Page 2 - CALIFORNIAN PROPOSITION 65; BATTERY WARNING; WASH HANDS
JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444AustraliaPhone: (61) 2 65 811111Fax: (61) 2 65 810122 JLG Industries (UK)Unit 12, SouthsideBredbury Park Industrial EstateBredburyStockportSK6 2sPEnglandPhone: (44) 870 200 7700Fax: (44) 870 200 7711 JLG Deutschland GmbH...
Page 3 - FOREWORD; and
FOREWORD The purpose of this manual is to provide users with the operating procedures essential for the promotion ofproper machine operation for its intended purpose. It is important to over-stress proper machine usage. Allinformation in this manual should be READ and UNDERSTOOD before any attempt i...
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Page 5 - – JLG Lift –; INTRODUCTION - OPERATION/SAFETY PRECAUTIONS; Instruction and warning placards must be legible.
INTRODUCTION - OPERATION/SAFETY PRECAUTIONS 3120782 – JLG Lift – a INTRODUCTION - OPERATION/SAFETY PRECAUTIONS A l l p r o c e d u r e s h e r e i n a r e b a s e d o n t h e u s e o f t h emachine under proper operating conditions, with no devi-ations from original design intent ... as per OSHA reg...
Page 6 - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS; B. HYDRAULIC SYSTEM SAFETY
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS b – JLG Lift – 3120782 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A. GENERAL Th is s ect io n con ta ins th e g en er al s af et y pr eca ut ion swhich must be observed during maintenance of the aerialplatform. It is of utmost importance that maintena...
Page 7 - EFFECTIVITY PAGE; EFFECTIVITY CHANGES; June 15, 1999 - Original Issue of Manual
EFFECTIVITY PAGE 3120782 – JLG Lift – c EFFECTIVITY CHANGES June 15, 1999 - Original Issue of Manual November 21, 2000 - Revised - Pages Affected:Section 2 - Pages 2-11, 2-18 thru 2-21. January 17, 2002 – Manual Revised October 31, 2003 – Manual Revised
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EFFECTIVITY PAGE d – JLG Lift – 3120782 This Page Left Intentionally Blank
Page 9 - TABLE OF CONTENTS
3120782 – JLG Lift – i TABLE OF CONTENTS TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE NO. INTRODUCTION -- OPERATION/SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A INTRODUCTION -- MAINTENANCE SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . ...
Page 11 - SECTION 3 - TROUBLESHOOTING
3120782 – JLG Lift – iii TABLE OF CONTENTS SECTION 3 - TROUBLESHOOTING 3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 TROUBLESHOOTING INFORMATION. . . . . . . . . . . . . . . . . . . . . . ...
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iv – JLG Lift – 3120782 TABLE OF CONTENTS (Continued) This page intentionally left blank.
Page 13 - SECTION 1 - SPECIFICATIONS; SECTION 1. SPECIFICATIONS; MODEL
SECTION 1 - SPECIFICATIONS 3120782 – JLG Lift – 1-1 SECTION 1. SPECIFICATIONS 1.1 CAPACITIES Hydraulic Oil Reservoir AC Models – 5 qts. U.S. (4.7 ltr.) DC Models – 5 qts. U.S. (4.7 ltr.) 1.2 COMPONENT DATA Hydraulic Pump/Electric Motor Assembly DC Models - 12 Volt DC motor/pump Motor - 12v - DC Stan...
Page 14 - HO
SECTION 1 - SPECIFICATIONS 1-2 – JLG Lift – 3120782 Maximum Working Height (Average person) 20EL-AC & DC - 26 ft. (7.92 m) 25EL-AC & DC - 31 ft. (9.45 m) 30EL-AC & DC - 36 ft. (11 m) 36EL-AC & DC - 42 ft. (12.80 m) 41EL-AC & DC - 47 ft. (14.33 m) Platform Cycle Performance Lift U...
Page 15 - HYDRAULIC PRESSURE ADJUSTMENT; Turning adjustment screw; clockwise, increases system; CYLINDER SPECIFICATIONS; Screw Located at Base of Pump Motor
SECTION 1 - SPECIFICATIONS 3120782 – JLG Lift – 1-3 1.6 HYDRAULIC PRESSURE ADJUSTMENT (See Figure 1-1.) Adjust system pressure so that platform will raise withrated capacity in platform. Turning adjustment screw clockwise, increases system pressure , turning screw counterclockwise, decreases system ...
