast chains for the following conditions: poor lubrication maintenance practice, and most tight
joint chains have been operated with little or no lubrica-
Wear: Always inspect that segment of chain that operates
tion. Tight joints on leaf chain are generally caused by:
over a sheave. As the chain flexes over the sheaves, joints
and plate edges very gradually wear. Chain “stretch” can a. Bent pins or plates.
be measured using a manufacturers wear scale or steel b. Rusty joints.
tape. When chains have elongated 3% they must be c. Peened plate edges.
removed and replaced. Refer to Table 2-3 for proper chain
Oil rusty chains, and replace chains with bent or peened
specifications and allowable stretch tolerances. Peening
chain components. Keep chains lubricated.
and wear of chain plate edges are caused by sliding over
a chain worn contact face of a sheave, or unusually heavy Protruding or Turned Pins: Chains operating with inade-
loads. All of the above require replacement of the chain quate lube generate tremendous friction between the pin
and correction of the cause. Chain side wear, noticeable and plates (pin and bushing on leaf chain). In extreme
when pin heads and outside plates show a definite wear cases, this frictional torque can actually turn the pins in
pattern, is caused by misalignment of the sheave/chain the outside press-fit plates. Inspect for turned pins, which
anchors and must be corrected promptly. Do not repair can be easily spotted as the “V” flats on the pin heads are
chains; if a section of chain is damaged, replace the entire no longer in line. Replace all chains showing evidence of
chain set. turned or protruding pins. Keep chains lubricated.
Rust and Corrosion: Rust and corrosion will cause a Chain Anchors and Sheaves: An inspection of the chain
major reduction in the load carrying capacity of the chain, must include a close examination of chain anchors and
because these are primary reasons for side plate crack- sheaves. Check chain anchors for wear breakage and
ing. The initial lubrication at the factory is applied in a hot misalignment. Anchors with worn or broken fingers should
dip tank to assure full penetration into the joint. Do not

3121136 – JLG Lift – 2-7

 SECTION 2 - GENERAL

be replaced. They should also be adjusted to eliminate Hydraulic Oil

twisting the chain for an even load distribution.
For best performance, JLG recommends the use of ISO-
Inspect the sheaves, sheave bearings, sheave grooves
Vg grade 32, 46 oil with a viscosity range between 15-250
and pins for extreme wear, replace as necessary. A worn
SUS at 100 degrees F (32-54 cST at 40 degrees C). Refer
sheave can mean several problems, as follows:
to Section 1-5 of this Service Manual for recommended
a. Chains too tight. hydraulic oils.
b. Sheave bearings/pin bad.
Changing Hydraulic Oil
c. Bent/misaligned chains.
Use of any of the recommended hydraulic oils eliminates
the need for changing the oil on a regular basis. If it is nec-
2.4 LUBRICATION INFORMATION essary to change the oil, use only those oils meeting or
exceeding the specifications appearing in this manual. If
Hydraulic System unable to obtain the same type of oil supplied with the
machine, consult local supplier for assistance in selecting
The primary enemy of a hydraulic system is contamina- the proper equivalent. Avoid mixing petroleum and syn-
tion. Contaminants enter the system by various means, thetic base oils. JLG Industries recommends changing the
e.g., using inadequate hydraulic oil, allowing moisture, hydraulic oil annually.
grease, filings, sealing components, sand, etc., to enter
Use every precaution to keep the hydraulic oil clean. If the
when performing maintenance, or by permitting the pump
oil must be poured from the original container into
to cavitate due to insufficient system warm-up or leaks in
another, be sure to clean all possible contaminants from
the pump supply.
the service container.
The design and manufacturing tolerances of the compo-
While the unit is shut down, a good preventive mainte-
nent working parts are very close, therefore, even the
nance measure is to make a thorough inspection of all
smallest amount of dirt or foreign matter entering a system
hydraulic components, lines, fittings, etc., as well as a
can cause wear or damage to the components and gener-
functional check of each system, before placing the
ally results in faulty operation. Every precaution must be
machine back in service.
taken to keep hydraulic oil clean, including reserve oil in
storage.
Lubrication Specifications
Cloudy oils indicate a high moisture content which per-
mits organic growth, resulting in oxidation or corrosion. If Specified lubricants, as recommended by the component
this condition occurs, the system must be drained, manufacturers, are always the best choice, however,
flushed, and refilled with clean oil. multi-purpose greases usually have the qualities which
It is not advisable to mix oils of different brands or types, meet a variety of single purpose grease requirements.
as they may not contain the same required additives or be Should any question arise regarding the use of greases in
of comparable viscosities. Good grade mineral oils, with maintenance stock, consult your local supplier for evalua-
viscosities suited to the ambient temperatures in which tion. Refer to Section-1 in this Service Manual for an expla-
the machine is operating, are recommended for use. nation of the lubricant key designations appearing in the
Lubrication Chart.
NOTE: Metal particles may appear in the oil of new
machines due to the wear-in of meshing compo-
nents.

2-8 – JLG Lift – 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 1
the full weight of the machine.
2. Locate work area on a firm, level surface.

KEEP MACHINE LEVEL OR SLIGHTLY TILTED TOWARD FORK- 2

LIFT TRUCK WHEN LIFTING TO PREVENT MACHINE FROM SLID-
ING OFF LIFTING TINES.

3. When lifting with a fork truck, lift only using the fork
lift-truck pockets running the length of the machine’s
base frame from rear to front.
4. After lifting machine to desired work height, place
support stands under the machine. The support
stands must reach from the floor to the bottom of the 1. Lift using only the fork lift pockets in the base frame.
machine and be capable of safely handling the
weight of the machine. 2. Place support stands between machine and floor.

Figure 2-1. Accessing Machine Underside

Components by Lifting with a Fork Truck.

3121136 – JLG Lift – 2-9

 SECTION 2 - GENERAL

This page intentionally left blank.

2-10 – JLG Lift – 3121136

 SECTION 3 - BASE COMPONENTS

SECTION 3. BASE COMPONENTS

3.1 BASE ASSEMBLY COMPONENTS

11
5

7 9

10

1. Base Mounted Beacon 4. Base Frame 7. Pot Hole Protection System 10. Drive Motor Cover
2. Battery Charger Cover 5. Front Caster Wheels 8. Drive Motor Mount Assy.- (To S/N-0130005270) 11. Rear Tie Down Lug
3. Battery Charger Assembly 6. Front Tie Down Lug 9. Drive Motor Mount Assy.- (Since S/N-0130005271)

Figure 3-1. Base Components.

3121136 – JLG 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

3 4

4
6
5

4
2 3
1 2
5
1. Wheel Retaining Screw (a) 4. Drive Wheel
2. Retaining Washer 5. Drive Shaft Key
1. Hex Head Screws/Washers - 3. Drive Motor Mount
3. 2mm x 10mm Dia. Washer (b) 6. Drive Shaft Key Slot
(Apply Loctite 242) 4. Motor Mount Interlock Slots
2. Front Support Tab 5. Static Strap Note: (a) On assembly, apply Loctite 242, torque to 35 ft. lb.
(b) Install as required; Must be .005" minimum distance
between retaining washer (item 2) and wheel hub face
Battery Charger Cover - Installation (item 4) with retaining screw torqued.

Caster Wheels - Installation

1
4

2
3
2

1. Caster Wheel Assembly 3. Caster Shim (b)

2. Hex Head Screw/Flat Washer (a)
1. Battery Charger Cover 3. Hex Head Screws/Washers
Note: (a) On assembly, apply Loctite 242 to threads.
2. Cap Screws/Washers 4. Base Mounted Beacon (a)
(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.

3-2 – JLG Lift – 3121136

 SECTION 3 - BASE COMPONENTS

Wheel Retention for Rough Terrain Drive

3.4 DRIVE MOTOR COMPONENT -
Wheel (Option)
SERVICING
1. The rought terrain drive wheel is installed same as
the regular drive wheel except - place the wheel onto Torque Limiting Clutch Maintenance
drive motor shaft ensuring that the deepest point of
the rim, 5/8" as shown below, is facing out. DVL Series and DVSP machines are equipped with a torque
limiting clutch coupling on each drive axle. The clutch is
Failure to do so will result in the drive wheel rubbing mounted in line on a split drive axle between the drive wheel
the drive motor cover. and the drive motor gear box. The clutch is designed to slip
at a preset torque (220 ft. lb.) if the machines rear wheels are
over-driven while the machine is being towed, pushed or
5/8”
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
Note* Do not forget to replace
shim(s), .005”min. Gap is However, if the lift is being moved via a fork truck on a regu-
critical between retaining lar or frequent basis, then the torque clutch may be forced
washer and wheel hub. 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;
2. Replace shims and the retaining washer. • Machine does not drive straight.
3. Apply Loctite #242 onto retaining screw and install NOTE: Machine pulling to one side can also be the result of
with a torque rating of 35 ft lb. low battery voltage. Be sure and check battery volt-
age before clutch maintenance begins.
IMPORTANT
• There is gray dust accumulating around the drive
FAILURE TO APPLY LOCTITE #242 TO THE RETAINING SCREW motor(s) due to excessive clutch wear.
AND TORQUING THE RETAINING SCREW TO 35 FT LB MAY
RESULT IN THE WHEEL COMING LOOSE AND FALLING OFF

3121136 – JLG Lift – 3-3

 SECTION 3 - BASE COMPONENTS

Visual Inspection and Limiting Torque Check Clutch Torque Setting

Checking Procedure
1. Select a torque wrench capable of setting a torque
Special tools required: of 220 ft. lb. Insert special tool (P/N-0080229) into a
1-3/4" socket on the torque wrench.
• Torque Wrench (capable of setting torque in the range
of 220 ft. lb. 2. Slide the tool onto the end of the drive axle aligning
the key on the axle shaft (install key on axle, if nec-
• Special tool part # 0080229 essary), with key slot in the tool.
• 2-3/8" open end wrench
• Loctite #242
1. Locate the machine on a firm level surface.
2. Before clutch torquing can begin, you must remove 2
the wheels using the following procedure:

NOTE: Machines equipped with Rough 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"

off the floor and support in a safe manner.

NOTE: (See Section 3.3, Drive And Caster Wheels, illustra-

tion) 1

b. Remove the wheel retaining screw (1) from axle

assembly. Clean threads of screw. 3
c. Remove retaining washer (2), and shim(s) (3).
d. Slide wheel (4) from axle.
3. Remove the Drive Motor Cover from under machine, Checking Clutch - Torque Setting
see instructions previously outlined in this section of 1. Torque Limiting Clutch (a) 3. Clutch Torque Setting -
the manual. 2. Socket Tool Insert 220 ft. lb.
4. Carefully raise the lift to gain access to the under- Notes: (a) DO NOT lubricate chain, lubricant could drip onto the
side of the base frame. Refer to "Positioning Lift For torque clutch friction disk surfaces and cause the
Access to Components Located Under the Base clutch to slip.
Frame" in Section 2.
5. Locate the clutch assembly on each rear drive axle 3. Set the torque wrench to the proper torque setting -
and check for the following; 220 ft. lb.
a. Check the coupling chains for any loose or miss- 4. Turn the torque wrench and note the torque setting
ing parts, i.e. pins, links, etc., replace if neces- when the torque limiting clutch slips. Check both
sary. rear drive axles.
b. Check that at least three (3) of the lock tabs on
5. If torque setting is OK, re-install the drive motor
the clutch adjusting nut - lock washer are prop-
cover and drive motor wheels and lower machine.
erly bent and the nut is secure.
c. Check for any debris wedged in or wrapped IF NOT, continue with Torque Limiting Clutch Adjust-
around the clutch coupling chains and axle ment following.
shafts. Remove debris and clean area if neces-
sary.

3-4 – JLG Lift – 3121136

 SECTION 3 - BASE COMPONENTS

Torque Limiting Clutch Adjustment Drive Wheel Alignment -

(Machines built prior to S/N-0130005271)
NOTE: The large adjusting nut on the side of the clutch
assembly is a standard type thread. The following procedure corrects DVL/DVSP machine drive
If the torque (slip) setting of the clutch assembly is wheel alignment, if required. A drive wheel must be aligned if
off spec 220 ft. lb., the large adjusting nut must be the wheel is more than 1/16" (2mm) off of vertical alignment
(tightened) turned clockwise to increase the torque with machine resting on a level surface.
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- 1
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), 2
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. 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 Square or equivalent to Check.
2 Note: Check with machine resting on a smooth level surface.

Torque Clutch Adjust Nut and Nut Lock Tabs

1. Clutch Adjust Nut 2. Lock Tab Washer (Bend 3 Tabs Over) 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.

3121136 – JLG Lift – 3-5

 SECTION 3 - BASE COMPONENTS

Drive Motor Assembly - Removal

3.5 DRIVE MOTOR ASSEMBLY - SERVICING
NOTE: The following drive motor servicing instructions refer (See Figure 3-2. or Figure 3-3.)
to machines built to both the original design - The DVL/DVSP drive motor assemblies are mounted inde-
(Machines built prior to Serial Number - pendently of each other on a completely removable drive
0130005271) and a new design - (Machines built assembly mounting frame(s) at the rear of the machine. The
since Serial Number - 0130005271). The major differ- drive assembly mounting frame is fastened to the base
ence between the two designs is the drive motor frame at the top and interlocks with slots in the drive motor
mounting frame, the original is two separate mount- cover at the bottom.
ing frames the new design is a one piece frame
mount. 1. Disconnect the positive battery terminal from the left
side battery.
Components on the drive motor assemblies may be ser-
viced without removing the motor mounting frame assem- 2. Remove the drive motor assembly cover and set
bly(s) from the machine, if necessary. aside, see Section 3.2, Base Frame Covers.

The component parts of the left and right drive motor assem- 3. Disconnect the drive motor harness connector(s)
blies are identical except for the drive motor mounting frame from the traction module mounted just above the
assembly. hydraulic pump motor, located under the rear
machine covers. Guide motor harness down
through base frame.
4. 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".
5. Remove the hex head cap screw and washer from
the front of the drive assembly mounting frame.
6. 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.
7. Lower the drive motor assembly from the machine
and place on a suitable work bench for disassembly.

3-6 – JLG Lift – 3121136

 SECTION 3 - BASE COMPONENTS

2
1
3

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
3

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 – JLG Lift – 3-7

 SECTION 3 - BASE COMPONENTS

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: (a) Apply Loctite #242 to threads of screw/nut fastener on final assembly. Stud uses a lock nut.

1 2

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: (a) Apply Loctite #242 to threads of screw/nut fastener on final assembly. Stud uses a lock nut.

3-8 – JLG Lift – 3121136

 SECTION 3 - BASE COMPONENTS

13

9 14

5 12
7 11
8 9 10
4 6
2 3
1

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 Clutch 12. Drive Motor Assembly

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) Tighten bearing collar set screws on bearing, into the drive shaft when assembling.
(b) Install with item #6 inside of item #5 before driving into shaft.
(c) Apply Loctite 242 to the threads of item 8 and to the threads of the countersunk screws mounting the drive motor to item 9.
(d) 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 – JLG Lift – 3-9

 SECTION 3 - BASE COMPONENTS

13
12
4 11

1 2 5 6 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 Mount Frame 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) 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 – JLG Lift – 3121136

 SECTION 3 - BASE COMPONENTS

10 11
13

9 12
7 8
5 6
4
2 3
1

1. Adjusting Nut (a) 4. Pressure Plate (b) 7. Friction Disk (b) 10. Dual Sprocket Chain (c) 13. Drive Hub Sprocket
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
Notes: (a) Adjust on machine, see adjustment procedure this section of manual. (c) DO NOT lubricate chain.
(b) When assembling check that disk mating surfaces are free of oil, dirt, and moisture.

Figure 3-6. Torque Limiting Clutch Assembly

Drive 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- 1
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, 2
once released the brakes are not engaged again
until the machine comes to a complete stop.

Drive Motor Brake Location

1. Drive Motor Brake
2. Motor/Brake Power Cable from Traction Control Module
3. Boot Assembly (Shown Cutaway)

3121136 – JLG Lift – 3-11

 SECTION 3 - BASE COMPONENTS

Brake Operation (See Figure 3-7.) Checking/Adjusting Armature Plate Gap

Setting
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 1. First inspect that all parts of the brake assembly are
coil housing. This pressure forces the armature plate against tight and secure. Tighten as necessary.
the friction brake disk holding it tight between the armature 2. Inspect the brake for any debris which may be
plate and the mounting plate. The friction brake pad is lodged in the air gap between the armature plate
mated to the drive motor armature shaft. The brake is not and magnetic coil when the brakes are ENGAGED
released until the magnetic coil is energized pulling the (brakes on); on either side of the friction disk when
armature plate away from the friction brake disk. the brake is RELEASED (brakes off). Clean and
A correctly adjusted brake will ideally have a measurement remove debris as necessary.
of approximately .006" (but will operate normally at .004" to 3. With the brakes ENGAGED measure the air gap
.010") between the armature plate and magnetic coil hous- between the armature plate and the magnetic coil
ing surface when the brakes are ENGAGED (brakes on). housing. The correct setting should be .006", how-
Never allow any type of lubricant (oil, grease, hydraulic fluid, ever the brakes will operate properly if the measure-
etc.) to come in contact with the brake friction disk or it’s ment is a minimum of .004" and a maximum of .010".
contacting surfaces. Also if the brake becomes clogged with (See "Gap Setting" Illustration this Section)
debris or dirt the brake may not release properly. 4. If the air gap falls outside the maximum allowable
setting of .010" the friction disk has worn. To correct
Brake Assembly Removal this replace the disk with a new one.

1. Lift the machine to gain access to the underside 5. If the air gap is below the minimum allowable setting
(See Section 2-5.). of .004", recheck the areas between the magnetic
coil housing, armature plate, friction disk and
2. Remove the drive motor cover (See Section 3.2). mounting plate for debris. Clean as necessary.
3. Disconnect the drive motor power connector from
it’s wiring harness connector.
4. Loosen the boot clamp, and slide the protective rub- 2
ber boot off the end of the drive motor housing 3
exposing the brake assembly. 4

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.

3
2
1

5
6

7
8

1. Magnetic Coil Housing 5. Plate Springs

2. Armature Plate 6. Shim Washers
3. Friction Brake Disk 7. Spacer
Boot and Brake Removal 4. Mounting Plate 8. Mounting Plate Screws
1. Protective Rubber Boot 2. Boot Clamp 3. Brake Assembly
Figure 3-7. Brake Assembly Components

3-12 – JLG Lift – 3121136

 SECTION 3 - BASE COMPONENTS

3 3
4 4
2 2
1 1

5 5

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 Compressed

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. lbs.
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 – JLG Lift – 3-13

 SECTION 3 - BASE COMPONENTS

Drive Motor Boot Assembly Installation

4
3

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

WIRING HARNESS WIRING HARNESS

NIPPLE NIPPLE

DRAIN HOLE

RIGHT DRIVE MOTOR BOOT LEFT DRIVE MOTOR BOOT

3-14 – JLG Lift – 3121136

 SECTION 3 - BASE COMPONENTS

Drive Motor Brush Replacement Brush Removal

Each drive motor contains two (2) brushes, the brushes are Removal of the brushes also requires the removal of the
located under the two (2) large round slotted brush caps on drive motor(s) from the machine, see procedure described
the front end of each drive motor. earlier in this section for instructions to remove the drive
motors. If not already done, disconnect the 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
2 possible.
1
3. The brushes are retained by constant-force, roll-type
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.
2 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

3 remove the pig-tail terminal from it’s connection to
the brush box.
5. Loosen the screw securing the pig-tail terminal end
Drive Motor Brush Location to the brush box and slide the terminal end out from
1. Brush Location 3. Protective Rubber Boot under the screw completely removing the brush
2. Brush Caps (shown removed) from the drive motor.

