JLG Ecolift50 Service And Maintenance Manual
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JLG Ecolift50 Service And Maintenance Manual

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Service and Maintenance Manual
Model(s)
Ecolift50
Ecolift70
830P
3121741
June 29, 2018 - Rev B
ANSI

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Summary of Contents for JLG Ecolift50

  • Page 1 Service and Maintenance Manual Model(s) Ecolift50 Ecolift70 830P 3121741 June 29, 2018 - Rev B ANSI...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 4: General

    STOWED IN THEIR PROPER PLACE. sures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any por- • USE ONLY APPROVED, NONFLAMMABLE CLEANING tion of the system. SOLVENTS. 3121741 – JLG Lift –...

  • Page 5: Revision Log

    INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISION LOG Original Issue A - January 20, 2017 Revised B - June 29, 2018 - Revised Covers 3121741 – JLG Lift –...

  • Page 6: Table Of Contents

    Ecolift50 ........
  • Page 7 3.7 ECOLIFT50/70 MAST INSTALLATION ........
  • Page 8 Flywheel Crank Cover Installation - Ecolift50 and 70 ....... . .
  • Page 9 TABLE OF CONTENTS NOTES: – JLG Lift – 3121741...

  • Page 10: Section 1 - Machine Specifications

    50.3 in. (1280 mm) 3.92 ft. (1.195m) Width 28.3 in. (700mm) 29.1in. (740mm) 2.46 ft. (0.750m) Height 61 in. (1550mm) 76.77 in. (1950mm) 5.11 ft. (1.560m) Weight 397 lb. (180kg) 672 lb. (305 kg) 628 lbs. (285 kg) 3121741 – JLG Lift –...

  • Page 11: Operating Specification (Ecolift 50)

    3.3 ft. (1m) 3.28 ft (1.0m) Figure 1-1. Operating Specification (Ecolift 50) Figure 1-3. Operating Specification (830P) 14 ft (4.2m) 9.84 ft (3m) 6.5 ft (2m) 3.28 ft (1m) Figure 1-2. Operating Specification (Ecolift 70) – JLG Lift – 3121741...

  • Page 12: Lubrication

    (Timken OK 40 pounds mini- mum.) EPGL - Extreme Pressure Gear Lube (oil) meeting API service classifi- cation GL-5 or MIL-Spec MIL-L-2105. HO - Hydraulic Oil - Grade 32 Mineral Oil 3121741 – JLG Lift –...
  • Page 13 (b) 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. – JLG Lift – 3121741...

  • Page 14: Torque Charts

    1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND JLG P/N Loctite® P/N...

  • Page 15: Torque Chart (Sae Fasteners - Sheet 2 Of 7))

    1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER Figure 1-5. Torque Chart (SAE Fasteners - Sheet 2 of 7)) – JLG Lift – 3121741...
  • Page 16 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-6. Torque Chart (SAE Fasteners - Sheet 3 of 7) 3121741 – JLG Lift –...
  • Page 17 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-7. Torque Chart (SAE Fasteners - Sheet 4 of 7) – JLG Lift – 3121741...

  • Page 18: Torque Chart (Metric Fasteners - Sheet 5 Of 7))

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 5 of 7)) 3121741 – JLG Lift –...
  • Page 19 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 6 of 7) 1-10 – JLG Lift – 3121741...
  • Page 20 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-10. Torque Chart (METRIC Fasteners - Sheet 7 of 7) 3121741 – JLG Lift – 1-11...
  • Page 21 SECTION 1 - MACHINE SPECIFICATIONS NOTES: 1-12 – JLG Lift – 3121741...

  • Page 22: Section 2 - General Service Information

    (13) months from the date of the prior machine into service. Annual Machine Inspection. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a person who has Preparation, Inspection, and Maintenance successfully completed the JLG Service Training School for the subject JLG product model.

  • Page 23: Preventive Maintenance And Inspection Schedule

    Service and Maintenance Manual Qualified JLG Mechanic Inspection rental delivery. User and applicable JLG inspection form. In service for 3 months; or Out of service for a Frequent Owner, Dealer, or Service and Maintenance Manual period of more than 3 months; or Purchased...
  • Page 24 General Structural Condition and Welds 2, 4 2, 4 All Fasteners, Pins, Shields, and Covers 1, 2 Function Test of All Systems Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership 3121741 – JLG Lift –...