Page 17 - Hydraulic Oil
SECTION 1 - SPECIFICATIONS 3120782 – JLG Lift – 1-5 Figure 1-3. Lubrication Locations (See Table below) . 1 4 2 3 Table 1-4. Lubrication Intervals for Various Components ITEM COMPONTENT NO/TYPE LUBE POINTS LUBE/METHOD INTERVAL HOURS COMMENTS 3 MONTHS 150 Hrs. 6 MONTHS 300 Hrs. 1 YEAR 600 Hrs. 2 YEAR...
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Page 19 - SECTION 2 - SERVICE PROCEDURES; SECTION 2. SERVICE PROCEDURES; General
SECTION 2 - SERVICE PROCEDURES 3120782 – JLG Lift – 2-1 SECTION 2. SERVICE PROCEDURES 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information neededby t hose pe rsonne l t hat are re spon sibl e t o pl ace t hemachine in operation readine ss and m...
Page 21 - INTERVAL
SECTION 2 - SERVICE PROCEDURES 3120782 – JLG Lift – 2-3 Table 2-2. EL Model - Preventive Maintenance & Inspection Schedule. AREA ON MACHINE INTERVAL PRE-START (1) INSPECTION WEEKLY PREVENTATIVE MAINTENANCE 3 MONTH PREVENTATIVE MAINTENANCE PRE-DELIVERY (2)OR FREQUENT (3) INSPECTION ANNUAL (4) (YE...
Page 23 - should be parallel to each other and as near
SECTION 2 - SERVICE PROCEDURES 3120782 – JLG Lift – 2-5 2.3 SERVICING AND MAINTENANCE GUIDELINES General The following information is provided to assist you in theuse and application of servicing and maintenance proce-dures contained in this chapter. WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURE...
Page 24 - . Service applicable components with the amount,; Chain Size
SECTION 2 - SERVICE PROCEDURES 2-6 – JLG Lift – 3120782 Bolt Usage and Torque Application Use bolts of proper length. A bolt which is too long willbottom before the head is tight against its related part. If abolt is too short, there will not be enough thread area toengage and hold the part properly...
Page 25 - Mast Cable Inspection Procedure; NOTE: A good indicator of a stretched extend/retract cable
SECTION 2 - SERVICE PROCEDURES 3120782 – JLG Lift – 2-7 Tight Joints: All joints in the leaf chain should flex freely. On leaf chain, tight joints are usually caused by rust/corro-sion, or the inside plates “walking” off the bushing. Limberup rusty/corroded chains (after inspecting care fully) with ...
Page 26 - LUBRICATION INFORMATION; NOTE: Metal particles may appear in the oil of new
SECTION 2 - SERVICE PROCEDURES 2-8 – JLG Lift – 3120782 2.4 LUBRICATION INFORMATION Hydraulic System The primary enemy of a hydraulic system is contamina-tion. Contaminants enter the system by various means,e.g., using inadequate hydraulic oil, allowing moisture,grease, filings, sealing components, ...
Page 27 - General Information
SECTION 2 - SERVICE PROCEDURES 3120782 – JLG Lift – 2-9 2.5 BATTERY CHARGER - ASSEMBLY AND DISASSEMBLY General Information DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGERIF MACHINE IS STILL UNDER WARRANTY. OPENING THE BAT-TERY CHARGER W HILE THE MACHINE IS UNDER WARRANT YWILL VOID THE CHARGER WARR...
Page 28 - Printed Circuit Board Replacement; Remove the circuit board.; DC Circuit Breaker Replacement; Remove the wiring from the breaker terminals.
SECTION 2 - SERVICE PROCEDURES 2-10 – JLG Lift – 3120782 Printed Circuit Board Replacement 1. Disconnect the wide wiring connector from the endof the circuit board. 2. Remove the four (4) screw attaching the card to thefront face of the charger chassis. 3. Remove the circuit board. DC Circuit Breake...
Page 29 - Remove the wiring from the SCR Rectifier.
SECTION 2 - SERVICE PROCEDURES 3120782 – JLG Lift – 2-11 Shunt Assembly, Varistor, and SCR Rectifier Replacement (See Illustration) Shunt Assembly (Item #1) 1. Carefully remove the screw from the end of theshunt assembly. The white insulator may need to berestrained to keep it from turning while rem...
