JLG 15DVL, 15DVSP, 20DVL, 20DVSP Vertical Mast Service Manual
164 pages · Publication 3121136
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What's inside
From the manual's own table of contents: 259 sections, 311 entries. See sample pages (PDF, 559 KB)
MAINTENANCE SAFETY PRECAUTIONS
GENERAL
HYDRAULIC SYSTEM SAFETY
MAINTENANCE
REVISION LOG1 topic
- CAPACITIES
System Voltage
Hydraulic System
Drive Motor GearBox (gear oil)1 topic
- COMPONENT DATA
Hydraulic Pump/Pump Motor Assembly
Rear Wheel Drive Motors
Batteries/Battery Charger1 topic
- PERFORMANCE DATA
Platform Capacities
Platform Size
Machine Height (platform stowed)
Base Footprint2 topics
- TORQUE REQUIREMENTS
- LUBRICATION
Hydraulic Oil
Lubrication Specifications1 topic
- HYDRAULIC PRESSURE SETTINGS AND ADJUSTMENT
Hydraulic Pressure Gauge Connection
After Filter Pressure Check3 topics
- CYLINDER SPECIFICATIONS
- SERIAL NUMBER LOCATIONS
- MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance1 topic
- PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE
Show all 259 sections
Inspection and Maintenance Codes
Footnotes1 topic
- SERVICING AND MAINTENANCE GUIDELINES
Safety and Workmanship
Cleanliness1 topic
- TABLE OF CONTENTS Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Lubrication and Servicing
Batteries
Mast Chain Inspection Procedure1 topic
- LUBRICATION INFORMATION
Changing Hydraulic Oil2 topics
- BASE ASSEMBLY COMPONENTS
- BASE FRAME COVERS
Drive Motor Cover - Installation
Battery Charger Cover - Installation1 topic
- DRIVE AND CASTER WHEELS
Drive Motor Wheel (Std.) - Installation
Caster Wheels - Installation
Wheel Retention for Rough Terrain Drive Wheel (Option)1 topic
- DRIVE MOTOR COMPONENT - SERVICING
Torque Limiting Clutch Maintenance
Diagnostics
Visual Inspection and Limiting Torque Checking Procedure
Check Clutch Torque Setting
Torque Limiting Clutch Adjustment
Drive Wheel Alignment - (Machines built prior to S/N-0130005271)1 topic
- DRIVE MOTOR ASSEMBLY - SERVICING
Drive Motor Assembly - Removal
Drive Motor Brake Removal and Adjustment
Brake Operation
Brake Assembly Removal
Checking/Adjusting Armature Plate Gap Setting
Brake Assembly Installation
Drive Motor Boot Assembly Installation
Drive Motor Brush Replacement
Brush Cleaning and Inspection
Brush Removal
Brush Reassembly
Gear Box Disassembly/Assembly
Gear/Pinion Shaft Assembly
Drive Shaft Assembly
Final Gear Box Assembly2 topics
- POT HOLE PROTECTION SYSTEM
- BATTERY/BATTERY CHARGER - SERVICE PROCEDURES
Battery Low Voltage Warning Indicators
Battery Condition Testing1 topic
- TABLE OF CONTENTS Battery Replacement
Battery Charger General Information
Battery Charger Troubleshooting
Battery Charge/Flash Code LED Indicator on Platform Control Console
Battery Charging Status Indicators Mounted on Ground Control Station Cover
Wet/VRLA Battery - Charging Profile Switch
General Component Installation Notes
Battery Charger Installation
Cover Installation
AC Line Fuse Installation
Interlock Relay Installation
Wet/VRLA Switch Installation
Shunt Assembly Installation
SCR Rectifier Installation (Either Side)
Transformer Installation
Printed Circuit Board Installation
DC Circuit Breaker/Voltage Select Switch Installation2 topics
- CONTROL COMPONENTS OVERVIEW
- CONTROLS COVER INSTALLATION
Battery Cover Doors
Center, Left and Right Lower Covers1 topic
- CONTROL COMPONENTS - INSTALLATION
Ground Control Module
Traction Control Module
Platform Control Console Installation
Battery Installation
Horn Installation
Alarm Installation
Battery Installation (EE Spec Machines Only)
Fuse Box - (EE Spec Machines Only)
Master Disconnect Switch - (EE Spec Machines Only)1 topic
- GROUND CONTROL MODULE - SERVICE PROCEDURE
Cover Removal/Installation
Power Selector/EStop Switch Installation1 topic
- GROUND CONTROL MODULE - PROGRAMMING
Programming Levels
Activating Programming Mode
Entering Password
Programming Mode Selection
Selecting Programmable Item to Adjust
