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JLG 20EL Service & Maintenance

JLG 20EL Service & Maintenance

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SERVICE & MAINTENANCE
Model
20EL
25EL
30EL
36EL
41EL
3120782
October 31, 2003
CORPORATE OFFICE
JLG INDUSTRIES, INC.
1 JLG Drive
McConnellsburg, PA.
17233-9533
USA
Telephone: (717) 485-5161
Fax: (717) 485-6417

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  • Page 1 SERVICE & MAINTENANCE Model 20EL 25EL 30EL 36EL 41EL 3120782 October 31, 2003 CORPORATE OFFICE JLG INDUSTRIES, INC. 1 JLG Drive McConnellsburg, PA. 17233-9533 Telephone: (717) 485-5161 Fax: (717) 485-6417...

  • Page 2: Battery Warning

    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.
  • Page 3 TRIES, INC. OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLE- TINS WHICH MAY HAVE BEEN ISSUED FOR YOUR JLG PRODUCT. ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COMPLETED ON THE AFFECTED JLG PRODUCT.

  • Page 4: This Page Left Intentionally Blank

    This page left intentionally blank.

  • Page 5: Introduction - Operation/Safety Precautions

    Nor shall the listing of these requirements platform, except in case of an emergency. constitute an assumption of responsibility of liability on the part of JLG Industries, Inc. 11. Regular inspection of the job site and aerial lift shall be performed by competent persons.

  • Page 6: Introduction - Maintenance Safety Precautions

    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. – JLG Lift – 3120782...

  • Page 7: 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 3120782 – JLG Lift –...
  • Page 8 EFFECTIVITY PAGE This Page Left Intentionally Blank – JLG Lift – 3120782...

  • Page 9: Table Of Contents

    Pressure-Fit Parts............2-5 3120782 – JLG Lift –...
  • Page 10 Clamp Installation (Drum/Socket Type) ........2-31 – JLG Lift –...
  • Page 11 20EL Mast Assembly Components. (5 - Section) ........
  • Page 12 TABLE OF CONTENTS (Continued) This page intentionally left blank. – JLG Lift – 3120782...

  • Page 13: Section 1. Specifications

    Machine Height (Platform Stowed) Set to 2800 PSI (193 bar) at factory 20EL-AC & DC - 77.3 in. (2.0 m) 25EL-AC & DC - 77.3 in. (2.0 m) Batteries (1) – DC Models. 30EL-AC & DC - 77.3 in. (2.0 m) 12 Volt –...

  • Page 14: Maximum Working Height (Average Person)

    Machine Overall Width and Length (Base) HYDRAULIC SYSTEM OPERATING SAE VISCOSITY 20EL Models - 29 in.(W) x 47 in.(L) (74 cm x 1.19 m) TEMPERATURE RANGE GRADE 25EL Models - 29 in.(W) x 49 in.(L) (74 cm x 1.24 m) 0°...

  • Page 15: Hydraulic Pressure Adjustment

    Make pressure adjustment with oil at nor- Lift Cylinder - 1.63 56.50 1.38 mal operating temperature. If pressure is set when oil is 20EL-AC & DC (4.14) (143.50) (3.50) cold, platform may not raise rated load after oil has Lift Cylinder - 1.63...

  • Page 16: Torque Chart

    SECTION 1 - SPECIFICATIONS Figure 1-2. Torque Chart. – JLG Lift – 3120782...

  • Page 17: Lubrication Locations (See Table Below)

    4. 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. 3120782 – JLG Lift –...
  • Page 18 SECTION 1 - SPECIFICATIONS This page left intentionally blank – JLG Lift – 3120782...

  • Page 19: Section 2. Service Procedures

    The Annual Machine Inspection must be performed by a machine into service. qualified JLG equipment mechanic on an annual basis, no later than thirteen (13) months from the date of the prior Preparation, Inspection, and Maintenance Annual Machine Inspection.

  • Page 20: Preventive Maintenance And Inspection Schedule

    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 150 hours, which- Owner, Dealer, or User Qualified JLG Service and Maintenance Man- Inspection ever comes first;...
  • Page 21 Hydraulic Cylinder 7, 9 2, 9 2, 9 Cylinder Attachment Pins and Pin Retainers 1, 2 Hydraulic Hoses, Lines, and Fittings 1, 9 Hydraulic Reservoir, Cap, and Breather 5, 7 5, 7 5, 7 Hydraulic Filter 3120782 – JLG Lift –...
  • Page 22 Grease and Lubricate to Specifications Function Test of All Systems Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership Footnotes: 9. Check for signs of leakage. (1) Prior to use each day; or at each Operator change 10.