1 3

DISCONNECT THE POWER LEADS FROM THE POWER SOURCE 2

4
BEFORE INSPECTING OR REPLACING BRUSHES.

Brush Cleaning and Inspection

Brush wear rate varies depending on the individual machine 5
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- 6 2
mutation.
Brush Component Installation
1. Roll Spring 4. Brush Box Insulator
2. Roll Spring Hooks 5. Brush
3. Brush Box 6. Pigtail Wire

3121136 – JLG Lift – 3-15

 SECTION 3 - BASE COMPONENTS

Brush Reassembly 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.

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-
1
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.
2
2. Slide the body of the brush into the brush box, be
certain that the wire (pig-tail) is aligned with the slot Correct/Incorrect Brush Installation
in the base of the brush box so that it can "feed" into 1. Correct 2. Incorrect
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 IMPORTANT
metallic surfaces other than the brush box by a mini- THE SPRING BRACKET MUST BE ALSO LIE COMPLETELY INSIDE
mum of .125 in. (3mm). THE BRUSH BOX AND NOT OUT OVER THE EDGE. THE ROLL END OF
3. Now install the brush retaining spring bracket. Grasp THE SPRING MUST BE CENTERED ON THE TOP OF THE BRUSH.
the tip of the spring bracket such that the roll-type (SEE CORRECT/INCORRECT BRUSH INSTALLATION ILLUSTRATION)
spring will be on the "brush side" of the brush box,
8. Also apply slight pressure by pulling up on the
and resting on top of the brush when the brush
spring bracket to be certain it is hooked securely
spring is completely installed.
around the brush box wall at the bottom of the brush
4. Push the spring bracket slowly into it’s slot while let- box.
ting it’s two attaching hooks slide on the wall of the
9. Screw the brush caps back into the end shield using
brush box.
the largest possible screwdriver.
5. Stop, but do not release the spring bracket when it’s
hooks slip around the edge of the brush box.
10. Reinstall the drive motor(s) to the machine and
6. While still grasping the spring bracket with the pliers, reconnect the power source.
slowly bring the spring back out of the brush box
until the hooks latch around the edge of the brush IMPORTANT
box.
NEW BRUSHES MAY BE SEATED BY RUNNING THE DRIVE MOTOR
AT NO LOAD. PROPER SEATING IS REQUIRED FOR LOWEST BRUSH
NOISE LEVEL.

3-16 – JLG Lift – 3121136

 SECTION 3 - BASE COMPONENTS

1. Gear Box Cover 5. Spacer 9. Drive Shaft 13. Shaft Key

2. Cover Screws 6. Gear 10. Shaft Seal 14. Bearing (32 x 12 x 10mm)
3. Wave Washer 7. Bearing (47 x 25 x 12mm) 11. Shaft Key 15. Wave Washer
4. Bearing (47 x 20 x 14mm) 8. Lip Seal, Bearing, Retaining Ring 12. Gear & Pinion 16. O-Ring

Figure 3-8. Drive Motor Gear Box Assembly - DVL/DVSP.

Gear Box Disassembly/Assembly NOTE: The gear oil can be drained out when the side cover
is removed in the next step. Remove the side cover
(See Figure 3-8.) from the gear box with the drive shaft side pointing
down, then tilt drive motor/gear box assembly to
The drive motor gear box is mounted on the rear of each drain the oil into a suitable container.
drive motor. Transferring power from the electric drive motor
to the rear drive wheels, the gear box is a right angle worm 2. Remove the four (4) hex cap screws securing the
gear type with a 40:1 reduction drive ratio. The internal gears side cover to the gear box housing, and remove the
and bearings of the gear box are lubricated by 6 oz. (176cc) side cover and rubber seal ring. (Note: Early model
of gear oil in an unvented aluminum alloy housing. The fol- machines did not have the rubber seal ring and were
lowing procedures disassemble and assemble the gear box sealed with sealant only.) Be careful not to scratch or
housing internal components. gouge the mating surfaces between the cover and
the gear box housing. This area is sealed by the rub-
Gear Box Disassembly ber ring/sealant and may leak oil if damaged.

1. Remove the drive motor/gear box/brake assembly 3. Remove the wave washers from atop the large and
from the machine using the procedure outlined pre- small bearings and lay inside their respective holes
viously in this section of the manual. in the side cover.

3121136 – JLG Lift – 3-17

 SECTION 3 - BASE COMPONENTS

4. Using a suitable catch container, drain the gear oil 13. Press the small (32mm) bearings onto the ends of
from the gear box housing. the pinion shaft. The inner race of the bearing on the
pinion gear side can be bottomed out against the
5. Remove the drive shaft assembly from the housing.
pinion gear. Do not press the bearing on the (brass)
Place the drive motor/gear box assembly on a
worm gear side of the shaft in tight against the
hydraulic press with the open side of the gear box
(brass) worm gear. This bearing must be flush with
housing facing down. Support the gear box housing
the end of the shaft on the outside, yet have clear-
surface but do not block the free travel of the drive
ance from the (brass) worm gear on the inside, so it
gear and bearings, on the drive shaft or the pinion
can rotate freely.
gear assembly.
6. With the open surface of the housing properly sup-
ported, carefully press the drive shaft down through 4
until it is free of the housing. When the drive shaft 3
assembly is free, slide it completely out of the hous-
ing. 2
1 5
7. 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.
8. 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.
6
9. 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 Gear/Pinion Shaft Assembly
key for reuse during assembly. 1. 32mm Bearing 4. Gap
2. Pinion Gear Shaft 5. 32mm Bearing
10. Inspect the drive shaft seal for cuts, cracks and
3. Worm Gear (brass) 6. Worm Gear Key
wear, or if showing signs of leakage. Replace if nec-
essary.
Drive Shaft Assembly
Gear/Pinion Shaft Assembly
11. Locate the pinion gear/shaft, place the key for the 1. Slide the (housing side), 42mm x 25mm x 12mm
(brass) worm gear into the slot on the gear shaft. (thinner) bearing onto the long end of the drive shaft.
Press the bearing inner race until it bottoms against
12. Press the (brass) worm gear onto the pinion shaft the shaft shoulder between the drive gear and the
and align the keyway in the (brass) worm gear with bearing.
the key on the pinion shaft. Press the (brass) worm
gear onto the shaft until it bottoms out against the 2. Slide the narrow spacer onto the drive gear end of
pinion gear teeth. the shaft and press the (cover side) 42mm x 20mm x
14mm (wider) bearing onto the drive shaft until it
NOTE: Press bearings onto the shaft pressing only against bottoms against the spacer. This bearing should be
the bearing inner race. Do not press against the flush with the end of the drive shaft.
outer race or damage could occur to the bearing.

3-18 – JLG Lift – 3121136

 SECTION 3 - BASE COMPONENTS

Final Gear Box Assembly 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
1. If necessary, install a new drive shaft lip seal into the it into it’s seat. When both are seated continue to
drive shaft hole in the gear box housing before next step.
assembling the drive shaft gear set into the gear
box. Install the seal so it is even with the bottom of 6. With the gear box still positioned with the open
the chamfer in the drive shaft hole on the outside of cover side up, fill the gear box with six (6) ounces
the housing and flush with the bearing seat on the (U.S.) (175cc’s) of good quality worm gear oil (Spec-
inside of the housing. ification - SAE 90 weight - AGMA#5 - EP Com-
pounded). When pouring the gear oil, wet the gears
2. Lube the drive shaft seal with a thin film of oil before and bearings with the oil.
sliding the drive shaft over the seal.
7. Wet with gear oil and place the large wave washer
3. Position the gear box with open cover side up, allow on the end of the drive shaft bearing and the small
space under the gear box for the drive shaft to wave washer on the end of the gear and pinion bear-
extend through without obstruction. ing.
4. Hold the gear and pinion, and drive shaft assemblies 8. Clean the mating surfaces of the side cover and the
together with the pinion gear and the ring gear on gear box and check that the cover dow guide pins
the drive shaft meshing. Now carefully slide these are properly installed in the cover.
assemblies into the gear box housing sliding the
drive shaft through the drive shaft lip seal. 9. Insert the rubber seal into the groove in the cover.

NOTE: While assembling the gear assemblies into the gear 10. Using the cover dow guide pins, place the cover
box housing, be careful with the drive shaft seal and onto the gear box housing.
the softer brass worm gear and brass drive worm 11. Secure using the four (4) hex cap screws, torque
gear from the drive motor. screws evenly to 90 in. lbs.
5. Continue to drop the gear assemblies into the gear 12. Install the drive motor back onto the machine.
box, align the bearings with the bearing seats in the

2 3
1

4
5

6
Drive Shaft Assembly
1. Spacer 3. Pinion Gear Key 5. Drive Shaft
2. Pinion Gear 4. 42 x 25 x 12m Bearing 6. 42 x 20 x 14mm Bearing

3121136 – JLG Lift – 3-19

 SECTION 3 - BASE COMPONENTS

3.6 POT HOLE PROTECTION SYSTEM

6
2
2
1

Pot-Hole-Protection Components
1. Actuator Assembly 3. Rear Hinge Hardware 5. Left Side PHP Bar 7. Machine Front
2. Actuator Cables 4. Front Hinge Hardware 6. Right Side PHP Bar

Figure 3-9. Pot-Hole-Protection System Components.

6
5
5
4
3
4

1 2 1

Front Hinge Assembly Installation Rear Hinge Assembly Installation

1. Flat Head Pin (a) 3. Torsion Spring 5. Cotter Pin 1. Flat Head Pin (a) 3. Torsion Spring 5. Cotter Pin
2. Limit Switch Cam 4. Flat Washer 2. Cable Attach Pin 4. Flat Washer 6. Actuator Cable

Notes: (a) Apply White Lithium Grease to shaft. Notes: (a) Apply White Lithium Grease to shaft.

3-20 – JLG Lift – 3121136

 SECTION 3 - BASE COMPONENTS

2
1
3
2
4

3
Actuator Cable Adjustment 4
(Bars DOWN - Engaged)
1. Actuator Cable Assembly 4. No Tension On Cable
2. Cable Attach Bracket 5. Bar Resting Against Frame PHP Limit Switch Adjustment
3. Adjusting Nuts 1. Limit Switch 3. Set Screws (b)
Notes: Adjust so cable is just released of tension (item 4). 2. Cam w/Countersunk Hole (a) 4. Bar in DOWN Position
Replace cable if excessively frayed in this area
Notes: (a) Loosen set 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.

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
Notes: Adjust until pothole bar is above bottom of base frame.

3121136 – JLG 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.

IMPORTANT: The 3 Levels of Battery Low Voltage Warning indication will only activate on DVL/DVSP machines with version 29 or later 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 ACTION REQUIRED TO
RESULT
LEVEL PLATFORM CONTROL LED GROUND CONTROL LCD CLEAR FAULT
• 3 LEDs/BARS Flashing with Charge batteries to a level of four
an audible beep. (4) LEDs/BARS or more before
00000.0 • Machine will Operate - No operating.
LEVEL-1
Control Functions Locked
Out.

• 2 LEDs/BARS Flashing with Charge batteries for a minimum

an audible beep. of four (4) continuous hours or
00000.0 38 • Platform Lift-UP Function is eight (8) LEDs/BARS lit before
LEVEL-2
Locked Out. operating. (a)
38

• 1 LED/BAR Flashing with an Charge batteries for a minimum

audible beep. of four (4) continuous hours or
00000.0 39 • Drive and Platform Lift-UP eight (8) LEDs/BARS lit before
LEVEL-3
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 bars 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 supplies a constant high current. This should

overcome any sulfated batteries.
Continued operation of the machine in a low voltage state
NOTE: When battery voltage becomes too low the machine
will damage (sulfate) the batteries. Eventually this will
will begin to pull to the left when driven.
cause shorter cycle times before recharge is needed as
well as progressively shorter charging time before 100%
charge complete light illuminates.
Battery Condition Testing

1. If the cycle time of your machine becomes drasti- NOTE: Batteries in storage should be kept at 12.5V or
cally reduced try the following solutions: higher.

a. Cycling the battery charger several times after Clean batteries terminals, using a non-metallic brush and
the green light comes on will break through a solution of baking soda and water. RInse with clean
most sulfated batteries. Do this by plugging the water. After cleaning, thoroughly dry batteries and coat
charger into the proper receptacle and charging battery terminals with an anti-corrosion compound.
until a full charge is indicated. After a full charge Before testing for battery condition, the open circuit voltage
is indicated unplug the battery charger and plug should be taken from each battery. If the voltage of the bat-
it in again. Repeat this procedure several times. teries differs by 0.3 volts or more, the lower voltage battery
b. Remove the batteries and place them, individu- should be replaced.
ally, on a 12 volt automotive type charger that

3-22 – JLG Lift – 3121136

 SECTION 3 - BASE COMPONENTS

Battery Testing Can Be Performed In Two Ways: Battery Charger General Information
1. The batteries can be tested using a battery tester
capable of testing 12V 100Ah AGM VRLA (Valve IMPORTANT
Regulated Lead Acid) batteries, using the instruc-
DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGER IF
tions of the battery tester manufacturer.
MACHINE IS STILL UNDER WARRANTY. OPENING THE BATTERY
2. If an appropriate battery tester is unavailable, the CHARGER WHILE THE MACHINE IS UNDER WARRANTY WILL VOID
batteries can be tested by fully charging them with THE CHARGER WARRANTY. IF UNDER WARRANTY REQUEST A
the charger that is installed in the machine. Then REPLACEMENT CHARGER FROM THE FACTORY.
check the battery voltage of each battery - 4 hours -
after charging is complete. Batteries less than 12.72 ALSO BEFORE REPLACING ANY COMPONENT, USE THE CHARGER
volts should be replaced. MANUFACTURERS TROUBLESHOOTING GUIDE SHIPPED WITH THE
MACHINE TO CHECK THE INTERNAL AC AND DC CIRCUITS AND
NOTE: If a faulty charger is suspected, the batteries can be DETERMINE WHICH COMPONENT HAS FAILED. A WIRING DIAGRAM
charged using a charger that supplies 2.45 volts/ FOR THIS MODEL DUAL VOLTAGE-SCR CHARGER IS INCLUDED AT
cell. Charging should be terminated when the THE END OF THIS SECTION OF THE MANUAL, SEE FIGURE 3-10.
charge current drops below 1 amp.
The DVL and DVSP battery charger allows for replacement
Battery Replacement of the following internal components. Consult your Illus-
trated Parts Manual for part numbers of these components
Replacement battery(s) must be of equivalent voltage and which are available from the JLG Parts Department:
amperage output as the OEM battery(s) in order for the
machine to operate to as manufactured specifications. • Transformer
Battery replacement part weight must also be 65 lb. • Printed Circuit Board
(30Kg) in order to maintain machine stability as manufac-
• Shunt Assembly
tured.
• Interlock Relay
• SCR Rectifier
DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BAT- • AC Circuit Breaker
TERIES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION.
DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY. • DC Circuit Breaker
• AC Voltage Selector Switch
• 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.
1. Be sure the charger is plugged into the proper
receptacle and there is power to that receptacle.
2. Be sure 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.

3121136 – JLG Lift – 3-23

 SECTION 3 - BASE COMPONENTS

Battery Charge/Flash Code LED Indicator on Wet/VRLA Battery - Charging Profile Switch
Platform Control Console
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.

NOTE: Normal battery charging will occur with a voltage The machine is equipped from the factory with VRLA - valve
reading as low as .24V. regulated lead acid batteries, and the switch is set from the
factory to VRLA. If the factory batteries are replaced with wet
On normal power-up and operation this series of LEDs visu- gassing batteries, set this switch to WET.
ally indicates the amount of charge left in the batteries.
• (+) GREEN LEDs lit indicate maximum charge. IMPORTANT
• (–) RED LED’s lit indicate minimum charge remaining. AN IMPROPER PROFILE SETTING MAY DAMAGE THE BATTERIES
AND SHORTEN THE BATTERY’S LIFE.
• 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. 1

Battery Charging Status Indicators Mounted

on Ground Control Station Cover
2
The battery charging status indicators are mounted just
3
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 status
after diagnostic test is complete. WET/VRLA Battery Selector Switch Location
NOTE: Be sure batteries are fully charged before discon- 1. WET/VRLA Battery Selector Switch
necting the battery charger. Failure to do so will 2. Battery Charger Rear Panel
result in reduced battery life. 3. AC Voltage Input Receptacle

- +

CHARGE COMPLETE

- +
GREEN (TOP) LED ON
100% Complete

- +

CHARGING
AMBER (MIDDLE) LED ON
- +
Charge Incomplete

- + CHARGING PROBLEM
RED (BOTTOM) LED ON
- + Consult Troubleshooting Section
of the Service Manual or the Charger
SCR Manual in Manual Storage Box.

3-24 – JLG Lift – 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. 1

The battery charger manual supplied with the machine con-

tains a wiring diagram for the charger as well as Figure 3-10.
at the end of this section of the manual.