Adjusting Programmable Setting
Service Programming Mode - (Level-2)
Operator Programming Mode - (Level-3)
Remove Platform Control Console
Display/Controller Module Electrical Connections
Mounting Bracket - Install/Remove
Rear Cover - Install/Remove
Display/Controller Module - Install/Remove
Drive/Lift Mode Switch - Install/Remove
Horn Button Switch - Install/Remove1 topic
- TABLE OF CONTENTS Key Switch - Install/Remove
E-Stop/ShutDown Switch - Install/Remove
Joystick Assembly - Install/Remove
Upper/Lower Shell Attach Screws
Emergency Stop Switch Installation
Upper/Lower Shell Component Connections
Button Pad Installation
Joystick Assembly Installation
Joystick Calibration Procedure1 topic
- PUMP-MOTOR ASSEMBLY - SERVICE PROCEDURE
Inline Hydraulic Filter Installation
Pump/Motor/Tank Installation
Motor Cap/Motor Installation
Motor Brush Installation
Brush Housing Final Assembly Tips
Tank Installation
Pump Installation
Filter Screen Installation
Pressure Adjust Valve Installation
Pressure Check Valve Installation1 topic
- OBSTRUCTION SENSOR SYSTEM - SERVICE PROCEDURE (DVSP - OPTION)
Transducer Sensor Check
OSS Component Installation2 topics
- MAST COMPONENTS OVERVIEW
- MAST CHAINS AND SEQUENCING CABLES ADJUSTMENT
Mast Chain/Cable Adjustment
Sequencing Cable Adjustment1 topic
- SEQUENCE CABLE REPLACEMENT KIT
Remove Old Cable
Replacement Cable Installation
Clamp Installation (Drum/Socket Type)1 topic
- HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILD
Lift Cylinder Removal
Cylinder Disassembly
Lift Cylinder Component Inspection
Cylinder Assembly
Cylinder Installation1 topic
- MAST ASSEMBLY INSTALLATION
Mast Removal
Mast Installation1 topic
- MAST ASSEMBLY AND DISASSEMBLY PROCEDURES
Mast Disassembly Procedure
Mast Assembly - DVL/DVSP7 topics
- DVSP - STOCKPICKER PLATFORM - INSTALLATION
- DVSP - STOCKPICKER PLATFORM - MID-GATE INTERLOCK INSTALLATION
- MAST BEACON - INSTALLATION
- GENERAL
- TROUBLESHOOTING INFORMATION
- HYDRAULIC CIRCUIT CHECKS
- ELECTRICAL CIRCUIT CHECKS
Ground Control Module LCD Display1 topic
- TROUBLESHOOTING TABLES INDEX
Specifications For Various Components
Special Pin Extractor Tools For Electrical Connectors
Fault Code Troubleshooting Tables
Main Power Circuit Troubleshooting
Mast Troubleshooting
Hydraulic Leak Troubleshooting
Base Frame Components Troubleshooting
Drive System Troubleshooting3 topics
- SPECIFICATIONS FOR VARIOUS COMPONENTS
- SPECIAL PIN EXTRACTOR TOOLS FOR ELECTRICAL CONNECTORS
- FAULT CODE TROUBLESHOOTING TABLES
Machine in Drive Speed Cut-Back (Turtle) Mode All The Time
Obstruction Sensor System - Detection
Battery Voltage Low - Warning Level 3 - Three (3) LED/LCDs lit
Code 02 - Left PHP Bar - UP
Code 03 - Right PHP Bar - UP
Code 04 - Tilt Condition
Code 05 - Reserved
Code 06 - Reserved
Code 07- Left Drive Motor - Disconnected
Code 08 - Right Drive Motor - Disconnected
Code 09 - Left Brake - Disconnected
Code 10 - Right Brake - Disconnected
Code 11 - Left Drive Motor - Short Circuit
Code 12 - Right Drive Motor - Short Circuit
Code 13 - Traction Module - In Fold Back
Code 14 - Pump Motor - Disconnected
Code 15 - Lift Down Valve - Disconnected
Code 16 - Lift Down Valve - Short Circuit
Code 17 - Ground Control Module - In Fold Back
Code 18 - Alarm - Short Circuit
Code 19 - Alarm - Disconnected
Code 20 - Beacon - Short Circuit
Code 21 - Beacon - Disconnected
Code 22 - Horn - Short Circuit
Code 23 - Horn - Disconnected
Code 24 - Auxiliary #1 Circuit - Short Circuit
Code 25 - Auxiliary #1 Circuit - Disconnected
Code 26 - Auxiliary #2 - Short Circuit
Code 27 - Auxiliary #2 - Disconnected
Code 28 - Reserved
Code 29 - Reserved
Code 30 - Traction Module - No Communication with Ground Control Module
Code 32 - Pump Motor - Over Current
Code 33 - Both PHP Bars - UP
Code 38 - Battery Voltage Low - Warning Level 2 - Two (2) LED/LCDs lit1 topic
- TABLE OF CONTENTS Code 39 - Battery Voltage Low - Warning Level 3 - One (1) LED/LCDs lit