  • Page 23: Servicing And Maintenance Guidelines

    New parts and thickness. Be sure to cut holes in the right location, as should remain in their containers until they are ready to be blank gaskets can cause serious system damage. used. 3120782 – JLG Lift –...

  • Page 24: Bolt Usage And Torque Application

    Fatigue and ultimate strength failures on JLG Lifts are incurred as a result of severe abuse as design specs are well within the rated lift- ing capacity of these chains.

  • Page 25: Mast Cable Inspection Procedure

    The inspection frequency shall be based on such factors as expected cable life as determined by experi- ence on the particular application or similar installations, severity of environment, percentage of capacity lifts, fre- quency rates of operation, and exposure to shock loads. 3120782 – JLG Lift –...

  • Page 26: Lubrication Information

    Hydraulic Oil For best performance, JLG recommends the use of ISO- Vg grade 32, 46 oil with a viscosity range between 15-250 SUS at 100 degrees F (32-54 cST at 40 degrees C). Refer to Section 7 for recommended hydraulic oils.

  • Page 27: Battery Charger - Assembly And Disassembly

    The EL Series dual AC input battery charger allows for replacement of the following internal components. Con- sult your Illustrated Parts Manual for part numbers of these components which are available from the JLG Parts Department: Transformer Replacement • Transformer 1.

  • Page 28: Printed Circuit Board Replacement

    DC Circuit Breaker Replacement 1. Remove the wiring from the breaker terminals. 2. Remove the bolt, nut and washer from each side of the breaker, remove the breaker from the housing. 2-10 – JLG Lift – 3120782...

  • Page 29: Shunt Assembly, Varistor, And Scr Rectifier Replacement (See Illustration)

    SCR Rectifier Replacement (Item #2) 1. Remove the wiring from the SCR Rectifier. 2. Remove the nut securing the rectifier to the insulated aluminum chassis bracket. 3. Remove the SCR Rectifier. 3120782 – JLG Lift – 2-11...

  • Page 30: Hydraulic Lift Cylinder - Removal, Inspection And Rebuild

    12. Before disassembling the cylinder, clean away all Visually inspect the outside surface for scratches or pol- dirt and foreign substances from openings, particu- ishing. Deep scratches are unacceptable. Polishing indi- larly the head area. 2-12 – JLG Lift – 3120782...

  • Page 31: Cylinder Assembly

    WIPER CYLINDER TUBE ASSEMBLY LOCKNUT (Torque PISTON 175-200 Ft. Lb.) WHEN ASSEMBLING CYLINDER APPLY ANTI-SEIZE CYLINDER COMPOUND CYLINDER HEAD AROUND THE HEAD IN THIS AREA ONLY Figure 2-1. Lift Cylinder Internal Component Assembly Cross-Section. 3120782 – JLG Lift – 2-13...

  • Page 32: Installation

    5. Install the setscrew in the cylinder attach block at the top of the mast, coat the threads of the setscrew with Loctite (RC/#640-blue) before tightening. 2-14 – JLG Lift – 3120782...

  • Page 33: Mast Assembly And Disassembly Procedures

    ATTACHED) BOTTOM (REFERS TO BOTTOM END OF MAST SECTION - CLOSED RAIL END WHICH SETS AT MACHINES BASE FRAME) (REFERS TO CLOSED RAIL BACK OF MAST SECTION) Figure 2-2. Mast Section - Assembly/Disassembly Reference. 3120782 – JLG Lift – 2-15...

  • Page 34: Platform Section Removal (All Masts)

    20 ft. mast, go to step 17. scratch or score the anodized finish in the slide pad channels. 11. Remove cable adjust nuts from threaded ends of cable attached to the cable anchor plate on bottom 2-16 – JLG Lift – 3120782...

  • Page 35: Mast Section 3 Removal (All Masts)

    Lay chain assembly to side. 33. Remove the hydraulic cylinder through the BOTTOM of mast section-2, be careful not to nick or score cyl- inder rod surface while removing. 3120782 – JLG Lift – 2-17...

  • Page 36: Mast Assembly

    15. Assemble chain sheaves on chain assembly anchor shim and mast or shim and slide pad when tight- block (attached to cylinder rod end) and attach to ened. mast section-2 using following steps; 2-18 – JLG Lift – 3120782...