Page 30 - Disassembly; NOTE: (Use a container to catch the hydraulic oil from cylin-; Cylinder Disassembly; NOTE: Always protect the chrome surface of the cylinder; Lift Cylinder Component Inspection; Cylinder Rod
SECTION 2 - SERVICE PROCEDURES 2-12 – JLG Lift – 3120782 2.6 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILD HYDRAULIC CYLINDERS ARE DESIGNED TO HOLD HYDRAULICFLUID UNDER HIGH PRESSURE. BE SURE ALL APPROPRIATEMEASURES ARE TAKEN TO RELIEVE RESIDUAL PRESSURE INTHE CYLINDER BEFORE DISCONNECTI...
Page 31 - Tube Assembly; Cylinder Assembly; NOTE: Re-check that seals are not twisted or pinched and
SECTION 2 - SERVICE PROCEDURES 3120782 – JLG Lift – 2-13 cates uneven loading and when this occurs, the diametershould be checked for out-of-roundness. If out-of-round-ness exceeds 0.007", this is unacceptable. Check the con-dition of the dynamic seals and bearings lookingparticularly for metall...
Page 32 - Installation; NOTE: The following step is easier done with two people,
SECTION 2 - SERVICE PROCEDURES 2-14 – JLG Lift – 3120782 6. When the rod assembly is ready to be installed intothe tube, liberally apply an anti-seize lubricant to thehead outer surface, especially the static seal. 7. Next dip the entire rod assembly into hydraulic fluidand stuff this assembly into ...
Page 33 - when sliding mast sec-; Mast Disassembly Procedure; Table 2-4. EL Series Mast Component Features; TOP
SECTION 2 - SERVICE PROCEDURES 3120782 – JLG Lift – 2-15 2.7 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES The EL Series personnel lift mast sections are contructedof extruded aluminum, protected with an anodized surfacefinish. The mast sections rails are interlocked into eachother whe n asse mble d and ...
Page 34 - Platform Section Removal; . Push threaded ends of cable; Mast Section 6 Removal; (be certain floor surface is clean and
SECTION 2 - SERVICE PROCEDURES 2-16 – JLG Lift – 3120782 Platform Section Removal (All Masts) 3. Remove cable adjust nuts from threaded ends ofcable attached to the cable anchor plate on BOT-TOM end of mast section-5/-6/-7 (short, platform mounting section) . Push threaded ends of cable through anch...
Page 35 - Mast Section 3 Removal; Mast Section 2 Removal; NOTE: When sliding mast sections apart, be careful not to; Mast Section 1 Disassembly; Mast disassembly should now be complete.
SECTION 2 - SERVICE PROCEDURES 3120782 – JLG Lift – 2-17 22. Carefully slide mast section-4 out BOTTOM of sec-tion-3. Remove slide pads, shims and chain anchorplate, if necessary. Mast Section 3 Removal (All Masts) 23. Remove chain adjust nuts from threaded ends ofchain attached to the chain anchor ...
Page 36 - MAST ASSEMBLY; (preferably a table or; Mast Section 2 - Assembly; NOTE: When sliding mast sections together, be careful not
SECTION 2 - SERVICE PROCEDURES 2-18 – JLG Lift – 3120782 2.8 MAST ASSEMBLY (See Figure 2-3., Figure 2-4. or Figure 2-5.) Mast Section 1 - Assembly (All Masts) 1. Place mast section-1, rail (open) side up (See Figure 2-1.) on a clean, flat surface (preferably a table or work bench capable of supporti...
Page 40 - SECTION 1; MAST SECTIONS
SECTION 2 - SERVICE PROCEDURES 2-22 – JLG Lift – 3120782 Figure 2-6. Mast Chain/Cable Routing Diagram. HYD. CYL. LIFTSHERE SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 CHAIN ASSY. CHAIN ASSY. CABLE ASSY. CHAIN / CABLE ASSY. ANCHOR PLATES MAST SECTIONS
Page 41 - (rectangular plate with; Mast Section 3 - Assembly; Mast Section 4 - Assembly
SECTION 2 - SERVICE PROCEDURES 3120782 – JLG Lift – 2-23 a. Insert sheave pin through anchor block on cylin-der rod end. b. Place sheave wheels (for wide chain) on sheave pin, one each side of anchor block. c. On outside of each sheave wheel, place asheave pin attach bar, (rectangular plate with thr...
