Troubleshooting and Maintenance of the JLG 20 DVL Series Boom Lift

[MikePhua]

The JLG 20 DVL Series boom lift is a versatile piece of equipment used extensively in various industries such as construction, maintenance, and industrial applications. Known for its compact design, efficient performance, and reach, this machine is favored for tasks requiring elevated work platforms. However, like any heavy equipment, it can encounter a range of issues over time. This guide delves into the most common problems associated with the JLG 20 DVL boom lift, offering solutions and preventive maintenance tips to ensure optimal performance and extend the life of the machine.
Overview of JLG 20 DVL Series Boom Lift
The JLG 20 DVL Series boom lift is a self-propelled aerial work platform that provides operators with the ability to reach high working heights with ease. The machine is designed for indoor and outdoor use, providing excellent maneuverability in tight spaces.
Key Specifications:

• Working Height: Approximately 20.1 meters (66 feet)
  
• Platform Capacity: 250 kg (550 lbs)
  
• Platform Dimensions: 0.76 x 1.83 meters (2.5 x 6 feet)
  
• Lift Capacity: Up to 227 kg (500 lbs) in the platform
  
• Overall Length: 5.6 meters (18.4 feet)
  
• Width: 2.2 meters (7.2 feet)
  
• Weight: 2,700 kg (5,950 lbs)
  
• Fuel Type: Diesel (for rough terrain models) or Electric (for indoor use)
  

This machine combines high reach and robust lifting capacity, making it suitable for a variety of jobs such as building maintenance, window cleaning, and installations that require significant height access.
Common Issues and Troubleshooting
While the JLG 20 DVL Series is built for reliability, like any piece of machinery, it can experience problems due to wear, misuse, or environmental factors. Below, we explore some of the most common issues and provide solutions.
1. Hydraulic System Failure
Hydraulic issues are among the most common problems in aerial work platforms. A malfunctioning hydraulic system can prevent the lift from moving smoothly or operating its boom arm properly. Some of the symptoms include:

• Slow or No Boom Movement: If the boom is slow to extend or doesn’t move at all, it could be due to a lack of hydraulic fluid or air in the hydraulic lines.
  
• Fluid Leaks: Leaking hydraulic fluid is a clear sign that there could be damaged seals, hoses, or valves.
  
• Erratic Movements: Sudden jerky movements can indicate air trapped in the hydraulic system, or a malfunctioning hydraulic pump.
  

Solution:

• Check Fluid Levels: Make sure the hydraulic fluid is at the correct level. Low fluid can cause the hydraulic system to fail, so ensure it's topped off with the appropriate fluid type.
  
• Inspect Hoses and Seals: Regularly inspect hydraulic hoses and seals for wear, cracks, or leaks. Replace any damaged components to avoid further issues.
  
• Bleed the System: If the issue is related to air in the system, bleeding the hydraulic system can restore smooth operation. Follow the manufacturer’s instructions for this procedure.
  

2. Electrical Issues
The JLG 20 DVL relies on a combination of electrical systems to control functions like platform elevation, tilt, and rotation. Electrical failures can manifest in various ways:

• Non-Responsive Controls: If the lift's controls stop responding or are intermittent, it might be due to a blown fuse or wiring issue.
  
• Warning Lights: Warning lights on the control panel can indicate problems such as low battery voltage, system faults, or sensor issues.
  
• Battery Drain: If the lift is not holding a charge or the battery is draining too quickly, it could signal a faulty alternator or charging system.
  

Solution:

• Check Fuses and Wiring: Start by inspecting the fuses in the system. Replace any blown fuses, and check the wiring for any exposed or corroded connections.
  
• Battery and Alternator Inspection: Test the battery voltage to ensure it’s within the required range. If the battery is old or faulty, replace it. Similarly, inspect the alternator to ensure it’s charging the battery correctly.
  