Battery Charger Installation

1. Disconnect the positive (+) battery cable from the
left side battery.
2. 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.
3. Disconnect the wiring connectors from the back of
the charger assembly.
4. Remove the four (4) capscrews and washers secur-
ing the charger to the base frame on the front of the 3
charger.
2
5. 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 Cover - Remove/Install
1. Charger Cover 3. Screws - Same on Both Sides
2. Bottom Tray Screws (Removal Optional)

1 2 AC Line Fuse Installation

3
2

Battery Charger - Remove/Install

1. Battery Charger Assembly
2. Charger Capscrews/Washers (4)
3. Front Tie Down Lug (Swing Up)
AC Line Fuse - Remove/Install
1. AC Line Fuse 3. Back of Charger
2. Cap Screw/Lock Washer/Nut

3121136 – JLG Lift – 3-25

 SECTION 3 - BASE COMPONENTS

Interlock Relay Installation Shunt Assembly Installation

1
2

Interlock Relay - Remove/Install Shunt Assembly - Remove/Install

1. Interlock Relay 3. Back of Charger 1. Shunt Assembly 3. Spacers (2)
2. Attach Screws (2) 2. Cap Screws (2)

Wet/VRLA Switch Installation SCR Rectifier Installation (Either Side)

SCR Rectifier - Remove/Install

(Same Mounting on Both Sides)
Wet/VRLA Switch - Remove/Install
1. SCR Rectifier 3. Aluminum Mount Plate
1. Wet/VRLA Switch 2. Back of Charger 2. Nut/Lock Washer

3-26 – JLG Lift – 3121136

 SECTION 3 - BASE COMPONENTS

Transformer Installation DC Circuit Breaker/Voltage Select Switch

Installation

3
2

DC Circuit Breaker/Voltage Select Switch - Remove/Install

1. DC Circuit Breaker 3. DC Circuit Breaker
2 2. 120/240 Voltage Selector Switch

Transformer Remove/Install
1. Transformer 2. Capscrews, Nuts/Washers (4)

Printed Circuit Board Installation

1
2

Circuit Board - Remove/Install

1. Circuit Board 3. Board Screws/Nuts/Washers (2)
2. Spacer (2) 4. Charger Face Plate

3121136 – JLG Lift – 3-27

 SECTION 3 - BASE COMPONENTS

RELAY
2 POS. CONNECTOR
BLK
COM
WHT SOLDER CONNECTION
BLK DC NEG
NC. NO. BLACK
HEAT SINK .001
OHM
AC BROWN WHT SPLICE TX PRI A SCREW CONNECTION
SHUNT
WH W/VARFLEX
BLUE T
GROUND SCR DC FUSE OR
CIRCUIT
SCREW CIRCUIT
AC BREAKER B BREAKER
YLW/GRN C
VARISTOR 2
D T
AC 120V 240V WH
DC POS
INLET 3 RED
SCR
120/240 HEAT SINK
SWITCH
CIRCUIT
BREAKER

WHITE
WHT/ORG 4

ORG

ORG

BLK
YEL

YEL
AC BLUE SPLICE
10 11 15 6 16 17
8 WHT BLUE
8 1
7 GRN GRN
7 7 5
NOTE: VARISTOR LEADS MUST BE WHT
COVERED WITH VARFLEX. 9 CIRCUIT
9 BOARD
HARNESS
13 WHT
13
12 BLK 4
12 12
WHT
14 3
14 4 32 1
2
WET/SEALED
SWITCH
REMOTE LIGHTS
CONNECTOR

BLACK PIN 1 RED

1
2 WHITE PIN 2 GREEN
3 GREEN PIN 3 WHITE
4 RED PIN 4 BLACK

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

3-28 – JLG Lift – 3121136

 SECTION 4 - CONTROL COMPONENTS

SECTION 4. CONTROL COMPONENTS

4.1 CONTROL COMPONENTS OVERVIEW

4
5

6
7

1. Platform Control Console 4. 12 Volt Sealed Batteries 7. Pump/Motor/Tank Assembly

2. Ground Control Module 5. Horn 8. Obstruction Sensor System (DVSP - Option)
3. Traction Control Module 6. Alarm

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

3121136 – JLG Lift – 4-1

 SECTION 4 - CONTROL COMPONENTS

4.2 CONTROLS COVER INSTALLATION

Battery Cover Doors

2 2

1
1

1. Left Side Cover 2. Mast Support Column 1. Right Side Cover 2. Mast Support Column

Center, Left and Right Lower Covers

Center Cover, Lower Left and Right Covers (Rear View)

Lower Left Cover (Front View) Lower Right Cover (Front View)
Note: Center Cover requires unplugging the Charger AC Receptacle
and LED Indicator wires when removing.

4-2 – JLG Lift – 3121136

 SECTION 4 - CONTROL COMPONENTS

Traction Control Module

4.3 CONTROL COMPONENTS -
INSTALLATION The Traction Control Module is mounted below the Ground
Control Module on the mast support column.
IMPORTANT
This module controls the voltage to the drive motors as reg-
BEFORE REMOVING ANY COMPONENT FROM THE ELECTRICAL
ulated by the Ground Control Module from signals received
SYSTEM, DISCONNECT THE POSITIVE TERMINAL FROM THE LEFT
from the Joystick Controller located on the Platform Control
SIDE BATTERY.
Module.
Ground Control Module There are no internal parts serviced on this module.

The Ground Control Module is located under the center

cover at the rear of the machine and is mounted on the mast
support column. All electrical components on the machine 1
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 pro- 2
gramming to enable any optional equipment. See Section
4.5, Ground Control Module - Programming.

2
1

Traction Control Module Installation

2 1. Traction Control Module 2. Attach Screws/Washers

Note: See Figure 4-2. for wiring connection instructions.

2 Platform Control Console Installation

4 3 1

Ground Control Module Installation

1. Ground Control Module 2. Attach Screws/Washers
Note: See Figure 4-2. for wiring connection instructions.

Platform Control Console Installation

1. Platform Control Console 3. Cable Quick Disconnect
2. Console Cable 4. Platform Junction Box

3121136 – JLG Lift – 4-3

 SECTION 4 - CONTROL COMPONENTS

Battery Installation Alarm Installation

2
3
1
2

2
4
5

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

Horn Installation
1. Horn Assembly 2. Attach Screws/Washers
Note: See Figure 4-2. for wiring connection instructions.

4-4 – JLG Lift – 3121136

 SECTION 4 - CONTROL COMPONENTS

Battery Installation (EE Spec Machines Only) Master Disconnect Switch -

(EE Spec Machines Only)

1 1
5
2

4
2

6
7

3
4

Master Disconnect Switch Installation - (UL-EE - Only)

1. Switch Lever 5. Switch
Battery Installation - (UL-EE - Only) 2. Mounting Nut 6. + (Pos) Battery Cable
1. Box Cover 4. Hold-Down Bolt/Washer/Nut 3. Mounting Bracket 7. Cable Nuts
2. Battery 5. Hold-Down Bar 4. Mounting Nut
3. Box Assembly Note: See Figure 4-2. for wiring connection instructions.
Note: See Figure 4-2. for wiring connection instructions.
Installation same for either side battery.

Fuse Box - (EE Spec Machines Only)

1
2
3
4

Fuse/Box - Installation - (UL-EE - Only)

1. Fuse Box 3. Fuse Box Cover
2. Fuse 4. Cover Mounting Screws
Note: See Figure 4-2. for wiring connection instructions.

3121136 – JLG Lift – 4-5

 SECTION 4 - CONTROL COMPONENTS

10

1 P1
P2
P5
(–) (+) P4
2 3 P3 4

(–) (+)

5
(+) M1 M2 (–)
(–) (+)

8
(+) (–)
7

1. Ground Control Module (a) 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 Junction Box Harness (a)
Module Plugs: P2 - PHP, Elevation/Speed, Charger Limit Switch Harness (a) P5 - Joystick Protocol Harness (a)
P3 - Programmable Security Lock Harness (Option) (a)
Notes: (a) Apply di-electric grease JLG Part Number 3020038 to wiring harness terminals, to prevent moisture from entering module.
(b) Seal NEG (–) and POS (+) posts with battery grease to prevent corrosion.
(c) Machines equipped with the UL-EE specification (option) only.

Figure 4-2. Component Electrical Connections.

4-6 – JLG Lift – 3121136

 SECTION 4 - CONTROL COMPONENTS

The DVL Series and DVSP Ground Control Module allows

4.4 GROUND CONTROL MODULE - for field replacement of two (2) components internal to the
SERVICE PROCEDURE module.
• Emergency Stop Switch
IMPORTANT
DO NOT ATTEMPT TO DISASSEMBLE THE GROUND CONTROL MOD- • Power Selector Switch (Key)
ULE IF MACHINE IS STILL UNDER WARRANTY. OPENING THE
GROUND CONTROL MODULE WHILE THE MACHINE IS UNDER WAR- IMPORTANT
RANTY WILL VOID THE WARRANTY. IF UNDER WARRANTY ELECTROSTATIC DISCHARGE CAN DAMAGE COMPONENTS ON THE
REQUEST A REPLACEMENT MODULE FROM THE FACTORY. INTEGRATED CIRCUIT BOARD. PLACE THE GROUND CONTROL
MODULE ON A NON-CONDUCTIVE SURFACE WHEN OPENING.

5
4

1. Cover/LCD Assembly 4. Emergency Stop Switch 7. Heat Sink Base/Main Board Assembly
2. Power Selector Switch Nut 5. Power Selector Switch 8. Cover Attach Screws
3. Emergency Stop Button 6. Main Board to LCD Ribbon Cable Connector

Figure 4-3. Ground Control Module Components.

3121136 – JLG Lift – 4-7

 SECTION 4 - CONTROL COMPONENTS

Cover Removal/Installation

IMPORTANT 1
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.

Release Ribbon Cable

1. Ribbon Cable 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.

1
Cover Installation
1. Remove the (6) Hex Socket Screws from the Heat Sink/
Base. One screw is under the Warranty/Tamper Label.

Reconnecting Ribbon Cable

1. Ribbon Cable Connector Release Tabs
(Slide cable into connector then push tabs
back into connector)
3
Note: Connector same at both ends of the ribbon cable.
2
1

Disconnect the Ribbon Cable

1. Ribbon Cable Connector 3. Support for Cover
2. Ribbon Cable

4-8 – JLG Lift – 3121136

 SECTION 4 - CONTROL COMPONENTS

Power Selector/EStop Switch Installation

5
3
4

2 2

1
1

Emergency Stop Switch Installation

Power Selector/EStop Switch - Connectors Location
1. Emergency Stop Button 4. Nut
2. Button Seal 5. Emergency Stop Switch 1. LCD and Button Circuit Board
3. Square Lock Washer 6. Switch Lock/Release Lever 2. Emergency Stop Switch Connector
3. Main Power Selector Switch Connector
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.

2
3

Power Selector Switch Installation

1. Nut
2. Power Selector Switch
3. Align and insert tab on switch into slot on cover.
Note: Reattach wires to the same terminals on new switch.

3121136 – JLG Lift – 4-9

 SECTION 4 - CONTROL COMPONENTS

Activating Programming Mode

4.5 GROUND CONTROL MODULE -
PROGRAMMING
2
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 1
the field and that function must be enabled before
operation. Activating Programming Mode
• Customizing the machine to fit a specific application, 1. With machine power off, press and hold the Brake
such as changing the LCD display language, program- Release Button (1) on the Ground Control Module.
ming operating speeds such as braking, turning or lift-
ing speeds. 2. While holding the Brake Release Button in, power
machine up by turning the Main Power Selector
Programming Levels Switch (2), to either the Ground Control or Platform
Control Mode.
There are three (3) password protected programming lev- 3. Release the Brake Release Button (1) after machine is
els, from highest to lowest, the levels are: powered up. The LCD display should now display five
• Level-1: JLG Engineering Settings zeros, one with a box around. Continue to next step
Entering Password.
• Level-2: Service and Maintenance Settings -
Level-2 Password: 91101
NOTE: If machine did not power up, check that both the
• Level-3: Operator Settings -
Ground Control Module - Emergency Stop Button,
Level-3 Password: 33271
and the Platform Control Console - Emergency Stop
Button, are in the RESET position.
IMPORTANT
THE LEVEL 1: JLG ENGINEERING SETTINGS ARE NOT DISPLAYED IN Also, if machine is equipped with the (PSL) Program-
THE PROGRAMMABLE SETTINGS UNDER PASSWORD LEVEL-2 OR mable Security Lock option, see Section 3.10 of your
LEVEL-3. LEVEL-1 SETTINGS MUST NOT BE MODIFIED UNLESS Operators Manual for additional machine power-up
DIRECTED BY JLG ENGINEERING DEPARTMENT PERSONNEL. steps.

Level-1: JLG Engineering Settings include voltage, amper-

age, and ohm output settings that are within the operating
parameters 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 – JLG Lift – 3121136

 SECTION 4 - CONTROL COMPONENTS

Entering Password Selecting Programmable Item to Adjust

00000

2 1

1 2 3
Selecting Programmable Item to Adjust
Entering Password 1. Use the Platform UP/DOWN buttons (1) to scroll
1. The Brake Release button (1) moves the box (around through the list of programmable items available to
digit) from left to right to select which digit to change. your programming level.

2. Platform UP button (2) increases the numerical digit. 2. Once a programmable item to be adjusted is selected,
press the Brake Release button (2) to enter that set-
3. Platform DOWN button (3) decreases the numerical tings’ adjustment mode.
digit.
4. Change all five digits (4) to match password level, Adjusting Programmable Setting
then press the Brake Release button (1) again.

Programming Mode Selection

2 1

Adjusting Programmable Setting

1. Adjust the programmable setting using the Platform
3 1 UP/DOWN buttons (1), see Table 4-1 for range of set-
tings for the item selected.
Programming Mode Selection 2. Once parameter is set for the programmable item,
press the Brake Release button (2), this will enter the
1. Use Platform UP/DOWN buttons (1) to move the
parameter and return you to the Programmable Set-
selection box (2) up or down to select item to pro-
tings Menu.
gram.
2. Press the Brake Release button (3) to enter selected
mode then move on to Selecting Programmable Item TO EXIT Programming Mode after entering programma-
to Adjust. ble settings, power machine off with either the Main
Power Selector Switch or Emergency Stop Button.

3121136 – JLG Lift – 4-11

 SECTION 4 - CONTROL COMPONENTS

Service Programming Mode - (Level-2) 1. Position the machine on a level surface verified level
in both the X and Y axis with a digital level.
In the Service Programming Mode the following items are
2. Select "Zero Tilt Sensor" from the menu and press
shown on the main menu:
the Brake Release button.
• Reset Timers
3. The current tilt sensor readings are displayed. To
• Program zero both the X and Y direction sensor setting to the
• Tilt Sensor machines’ present resting surface, press the Brake
• OSS Sensor Release button.
NOTE: There are two production modules available at this 4. Select "Back to Main Menu" and press the Brake
time, one for North/South American and European Release Button.
languages, and one for Asian languages. All pro-
grammable items between these modules are identi- 5. Power machine off and begin operation.
cal with the exception of language selection. OSS Sensor
Reset Timers Displays current Obstruction Sensor System status (Detec-
tion - YES/NO). Also if an object is detected, the sensor(s)
This setting displays five (5) timers as described following:
detecting the object and distance the object is from the sen-
• Trip Time: This timer shows total accumulated hours sor is displayed.
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. 1
2
• Traction Time: Displays the amount of accumulated 4
DRIVE hours on the machine’s current drive compo- 3
nents.
• Lift UP Time: Displays the amount of accumulated OSS Sensor LCD Display Mode
time the machine has operated the Lift UP function.
1. Detection Indicator - Yes/No 3. Object distance from sensor
• Lift DOWN Time: Displays the amount of accumulated 2. Sensor numbers 4. Signal strength
time machine has operated the Lift DOWN function.
Note: This screen can be viewed while another person performs
• Total Time: Displays the total amount of time accumu- the transducer sensor check, see Section 4.9.
lated by the Traction, Lift UP and Lift DOWN Timers.
Of these five (5) timers, only the Trip Timer can be RESET Operator Programming Mode - (Level-3)
back to zero (00000.0).
Program In the Operator Programming Mode the following items are
shown on the main menu (Also See Table 4-1):
Allows service personnel to program the Level-2 and Level-3
items shown in Table 4-1. • Tilt Sensor
• Program
Tilt Sensor
NOTE: There are two production modules available at this
Allows service personnel to reset the Ground Control Mod-
time, one for North/South American and European
ule’s internal digital Tilt Sensor to zero (0.0) degrees in both
languages, and one for Asian languages. All pro-
the X and Y axis.
grammable items between these modules are identi-
cal with the exception of language selection.

ZEROING THE TILT SENSOR REQUIRES THE MACHINE TO BE Tilt Sensor

RESTING ON A SURFACE CHECKED WITH A DIGITAL LEVEL Allows viewing current tilt sensor individual X and Y direction
MEASURING WITHIN 0.0 DEGREES LEVEL IN BOTH THE X AND Y degree reading.
AXIS DIRECTIONS.
Program
NOTE: When entering this mode the LCD will display in real
time the current X and Y degree readings of the tilt Allows the Operator to program Level-3 items shown in
sensor. The reading being displayed is based on the Table 4-1.
previous zero setting and may not reflect level of the
machines current resting surface.

4-12 – JLG Lift – 3121136

 SECTION 4 - CONTROL COMPONENTS

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

Level-2: Service Level Settings On LCD Display: YES = ! HIGH = ↑

Level-3: Operator Level Settings NO = ✕ LOW = ↓
FACTORY
LEVEL PROGRAMMABLE ITEM SETTING RANGE
PRESET
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. 1 - English 3 - Japanese
2
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 Pot Hole Input 1 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 Input 2 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 Lowered) 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 Mode 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 preset to HIGH.
(b) DVSP Models equipped with 12 ft. lift-limit-switch option are factory preset to HIGH.
(c) DVSP Models this feature is standard equipment and are factory preset to YES.
(d) This circuit is currently unused on both DVL/DVSP Models.

3121136 – JLG Lift – 4-13

 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. 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 Switch
• 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 – JLG Lift – 3121136

 SECTION 4 - CONTROL COMPONENTS

Display/Controller Module Electrical Mounting Bracket - Install/Remove

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.

1
2
3
4

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

2 1

Platform Console - Circuit Board Connections

1. Horn Switch - (C5) 4. E-Stop/ShutDown Switch -
2. Communications Cable to (C4)
Platform Junction Box - 5. Drive/Lift ModeSelect
(C6) Switch - (C7)
3. ON/OFF Key Switch (C3) 6. Joystick - (C8) Platform Console - Rear Cover Installation
Note: The (C) numbers shown after the description above repre- 1. Rear Cover 2. Cover Mounting Screws
sent the corresponding identification of the plug on the
module’s circuit board.

3121136 – JLG Lift – 4-15

 SECTION 4 - CONTROL COMPONENTS

Display/Controller Module - Install/Remove Horn Button Switch - Install/Remove

Platform Console - Horn Switch Installation

1. Horn Button Switch (a) 3. Nut
Platform Console - Display Module
2. Lock Washer
1. Display/Controller 2. Mounting Screws
Note: (a) Remove rear cover, unplug wire, remove nut and lock
Module (a)
washer then slide switch out of console.
Note: (a) Unplug all connections on the back of the module
before removing from console. Key Switch - Install/Remove
Drive/Lift Mode Switch - Install/Remove

Platform Console - Key Switch Installaiton

Platform Console - Drive/Lift Mode Select Switch
1. Key Switch (a) 3. Attach Nut
1. Switch Assembly (a) 2. Locking Tabs 2. Notch 4. Key
Note: (a) Remove rear cover, unplug switch wire, press tabs to Note: (a) Remove mounting bracket on bottom of console to
remove. gain access to the key switch assembly.

4-16 – JLG Lift – 3121136

 SECTION 4 - CONTROL COMPONENTS

E-Stop/ShutDown Switch - Install/Remove Joystick Assembly - Install/Remove

4
3

5 4

Platform Console - E-Stop Switch Installation Platform Console - Joystick Installation

1. Loosen Switch Set Screw 5. Barrel Seal 1. Joystick Assembly 4. Rubber Boot/Gasket
2. Turn Switch 90° 6. Switch to Body Retainer 2. Attach Screws (Qty.-4) 5. Install/Remove through the
3. Pull Spring-Loaded Hooks (a) 3. Nylon Washers (Qty.-4) Access Hole in Bottom of
Release Lever Out 7. Switch Retainer Slots Housing. (a) (b)
4. Remove Barrel Assembly
Note: (a) Remove the console mounting bracket.
Note: (a) Use a small straight blade screwdriver to extend the (b) Remove the key switch and e-stop switch to remove
spring-loaded retainer hooks (6) out and release the joystick assembly through access hole in bottom of con-
switch from the body. sole.