Codes
Codes (100 - 199) Ground Control Module - Fault Condition
Codes (200 - 299) Platform Control Console - Fault Condition
Codes (300 - 399) Traction Control Module - Fault Condition1 topic
- MAIN POWER CIRCUIT TROUBLESHOOTING
Machine Will Not Power Up1 topic
- MAST TROUBLESHOOTING
Platform Will Not Lower Manually
Platform Lift Up And Down Jerky
Mast Noisy When Lifting And Lowering
Platform (Mast) Won’t Stay Elevated
Platform (Mast) Descends Too Slowly1 topic
- HYDRAULIC LEAK TROUBLESHOOTING
Miscellaneous Hydraulic Leak Troubleshooting1 topic
- BASE FRAME COMPONENTS TROUBLESHOOTING
Caster Wheels Not Operating Freely
Pot Hole Protection (PHP) Bars will not Lower1 topic
- DRIVE SYSTEM TROUBLESHOOTING
Won’t Climb Grade
Machine Drives in Opposite Direction
Machine Won’t Drive Straight
Noise From Drive Assembly
Hydraulic Pressure Adjustment Screw. (Machine Rear Covers Removed)
Typical Hydraulic Pressure Gauge Installation (Hydraulic Filter Removed)
Typical Hydraulic Pressure Gauge Installation (After Hydraulic Filter)
Torque Chart. (ANSI Spec.)
Torque Chart. (ANSI to METRIC Conversion)
Torque Chart (Metric Class Fasteners)
Accessing Machine Underside Components by Lifting with a Fork Truck
Base Components
Drive Motor Assembly Components. (Machines built prior to S/N-0130005271)
Drive Motor Assembly Components. (Machines built since S/N-0130005271)
Drive Motor Component Assembly (Machines built prior to S/N-0130005271)
Drive Motor Component Assembly (Machines built since S/N-0130005271)
Torque Limiting Clutch Assembly
Brake Assembly Components
Drive Motor Gear Box Assembly - DVL/DVSP
Pot-Hole-Protection System Components
DVL/DVSP - SCR Dual Voltage - Battery Charger Wiring Diagram
Control Components Location - DVL/DVSP
Component Electrical Connections
Ground Control Module Components
Platform Control Console Components
Mast Components. (DVL/DVSP)
DVL/DVSP - Mast Chain and Sequence Cable Adjustment Components
Machine Positioned for Cylinder Removal
Lift Cylinder Component Cross-Section (DVL/DVSP)
Mast Section - Assembly Reference
Mast Chain Routing Diagram. - DVL/DVSP
Mast Bottom End - Slide Pad Installation (Typical)
Mast Top End - Slide Pad Installation (Typical)
DVSP - StockPicker Platform Installation
Overview of Electrical System Components. (DVL/DVSP) (Sheet 1 of 2)
Electrical Diagram. (DVL/DVSP) (Sheet 1)
Electrical Diagram - (with Load Sensing System) (DVL/DVSP) (Sheet 2)
Hydraulic Diagram. (DVL/DVSP)
DVL and DVSP - Machine Specifications
Hydraulic Oil Operating Range
Cylinder Specifications
Lubrication Intervals for Various Components
Inspection and Maintenance
DVL/DVSP - Preventive Maintenance & Inspection Schedule
Chain Stretch Tolerance
DVL/DVSP Ground Control Module - Field Programmable Settings and Factory Preset
Obstruction Sensor System Components (Platform Cutaway)
DVL/DVSP Mast Component Features
LCD Display - Service Fault Code Conditions
Ohm Ratings for Various Components
Amperage Draw for Various Components
Code 07 - Left Drive Motor - Disconnected
Code 08 - Right Drive Motor Disconnected
Code 21 - Beacon - Short Disconnected
Code 31 - Platform Control Console - No Communication with Ground Control Module
Code 40 - OSS - No Communication with Ground Control Module
Code (200 - 299) Platform Control Console - Fault Condition
Machine Drive in Opposite Direction
Inside this manual
Real pages from this service manual (164 pages). Open the sample pages (PDF, 557 KB)
- Specifications, page 13: SECTION 1 - MACHINE SPECIFICATIONS
- Troubleshooting, page 115: SECTION 6. TROUBLESHOOTING
- Diagram, page 133: Code 19 - Alarm - Disconnected
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 15DVL, 15DVSP, 20DVL, 20DVSP are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 3121136$69.65
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 164 pages
Quantity one is the manual described above.
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