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JLG 20EL Service & Maintenance

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Table of Contents

Battery Warning
This Page Left Intentionally Blank
Introduction - Operation/Safety Precautions
Introduction - Maintenance Safety Precautions
General
Hydraulic System Safety
Maintenance
Effectivity Changes
Table of Contents
Section 1. Specifications
Capacities
Hydraulic Oil Reservoir
Component Data
Hydraulic Pump/Electric Motor Assembly
Batteries (1) - DC Models
Battery Charger - DC Models
Performance Data
Platform Capacity
Machine Weight (with Standard Platform)
Maximum Working Height (Average Person)
Platform Cycle Performance
Outrigger Footprint
Machine Overall Width and Length (Base)
Torque Requirements
Lubrication
Hydraulic Oil
Lubrication Specifications
Hydraulic Pressure Adjustment
Cylinder Specifications
Serial Number Locations
Hydraulic Pressure Setting - Adjustment Screw Located at Base of Pump Motor
Torque Chart
Lubrication Locations (See Table Below)
Section 2. Service Procedures
Machine Preparation, Inspection, and Maintenance
General
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance
Preventive Maintenance and Inspection Schedule
Servicing and Maintenance Guidelines
General
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication and Servicing
Batteries
Mast Chain Inspection Procedure
Mast Cable Inspection Procedure
Lubrication Information
Hydraulic System
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications
Battery Charger - Assembly and Disassembly
General Information
Battery Charger Removal
Cover Removal
Transformer Replacement
Printed Circuit Board Replacement
DC Circuit Breaker Replacement
AC Circuit Breaker and Voltage Selection Switch Replacement
Shunt Assembly, Varistor, and SCR Rectifier Replacement (See Illustration)
Hydraulic Lift Cylinder - Removal, Inspection and Rebuild
Disassembly
Cylinder Disassembly
Lift Cylinder Component Inspection
Cylinder Assembly
Lift Cylinder Internal Component Assembly Cross-Section
Installation
Mast Assembly and Disassembly Procedures
Mast Disassembly Procedure
Mast Section - Assembly/Disassembly Reference
Platform Section Removal (All Masts)
Mast Section 6 Removal (7 Section Mast)
Mast Section 5 Removal (6 & 7 Section Mast)
Mast Section 4 Removal (All Masts)
Mast Section 3 Removal (All Masts)
Mast Section 2 Removal (All Masts)
Mast Section 1 Disassembly (All Masts)
Mast Assembly
Mast Section 1 - Assembly (All Masts)
Mast Section 2 - Assembly (All Masts)
20EL Mast Assembly Components. (5 - Section)
25EL & 36EL Mast Assembly Components. (6 - Section)
30EL & 41EL Mast Assembly Components. (7 - Section)
Mast Chain/Cable Routing Diagram
Mast Section 3 - Assembly (All Masts)
Mast Section 4 - Assembly (All Masts)
Mast Section 5 - Assembly (25/30/36/41 Ft. Masts)
Mast Section 6 - Assembly (30/41 Ft. Masts)
Platform Mounting Section - Assy. (All Masts)
Mast to Base Frame Installation
Mast Chains/Cables and Sequencing Cables Adjustment
Mast Chain/Cable Adjustment
Mast Chain/Cable/Sequence Cable Adjustment Components. (Typical)
Sequencing Cable Adjustment
Sequence Cable Replacement Kit
Remove Old Cable
Replacement Cable Installation
Clamp Installation (Drum/Socket Type)
Section 3. Troubleshooting
General
Troubleshooting Information
Hydraulic Circuit Checks
Outrigger Interlock Contacts
Outrigger Socket and Outrigger Beam - Interlock Contacts
Outrigger Socket - Contactor Screw Mounting Instructions
Outrigger Beam - Interlock Contactor Plate Mounting Instructions
Outrigger Socket Contactor Heads and Outrigger Beam - Contactor Plate Mounting Hardware (ORIGINAL and 5/2001 - DESIGN)
Detent Screws
Hydraulic Schematic. (el Series) (2792491_A)
Electrical Diagram. (el Series - 12V-DC)

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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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JLG 20EL Service & Maintenance

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