• Inspect Control Panel and Sensors: If warning lights persist, check the control panel for any malfunctions or sensor failures. It may require calibration or replacement.
  

3. Platform and Boom Arm Movement Problems
Issues with the platform or boom arm not moving smoothly can severely hinder the functionality of the JLG 20 DVL Series boom lift. Common symptoms include:

• Uneven Platform Elevation: If the platform rises unevenly or doesn’t lift to its full height, it could be a sign of an issue with the lift mechanism or the hydraulic system.
  
• Boom Sticking: The boom arm might become stuck or hesitate during extension, which can be caused by dirt buildup, rust, or hydraulic fluid contamination.
  

Solution:

• Lubricate Moving Parts: Regular lubrication of the boom arm and platform mechanism is essential to prevent friction and wear. Use a high-quality grease recommended by the manufacturer.
  
• Check for Obstructions: Inspect the rails and boom arm for any obstructions or debris that might be impeding smooth movement.
  
• Hydraulic Fluid Check: If the movement remains sluggish, ensure the hydraulic system is in top condition. Low or contaminated hydraulic fluid can cause poor performance.
  

4. Tire and Traction Problems
The tires of the JLG 20 DVL Series are essential for traction and stability. If the lift is used on rough terrain, tire-related issues can become prevalent:

• Flat or Under-Inflated Tires: Flat tires can result in instability, reducing the machine's lifting capacity and safety.
  
• Uneven Wear: Uneven tire wear can indicate improper tire alignment or underuse/overuse of certain wheels.
  

Solution:

• Tire Pressure Check: Always check the tire pressure before use to ensure optimal traction. Use a pressure gauge to measure tire pressure, and inflate tires to the manufacturer’s recommended levels.
  
• Inspect for Damage: Check for punctures, cuts, or wear in the tires. Replace any tires that are damaged or worn excessively.
  
• Tire Alignment and Rotation: Ensure the tires are aligned and rotate them regularly to prevent uneven wear.
  

5. Engine Issues
Engine problems can prevent the JLG 20 DVL from starting or operating at full capacity. Some common signs include:

• Hard Starting: Difficulty starting the engine could be related to issues with the fuel system, spark plugs, or air filters.
  
• Loss of Power: If the engine runs but lacks power, it could be due to clogged fuel lines, a malfunctioning fuel pump, or dirty air filters.
  
• Excessive Smoke: White or black smoke from the engine could indicate a fuel mixture problem, engine overheating, or excessive carbon buildup.
  

Solution:

• Fuel System Inspection: Check the fuel lines, filters, and pump to ensure they are clean and free of obstructions. Replace any clogged filters.
  
• Air Filter Maintenance: Clean or replace the air filters to ensure proper airflow to the engine. Dirty air filters can reduce engine performance.
  
• Engine Diagnostics: For persistent engine issues, use an onboard diagnostic tool or consult with a qualified technician to diagnose internal engine problems.
  

Preventive Maintenance Tips
Regular maintenance is essential for keeping the JLG 20 DVL Series boom lift in good working order. Here are some preventive maintenance practices:

• Routine Inspections: Conduct visual inspections before each use, focusing on the hydraulic system, electrical connections, tires, and engine.
  
• Scheduled Servicing: Follow the manufacturer’s maintenance schedule, including oil changes, hydraulic fluid checks, and battery inspections.
  
• Clean the Lift: Keep the machine clean to prevent dirt buildup, especially in moving parts, tires, and hydraulic components.
  
• Calibration: Regularly calibrate the control system to ensure that the lift operates smoothly and responds accurately to input from the operator.
  

Conclusion
The JLG 20 DVL Series boom lift is a reliable and efficient machine used across many industries for elevated work. By following regular maintenance practices and addressing common issues promptly, operators can ensure the machine continues to perform well and remains safe to use. Whether dealing with hydraulic problems, electrical faults, or mechanical failures, timely repairs and preventive care can prolong the life of the equipment and improve productivity on the job site.