  • Page 25: Servicing And Maintenance Guidelines

    If it becomes necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious system damage. – JLG Lift – 3121741...

  • Page 26: Bolt Usage And Torque Application

    (See Torque Chart in Section-1 nents. of this manual.) Hydraulic Oil HYDRAULIC SYSTEM INFORMATION - (830P For best performance, JLG recommends the use of Grade Only) 32, Mineral oil. Refer to Section-1 for recommended hydraulic oils. Hydraulic Lines and Electrical Wiring...
  • Page 27 SECTION 2 - GENERAL SERVICE INFORMATION NOTES: – JLG Lift – 3121741...
  • Page 28 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 29: Section 3 - Component Servicing

    NOTE: Do not release the flywheel crank and raise the platform without weight in the platform. The mast contains a charged gas cylinder under constant pressure to help assist the lifting process. Figure 3-1. Frame Cover Installation - Ecolift50 1. Frame Cover 3.

  • Page 30: 830P

    SECTION 3 - COMPONENT SERVICING 830P Figure 3-3. Frame Cover Installation - 830P 1. Frame Cover 3. Slot in Frame 2. Screws – JLG Lift – 3121741...

  • Page 31: Tool Tray Installation

    Ecolift50 Figure 3-6. Tool Tray Installation - 830P 1. Tool Tray 3. Top Of Mast Mounting Holes Figure 3-4. Tool Tray Installation - Ecolift50 2. Attach Screws and Washers 1. Tool Tray 3. Top Of Mast Mounting Holes 2. Attach Screws and Washers Ecolift70 Figure 3-5.

  • Page 32: Castor Wheel Assembly

    Figure 3-8. Castor Wheel Installation - Ecolift50 1. Castor Wheel Assembly 3. Mounting Bolt and Washer 2.

  • Page 33: Rear Axle Assembly

    This brake system consists of a disc bolted to the back of the wheel hub assembly, the disc has a series of holes into which a spring loaded pin will engage when the platform is raised. Both rear axle wheels are equipped with the brake system. Figure 3-9. Rear Wheel and Brake Installation - Ecolift50/70 1. Wheel Bearing Cover 5.

  • Page 34: Rear Wheel And Brake Installation - 830P

    Adjusting the actuator bar lower in the L bracket slots raises the Pivoting Lever Bar (2) up in the front and lowers the frame at the rear, thereby decreasing the gap between the wheel (1) and the frame stop weldment (6). – JLG Lift – 3121741...

  • Page 35: Ecolift50/70

    2. Support platform from the top rails using suit- able overhead lifting equipment. Lift platform Figure 3-11. Platform Installation - Ecolift50 and 70 enough to take the weight of the platform off of 1. Platform Assembly 3.

  • Page 36: Ecolift50/70

    SECTION 3 - COMPONENT SERVICING ECOLIFT FLYWHEEL CRANK COVER ECOLIFT50/70 MAST INSTALLATION INSTALLATION (See Figure 3-15.) DO NOT RELEASE THE FLYWHEEL CRANK AND ATTEMPT TO RAISE THE THE MAST CONTAINS A GAS CHARGED CYLINDER UNDER CONSTANT PLATFORM WITHOUT WEIGHT IN THE PLATFORM. THE MAST CON- PRESSURE.
  • Page 37 1. Inner Mast Assembly 4. Outer Mast Section (Front Cover) 8. Mast Safety Interlock Pin 2. A - Ecolift50 - Pressurized Gas Cylinder 5. Belt Drive System 9. Flywheel Crank Drive Gear 2. B - Ecolift70 - Pressurized Gas Cylinder 6.

  • Page 38: Mast Re-Assembly

    13. Once step 8 and 9 are completed the complete and drive gear and the guide plate. (on item 4 and outer mast front cover and flywheel assembly can be lifted off the mast assembly for further disassembly, if required. 3-10 – JLG Lift – 3121741...
  • Page 39 SECTION 3 - COMPONENT SERVICING Figure 3-17. Belt Clamp Assembly - Ecolift 1. Belt Clamp to Inner Mast - Mounting Bolts 3121741 – JLG Lift – 3-11...