3121136 – JLG Lift – 4-17

 SECTION 4 - CONTROL COMPONENTS

4.7 PLATFORM CONTROL CONSOLE -

SERVICE PROCEDURES 9
(MACHINES PRIOR TO S/N -
0130007616)
8
General

IMPORTANT
DO NOT ATTEMPT TO DISASSEMBLE THE PLATFORM CONTROL 7
BOX IF MACHINE IS STILL UNDER WARRANTY. OPENING 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.
6
• Joystick Assembly
• Emergency Stop Switch
• Upper/Lower Shell Gasket
• Button Pad Switch 5
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.
3
Remove Platform Control Console 4
First remove the platform control console completely from
the platform assembly, See Section 4.3, Control Compo-
nents - Installation, Platform Control Console Installation.

2
1

1. Cover Attach Screws (4) 6. Emergency Stop Switch

2. Lower Console Shell 7. Upper Console Shell
3. Circuit Board 8. Joystick Knob/Switch
4. Lower/Upper Shell Seal 9. Button Pad Switch
5. Joystick Assembly

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

Upper/Lower Shell Installation

1. Remove the (4) Phillips Head Screws from the
Lower Shell Housing. 1

Platform Control Console Circuit Board Connections

IMPORTANT
CAREFULLY SLIDE THE UPPER SHELL HALF FROM THE LOWER 1. Connection to Ground Control Module
SHELL HALF. THE COMPONENTS MOUNTED IN THE UPPER SHELL 2. Emergency Stop Wiring Connector
HALF CONNECT TO THE CIRCUIT BOARD IN THE LOWER SHELL 3. External Programming Socket Connector
HALF. 4. Joystick Ribbon Cable Connector

Emergency Stop Switch Installation Button Pad Installation

1 2
3 4
5

Emergency Stop Switch Installation

1. Emergency Stop Button 4. Button Assembly Nut Button Pad Installation
2. Seal 5. Emergency Stop Switch 1. Button Pad Assembly
3. Square Lock Washer 6. Switch Release/Lock Lever (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 JLG Part Number 7024361 into the
1 programming socket under the front of the platform
control console. This will short pins two (2) and three
(3) in the socket.

2 1

Programming Socket
(On Front of Platform Control Module)
1. Pin-1 2. Pin-2 3. Pin-3
3
3. Turn the machine power on while holding down the
Joystick Installation turtle button on the platform control module button
1. Knob Set Screw (a) 3. Joystick 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.
Joystick replacement requires Joystick 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.

POINT G

Run Joystick Shaft Around Joystick 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 – JLG Lift – 3121136

 SECTION 4 - CONTROL COMPONENTS

Pump/Motor/Tank Installation
4.8 PUMP-MOTOR ASSEMBLY -
SERVICE PROCEDURE
IMPORTANT
General BE CERTAIN THE MAST IS FULLY LOWERED BEFORE REMOVING
ANY HYDRAULIC LINES FROM THE PUMP UNIT. WEAR PROTECTIVE
The following is a complete disassembly/assembly of the GEAR WHEN WORKING AROUND PRESSURIZED HYDRAULIC LINES.
DVL/DVSP machines’ pump/motor assembly. No internal REMOVE CONNECTIONS CAREFULLY AND CAP ALL LINES.
parts to the hydraulic pump are serviced by JLG except for 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 JLG recommended hydraulic
fluid to all seals and o-rings.
Also keep all internal metal parts clean and coated
with hydraulic fluid to prevent surface corrosion. 1
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 2

2
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 3
Installation instructions following.

Inline Hydraulic Filter Installation

1 2

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.

Pump/Motor/Tank Assembly Installation

1. Valve Body Extend Line Fitting 3. Extend Line to Lift Cylinder
2. Inline Hydraulic Filter

3121136 – JLG Lift – 4-21

 SECTION 4 - CONTROL COMPONENTS

Motor Cap/Motor Installation Motor Brush Installation

1 2

1
3

2
Motor Cap Installation
1. Cap Assembly Screws 2. Cap Assembly

Brush Housing Installation

1. Brush Housing
2. Brush Housing Screws
2 3. Mark Front of Motor and Brush Housing For Reference
when reassembling.

4 1
2

3
1

4
3

3
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 – JLG Lift – 3121136

 SECTION 4 - CONTROL COMPONENTS

Once brush housing has been removed, inspect the rotor Brush Housing Final Assembly Tips
commutator for excessive wear before installing a new brush
set. It is easier to install the brush housing assembly by sliding
the rotor assembly completely out of the other end of the
The rotor commutator surface when new, is approximately
motor housing, then attach the brush housing first. After the
1/8 in. (3mm) in thickness.
brush 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-
2 tioned around the motor housing.
1 3
4 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.

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 Brush Final Positioning
(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 IMPORTANT
during reassembly.
ONCE THE ROTOR ASSEMBLY IS IN PLACE, REMEMBER TO
Clean the rotor commutator with a non-conductive electrical PUSH EACH BRUSH DOWN UNTIL THE BRUSH FACE IS IN CON-
cleaner before assembling the brush housing to the motor hous- TACT WITH THE COMMUTATOR ON THE ROTOR SHAFT AND THE
ing. BRUSH SPRING IS PUSHING DOWN ON TOP OF THE BRUSH.

3121136 – JLG Lift – 4-23

 SECTION 4 - CONTROL COMPONENTS

Tank Installation

3
2
3
2

Tank Installation
1. Tank Assembly 3. O-Ring Seal
Pump O-Ring Installation
2. Tank Screws (4) 4. Use Screwdriver to pry tank
away from pump head. 1. Pump Assembly 2. O-Ring Seal 3. O-Ring Seal

Pump Installation Filter Screen Installation

2
3 2

1
2
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 – JLG Lift – 3121136

 SECTION 4 - CONTROL COMPONENTS

Pressure Adjust Valve Installation Pressure Check Valve Installation

7
6 5
6
4
3
2 4
3
2
1

Pressure Adjust Valve Installation Pressure Check Valve Installation

1. Adjust Valve Cap 4. Valve Ball 1. Check Valve Assembly 5. Check Valve Port
2. Adjustment Screw 5. Adjust Valve Port 2. O-Ring Seal 6. Extend (Pressure) Port
3. Valve Spring 6. Extend (Pressure) Port 3. O-Ring Seal 7. Return Port
(Shown Plugged) 4. Backing Ring
Note: Adjust pressure per specification shown in Section-1 of this Note: Extend (Pressure) and Return Ports Shown Plugged
Service Manual.

3121136 – JLG Lift – 4-25

 SECTION 4 - CONTROL COMPONENTS

beneath the platform and detect if an object has entered that

4.9 OBSTRUCTION SENSOR SYSTEM - zone when the platform is being lowered.
SERVICE PROCEDURE (DVSP - OPTION)
NOTE: The OSS only operates normally when the Ground
General Control Module - Power Selector Switch (Key) is set
to PLATFORM CONTROL MODE.
The Obstruction Sensor System (OSS) Control Module is When the Power Selector Switch (Key) is set to
mounted between the rails of the mast platform header sec- GROUND CONTROL MODE the OSS will detect an
tion under the platform decal billboard at the rear of the obstruction but will not stop platform downward
DVSP model platform, see illustration below. movement or sound the horn. However, the OSS
Control Module LED will flash if a sensor detects the
The OSS Control Module communicates with the Ground presence of an object.
Control Module through the platform electrical junction box
also mounted on the mast behind the platform decal bill- An OSS Sensor replacement kit is available from the JLG
board. Parts Department for individual sensors. The kit provides
instructions and everything necessary to connect the new
The OSS Control Module circuit board monitors six (6) chan- sensor to the existing soldered wire ends.
nels each channel is wired to an individual transducer sen-
sor mounted under the DVSP model platform. The sensors If the OSS Control Module has failed it is recommended to
are mounted in a manner to provide a detection zone replace the complete OSS system. See Section 6 of this
manual for further OSS Troubleshooting instructions.

1. Mast Platform Header Section 3. Obstruction Sensor Control Module

2. Platform Electrical Junction Box 4. Transducer Sensor Arrangement

Table 4-2. Obstruction Sensor System Components (Platform Cutaway)

4-26 – JLG Lift – 3121136

 SECTION 4 - CONTROL COMPONENTS

Transducer Sensor Check The Ground Control Module can also display the following
sensor detection information when in Level 2 password Ser-
Perform the following daily Pre-Start Inspection to check if vice and Maintenance Settings mode.
each transducer sensor is working properly.
OSS Sensor
1. Power up machine by setting the Power Selector
Displays current Obstruction Sensor System status (Detec-
(Key) Switch to Ground Control Mode.
tion - YES/NO). Also if an object is detected, the sensor(s)
2. Raise the platform approximately four (4) to five (5) detecting the object and distance the object is from the sen-
feet. sor is displayed.

3. Hold an object about the size of 8-1/2 x 11 inches

directly under one of the sensors. The OSS Control
Module (RED) LED will flash if the sensor is working 1
properly. 2
4. Remove object, allow the LED to stop flashing and 4
check the next sensor, repeat this for all six (6) sen- 3
sors.
OSS Sensor LCD Display Mode
1. Detection Indicator - Yes/No 3. Object distance from sensor
2. Sensor numbers 4. Signal strength
Note: This screen can be viewed while another person performs
the transducer sensor check, see Section 4.9.

1 1

#6 #5

3 #4 #3

Transducer Sensor Check

1. Electronic Module LED Indicator (a) #2 #1
2. Detection Zone
3. Place a pad of paper or similar size object, 6 to
12 in. (15 to 30cm) individually beneath each 2
transducer to check detection.
Transducer Sensor Locations
Note: (a) The LED Indicator will flash when an object is
detected at each sensor. Remove object and allow 1. Transducer Sensors #1 through #6
the LED to stop flashing before testing next sensor. 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 1
under sides must be properly installed and undam-
aged to prevent sensor detection of objects outside the
platform parameter. 3 2
• 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 Connections

1. RED LED Detection Indicator 3. Junction Box Harness
2. Sensor Harness

4
3 1
5 2

4
OSS Control Module Installation 2 3
1. OSS Control Module 4. Insulating Bushing
Internal View of OSS Control Module
2. Mounting Screw (a) 5. Decal Billboard (b)
3. Nylon Washer 1. Sensor Comm Channels (a) 3. Wires to Platform Junction Box
2. Sensor Cables 4. LED Indicator Light
Notes: (a) Apply Loctite 222 to threads.
(b) Drill out pop rivets to remove. Notes: (a) Channel 1-Sensor 1, Channel 2-Sensor 2, etc.

4-28 – JLG Lift – 3121136

 SECTION 4 - CONTROL COMPONENTS

3 2

1 3

2
4
2
1
5

Transducer Sensor Installation (Typical)

1. Mounting Screws (a) 4. DO NOT Pressure Wash Decal
Sensor Side Deflectors
2. Bushings 5. Sensor Side Deflector
3. Transducer Sensor (b) 1. Sensor Side Deflector (a) 3. Platform Side Frame
2. Pop Rivet
Notes: (a) Apply Loctite 222 to screw threads and torque to
15 in. lb. Note: (a) One deflector required on each side of platform.
(b) Mount sensor with (circular) membrane Deflector must be even with, and not extend inside
facing down. of the platform side frame.

Secure Transducer Sensor Wiring

1. Nylon Tie Wraps (a) 2. Platform Floor Supports
Note: (a) Secure ALL sensor wire cables to platform side
frame.

3121136 – JLG Lift – 4-29

 SECTION 4 - CONTROL COMPONENTS

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4-30 – JLG Lift – 3121136

 SECTION 5 - MAST COMPONENTS

SECTION 5. MAST COMPONENTS

5.1 MAST COMPONENTS OVERVIEW

14

13

12

11

10

1. Mast Section - 1 4. Mast Section - 4 7. Lift Cylinder Mount 10. Lanyard Attach 13. Chain/Equalizer -
2. Mast Section - 2 5. Mast Section - 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 – JLG Lift – 5-1

 SECTION 5 - MAST COMPONENTS

6. Tighten (to raise mast section), or loosen (to lower

5.2 MAST CHAINS AND SEQUENCING mast section) the adjusting nut against the anchor
CABLES ADJUSTMENT plate on each chain/cable. Adjust the nut the
amount required to raise or lower the top of the mast
Mast Chain/Cable Adjustment section to match the side profile shown in Figure 5-
The intention of this procedure is to assure equal load distri- 2. when the mast is retracted.
bution between the individual chains of a mast section chain NOTE: It is more important that the (threaded ends) studs
sets. Also to step each front mast section up approximately protruding on the adjustments are equal side to side
7/16 in. (12mm) from the section behind it to allow clearance on a mast section, than it is that the tension in the
for the individual mast section covers. chains is equal. The chain equalizers will always
Adjust using the following procedure; assure equal tension, but if the adjustment isn’t
equal as described, the chains may tend to pull to
1. With mast retracted, step into the platform and one side or the other.
bounce your weight up and down a few times to be The threaded end of the chain/cable may need to be
certain platform is at the bottom of travel. Be certain restrained while tightening the adjust nut to keep the
all chain/cable sets are seated in their sheaves prop- chain/cable from twisting.
erly at the top of each mast section.
7. Retract the mast all the way and check if the top of
2. Then with no load in the platform check the side pro- the mast sections appear as shown in Figure 5-2.
file of the top of the mast for the amount of adjust-
ment necessary to obtain the 7/16 in. (12mm) step 8. Repeat steps (1) through (7) for remaining mast sec-
for mast sections-3 and up. (See Illustration) tions.

NOTE: Mast section-1 is fixed to the base and mast section- 9. Once mast section adjustment is completed, apply
2 is attached to the lift cylinder, these sections loctite #242 to the threads under the (jam) nuts that
require no adjustment. were loosened. Then re-tighten the loosened (jam)
nuts until tight against the top (adjust) nut. Chain/
3. Adjust one mast section at a time starting from the cable should have slight tension but should not be
back (section-3, section-4, etc.) of the mast and taut.
work forward. (i.e. if three is OK, then jump to four,
etc.) 10. (DVSP Only) After all mast adjustments are com-
plete, if necessary adjust the bumpers on the under-
4. To adjust, elevate the platform until the chain/cable side of the stock-picker platform so the platform
anchor adjust nuts are accessible at the front and rests slightly above the base frame when it is low-
bottom of each mast section. ered and empty.

Sequencing Cable Adjustment

NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM
1. Retract mast completely, and check each sequenc-
HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCK-
ing cable on outside of masts for excessive slack.
ING OR OVERHEAD SLING.
Adjust only to remove slack from cable.
5. Start with the mast section which needs adjustment 2. Tighten nylock-nut just enough to remove excessive
and loosen the bottom (jam) nut on each chain/ slack from sequencing cable. The springs should
cable. not be compressed more than 25% after adjusting.
3. Run mast through several cycles to verify cable/
chain adjustments and ensure no interference exists
between chain anchor brackets and mast.

5-2 – JLG Lift – 3121136

 SECTION 5 - MAST COMPONENTS

7/16 in. (12mm)

7 2

9
10

11

1. Sequence Cable Adjust Nut 4. Mast Section - 3 7. Check Mast Stowed Height 10. Chain Lock Nut
2. Mast Section - 1 5. Mast Section - 4 8. Chain Anchor Plate 11. Threaded Chain End
3. Mast Section - 2 6. Mast Section - 5 9. Chain Adjust Nut

Figure 5-2. DVL/DVSP - Mast Chain and Sequence Cable Adjustment Components.

3121136 – JLG Lift – 5-3

 SECTION 5 - MAST COMPONENTS

Clamp Installation (Drum/Socket Type)

5.3 SEQUENCE CABLE REPLACEMENT KIT
A sequence cable replacement kit is available from the JLG
Parts Department to service broken or worn sequence
IMPORTANT
cables. This kit consists of a replacement sequence cable THE MANUFACTURER OF THE DRUM/SOCKET CLAMP RECOM-
with the threaded (top) end attached same as the top end of MENDS THE USE OF THEIR CABLE CLAMP ASSEMBLY KIT (JLG P/N
the factory cable. Also included is a clamp (drum/socket - 7023275) TO ASSEMBLE THE CLAMP TO THE WIRE ROPE. THE KIT
type) to secure the bottom end of the cable. Use the follow- CONSISTS OF VISE JAWS TO HOLD THE WIRE ROPE IN A VISE
ing procedure to install the replacement cable and clamp kit. PROPERLY WITHOUT DAMAGING ANY ROPE STRANDS AND A PLUG
DRIVER TO DRIVE THE PLUG INTO THE CENTER OF THE WIRE ROPE
Remove Old Cable AND IS ALSO USED TO FORM THE STRANDS OF THE ROPE DURING
ASSEMBLY.
1. Remove the locking nut from the threaded end of
the cable at the top of the mast and then remove the NOTE: The tools in the clamp assembly kit may be frabra-
spring cap, spring, and spacer washers if installed. cated if necessary. The vise clamp consists of vise
jaws with a hole drilled 1/32 in. smaller than the
2. Slide the threaded top end out of the upper anchor diameter of the wire rope you are working with (i.e.
bracket, then at the bottom end pull the cable out 1/8 in. rope - 3/32 in. hole.)
though the sheave pulley/anchor bracket until it is The plug driver is a metal tube with a hole in the bot-
completely clear of the machine. 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.
Replacement Cable Installation
1. Using the recommended vise jaws, clamp the wire
1. Be certain the mast is completely retracted and at rope into a vise with the bottom edge of the black
the bottom of travel. Check the mast "Side Profile" at mark made on the wire rope resting just above the
the top of the mast as shown in Figure 5-2., adjust vise jaws.
mast sections to proper height if necessary.
2. To determine where the clamp will be installed at the
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. At the bottom of the mast, thread the loose end of
the replacement cable through the proper sheave
pulley and through the hole in 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 1. Cable 3. Recommended Vise Jaws
side of the sheave pulley/anchor bracket. This will 2. Mark on Cable
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 – JLG Lift – 3121136

 SECTION 5 - MAST COMPONENTS

2. Twist the sleeve from the clamp kit onto the rope
until it is flat against the vise jaws at the mark made
made on the wire rope.

1. Cable Strands Unlayed

5. 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
1. Sleeve Installed on Cable
somewhat equally around the plug. Drive the plug
until it is firmly seated and no more than 1/3 of the
3. Use a suitable tool and cut the cable as shown in the plug is visible from above the sleeve.
illustration following. For 1/8 in. cable the recom-
mended length is 5/8 in. past the end of the sleeve.