Page 42 - . Attach through inner; Mast Section 5 - Assembly
SECTION 2 - SERVICE PROCEDURES 2-24 – JLG Lift – 3120782 30. Locate mast section-4, carefully slide section-4closed rail into section-3 open rail. Slide sectionstogether until ends are even. 31. Locate one (1) of the chain/cable anchor plates (one with two threaded holes vertically aligned in center...
Page 43 - Insert threaded ends of cable assembly; Mast Section 6 - Assembly; . Attach through outer set of holes
SECTION 2 - SERVICE PROCEDURES 3120782 – JLG Lift – 2-25 x 3/4" long bolts, place a flatwasher under head ofeach bolt. 45. Slide mast section-5 out the top of mast section-4 sothe chain/cable anchor plate on bottom of mast sec-tion-5 is easily accessible near top end of mast sec-tion-4. Rest the...
Page 45 - Mast assembly should now be complete.
SECTION 2 - SERVICE PROCEDURES 3120782 – JLG Lift – 2-27 shim stock and slide pad to mast section rail withshim stock against rail and slide pad with bev-eled side out) . PR I O R T O C # 1 4 2 9 2 0 T HE E L M AS T I N S TA LL E D T W O S HO R TS L I D E P AD S O N E A C H S I D E O F T H E P L A T...
Page 46 - MAST TO BASE FRAME INSTALLATION; (base frame and mast assembly must be
SECTION 2 - SERVICE PROCEDURES 2-28 – JLG Lift – 3120782 2.9 MAST TO BASE FRAME INSTALLATION 1. Using an overhead crane or suitable lifting devicecapable of supporting the weight of base frame,attach a sling strap or chain to the front crossmem-ber of the base frame, raise base frame. 2. Extend hydr...
Page 47 - SEQUENCING CABLES ADJUSTMENT; from the section; MAST SIDE PROFILE
SECTION 2 - SERVICE PROCEDURES 3120782 – JLG Lift – 2-29 2.10 MAST CHAINS/CABLES AND SEQUENCING CABLES ADJUSTMENT Mast Chain/Cable Adjustment The intention of this procedure is to assure equal load dis-tribution between the individual chains/cables of a mastsection chain/cable set. Also to step each...
Page 48 - Sequencing Cable Adjustment
SECTION 2 - SERVICE PROCEDURES 2-30 – JLG Lift – 3120782 NOTE: Mast section-1 is fixed to the base and mast section- 2 is attached to the lift cylinder, these sectionsrequire no adjustment. 3. Adjust one mast section at a time starting from theback (section-3, section-4, etc.) of the mast and work f...
Page 51 - SECTION 3. TROUBLESHOOTING; GENERAL; so that oil is available; HYDRAULIC CIRCUIT CHECKS; NOTE: For aid in Hydraulic troubleshooting, refer to Figure
SECTION 3 - TROUBLESHOOTING 3120782 – JLG Lift – 3-1 SECTION 3. TROUBLESHOOTING 3.1 GENERAL This section contains troubleshooting information to beused for locating and correcting most of the operatingproblems which may develop in the aerial platform. If aproblem should develop which is not presente...
Page 54 - OUTRIGGER INTERLOCK CONTACTS; While holding first brass nut, jam; ORIGINAL DESIGN; through the insulating bushings.
SECTION 3 - TROUBLESHOOTING 3-4 – JLG Lift – 3120782 3.4 OUTRIGGER INTERLOCK CONTACTS Outrigger Socket and Outrigger Beam - Interlock Contacts It is very important that the outrigger interlock contactslocated on the bottom surface inside the outrigger socketsof the base frame, and the contactor plat...
Page 56 - washers on the the other screw; Detent Screws; mounted around the CONTAC-
SECTION 3 - TROUBLESHOOTING 3-6 – JLG Lift – 3120782 5. On the inside of the outrigger beam, install twonylon washers on the screw with the two (2) o-ringsinstalled (one towards jack end) and three (3) nylon washers on the the other screw (towards open end of beam) . 6. Coat the threads of the screw...
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