  • Page 40: Gas Cylinder Pressurizing

    59° F to 77° F 1031 PSI +/- 7 PSI (+15.0 to +24.9°C) (78 bar +/- 0.5 bar) 77° F to 95° F 1175 PSI +/- 7 PSI (+25.0 to +34.9°C) (81 bar +/- 0.5 bar) 3-12 – JLG Lift – 3121741...

  • Page 41: 830P Mast Installation

    3121741 – JLG Lift – 3-13...

  • Page 42: Hydraulic System - Pressure And Leak Check

    6. Top off the pump reservoir oil level to FULL if greater than the set hydraulic pressure. needed. 3. Fully extend and retract the mast through two or three lift cycles. Recheck the pump reservoir oil level. 3-14 – JLG Lift – 3121741...
  • Page 43 3. Outer Mast Section 7. Inner and Mid - Mast Rear Guide Roller 11. Spring Damper Stop 4. Mast Top Cap, Mounting and Cylinder Screws 8. Mid and Outer - Mast Front Guide Roller 3121741 – JLG Lift – 3-15...

  • Page 44: 830P Electrical/Hydraulic Components

    2. Battery Charger 6. Emergency Stop Switch w/Key 10. Hydraulic Lift Cylinder 3. Hydraulic Pump and Resevoir 7. Safety Solenoid 11. Platform Control Station with Enable Button 4. Lowering Valve w/Manual Override 8. Pump Starter Solenoid 3-16 – JLG Lift – 3121741...

  • Page 45: Contactor Solenoid Replacement

    2. Slow pulse, indicates slower charging. 3. Continuous illumination indicates float charge. Both LEDs go “off” when fully charged. The battery charger can be connected to the AC power supply at any time or left for extended periods. 3121741 – JLG Lift – 3-17...

  • Page 46: Charger Leds

    In such an event, the fuse is simple to replace; ensure battery disconnect is switched off and that the positive RED battery cable is disconnected before attempting to check or change fuse. 3-18 – JLG Lift – 3121741...

  • Page 47: Section 4. 830P - Troubleshooting And Schematics

    Min/Max Use of the "Min/Max" recording feature of some meters can help when taking measurements of intermittent con- ditions while alone. For example, you can read the voltage 3121741 – JLG Lift –...

  • Page 48: Polarity

    To find the problem, start at step 1 and use the entire pro- cedure. • Jumper or method to connect contacts on one side of harness. • Meter that can measure resistance or continuity. – JLG Lift – 3121741...

  • Page 49: Resistance Measurement

    • Circuit power must be turned OFF before testing resistance • Disconnect component from circuit before testing • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with meter leads 3121741 – JLG Lift –...

  • Page 50: Continuity Measurement

    (See multi meter’s operation manual) • Use firm contact with meter leads • Use firm contact with meter leads • First test meter and leads by touching leads together. Meter should produce an audible alarm, indicating continuity – JLG Lift – 3121741...

  • Page 51: Electrical Switch Testing

    Another type of limit switch used by JLG is the inductive the battery negative side or grounded to the vehicle. What proximity switch, also referred to as a "prox switch".
  • Page 52 Breather cap on tank is saturated or clogged with Replace breather cap on tank. oil. Hydraulic oil tank over-filled. Lower oil level to full mark on dipstick. Unit lowers very slowly. Lift DOWN solenoid valve not functioning. Replace Lift DOWN solenoid valve. – JLG Lift – 3121741...

  • Page 53: 830P Electrical Diagram

    SECTION 4 - 830P - TROUBLESHOOTING AND SCHEMATICS 830P ELECTRICAL DIAGRAM N.C. Figure 4-5. 830P - Electrical Diagram. 3121741 – JLG Lift –...

  • Page 54: 830P Hydraulic Diagram

    SECTION 4 - 830P - TROUBLESHOOTING AND SCHEMATICS 830P HYDRAULIC DIAGRAM Figure 4-6. 830P - Hydraulic Diagram. – JLG Lift – 3121741...
  • Page 56 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

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