1. Cut To This Length 2. Sleeve

1. Plug Driver 3. Insert Plug in this Position
2. Plug
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 – JLG Lift – 5-5

 SECTION 5 - MAST COMPONENTS

6. 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. Inspection Hole 3. Four Threads or Less Showing

2. Install Socket and Tighten

8. Inspect for proper assembly prior to loading the

cable. Strands visible through the inspection hole
1. Use Plug Driver, Metal Tube or Pliers are your assurance of a proper assembly.
2. Shape Strands Around Plug
NOTE: The end of the rope may not be visible in the inspec-
tion hole after loading.
NOTE: When assembling stainless steel parts all threads
must be coated with a dry lubricant or an anti-seize 9. Install cable on machine and adjust per instructions
lubricant to prevent seizing. shown previously in Section 5.2, MAST CHAINS
AND SEQUENCING CABLES ADJUSTMENT.
7. 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.)

5-6 – JLG Lift – 3121136

 SECTION 5 - MAST COMPONENTS

4. At the base end, remove and cap the extend and

5.4 HYDRAULIC LIFT CYLINDER - return hydraulic lines.
REMOVAL, INSPECTION AND REBUILD

3 2
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.
1
Lift Cylinder 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)
4
• Drive Motor Cover (See Section 3)
2. Seal the vented cap on the hydraulic fluid reservoir Hydraulic Extend and Return Lines
by removing the cap, covering the hole with a few 1. Cylinder Return Line 3. Cylinder Valve Block
layers of plastic wrap or equivalent. Then install and 2. Cylinder Extend Line 4. Drive Motor Assemblies
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. 5. Remove the mini covers from the tops of the mast
sections.
3. Use a forklift truck or overhead crane and carefully
lay the machine on it’s back, place a support under 6. Manually extend the mast assembly until the top of
the mast end, keeping mast close to level. (See Fig- mast section-2 is extended approximately one (1)
ure 5-3.) foot (31cm), to allow access to the sheave wheel-
anchor block at the top of mast section-2 and the lift
cylinder.

2
1 2
Extending Mast Sections
1. Be Careful of Control Components in this Area 1. Mast Section-2 2. 1 ft. (31cm) Extended
2. Support Mast Here - Keep Mast Approximately Level

Figure 5-3. Machine Positioned for Cylinder

Removal.

3121136 – JLG Lift – 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.

1 1

2 2

3
4
3
4

Snap Ring Installation

1. Back of Mast Section-2 3. Pin and Snap Ring
2. Cyl./Chain Anchor Block 4. Cylinder Rod
Chain Assembly - Bottom of Mast Section-3
1. Mast Section-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

base assembly allowing the top of mast section-2 to
1
be completely exposed.

3
1
2

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

5-8 – JLG Lift – 3121136

 SECTION 5 - MAST COMPONENTS

11. At the bottom of mast section-1, remove the cylinder Cylinder Disassembly
mount bolts, and mount reinforcement plates.
(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.
3. Compress the head retraining ring enough to allow
the cylinder head to be removed.
1
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-
2 der tube.
3
4 5. Place the head/rod/piston assembly on a surface
that will not damage the chrome.

Lift Cylinder Mount Installation 6. Remove the piston locknut and separate the piston
from the rod.
1. Cylinder/Mount Assembly 3. Washers
2. Reinforcement Plate 4. Mount Mounting Screws (a) 7. Slide the head off the rod from the piston end.

Notes: (a) Apply Loctite #242 to threads at final assembly. 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
12. Slide the cylinder and mount assembly out of the may cause by-pass.
bottom of mast section-1 and -2 and place on a suit-
able work surface. 8. Remove and discard all old seals.

Lift Cylinder 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.
2
Cylinder Head
1 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-roundness. If out-of-roundness exceed
0.007", this is unacceptable. Check the condition of the
Cylinder Installation dynamic seals (wiper, rod seals) looking particularly for
metallic particles embedded in the seal surface. It is normal
1. Lift Cylinder and Cylinder Mount Assembly to cut the static seal on the retaining ring groove upon disas-
2. Mount Shims (Mark Shim Packs for Reinstallation) sembly. Remove the rod seal, static o-ring and backup and

3121136 – JLG 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 out-of-roundness. If out-of-roundness 1
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 3 2
occurs, the piston should be replaced.
4
Tube Assembly
5
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 7
6
0.5 inch long and primarily in the circumferential direction
are acceptable provided they cannot cut the piston seal. The
roughness of the bore should be between 10 and 20 µ
inches RMS. Significant variation (greater than 8 µ 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- 8
nal components of any foreign material.
9
2. Lubricate the head and all seals with hydraulic fluid 12
10
prior to installation. Install the seal, wiper, o-ring,
back-up ring, and retraining ring to the cylinder 11
head.
3. Lubricate the piston and all components with 13
hydraulic fluid. Install the seal and wear ring to the
piston.

NOTE: Re-check that seals are not twisted or pinched and

are properly seated.
4. Place the rod on a clean table. Install the static pis- 1. Cylinder Rod 6. Apply Anti-Seize 10. Piston
ton o-ring seal into the groove on the piston end of 2. Cylinder Head 7. Cylinder Tube 11. Wear Ring
the rod. 3. Rod Wiper 8. Spacer 12. Piston O-Ring
4. Rod Seal 9. Piston Seal 13. Piston Lock Nut (a)
5. Install the head followed by the piston onto the rod
5. O-Ring
noting the proper orientation of each component.
Torque the piston nut to 100-120 ft. lbs. Note: (a) - Torque 100 - 120 ft. lbs.

Figure 5-4. Lift Cylinder Component Cross-Section

(DVL/DVSP).

5-10 – JLG Lift – 3121136

 SECTION 5 - MAST COMPONENTS

5 4
6 1
7

Lift Down Valve and Manual Release Installation (DVL/DVSP)

1. Lift Down Valve (a) 3. Solenoid Retaining Nut 5. O-Ring with Backing Rings (a) 7. Solenoid O-Ring (a)
2. Valve Solenoid (b) 4. Manual Release Assembly 6. Valve O-Ring (a)

Notes: (a) Coat all o-rings with clean hydraulic fluid before assembling.
(b) Mount with electrical terminals pointing down.

6. When the rod assembly is ready to be installed into Cylinder Installation

the tube, liberally apply an anti-seize lubricant to the
To install the lift cylinder reverse the Lift Cylinder Removal
cylinder head surface which slides into the cylinder
instructions at the start of this section, however perform the
tube.
following additional steps during re-assembly.
7. Next dip the entire rod assembly into hydraulic fluid
1. Apply Loctite #222 (purple) and torque to 85 ft. lbs.
and stuff this assembly into the tube. Watch the
the cylinder mount shoulder screws securing the lift
seals as they pass over the rod port (if visible) to be
cylinder mount halves together at the bottom of the
sure they are not nicked or cut.
mast.
8. Install the head until the retaining ring seats in it’s
2. Check that the platform electrical control cables and
groove.
the sequence cables are seated in their sheave
wheel assemblies when extending mast sections for
reassembly.
3. After assembly, readjust the chain at the bottom of
mast section-3 and apply Loctite #242 to the lock
nuts before final tightening.
4. Remove the plastic from under the hydraulic reser-
voir tank cap.

3121136 – JLG Lift – 5-11

 SECTION 5 - MAST COMPONENTS

5.5 MAST ASSEMBLY INSTALLATION

Mast Removal

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
1
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 2 2
cable from inside the mast mounting column.
9. Disconnect the spring and clamp attaching the AC
receptacle cable inside the mast mounting column.
10. Under the machine, disconnect and cap the hydrau-
lic extend and return lines from the hydraulic cylin-
der.
11. Using an overhead crane or suitable 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 mast to the mounting column.
13. Lift the mast off the base frame and place on a suit-
able work surface.

Mast Installation
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 – JLG Lift – 3121136

 SECTION 5 - MAST COMPONENTS

pads inserted into the slide pad channels, (ends of mast

5.6 MAST ASSEMBLY AND DISASSEMBLY sections even). Applying silicone spray onto the slide pads
PROCEDURES and slide pad channels before assembly will help mast sec-
The DVL/DVSP lift mast sections are constructed of extruded tions slide easier after slide pads have been properly
aluminum, protected with an anodized surface finish. The shimmed.
mast sections are interlocked into each other when assem-
bled, by internally mounted slide pads at the top and bottom Mast Disassembly Procedure
of each mast section. These slide pads run up and down in
slide pad channels on each side of the mast. 1. After the mast assembly has been removed from the
machine, lay the mast assembly down on a suitable
The DVL/DVSP model mast assembly contains a different work table with the platform mounting section on
number of mast sections as shown following; top, facing up.

Table 5-1. DVL/DVSP Mast Component Features 2. Remove the sequencing cables and hardware from
the sides of the mast assembly. Also remove the
No. of Mast Extend/Retract covers from the top of the mast assembly.
Model
Sections Device
MAST SECTION-5 - REMOVAL
DVL Series
5 Chain 3. Remove chain adjust nuts from threaded ends of
& DVSP
chain attached to the chain anchor plate (lower) on
BOTTOM end of mast section-5 (platform mounting
Assembly procedures for all mast sections is basically the
section). Push threaded ends of chain through
same, carefully slide the mast sections together until mast
anchor plate.
ends are even. (When sliding the mast sections together, be
careful not to scratch the anodized surface). Assemble the 4. At the TOP of mast section-5, pull chains out and
hardware to the bottom of mast section first, slide this sec- allow to hang loose. (Be certain floor surface is
tion out the top of previous section and assemble hardware clean and free of any metal chips or debris which
to the top of mast. Always install slide pad shims with slide may stick to lubricated chains)

OPEN RAIL
(REFERS TO OPEN RAIL
FRONT OF MAST SECTION) TOP
(REFERS TO TOP END
OF MAST SECTION
WHERE COVER AND
SHEAVE WHEELS
ARE ATTACHED)

BOTTOM
CLOSED RAIL (REFERS TO BOTTOM END OF
(REFERS TO CLOSED RAIL MAST SECTION WHICH SETS IN
BACK OF MAST SECTION) MACHINE’S BASE FRAME)

Figure 5-5. Mast Section - Assembly Reference.

3121136 – JLG Lift – 5-13

 SECTION 5 - MAST COMPONENTS

NOTE: When sliding mast sections apart, be careful not to NOTE: When sliding mast sections apart, be careful not to
scratch or score the anodized surface in the slide scratch or score the anodized finish in the slide pad
pad channels. channels.

5. Carefully slide mast section-5 out the BOTTOM of 16. Carefully slide mast section-3 out BOTTOM of sec-
mast section-4 rails. Disassemble slide pads, shims tion-2. Remove slide pads, and shims, if necessary.
and chain anchor plate from mast section-5, if nec-
MAST SECTION-2 - REMOVAL
essary.
17. Slide mast section-2 out TOP of mast section-1 far
MAST SECTION-4 - REMOVAL
enough to allow access to the chain assembly
6. Remove chain adjust nuts from threaded ends of anchor block/sheave wheel assembly.
chains attached to the chain anchor plate (lower) on
18. Remove countersunk-flathead screws securing
BOTTOM end of mast section-4. Push threaded
chain anchor block/sheave wheel assembly attach
ends of chains through anchor plate.
bars on both side rails at TOP of mast section-2.
7. At TOP of mast section-4, pull chains out and allow
19. Slide the chain anchor block/sheave wheel assem-
to hang loose. (Be certain floor surface is clean and
bly and hydraulic cylinder out the TOP of mast sec-
free of any metal chips or debris which may stick to
tion-2 far enough to allow removal of the sheave
lubricated chains)
wheel attach bars, sheave wheels and sheave pin
8. Slide mast section-4 out the TOP of mast section-3 from chain assembly anchor block.
far enough to allow access to the chain sheave
20. Remove the setscrew holding the hydraulic cylinder
wheel assembly.
rod onto the chain assembly anchor block. Lay
9. Remove countersunk-flathead screws securing chain assembly/anchor block to side.
chain sheave wheel assembly attach bars on both
21. Remove the hydraulic cylinder through BOTTOM of
side rails at TOP of mast section-4 and remove
mast section-2, be careful not to nick or score cylin-
sheave wheel assembly.
der rod surface while removing.
NOTE: When sliding mast sections apart, be careful not to
NOTE: When sliding mast sections apart, be careful not to
scratch or score the anodized finish in the slide pad
scratch or score the anodized finish in the slide pad
channels.
channels.
10. Carefully slide mast section-4 out BOTTOM of sec-
22. Carefully slide mast section-2 out BOTTOM of sec-
tion-3. Remove slide pads, shims and cable anchor
tion-1. Remove slide pads and shims, if necessary.
plate, if necessary.
MAST SECTION-1 - DISASSEMBLY
MAST SECTION-3 - REMOVAL
23. Slide the TOP of remaining mast section-1 out over
11. Remove chain adjust nuts from threaded ends of
edge of work surface and remove the pins attaching
chain attached to the chain anchor plate on BOT-
the chain anchor block to mast section-1. Remove
TOM end of mast section-3. Push threaded ends of
chain/anchor block assemblies from mast and lay
chain through the anchor plate.
aside.
12. At TOP of mast section-3, pull chains out and allow
24. Remove slide pads and shims from mast section-1.
to hang loose, (be certain floor surface is clean and
free of any metal chips or debris which may stick to
lubricated chains).
Mast disassembly should now be complete.
13. Slide mast section-3 out TOP of mast section-2 far
enough to allow access to the chain sheave wheel
assembly.
14. 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.
15. 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.

5-14 – JLG Lift – 3121136

 SECTION 5 - MAST COMPONENTS

Figure 5-6. Mast Chain Routing Diagram. - DVL/DVSP

3121136 – JLG Lift – 5-15

 SECTION 5 - MAST COMPONENTS

Mast Assembly - DVL/DVSP MAST SECTION 2 - ASSEMBLY

(See Figure 2-2.) NOTE: When sliding mast sections together, be careful not
to scratch or score the anodized finish in the slide
MAST SECTION 1 - ASSEMBLY pad channels.
1. Place mast section-1, rail (open) side up (See Figure 4. Locate mast section-2, carefully slide mast section-2
2-1.) on a clean, flat surface (preferably a table or closed rail into section-1 open rail. Slide sections
work bench capable of supporting the weight of the together until ends are even.
entire mast assembly). Slide mast out over end of
work surface far enough to allow access to the chain 5. Insert slide pads into the slide pad channels at bot-
anchor attach hole near the top of the mast. tom end of mast between section-1 and -2, (one on
each side of the mast), with beveled surface facing
2. Locate the two (2) single (wide) chain assemblies out towards section-1.
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-
3
cated chains).
3. 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.
2

4 1. Slide Pads 2. Shim Stock 3. Slide Pad Bolts/Washers (a)

Note: (a) Apply Loctite #242 to threads.

1 Figure 5-7. Mast Bottom End - Slide Pad Installation

6
(Typical)

2 6. Thread slide pad attaching bolts, (two (2) 1/4"-

5
3 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.
7. Shim slide pads using the following steps:
Chain/Anchor Plate Installation
(Mast Section-1 - Shown Cut-Away) NOTE: Always use the an even amount of shim material
1. Anchor Plate Pin 4. Long Spacer behind slide pads on both sides of the mast rails.
2. Short Spacer 5. Pin Keeper This will keep mast sections centered in rail chan-
3. Chain/Anchor Plate Assy. 6. Keeper Screw (a) nels and prevent any distortion of the mast section.

Note: (a) Apply Loctite #242 to threads. a. Start with a .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.

5-16 – JLG Lift – 3121136

 SECTION 5 - MAST COMPONENTS

c. Check mast section for side play. If play exists 11. Install the lift cylinder mount into the bottom of Mast
add .015" shims dividing the thickness equally Section 1.
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.
8. 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 3 4
section-2.
2
NOTE: Before fastening and shimming the slide pad on the
top left side of the mast, install a sequence cable 1
bracket against the mast under the flatwasher.
Lift Cylinder Mount Installation
1. Cylinder Mount 3. Mount Reinforcement Plate
2. Shim Stock 4. Mount Bolts/Washers (a)

4 Note: (a) Apply Loctite #242 to threads.

2
3

12. 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.
4
NOTE: If hydraulic cylinder needs to be extended, the pro-
tective caps on the extend and return ports will need
1 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
1. Slide Pads 3. Sequence Cable Bracket area.
2. Shim Stock 4. Slide Pad Bolts/Washers (a)
13. Slide mast section-2 out of mast section-1 approxi-
Note: (a) Apply Loctite #242 to threads.
mately one foot.

Figure 5-8. Mast Top End - Slide Pad Installation 14. Slide the lift cylinder into the closed rail side of mast
(Typical) 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-
9. Thread slide pad attaching bolts, two (2) 1/4"- inder mount at the bottom of the mount. The manual
20UNC x 3/8" long hex head bolts, place a flat descent valve should be pointing down towards the
washer under head of each bolt, through holes in back of the mast assembly.
mast section-1 outside rail (top of mast) and into the
15. Loosely assemble the cylinder mount cap onto the
slide pad inserts. Thread in enough to hold pad in
lift cylinder mount to hold the cylinder assembly in
place.
place.
10. Shim per instructions in step 7, Mast Section 2 -
Assembly.

3121136 – JLG Lift – 5-17

 SECTION 5 - MAST COMPONENTS

16. Assemble one of the narrow chains sets (#444) and f. Align the threaded holes in the attach bars on
to the small chain equalizer anchor plate using the each side of the mast and attach to top of mast
pins, washers and cotter keys. Set aside. section-2 using two (2) 3/8"-16UNC x 1/2" long
socket head-countersunk-flathead cap screws
17. Locate the chain anchor block and slide it onto the
each side. Coat threads with Loctite #171 and
hydraulic cylinder rod end sticking out the top of
tighten.
mast section 2.
18. Lay out the chain(#444)/anchor plate assembly with
anchor plate end towards mast, (be certain floor sur- 3 4 3 5 3 4 3
2 2
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. 1 1

3
6
2

1 4
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

5 Note: (a) Apply Loctite #242 to threads.

21. Remove the cylinder mount cap - shoulder screws

Install Chain/Anchor Block to Top of Lift Cylinder and apply Loctite #242 to the threads. Install the
1. Attach Pin 4. Attach Pin - Snap Ring screws and torque to 85 ft. lbs.
2. Chain/Equalizer Assembly 5. Cylinder Rod (Extended) 22. Tighten the center lift cylinder mount screw, this
3. Chain/Anchor Block screw keeps the cylinder assembly from rotating in
the mount.
20. Assemble chain sheaves on chain assembly anchor 23. Slide mast section-2 back into section-1 until top
block (attached to cylinder rod end) and attach to and bottom ends are even.
mast section-2 using following steps;
MAST SECTION 3 - ASSEMBLY
a. Insert sheave pin through anchor block and cyl-
inder rod on cylinder rod end. NOTE: When sliding mast sections together, be careful not
to scratch or score the anodized finish in the slide
b. Load three 1" flat washers onto the sheave pin
pad channels.
on each side of the anchor block.
c. Place sheave wheels (for wide #544 chain) on 24. Carefully slide mast section-3 into section-2 until
sheave pin, one each side of anchor block. ends are even.
d. On the outside of each sheave wheel, place 25. Insert slide pads into the top end mast rails between
another 1" flatwasher, a roll pin (into the slot in section-2 and -3, (one on each side of the mast),
each end of the pin), and then place a sheave with beveled surface facing inward towards section-
pin support bar (rectangular plate with threaded 3. (Same as Figure 5-8.)
holes on each side of pin bore hole).
NOTE: Before fastening and shimming the slide pad on the
e. Slide the whole anchor block/cylinder assembly
top left side of the mast, install a sequence cable
with sheave pin, wheels and pin support bars
bracket against the mast under the flatwasher.
into top of mast section-2.