  • Page 37: 20El Mast Assembly Components. (5 - Section)

    SECTION-5 MAST SECTION-2 SECTION-5 UPPER SLIDE PAD MOUNTING POSITION PRIOR TO C# 142920 SECTION-5 UPPER SLIDE PAD LOWER AS OF SEQUENCE C# 142920 CABLE ASSEMBLY Figure 2-3. 20EL Mast Assembly Components. (5 - Section) 3120782 – JLG Lift – 2-19...

  • Page 38: 25El & 36El Mast Assembly Components. (6 - Section)

    SECTION-6 SECTION-6 UPPER SLIDE PAD MOUNTING POSITION PRIOR TO C# 142920 LOWER SECTION-6 SEQUENCE UPPER CABLE SLIDE PAD ASSEMBLY AS OF C# 142920 Figure 2-4. 25EL & 36EL Mast Assembly Components. (6 - Section) 2-20 – JLG Lift – 3120782...

  • Page 39: 30El & 41El Mast Assembly Components. (7 - Section)

    UPPER SLIDE PAD MOUNTING POSITION PRIOR TO C# 142920 41AM 30AM LOWER SEQUENCE CABLE ASSEMBLY SECTION-7 UPPER SLIDE PAD AS OF C# 142920 Figure 2-5. 30EL & 41EL Mast Assembly Components. (7 - Section) 3120782 – JLG Lift – 2-21...

  • Page 40: Mast Chain/Cable Routing Diagram

    MAST SECTIONS SECTION 5 SECTION 4 SECTION 3 SECTION 2 SECTION 1 HYD. CYL. LIFTS HERE CHAIN ASSY. CABLE ASSY. CHAIN ASSY. CHAIN / CABLE ASSY. ANCHOR PLATES Figure 2-6. Mast Chain/Cable Routing Diagram. 2-22 – JLG Lift – 3120782...

  • Page 41: Mast Section 3 - Assembly (All Masts)

    Slide two (2) short spacer tubes onto sheave NOTE: When sliding mast sections together, be careful not pin, one each end of sheave pin to outside of to scratch or score the anodized finish in the slide sheave wheels. pad channels. 3120782 – JLG Lift – 2-23...

  • Page 42: Mast Section 5 - Assembly (25/30/36/41 Ft. Masts)

    44. Locate one (1) of the chain/cable anchor plates (one with Loctite #171 and tighten. with threaded holes horizontally aligned to outside edges of bracket). Attach through outer set of holes in bottom of mast section-5 with two (2) 1/4"-20UNC 2-24 – JLG Lift – 3120782...

  • Page 43: Mast Section 6 - Assembly (30/41 Ft. Masts)

    Rest the top end of mast section-6 on a 50. Carefully slide mast section-5 back into section-4 support while performing next step. until ends are even. Check to make sure cable set from top of section-3 is seating properly in cable 3120782 – JLG Lift – 2-25...

  • Page 44: Platform Mounting Section - Assy. (All Masts)

    Attach shim stock and slide pads to both sides place. of mast section-5/-6/-7 using five (5) 1/4"-20UNC x 1-1/4" long, hex head cap screws per side, with flatwasher under each bolt head. (Assemble 2-26 – JLG Lift – 3120782...
  • Page 45 (SHORT) UPPER SLIDE PAD IN THE UPPER SET OF SLIDE PAD 5 is seating properly in cable sheave wheels MOUNTING HOLES. THE 20EL, 25EL, 30EL AND 36EL MACHINES attached to top of mast section-4/-5/-6. (Mast sec- MOUNT THE UPPER SLIDE PAD IN THE LOWER SET OF SLIDE tions-2, -3, -4 and -5 may need to be restrained to PAD MOUNTING HOLES.

  • Page 46: Mast To Base Frame Installation

    (plumb) on base (place a flatwasher under bolt head and nut and frame. mount with nuts on inside of frame). Mast installation should now be complete. 2-28 – JLG Lift – 3120782...

  • Page 47: Mast Chains/Cables And Sequencing Cables Adjustment

    JAM NUT is complete, before tightening the jam nut THREADED against the adjust nut, CHAIN/CABLE pply Loctite #242 to the threads under the jam nut. Figure 2-7. Mast Chain/Cable/Sequence Cable Adjustment Components. (Typical) 3120782 – JLG Lift – 2-29...

  • Page 48: Sequencing Cable Adjustment

    2 is attached to the lift cylinder, these sections require no adjustment. A sequence cable replacement kit is available from the JLG Parts Department to service broken or worn 3. Adjust one mast section at a time starting from the sequence cables. This kit consists of a replacement back (section-3, section-4, etc.) of the mast and...

  • Page 49: Clamp Installation (Drum/Socket Type)

    5/8 in. past the end of the sleeve. THE MANUFACTURER OF THE DRUM/SOCKET CLAMP RECOM- MENDS THE USE OF THEIR CABLE CLAMP ASSEMBLY KIT (JLG P/N - 7023275) TO ASSEMBLE THE CLAMP TO THE WIRE ROPE. THE KIT CONSISTS OF VISE JAWS TO HOLD THE WIRE ROPE IN...
  • Page 50 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.) 2-32 – JLG Lift – 3120782...

  • Page 51: Section 3. Troubleshooting

    This can be ascertained by overriding the bypass valve (mechanically 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. 3120782 – JLG Lift –...
  • Page 52 Breather cap on tank is saturated or Replace breather cap on tank. clogged with oil. Hydraulic oil tank over-filled. Lower oil level to full mark on dipstick. Unit lowers very slowly. Flow control valve not functioning. Replace flow control valve. – JLG Lift – 3120782...
  • Page 53 Breather cap on tank is saturated or Replace breather cap on tank. clogged with oil. Hydraulic oil tank over-filled. Lower oil level to full mark on dipstick. Unit lowers very slowly. Flow control valve not functioning. Replace flow control valve. 3120782 – JLG Lift –...

  • Page 54: Outrigger Interlock Contacts

    Install the screw with two (2) o-rings towards jack 3. Install two (2) #8 nylon washers onto contactor end of outrigger beam. Hold in place if necessary. screw threads against insulating grommet, on the underside of the outrigger socket. – JLG Lift – 3120782...

  • Page 55: Outrigger Socket Contactor Heads And Outrigger Beam - Contactor Plate Mounting Hardware (Original And 5/2001 - Design)

    INSULATOR BUSHING NYLON WASHERS OUTRIGGER SOCKET (FLOOR) OPEN END OF OUTRIGGER SOCKET APPLY LOCTITE #242 TO THREADS Figure 3-1. Outrigger Socket Contactor Heads and Outrigger Beam - Contactor Plate Mounting Hardware (ORIGINAL AND 5/2001 - DESIGN). 3120782 – JLG Lift –...

  • Page 56: Detent Screws

    EL model to assure machine stability, i.e. the shorter outrigger beams of the 20EL, 25EL and 30EL models cannot be mistakenly used on higher reaching 36EL or 41EL models. – JLG Lift –...

  • Page 57: Hydraulic Schematic. (El Series) (2792491_A)

    SECTION 3 - TROUBLESHOOTING 2792491_A Figure 3-2. Hydraulic Schematic. (EL Series) (2792491_A) 3120782 – JLG Lift –...

  • Page 58: Electrical Diagram. (El Series - 12V-Dc)

    SECTION 3 - TROUBLESHOOTING 4933203_C Figure 3-3. Electrical Diagram. (EL Series - 12v-DC) – JLG Lift – 3120782...
  • Page 59 SECTION 3 - TROUBLESHOOTING 4933203_C Figure 3-3. Electrical Diagram. (EL Series - 12v-DC) 3120782 – JLG Lift –...
  • Page 60 SECTION 3 - TROUBLESHOOTING 4933204_H Figure 3-4. Electrical Diagram. (EL Series - 120V-AC) 3-10 – JLG Lift – 3120782...
  • Page 61 SECTION 3 - TROUBLESHOOTING 4933204_H Figure 3-4. Electrical Diagram. (EL Series - 120V-AC) 3120782 – JLG Lift – 3-11...
  • Page 62 SECTION 3 - TROUBLESHOOTING 4933205_H Figure 3-5. Electrical Diagram. (EL Series - 240V-AC) 3-12 – JLG Lift – 3120782...
  • Page 63 SECTION 3 - TROUBLESHOOTING 4933205_H Figure 3-5. Electrical Diagram. (EL Series - 240V-AC) 3120782 – JLG Lift – 3-13...
  • Page 64 SECTION 3 - TROUBLESHOOTING This page left intentionally blank. 3-14 – JLG Lift – 3120782...

This manual is also suitable for:

25el30el36el41el

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