5-18 – JLG Lift – 3121136

 SECTION 5 - MAST COMPONENTS

26. Thread slide pad attaching bolts, two (2) 1/4"- 33. Slide section-3 out the top of section-2 approxi-
20UNC x 3/8" long hex head bolts, place a flat mately one (1) foot.
washer under head of each bolt, through holes in
34. Locate the remaining narrow chain set (#444) and
outside rail, on top of mast section-2 and into the
attach them to the remaining triangular shaped
slide pad inserts. Thread in enough to hold pad in
anchor plate using the attach pins, flat washers and
place.
cotter keys.
27. Shim per instructions in step 7, Mast Section 2 -
Assembly.
28. 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.)
29. 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. 3
1
30. Shim per instructions in step 7, Mast Section 2 - 4
Assembly.
31. Slide section-3 out the bottom of section-2 approxi- 2
mately one (1) foot. 5
32. Locate one (1) of the chain (bottom) anchor brackets
(one with threaded holes horizontally aligned to out-
side 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 Mast Section 3 - Chain/Anchor Plate Installation
each bolt. (Mast Section-3 Shown Cut-away)
1. Chain/Anchor Plate Assy. 4. Pin Keeper
3 2. Anchor Pin 5. Keeper Screw (a)
3. Spacer
Note: (a) Apply Loctite #242 to threads.

35. Install the chain/anchor plate assembly into the top

of mast section-3, using the remaining large pin and
2
pin keeper. Allow to hang out the top of mast sec-
tion-3 for later assembly.
36. Insert the threaded the ends of chain assembly
(attached to top of mast section-1), into the opening
1 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 slack in the
chains. Chains will be adjusted later in assembly.
Mast Section 3 - Chain Anchor Bracket
(Bottom of Mast)
1. Chain Anchor Bracket 3. Anchor Bolts/Washers (a)
2. Mast Section 3
Note: (a) Apply Loctite #242 to threads.

3121136 – JLG Lift – 5-19

 SECTION 5 - MAST COMPONENTS

37. Assemble chain sheaves (for narrow chain assem- MAST SECTION 4 - ASSEMBLY
bly) to top of mast section-3 as follows;
NOTE: When sliding mast sections together, be careful not
a. Place four (4) of the 1" flat washers onto one of to scratch or score the anodized finish in the slide
the remaining sheave pins. Locate two (2) nar- pad channels.
row chain sheave wheels and slide onto sheave
pin on each side of the flat washers. 39. Carefully slide mast section-4 into section-3 until
ends are even.
b. Slide two (2) short spacer tubes onto sheave
pin, one each end of sheave pin to outside of 40. Insert slide pads into the top end mast rails between
sheave wheels. section-2 and -3, (one on each side of the mast),
c. Place two (2) sheave pin support bars, one each with beveled surface facing inward towards section-
end of sheave pin onto outside of spacer tubes. 3. (Same as Figure 5-8.)
Place a roll pin in the slots at each end of the NOTE: Before fastening and shimming the slide pad on the
sheave pins and align with the cutouts in the pin top left side of the mast, install a sequence cable
support bars. bracket against the mast under the flatwasher.
d. Holding complete sheave wheel assembly, slide
assembly into top of mast section-3 and align 41. Thread slide pad attaching bolts, two (2) 1/4"-
threaded holes in sheave pin support bars with 20UNC x 3/8" long hex head bolts, place a flat
holes in mast rails. washer under head of each bolt, through holes in
outside rail, on top of mast section-2 and into the
e. Attach to top of mast section-3 using two (2) 3/
slide pad inserts. Thread in enough to hold pad in
8"-16UNC x 1/2" long socket head-countersunk-
place.
flathead cap screws, each side. Coat threads
with Loctite #171 and tighten. 42. Shim per instructions in step 7, Mast Section 2 -
Assembly.

6 43. Insert slide pads into the bottom end mast rails
2 2 between section-2 and -3, (one on each side of the
3 4 4 3
mast), with beveled surface facing out towards sec-
tion-2. (Same as Figure 5-7.)
44. Thread slide pad attaching bolts, two (2) 1/4"-
20UNC x 3/8" long hex head bolts, place a flat
1 1 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.
45. Shim per instructions in step 7, Mast Section 2 -
7 Assembly.
46. Slide section-4 out the bottom of section-3 approxi-
mately one (1) foot.
Mast Section 3 - Sheave Wheel Assembly
47. Locate one (1) of the chain bottom anchor plates
1. Support Bar Screws (a) 5. Narrow Washer (one with threaded holes horizontally aligned to cen-
2. Pin Support Bars 6. Sheave Pin ter of bracket). Attach using holes in bottom of mast
3. Wide Spacers 7. Square Keys section-4 with three (3) 1/4"-20UNC x 3/4" long bolts,
4. Sheave Wheel Assys. place a flatwasher under head of each bolt.
Note: (a) Apply Loctite #242 to threads.

38. Slide mast section-3 back into section-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 – JLG Lift – 3121136

 SECTION 5 - MAST COMPONENTS

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
3
wide tube spacer onto the pin shaft.
b. Place two (2) of the narrow chain sheave wheels
onto the sheave pin on each side of the wide
2 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
1 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/
Mast Section 4 - Chain Anchor Bracket 8"-16UNC x 1/2" long socket head-countersunk-
(Bottom of Mast) flathead cap screws, each side. Coat threads
with Loctite #171 and tighten.
1. Chain Anchor Bracket 3. Anchor Bolts/Washers (a)
2. Mast Section 4
Note: (a) Apply Loctite #242 to threads. 3 4 6 4 3
2 5 2
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 1
1
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.
7
Chains will be adjusted later in assembly.

Mast Section 4 - Sheave Wheel Assembly

1. Support Bar Screws (a) 5. Wide Spacer
2. Pin Support Bars 6. Sheave Pin
3. Narrow Washers 7. Square Keys
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.

3121136 – JLG Lift – 5-21

 SECTION 5 - MAST COMPONENTS

MAST SECTION 5 - ASSEMBLY c. Attach shim stock and slide pads to both sides
of mast section-5 using five (5) 1/4"-20UNC x 1-
1. Locate the remaining mast section-5 (platform
1/4" long, hex head cap screws per side, with
mounting - mast section). Lay mast section on flat
flatwasher under each bolt head. (Assemble
stable surface.
shim stock and slide pad to mast section 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
there are no air gaps between shims, shim and
NOTE: The platform mounting section slide pads, are
mast or shim and slide pad when tightened.
assembled differently than the slide pads for the
other mast sections. Mast section-5 slide pads may 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 slide pads into slide pad
channels at bottom of mast section-4’s open rail.
NOTE: Always use the an even amount of shim material
Continue to push section-5 into section-4 until
behind slide pads on both sides of the mast rails.
BOTTOM ends of mast sections are even.
This will keep mast sections centered in rail chan-
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.
g. When mast slide pads are 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.

5 2

4
3
5

3
5

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 – JLG 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
threads 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. At bottom 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 not assemble the mini covers to the top of mast Lanyard Attach Installation
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 – JLG Lift – 5-23

 SECTION 5 - MAST COMPONENTS

5.7 DVSP - STOCKPICKER PLATFORM -

INSTALLATION

6
3
2

1. Mast Platform Header Section 3. Washers 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 – JLG Lift – 3121136

 SECTION 5 - MAST COMPONENTS

5.8 DVSP - STOCKPICKER PLATFORM - 5.9 MAST BEACON - INSTALLATION

MID-GATE INTERLOCK INSTALLATION

5
3

2 1
5
1

4
6

3
DVSP - Platform - Mid-Gate Interlock Switch Installation

1. Pop Rivets 4. Mounting Holes Mast Mounted Beacon Installation (DVL/DVSP)

2. Interlock Switch 5. Mid-Gate 1. Beacon Mounting Bracket 4. Beacon Assembly
3. Spacer 6. Wire Harness Clamp 2. Bracket Screws/Nuts/Washers 5. Beacon Guard (a)
3. Beacon Screws/Nuts/Washers
Notes: (a) Guard on UL-EE specification machines only.

1
4

DVSP - Platform - Mid-Gate Interlock Switch

Wiring Harness Routing
1. Interlock Switch 3. Connection at Junction Box
2. Wire Routing 4. Platform Junction Box
Notes: Decal billboard removed in above illustration.

3121136 – JLG Lift – 5-25

 SECTION 5 - MAST COMPONENTS

This page intentionally left blank.

5-26 – JLG 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 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 at the 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).
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 at the 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 – JLG Lift – 6-1

 SECTION 6 - TROUBLESHOOTING

Ground Control Module LCD Display

At power-up and during operation the LCD display on the Ground Control Module displays the current machine operating
status. The following illustration explains the symbol indications.

1 2

00000.0 00
3 4

00
5

LCD Display Symbols

1. Battery Charge Indicator (BCI)
2. Function Display or Function Disable Indicators
3. Hour Meter Display
4. Fault Code Indicator
5. 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:

Both LIFT UP and LIFT DOWN

DRIVE Disabled
Disabled

Drive Speed Cut-Back (Turtle)

LIFT UP Disabled
Mode Engaged

LIFT DOWN Disabled Battery Charger Plugged In

6-2 – JLG Lift – 3121136

 SECTION 6 - TROUBLESHOOTING

10

1 P1
P2
P5
(–) (+) P4
2 3 P3 4

(–) (+)

5
(+) M1 M2 (–)
(–) (+)

8
(+) (–)
7

1. Ground Control Module (a) 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 Junction Box Harness (a)
Module Plugs: P2 - PHP, Elevation/Speed, Charger Limit Switch Harness (a) P5 - Joystick Protocol Harness (a)
P3 - Programmable Security Lock Harness (Option) (a)
Notes: (a) Apply di-electric grease JLG Part Number 3020038 to wiring harness terminals, to prevent moisture from entering module.
(b) Seal NEG (–) and POS (+) posts with battery grease to prevent corrosion.
(c) Machines equipped with the UL-EE specification (option) only.

Figure 6-1. Component Electrical Connections.

3121136 – JLG Lift – 6-3

 SECTION 6 - TROUBLESHOOTING

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

PLATFORM
FAULT CONSOLE FAULT DESCRIPTION/
CODE LEDs
LCD SYMBOL SCREEN LCD TEXT SCREEN TROUBLESHOOTING
MACHINE CONDITION
FLASHING

Machine In Drive Speed

See Table 6-5,
— — — Cut-Back (Turtle) Mode
00000.0 Page 6-11
All The Time

Engage Brakes -
Brakes Released
— — Press Brake Release Button
00000.0
DRIVE Disabled
on Ground Control Station

Unplug Charger
Charger AC Plugged In
— — — AC Input Power Cord
DRIVE Disabled
00000.0 from Machine

Obstruction Sensor System

See Table 6-6,
— — (Platform Elevated)
00000.0
Page 6-12
LIFT DOWN Disabled

Type in Code At PSL Key Pad

Programmable Security
— — See Operators Manual for
Lock Password
00000.0 Proper Operation

— 1 Low Battery Voltage See Page 6-12

00000.0

Left PHP Bar UP

See Table 6-7,
02 2 (Platform Elevated)
00000.0 02 02 Page 6-13
DRIVE and Lift UP Disabled

Right PHP Bar UP

See Table 6-8,
03 2 (Platform Elevated)
Page 6-13
00000.0 03 03 DRIVE and Lift UP Disabled

Tilt Condition
See Table 6-9,
04 3 (Platform Elevated)
Page 6-14
00000.0 04 04 DRIVE and Lift UP Disabled

05 — RESERVED RESERVED

06 — RESERVED RESERVED

Left Drive Motor

See Table 6-10,
07 6 Disconnected
Page 6-14
00000.0 07 07 DRIVE Disabled

Right Drive Motor

SeeTable 6-11,
08 6 Disconnected
00000.0 08 08 Page 6-15
DRIVE Disabled

Left Brake Disconnected

See Table 6-12,
09 6 DRIVE, Lift UP/DOWN
00000.0 09 09 Page 6-15
Disabled

6-4 – JLG 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 Disconnected

SeeTable 6-13,
10 6 DRIVE, Lift UP/DOWN
00000.0 10 10 Page 6-15
Disabled

Left Drive Motor

See Table 6-14,
11 6 Short Circuit
00000.0 11 11 Page 6-16
DRIVE Disabled

Right Drive Motor

See Table 6-15,
12 6 Short Circuit
00000.0 12 12 Page 6-16
DRIVE Disabled

Traction Module
See Table 6-16,
13 6 In Fold Back
00000.0 13 13
Page 6-16
DRIVE Disabled

Pump Motor Disconnected See Table 6-17,

14 7
Lift UP Disabled Page 6-17
00000.0 14 14

Lift Down Valve

See Table 6-18,
15 7 Disconnected
Page 6-17
00000.0 15 15 Lift UP/DOWN Disabled

Down Valve or Down Valve

See Table 6-19,
16 7 Circuit Short
00000.0 16 16 Page 6-18
Lift UP/DOWN Disabled

Ground Control Module

See Table 6-20,
17 7 In Fold Back
00000.0 17 17 Page 6-18
(Machine Stopped)

Alarm or See Table 6-21,

18 —
00000.0 18 18 Alarm Circuit Short Page 6-18

See Table 6-22,

19 — Alarm Disconnected
00000.0 19 19
Page 6-19

Beacon or See Table 6-23,

20 —
Beacon Circuit Short Page 6-19
00000.0 20 20

See Table 6-24,

21 — Beacon Disconnected
00000.0 21 21
Page 6-20

See Table 6-25,

22 — Horn or Horn Circuit Short
Page 6-20
00000.0 22 22

3121136 – JLG 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

See Table 6-26,

23 — Horn Disconnected
Page 6-21
00000.0 23 23

See Table 6-27,

24 — Auxiliary #1 Circuit Short
Page 6-21
00000.0 24 24

Auxiliary #1 Circuit SeeTable 6-28,

25 —
Disconnected Page 6-22
00000.0 25 25

See Table 6-29,

26 — Auxiliary #2 Circuit Short
00000.0 26 26 Page 6-22

Auxiliary #2 Circuit See Table 6-30,

27 —
00000.0 27 27
Disconnected Page 6-23

28 — RESERVED RESERVED

29 — RESERVED RESERVED

Traction Module
See Table 6-31,
30 6 No Communication
Page 6-24
00000.0 30 30 with Ground Control Module

Platform Control Console

See Table 6-32,
31 — No Communication with
31
Page 6-25
00000.0 31 Ground Control Module

Pump Motor Over Current See Table 6-33,

32 7
32
LIFT UP Disabled Page 6-25
00000.0 32

Both PHP Bars UP See Table 6-34,

33 2
DRIVE and Lift UP Disabled Page 6-26
00000.0 33 33

2 LEDs/BARS Flashing with

an audible beep.
38 2 See Page 6-26
00000.0 38 38 Platform Lift-UP Function is
Locked Out.
1 LED/BAR Flashing with an
audible beep.
39 1 See Page 6-26
00000.0 39 39 Drive and Platform Lift-UP
Functions Locked Out.
Obstruction Sensor System
See Table 6-35,
40 5 No Communication With
00000.0 40 40
Page 6-27
Ground Control Station

6-6 – JLG 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

Internal OSS Sensor #1 See Table 6-36,

41 —
00000.0 41 41 Fault Condition Page 6-28

Internal OSS Sensor #2 SSee Table 6-36,

42 —
00000.0 42 42
Fault Condition Page 6-28

Internal OSS Sensor #3 See Table 6-36,

43 —
Fault Condition Page 6-28
00000.0 43 43

Internal OSS Sensor #4 See Table 6-36,

44 —
00000.0 44 44 Fault Condition Page 6-28

Internal OSS Sensor #5 See Table 6-36,

45 —
00000.0 45 45
Fault Condition Page 6-28

Internal OSS Sensor #6 See Table 6-36,

46 —
00000.0 46 46
Fault Condition Page 6-28

Ground Control Module See Table 6-37,

100 10
Fault Condition Page 6-29
00000.0 100 100

Platform Control Console See Table 6-38,

200 10
00000.0 200 200 Fault Condition Page 6-30

Traction Control Module See Table 6-39,

300 10
300
Fault Condition Page 6-31
00000.0 300

OSS Control Module See Table 6-35,

400 —
Low Internal Supply Page 6-27
00000.0 400 400

OSS Control Module See Table 6-35,

401 —
00000.0 401 401 Amplifier Fault Page 6-27

3121136 – JLG Lift – 6-7

 SECTION 6 - TROUBLESHOOTING

6.5 TROUBLESHOOTING TABLES INDEX

SPECIFICATIONS FOR VARIOUS COMPONENTS PAGE

Ohm Ratings for Various Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Amperage Draw for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 - Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Battery Voltage Low - Warning Level 3 - Three (3) LED/LCDs lit . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 02 - Left PHP Bar - UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 03 - Right PHP Bar - UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 04 - Tilt Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 05 - Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 06 - Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 07- Left Drive Motor - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 08 - Right Drive Motor - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 09 - Left Brake - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 10 - Right Brake - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 11 - Left Drive Motor - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 12 - Right Drive Motor - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 13 - Traction Module - In Fold Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 14 - Pump Motor - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 15 - Lift Down Valve - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 16 - Lift Down Valve - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 17 - Ground Control Module - In Fold Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 18 - Alarm - Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 19 - Alarm - Disconnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 20 - Beacon - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 21 - Beacon - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 22 - Horn - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 23 - Horn - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 24 - Auxiliary #1 Circuit - Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 25 - Auxiliary #1 Circuit - Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 26 - Auxiliary #2 - Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 27 - Auxiliary #2 - Disconnected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code 28 - Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code 29 - Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 - UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code 38 - Battery Voltage Low - Warning Level 2 - Two (2) LED/LCDs lit . . . . . . . . . . . . . . . . . 6-26

6-8 – JLG Lift – 3121136

 SECTION 6 - TROUBLESHOOTING

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 Module . . 6-27
Codes 41 thru 46 - OSS - Sensor 1 through 6 - Fault Condition. . . . . . . . . . . . . . . . . . . . . . . . 6-28
Codes (100 - 199) Ground Control Module - Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Codes (200 - 299) Platform Control Console - Fault Condition. . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Codes (300 - 399) Traction Control Module - Fault Condition. . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

MAIN POWER CIRCUIT TROUBLESHOOTING

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

MAST TROUBLESHOOTING
Platform Will Not Lower Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Platform Lift Up And Down Jerky . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Mast Noisy When Lifting And Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Platform (Mast) Won’t Stay Elevated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Platform (Mast) Descends Too Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

HYDRAULIC LEAK TROUBLESHOOTING

Miscellaneous Hydraulic Leak Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

BASE FRAME COMPONENTS TROUBLESHOOTING

Caster Wheels Not Operating Freely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Pot Hole Protection (PHP) Bars will not Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

DRIVE SYSTEM TROUBLESHOOTING

Won’t Climb Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Machine Drives in Opposite Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Machine Won’t Drive Straight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Noise From Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

3121136 – JLG 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 @ TEMPERATURE RESISTANCE RANGE POSSIBLE

Pump Motor 0.2ohm - 0.4ohm @ 77deg F 0.12ohm - 0.49ohm

Brake Coil 44.7ohm - 52ohm @ 68deg F 31.4ohm - 65.3ohm

Drive Motor (Bodine) .1 to .3ohm

(Can change depending on the rotation of the N/A
armature and temperature.)

Table 6-3. Amperage Draw for Various Components

COMPONENT AMPERAGE
20DVL - 95 Amps @ room temperature with rated load
Ground Control Module 15DVSP - 110 Amps @ room temperature with rated load
LEVEL SURFACE 15% GRADE
NO LOAD (24V)
(24V) (RATED LOAD) (24V) (RATED LOAD)
Traction Control Module
7 to 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 JLG PART NUMBER ILLUSTRATION

Ground Control Station For removal of electrical

connector pins from the
Ground Control Station 7016618
connectors.

Drive Motor For removal of electrical

connector pins from the 7002841
Drive Motor main power
connectors.

Drive Motor Brake For removal of electrical

connector pins from the 7002842
Drive Motor Brake power
connectors.

6-10 – JLG Lift – 3121136

 SECTION 6 - TROUBLESHOOTING

6.8 FAULT CODE TROUBLESHOOTING TABLES

Machine in Drive Speed Cut-Back (Turtle) Mode All 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:

• Mast drive 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
down when the platform is fully lowered. — Go to Step 2
operation of
the PHP System
2. With the platform fully lowered, check for continuity on the Cutback Repair or Replace
Proximity Switch wires between pins-8 and 18 on the P2 connector Speed Cutback
at the Ground Control Module. — Go to Step 3
(Proximity)
Switch
3. With the platform fully lowered, bars raised, check for continuity on Repair or Replace Right Side
the Right Side PHP bar limit switch, between pins-9 and 19 on the P2 — PHP Limit Switch
connector at the Ground Control Module. Go to Step 4
4. With the platform fully lowered, bars raised, check for continuity on
Repair or Replace Left Side
the Left Side PHP bar limit switch, between pins-10 and 20 on the P2 —
connector at the Ground Control Module. PHP Limit Switch

3121136 – JLG 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.
• Are any of the "Do not pressure wash" decals loose and protruding into the sensor detection area?

Table 6-6. Obstruction Sensor System - Detection

STEP ACTION SPEC YES NO

1. Perform Daily Pre-Start Inspection to test each transducer sensor.

Did all sensors pass test? — Go to Step 2 Replace Sensor

2. Disconnect the OSS Control Module connection to the Platform

Junction Box mounted on the mast platform header section above Replace Ground
— Go to Step 3
the OSS Control Module. Does the Ground Control Module now Control Module
show a Fault Code 5?
3. Reconnect the OSS Control Module connection to the Platform Replace OSS
Junction Box. Check for original fault condition. — —
System

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

• 3 LEDs/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.

6-12 – 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 at the base of the 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. Go to the 20 pin molex connector at the Ground Control Module,

Replace Ground
back probe to check for continuity of pin 10, (BLK #8 wire) with pin — Go to Step 2
20, (ORG/RED 49-1 wire). Is there continuity? Control Module

2. Check the actuator cables for adjustment or damage. — Adjust or Replace Go to Step 3
3. Check the PHP limit switch(s) at both sides of the machine for dam-
Replace, Adjust
age, adjustment and for continuity through switch to ground when — —
bars are down. or Repair 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 at the Ground Control Module,

Replace Ground
back probe to check for continuity of pin 9, (BLK #9 wire) with pin — Go to Step 2
19, (ORG/RED 49-2 wire). Is there continuity? Control Module

2. Check the actuator cables for adjustment or damage. — Adjust or Replace Go to Step 3
3. Check the PHP limit switch(s) at both sides of the machine for dam-
Replace, Adjust
age, adjustment and for continuity through switch to ground when — —
bars are down. or Repair Wiring

3121136 – JLG Lift – 6-13

 SECTION 6 - TROUBLESHOOTING

Code 04 - Tilt Condition

Check For These Obvious Conditions First:

• If 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
1.5° Drive Machine to
surface in both the X and the Y directions. Does surface check within Go to Step 2
X and Y Direction Level Surface
machine specification.
2. At the Ground Control Module, enter the programming mode (See
Ground Control Programming, Section-3 of Service Manual) and 1.5° Replace Ground
Go to Step 3
check the tilt sensor X and Y readings. Are readings within machine X and Y Direction Control Module
specification?
3. Zero Tilt Sensor on a 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

Code 06 - Reserved

Code 07- Left Drive Motor - Disconnected

Check For These Obvious Conditions First:

• Check left drive motor M1 connector at the Traction Control Module for secure and proper connection.

Table 6-10. Code 07 - Left Drive Motor - Disconnected

STEP ACTION SPEC YES NO

1. Check resistance across positive (+) and negative (–) drive motor
Replace Traction
leads in M1 connector wiring harness going to the left drive motor. Is .1 to .3 ohms Go to Step 2
reading within spec? Module

2. Repair or replace left drive motor wiring, brushes or motor.

(For brush replacement, see Section 3 of this Service Manual) — — —

6-14 – JLG Lift – 3121136

 SECTION 6 - TROUBLESHOOTING

Code 08 - Right Drive Motor - Disconnected

Check For These Obvious Conditions First:

• Check right drive motor M2 connector at the 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 .1 to .3 ohms Go to Step 2
Module
within spec?
2. Repair or replace right drive motor wiring, brushes or motor.
(For brush replacement, see Section 3 of this Service Manual) — — —

Code 09 - Left Brake - Disconnected

Check For These Obvious Conditions First:

• Check left drive motor M1 connector at the 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 (–) leads in M1 Replace Traction
connector wiring harness going to the left drive motor brake assem- See Table 6-2 Go to Step 2
Module
bly. Is reading within spec?
2. Repair or replace left brake wiring or left brake assembly.
— — —

Code 10 - Right Brake - Disconnected

Check For These Obvious Conditions First:

• Check right drive motor M2 connector at the 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 Table 6-2 Go to Step 2
Module
assembly. Is reading within spec?
2. Repair or replace right brake wiring or right brake assembly.
— — —

3121136 – JLG Lift – 6-15

 SECTION 6 - TROUBLESHOOTING

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. Remove the M1 connector from the Traction Control Module and This circuit
check both the pins to the drive motor for any voltage. No Voltage should be 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. or Replace Replace
No Ground Components 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. Remove the M2 connector from the Traction Control Module and This circuit
check both the pins to the drive motor for any voltage. No Voltage should be 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 the drive motor to ground. or Replace 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

NOTE: If this is a recurring problem compare current draw of your machine with Traction Control Module specifications in
Table 6-3 - Amperage Draw for Various Components.

6-16 – JLG Lift – 3121136

 SECTION 6 - TROUBLESHOOTING

Code 14 - Pump Motor - Disconnected

Check For These Obvious Conditions First:

• Check the 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 Repair or Replace
Replace Ground
the pump motor. SeeTable 6-2 Pump Motor or
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 at the P1 connector on the Ground Control Module

Replace Ground
between pin-10 and pin-3. Is reading within spec? 2 - 4 V DC Go to Step 2
Control Module

2. Check resistance between the terminals on the lift down valve, Repair or Replace
located at the base of the lift cylinder. Is reading within spec? Replace the
Wiring Harness
24.5 Ohms Lift Down Valve
from Ground
Solenoid
Control Module
3. With the terminals still removed from the lift down valve coil, check
Repair or Replace
continuity of the wires from pins 10 and 3 on the P1 connector to the .00 Ohms —
lift down valve. Wiring

3121136 – JLG Lift – 6-17

 SECTION 6 - TROUBLESHOOTING

Code 16 - Lift Down Valve - Short Circuit

Check For These Obvious Conditions First:

• Damaged wiring in 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. At the Ground Control Module, P1 connector, check the voltage

Replace Ground
across pins 10 and 3 to the lift down valve coil. Is reading within 0 - 2V DC Go to Step 2
Control Module
specification?
2. Remove the wire terminals at the 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
Repair or Replace
continuity of the wires from pins 10 and 3 on the P1 connector to the .00 Ohms —
Wiring
lift down valve.

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 Module to cool for 30 minutes. Does the Replace Ground
machine operate OK after cooling. — —
Control Module
NOTE: If this is a recurring problem compare current draw of your machine with Ground Control Module specifications in
Table 6-3 - Amperage Draw for Various Components.

Code 18 - Alarm - Short Circuit

Check For These Obvious Conditions First:

• Damaged wiring in the alarm wiring harness or a damaged alarm.

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

STEP ACTION SPEC YES NO

1. At the Ground 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. Remove the wire terminals at the alarm, check continuity of each of Replace the Repair or
the wires from pins 13 and 6 on the P1 connector to the alarm end. —
Alarm Replace Wiring

6-18 – JLG 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 at the P1 connector on the Ground Control Module Replace Ground
between pin-13 and pin-6. Is reading within specification? 2 - 4V DC Go to Step 2
Control Module

2. Remove the wire terminals at the alarm, check continuity of each of Replace the Repair or
the wires from pins 13 and 6 on the P1 connector to the alarm end. —
Alarm 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. At the Ground Control Module, P1 connector, check the voltage Replace Ground
across pins-12 and 5 to the beacon. Is reading within specification? 0 - 2V DC Go to Step 2
Control Module

2. Remove the wire terminals at the beacon, check continuity of each

Replace the Repair or
of the wires from pins 12 and 5 on the P1 connector to the beacon —
Beacon Replace Wiring
end.

3121136 – JLG Lift – 6-19

 SECTION 6 - TROUBLESHOOTING

Code 21 - Beacon - Disconnected

Check For These Obvious Conditions First:

• Is machine equipped with flashing amber beacon light.

Table 6-24. Code 21 - Beacon - Short Disconnected

STEP ACTION SPEC YES NO

1. Is machine equipped with a flashing amber beacon light.

— Go to Step 3 Got to Step 2

2. At the Ground Control Module enter the programming mode, check Replace Ground
if the Beacon light open circuit detection is enabled. — Disable It
Control Module

3. Check voltage at the P1 connector on the Ground Control Module Replace Ground
between pin-12 and pin-5. Is reading within specification? 2 - 4 V DC Go to Step 4
Control Module

4. Remove the wire terminals at the beacon, check continuity of each Replace the Repair or
of the wires from pins-12 and 5 on the P1 connector to the beacon —
Beacon Replace Wiring
end.

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

STEP ACTION SPEC YES NO

1. At the Ground 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 at the horn, check continuity of each of Replace the Repair or
the wires from pins-14 and 7 on the P1 connector to the horn end. —
Horn Replace Wiring

6-20 – JLG Lift – 3121136

 SECTION 6 - TROUBLESHOOTING

Code 23 - Horn - Disconnected

Check For These Obvious Conditions First:

• Is machine equipped with a horn unit.

Table 6-26. Code 23 - Horn - Disconnected

STEP ACTION SPEC YES NO

1. Is machine equipped with a horn unit.

— Go to Step 3 Got to Step 2

2. At the Ground Control Module enter the programming mode, check Replace Ground
if the horn open circuit detection is enabled. — Disable It
Control Module

3. Check voltage at the P1 connector on the Ground Control Module Replace Ground
between pin-14 and pin-7. Is reading within specification? 2 - 4 V DC Go to Step 4
Control Module

4. Remove the wire terminals at the horn, check continuity of each of Replace the Repair or
the wires from pins-14 and 7 on the P1 connector to the horn end. —
Horn 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.

Table 6-27. Code 24 - Auxiliary #1 Circuit - Short Circuit

STEP ACTION SPEC YES NO

1. At the Ground 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 Module

2. Remove the wire terminals at the horn, check continuity of each of

Replace the Repair or
the wires from pins-9 and 2 on the P1 connector to the component —
end. Component Replace Wiring

3121136 – JLG Lift – 6-21

 SECTION 6 - TROUBLESHOOTING

Code 25 - Auxiliary #1 Circuit - Disconnected

Check For These Obvious Conditions First:

• Is 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. Is machine equipped with a component on the Auxiliary #1 circuit.

— Go to Step 3 Got to Step 2

2. At the 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 at the P1 connector on the Ground Control Module Replace Ground
between pin-9 and pin-2. Is reading within specification? 2 - 4 V DC Go to Step 4
Control Module

4. Remove the wire terminals at the Aux. #1 component, check conti- Replace the Repair or
nuity of each of the wires from pins-9 and 2 on the P1 connector to —
Component Replace Wiring
the Aux. #1 component.

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. At the Ground 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
Control Module
specification?
2. Remove the wire terminals at the Aux. #2 component, check conti-
Replace the Repair or
nuity of each of the wires from pins-8 and 1 on the P1 connector to —
the Aux. #2 component end. Component Replace Wiring

6-22 – JLG Lift – 3121136

 SECTION 6 - TROUBLESHOOTING

Code 27 - Auxiliary #2 - Disconnected

Check For These Obvious Conditions First:

• Is machine equipped with a component on the Auxiliary #2 circuit.

Table 6-30. Code 27 - Auxiliary #2 - Disconnected

STEP ACTION SPEC YES NO

1. Is machine equipped with a component on the Auxiliary #2 circuit.

— Go to Step 3 Got to Step 2

2. At the 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 at the P1 connector on the Ground Control Module Replace Ground
between pin-8 and pin-1. Is reading within specification? 2 - 4 V DC Go to Step 4
Control Module

4. Remove the wire terminals at the Aux. #2 component, check conti- Replace the Repair or
nuity of each of the wires from pins-8 and 1 on the P1 connector to —
Component Replace Wiring
the Aux. #2 component.

Code 28 - Reserved

Code 29 - Reserved

3121136 – JLG Lift – 6-23

 SECTION 6 - TROUBLESHOOTING

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 at the main power Positive (+)/Negative Repair or Replace
(–) cable connection on the Traction Control Module. Positive (+) or
24v DC Go to Step 2
Negative (–)
Cable
2. Remove the communications cable, P5 connector at the Ground
Control Module and round connector at the Traction Control Module. Repair or Replace
— Go to Step 3
Check continuity of all three (3) wires in the communications cable Wire(s)
from end to end. P5 - Pins 2, 3, and 4.
3. With communications cable disconnected at both ends, check for Repair or Replace
continuity between Pins 2, 3, and 4 of the P5 connector end. — Go to Step 4
Wires

4. Plug the communications cable on the Traction Control Module to

Replace Traction
the round socket on the opposite end of the module. Does this fix — Done
problem? Control Module

5. Unplug the P5 connector at the Ground Control Module. Check volt- Replace Ground
age between pins 2 (– lead-in) and 5 (+ lead-in). Is voltage within 4.5v DC Done
Control Module
spec.

6-24 – JLG 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 Junction Box.

Table 6-32. Code 31 - Platform Control Console - No Communication with Ground Control Module

STEP ACTION SPEC YES NO

1. Check if LEDs are illuminated on the Platform Control Console.

— Go To Step 2 Go to Step 3

2. Remove the 9 pin Platform Control Console connector from the side Repair or Replace
of the Platform Junction Box and the P4 connector at the Ground Repair or Replace
— Platform Control
Control Module. Check continuity from the P4 connector, pin-5 to Wiring
Junction Box pin-3 and P4, pin-9 to Junction Box pin-4. Console

3. Remove the 9 pin Platform Control Console connector from the side Repair or Replace
of the Platform Junction Box. Check the voltage across pins-1 and 5 24V DC Platform Control Go to Step 4
in the Junction Box connector. Console
4. Check voltage across pins-10 and 2 on connector P4 at the Ground Replace Ground
Control Module. 24V DC Go to Step 5
Control Module

5. Check continuity of P4 connector, pin-10 to Platform Junction Box

pin-1. Also P4 connector, pin-2 to Platform Junction Box, pin-5. — Repair or Replace Wires

Code 32 - Pump Motor - Over Current

Check For These Obvious Conditions First:

• Platform overload condition.
• 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
height and load pump by continuing to press the UP button. Go to Step 2 Go to Step 3
145 Amps
Is reading within spec?
2. Did unit give a 32 Fault Code while performing Step 1? Replace Ground
— —
Control Module

3. Is the pump hydraulic pressure setting within specification as show Adjust to

in Section 1.6 of this Service Manual? See Section 1.6 Go to Step 4
Specification

4. Check pump motor brushes and rotor commutator for abnormal Replace as Replace
wear. —
Required Pump Motor

3121136 – JLG Lift – 6-25

 SECTION 6 - TROUBLESHOOTING

Code 33 - Both PHP Bars - UP

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

STEP ACTION SPEC YES NO

1. Perform steps in Code 2, Left PHP Bar UP then, Code 3, Right PHP
Bar UP. Do either of these steps correct the problem? — Done Go to 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 Consult Factory

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 – JLG Lift – 3121136

 SECTION 6 - TROUBLESHOOTING

Code 40 - Obstruction Sensor System - No Communication with Ground Control Module

Check For These Obvious Conditions First:

• Is machine equipped with an Obstruction Sensor System?
• Are the electrical harness connectors from the OSS Module through the Platform Junction 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. Is machine equipped with an OSS system?

— Got to Step 4 Go to Step 2

2. At the Ground Control Module, enter programming mode and view if Replace Ground
OSS is enabled. Is OSS enabled? X = No Go to Step 3
Control Module

3. In Service Level Programming mode, Disable Obstruction Senor

System. X=No — —

4. With machine powered up, check if the RED LED is lit on the front of
the OSS Module. — Go to Step 5 Go to Step 10

5. Check continuity from pin-9 on the OSS module (9-pin connector) Inspect Wiring
to the 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) pin-7. Connection at the
— Go to Step 8
Platform Junc-
tion Box
8. Program the Ground Control Module to Disable the OSS System. Replace the
Does fault condition still appear? — Ground Control Go to Step 9
Module
9. Replace the Obstruction Sensor System and check for fault. Replace the
— Ground Control —
Module
10. Disconnect 9-pin connector at the OSS Module. Place a positive
Replace the OSS
(+) lead on Pin-1 and a negative (–) lead on pin-5. Check for 24v 24V (DC) Go to Step 11
Module
DC.
11. Check the wiring harness from the Platform Junction 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) Go to Step 12
Junction Box
Wire Harness

3121136 – JLG Lift – 6-27

 SECTION 6 - TROUBLESHOOTING

Table 6-35. Code 40 - OSS - No Communication with Ground Control Module (Continued)

STEP ACTION SPEC YES NO

12. At the Ground Control Module (P-4 connector) check voltage Repair or
between pin-8 and pin-2, place positive (+) lead on pin-8. Replace, Junc-
tion Box to Replace Ground
24V (DC)
Ground Control Control Module
Module
Wire Harness

Codes 41 thru 46 - OSS - Sensor 1 through 6 - Fault Condition

Check For These Obvious Conditions First:

• Is there an obstruction under the sensor showing the fault?
• Is 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. Is machine equipped with an OSS system?

— Got to Step 4 Go to Step 2

2. At the Ground Control Module, enter programming mode and view if Replace Ground
OSS is enabled. Is OSS enabled? X = No Go to Step 3
Control Module

3. In Service Level Programming mode, Disable Obstruction Senor

System. X=No — Go to Step 4

4. Replace the sensor showing the fault. Does this correct the prob-
lem. — Done Go to Step 5

5. Replace the complete OSS system, module and sensors.

— — —

6-28 – JLG 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 power 5 times allowing a 10 second interval

between each power recycle. Does fault clear? — Done Go to Step 2

2. Which code number is 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. Replace with
12V DC Go to Step 4
proper Batteries

4. Check battery voltage while charger is operating. Is voltage within Replace

specification? Maximum of Repair or Replace
Ground Control
31 Volts DC Battery Charger
Module
5. Remove the communications cable, P5 connector at the Ground
Control Module and round connector at the Traction Control Module. Repair or Replace
— Go to Step 6
Check continuity of all three (3) wires in the communications cable Wire(s)
from end to end. P5 - Pins 2, 3, and 4.
6. With communications cable still disconnected at both ends, check Repair or Replace
for continuity between Pins 2, 3, and 4 at the P5 connector end. — Go to Step 7
Wires

7. Plug the communications cable on the Traction Control Module to Replace

the round socket on the opposite end of the module. Does this fix — Done Ground Control
problem? Module

3121136 – JLG 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.
• Secure harness connections from Platform Control Console to Platform Junction Box to Ground Control Module.
• Confirm that the 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 power 5 times allowing a 10 second interval

between each power recycle. Does fault clear? — Done Go to Step 2

2. Which 200 code number is displaying? Code - 200/207/213 Go to Step 3 Replace

Platform
Code - 202/205/206 Go to Step 4 Control Module
3. Remove the 9 pin Platform Control Module connector from the
side of the Platform Junction Box and the P4 connector at the Replace
Repair or
Ground Control Module. Check continuity from the P4 connector, — Platform
Replace Wiring
pin-5 to Junction Box pin-3 and P4, pin-9 to Junction Box pin-4. Control Module
Is there continuity on these wires?
4. Perform the Joystick Calibration Procedure in Section 4.5 of this Replace
Service Manual. Does this clear the fault code? — Done Platform
Control Module

6-30 – JLG 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 power 5 times allowing a 10 second interval

between each power recycle. Does fault clear? — Done Go to Step 2

2. Is a code number displaying on the Ground Control Station? Replace

Code - 316 Go to Step 3 Traction Control
Module

Code - 325 Go to Step 5 —

3. Confirm that both installed batteries are 12 Volt DC. Replace with
12V DC Go to Step 4
proper Batteries

4. Check battery voltage while charger is operating. Is voltage within Replace

Maximum of Repair or Replace
specification? Traction Control
31 Volts DC Battery Charger
Module
5. Check for short in harness wires from Ground Control Station con-
nector P5 to Traction Module (round din plug). Repair or Replace
— —
Note: This harness contains 6 wires only 3 are used, (See Figure 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:

• Battery voltage is 24 volts. (Sufficient Charge in Batteries to Operate Machine)
• Positive (+) and negative (–) battery cable connections clean and tight at both the Batteries and the Ground Control Mod-
ule lugs.
• Main Power Selector Switch (key) positioned to either Platform or Ground Control Mode.
• 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. Check for 24V DC at the positive (+) and negative (–) main power Replace the 175
cable connections on the Ground Control Module. Amp Inline Fuse
24V DC Go to Step 2
on the 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 at the — Ground Control Go to Step 3
Ground Control Module. Module
3. Remove the 9-pin Platform Control Console connector at the Plat- Replace the
form Junction Box and check continuity between pins-1 and 2 to the — Go to Step 4 Platform Control
Emergency Stop Switch in the Platform Control Console cable. Console
4. Check continuity of the wires running from the P4 connector on
Ground Control Module to the Platform Junction Box; Replace Platform Repair or Replace
—
P4 connector, Pin-1 to Junction Box Pin-2 and Control Console Wiring
P4 connector, Pin-10 to Junction Box Pin-1

6-32 – JLG Lift – 3121136

 SECTION 6 - TROUBLESHOOTING

6.10 MAST TROUBLESHOOTING

Platform Will Not Lower Manually

Check For These Obvious Conditions First:
• Is there an obstruction in the mast assembly?
• Is there a restricted hydraulic line (smashed)?
• Are the mast slide pads shimmed properly (not too 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 lower from the Ground Control Sta- Repair or Replace
tion in Ground Control Mode. the Manual
— Go to Step 2
Descent Control
Valve
2. Check to see if the lift down valve is opening completely. Replace the Lift
— Go to Step 3
Down Valve
3. Check the flow valve in the lift cylinder for a restriction. Clean or Replace
— Consult Factory
Flow Valve

Platform Lift Up And Down Jerky

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 mast is not running smooth or has tight and rough spots, refer to the Mast Section 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 Jerky

STEP ACTION SPEC YES NO
CONTROLS (ELECTRICAL)
1. Is platform control console, platform enable, up or down pad defec-
— Replace pad Go to Step 2
tive or worn out?
2. Loose connections, ground and power. Repair
— Go to Step 3
connection
3. Valve solenoid keeps opening and closing. Repair Connec-
— tion or Replace Go to Step 4
Valve
4. Problem internal to the Ground Control Module. — Replace Module Go to Step 5
HYDRAULIC
5. Is the hydraulic valve working properly. — Go to Step 6 Replace Valve
6. Pump drive cavatating. — Replace Pump Go to Step 7
7. Lift cylinder Rebuild or
— —
Replace Cylinder

3121136 – JLG 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. Do slide pads and slide pad channels need to be cleaned of dust, Clean Pads and
dirt, or other debris? — Go to Step 2
Channels
2. Do mast chains need to be lubricated per JLG specification in the Lubricate as
— Go to Step 3
Service Manual? Required
3. Are the chain/cable sheave wheels dry and need lubrication? Lubricate or
Note: Plastic wheels will howl on the sheave pin when they are dry.
— Replace Sheave Go to Step 4
Sheave wheels may seize to the sheave pin and the pin may turn in
the pin retainer blocks. Pins and Wheels

4. Are the sequence cables (located on the side of mast) chattering

when the springs are compressed? Clean Slide Pads/
Note: This noise is normal at the sequence cable sheave wheels
Channels or Re-
when the mast is completely lowered. However if the sequence — Go to Step 5
shim Mast per
cable chattering is happening no matter what position the mast is in,
it could be a result of the mast being shimmed to tight or dirt and Service Manual
debris in the slide pad channels causing the mast to be tight.
5. Is the bore of the lift cylinder dry? Replace Packing
— Go to Step 6
or Lift Cylinder
6. Are the bearings in the lift pump motor and pump drive worn? Repair or Replace
— Go to Step 7
Pump
7. Are the hydraulic lines vibrating together? Adjust the Posi-
— Go to Step 8
tion of the Lines
8. Check if the pump motor is loose to it’s mounting plate. Tighten pump
— mounting Go to Step 9
fasteners
9. Hydraulic oil could be cavatating inside the pump. Repair or Replace
— —
Pump

6-34 – JLG Lift – 3121136

 SECTION 6 - TROUBLESHOOTING

Platform (Mast) Won’t Stay Elevated

Overview Of Procedure
The following procedure requests that the lift down, dump, 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
1. Is the lift down valve stuck open? Repair or Clean
— Go to Step 2
Valve
2. Lift down valves could be open due to incorrect electrical signal. Check Pump
— Valve Electrical Go to Step 3
Circuit
3. Oil could 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 mast slide pads shimmed to tight. — Reshim Mast Go to Step 2
2. Is there an obstruction in the mast? Remove
— Go to Step 3
Obstruction
3. The lift cylinder packing could be too tight in the bore of the cylinder Rebuild or
barrel. — Go to Step 4
Replace Cylinder
4. Check if the lift down valve is opening completely. Clean or Replace
— Go to Step 5
Valve
5. Is there a restricted hydraulic line (smashed)? Replace Hydrau-
— Go to Step6
lic Line
6. Check the flow valve in the cylinder valve block for a 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. Oil leaking around the lift cylinder rod. Replace the Seal
at the end of the
— —
Piston and
Cylinder Barrel
2. Oil leaking around the cylinder extend or return line fittings. Tighten or
— —
Replace Fittings
3. Oil leaking around the hydraulic lines. Tighten or
— Replace —
Hydraulic Lines
4. Oil leaking around the lift down valve. Tighten Cartridge
— —
in Pump Case
5. Oil leaking around the (Red) manual descent valve. Replace Lift
— —
Down Valve

Note: Do not overtighten the nut on the solenoid in step 5.

6-36 – JLG Lift – 3121136

 SECTION 6 - TROUBLESHOOTING

6.12 BASE FRAME COMPONENTS TROUBLESHOOTING

Caster Wheels Not Operating Freely

Check For These Obvious Conditions First:

• Is machine operating on a smooth, level surface?

Table 6-47. Caster Wheels Not Operating Freely.

STEP ACTION SPEC YES NO
1. Is the caster rotating freely? Lubricate or
— Go to Step 2 Replace Caster
Housing
2. Is the wheel spinning freely? Lubricate or
— Go to Step 3
Replace Wheel
3. Is debris stuck in the rubber wheel? Remove Debris or
— —
Replace Wheel

Pot Hole Protection (PHP) Bars will not Lower

Check For These Obvious Conditions First:

• Obstruction under pot hole bar on 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. Check the actuator assembly and cables for adjustment or damage.
— Adjust or Replace Consult Factory

3121136 – JLG Lift – 6-37

 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
• Is Grade within the Maximum Allowable Specification of 20% Grade
• Does the Travel Surface allow for Proper Drive Wheel Traction
• Is Platform Load within the Maximum Rated Capacity

Table 6-49. Won’t Climb Grade

STEP ACTION SPEC YES NO
1. Does machine drive straight on a level surface? Refer to Machine
Won’t Drive
— Go to Step 2
Straight
(Table 6-51)
2. Are both the left and right drive motor, slip-clutches, located Repair, Replace
between the drive motor and the drive wheels, working properly? — Go to Step 3 or Adjust Slip
Clutch
3. Do the left and 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. Check the amperage output of the on the drive motor leads. They Controller will
should not exceed 100 amps while pulling a grade. Shut Drive Down
— Go to Step 5
and will flash a 7
LED Code
5. Check the condition of the drive motor brushes. Worn down,
— OK, go to Step 6 replace brushes
or drive motor
6. If all above is OK, Drive motors are working properly. Consult Fac-
— — —
tory.

6-38 – JLG Lift – 3121136

 SECTION 6 - TROUBLESHOOTING

Machine Drives in Opposite Direction

Table 6-50. Machine Drive in Opposite Direction

STEP ACTION SPEC YES NO
1. At the Traction Control Module, check if the left drive motor power Switch the Left
lead is plugged into the M1 socket. and Right Drive
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-
Rewire as
tive (+) terminal and the BLACK wire is connected to the negative — Go to Step 3
Necessary
(–) terminal. (Reference Figure 6-3., Electrical Diagram. (DVL/
DVSP) (Sheet 1)
3. Remove the Left Drive Motor power lead at the Traction Control
Module (M1) 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 due to the reverser harness. (Reference Figure 6-3.,
Electrical Diagram. (DVL/DVSP) (Sheet 1)

3121136 – JLG 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 of the 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 on the drive assembly, drive attachment Repair/Replace/
— Go to Step 2
weldments; is bent, has broken welds, or loose hardware. Tighten weldment
2. Check for the following on the drive assembly, drive motor mounting
Repair/Replace/
plates; are bent, are square with drive weldments, or is hardware — Go to Step 3
Tighten weldment
loose?
3. Check for the following on the drive assembly, drive motor hard- Repair/Replace/
ware; is hardware loose, flange bearing - bad/loose, slip clutch - — Tighten compo- Go to Step 4
check torque settings or adjustment. nent
4. Check the left and right drive motor brakes for loose hardware & not Tighten or Adjust
releasing properly. per procedure
— Go to Step 5
in this
Service Manual
5. Is the electrical signal and amperage draw to the drive motors Recheck Steps
equal? Check with machine on level surface. See Table 6-3. Go to Step 6
1 thru 5
6. Check the drive motor brushes, do they need replaced? Replace per
— procedure in this Go to Step 7
Service Manual
7. Calibrate joystick on Platform Control Console per procedure in
— Done Go to Step 8
Section-4 of this Service Manual. Does this fix the problem?
8. Is joystick control defective? Repair/Replace
If possible, swap out with another platform control. — Go to Step 9
Platform control
9. Is the Traction Control Module defective or connections not tight? Tighten Connec-
If possible, swap out with another Traction Control Module. tions or Replace
— Go to Step 10
Traction Control
Module
10. Inside the drive motor gear box check if; the drive shaft is exces- Repair/Replace gear box
sively loose & condition of drive shaft bearings. — components per procedure in this
Are any gears broken or gear teeth excessively worn. Service Manual

6-40 – JLG Lift – 3121136

 SECTION 6 - TROUBLESHOOTING

Noise From Drive Assembly

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 of the 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 on the drive assembly, drive attachment Repair/Replace/
weldment; is bent, has broken welds, or loose hardware. — Go to Step 2
Tighten weldment
2. Check for the following on the drive assembly, drive motor mounting
Repair/Replace/
plates; are bent, are square with drive weldments, or is hardware — Go to Step 3
loose? Tighten weldment

3. Check for the following on the 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. Check the left and right drive motor brakes for loose hardware & not Tighten or Adjust
releasing properly. per procedure
— Go to Step 5
in this
Service Manual
5. Is the electrical signal and amperage draw to the drive motors Recheck Steps
See Table 6-3. Go to Step 6
equal? Check with machine on level surface. 1 thru 5
6. Check the drive motor brushes, do they need replaced? Replace per
— procedure in this Go to Step 7
Service Manual
7. Inside the drive motor gear box check if; the drive shaft is exces- Repair/Replace gear box
sively loose & condition of drive shaft bearings. — components per procedure in this
Are any gears broken or gear teeth excessively worn. Service Manual

3121136 – JLG Lift – 6-41

 SECTION 6 - TROUBLESHOOTING

PROGRAMMABLE GROUND
SECURITY PUMP/
CONTROL
LOCK MOTOR STATION
(OPTION)

MASTER
SWITCH
(UL-EE OPTION)

P1

FUSE P2
P3
P4
P5

ALARM

BATTERIES
HORN
AUX 1
OUTPUT
POWER AUX 2
OUTPUT
POWER

LEFT
DRIVE TRACTION
MOTOR MODULE
HARNESS
REVERSER

LEFT BEACON
DRIVE LIGHT
MOTOR (MAST)
(OPTION)

BEACON
LIGHT (BASE) (DVSP)

RIGHT
DRIVE
MOTOR

Figure 6-2. Overview of Electrical System Components. (DVL/DVSP) (Sheet 1 of 2)

6-42 – JLG Lift – 3121136

 SECTION 6 - TROUBLESHOOTING

BATTERY
CHARGER

BATTERY
L.E.D.
LIGHT

BATTERY
CHARGER
RECEPTACLE
SPARE
ANALOGUE
INPUT

PLATFORM INHIBITS
AUX 2 LIFT/DRIVE

PHP
SWITCHES

ACCESSORY
RECEPTACLE
MAST
JUNCTION
ELEVATION
BOX SPEED
12 FT. CUTOUT
LIFT SWITCH
LIMIT
SWITCH
(OPTION)
PLATFORM
CONSOLE

OBSTRUCTION
ELECTRONICS
BOX
(OPTION)

OBSTRUCTION
SENSORS

Figure 6-2. Overview of Electrical System Components. (DVL/DVSP) (Sheet 2 of 2)

3121136 – JLG Lift – 6-43

 SECTION 6 - TROUBLESHOOTING

RIGHT
MOTOR

LEFT
MOTOR

4933184_D-1
Figure 6-3. Electrical Diagram. (DVL/DVSP) (Sheet 1)

6-44 – JLG Lift – 3121136

 SECTION 6 - TROUBLESHOOTING

4933184_D-1
Figure 6-3. Electrical Diagram. (DVL/DVSP) (Sheet 1)

3121136 – JLG Lift – 6-45

 SECTION 6 - TROUBLESHOOTING

RIGHT
MOTOR

LEFT
MOTOR

(CEOPTION ONLY) 4933184_D-2

Figure 6-4. Electrical Diagram - (with Load Sensing System) (DVL/DVSP) (Sheet 2)

6-46 – JLG Lift – 3121136

 SECTION 6 - TROUBLESHOOTING

(CEOPTION ONLY) 4933184_D-2

Figure 6-4. Electrical Diagram - (with Load Sensing System) (DVL/DVSP) (Sheet 2)

3121136 – JLG Lift – 6-47

 SECTION 6 - TROUBLESHOOTING

12

11

10
9

6 8
5

1
2792504_B

1. Tank 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. Lift Cylinder

Figure 6-5. Hydraulic Diagram. (DVL/DVSP)

6-48 – JLG Lift – 3121136

 Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Fax: (717) 485-6417

JLG Worldwide Locations

JLG Industries (Australia) JLG Industries (UK) JLG Deutschland GmbH JLG Industries (Italia)
P.O. Box 5119 Unit 12, Southside Max Planck Strasse 21 Via Po. 22
11 Bolwarra Road Bredbury Park Industrial Estate D-27721 Ritterhude/lhlpohl 20010 Pregnana Milanese - MI
Port Macquarie Bredbury Bei Bremen Italy
N.S.W. 2444 Stockport Germany Phone: (39) 02 9359 5210
Australia SK6 2sP Phone: (49) 421 693 500 Fax: (39) 02 9359 5845
Phone: (61) 2 65 811111 England Fax: (49) 421 693 5035
Fax: (61) 2 65 810122 Phone: (44) 870 200 7700
Fax: (44) 870 200 7711

JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska
Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI. Krolewska
80-Suite 71 2132 HJ Foofddorp N-1412 Sofienyr 00-060 Warsawa
13092-310 Campinas-SP The Netherlands Norway Poland
Brazil Phone: (31) 23 565 5665 Phone: (47) 6682 2000 Phone: (48) 91 4320 245
Phone: (55) 19 3295 0407 Fax: (31) 23 557 2493 Fax: (47) 6682 2001 Fax: (48) 91 4358 200
Fax: (55) 19 3295 1025

JLG Industries (Europe) JLG Industries (Pty) Ltd. Plataformas Elevadoras JLG Industries (Sweden)
Kilmartin Place, Unit 1, 24 Industrial Complex JLG Iberica, S.L. Enkopingsvagen 150
Tannochside Park Herman Street Trapadella, 2 Box 704
Uddingston G71 5PH Meadowdale P.I. Castellbisbal Sur SE - 175 27 Jarfalla
Scotland Germiston 08755Castellbisbal Sweden
Phone: (44) 1 698 811005 South Africa Spain Phone: (46) 8 506 59500
Fax: (44) 1 698 811055 Phone: (27) 11 453 1334 Phone: (34) 93 77 24700 Fax: (46) 8 506 59534
Fax: (27) 11 453 1342 Fax: (34) 93 77 11762