JLG 25EL Manuals

Manuals and User Guides for JLG 25EL. We have 1 JLG 25EL manual available for free PDF download: Service & Maintenance

JLG 25EL Service & Maintenance (64 pages)

Brand: JLG | Category: Boom Lifts | Size: 2 MB

Battery Warning
2
This Page Left Intentionally Blank
4
Introduction - Operation/Safety Precautions
5
Introduction - Maintenance Safety Precautions
6
General
6
Hydraulic System Safety
6
Maintenance
6
Effectivity Changes
7
Table of Contents
9
Section 1. Specifications
13
Capacities
13
Hydraulic Oil Reservoir
13
Component Data
13
Hydraulic Pump/Electric Motor Assembly
13
Batteries (1) - DC Models
13
Battery Charger - DC Models
13
Performance Data
13
Platform Capacity
13
Machine Weight (with Standard Platform)
13
Maximum Working Height (Average Person)
14
Platform Cycle Performance
14
Outrigger Footprint
14
Machine Overall Width and Length (Base)
14
Torque Requirements
14
Lubrication
14
Hydraulic Oil
14
Lubrication Specifications
14
Hydraulic Pressure Adjustment
15
Cylinder Specifications
15
Serial Number Locations
15
Hydraulic Pressure Setting - Adjustment Screw Located at Base of Pump Motor
15
Torque Chart
16
Lubrication Locations (See Table Below)
17
Section 2. Service Procedures
19
Machine Preparation, Inspection, and Maintenance
19
General
19
Preparation, Inspection, and Maintenance
19
Pre-Start Inspection
19
Pre-Delivery Inspection and Frequent Inspection
19
Annual Machine Inspection
19
Preventative Maintenance
19
Preventive Maintenance and Inspection Schedule
20
Servicing and Maintenance Guidelines
23
General
23
Safety and Workmanship
23
Cleanliness
23
Components Removal and Installation
23
Component Disassembly and Reassembly
23
Pressure-Fit Parts
23
Bearings
23
Gaskets
23
Bolt Usage and Torque Application
24
Hydraulic Lines and Electrical Wiring
24
Hydraulic System
24
Lubrication and Servicing
24
Batteries
24
Mast Chain Inspection Procedure
24
Mast Cable Inspection Procedure
25
Lubrication Information
26
Hydraulic System
26
Hydraulic Oil
26
Changing Hydraulic Oil
26
Lubrication Specifications
26
Battery Charger - Assembly and Disassembly
27
General Information
27
Battery Charger Removal
27
Cover Removal
27
Transformer Replacement
27
Printed Circuit Board Replacement
28
DC Circuit Breaker Replacement
28
AC Circuit Breaker and Voltage Selection Switch Replacement
28
Shunt Assembly, Varistor, and SCR Rectifier Replacement (See Illustration)
29
Hydraulic Lift Cylinder - Removal, Inspection and Rebuild
30
Disassembly
30
Cylinder Disassembly
30
Lift Cylinder Component Inspection
30
Cylinder Assembly
31
Lift Cylinder Internal Component Assembly Cross-Section
31
Installation
32
Mast Assembly and Disassembly Procedures
33
Mast Disassembly Procedure
33
Mast Section - Assembly/Disassembly Reference
33
Platform Section Removal (All Masts)
34
Mast Section 6 Removal (7 Section Mast)
34
Mast Section 5 Removal (6 & 7 Section Mast)
34
Mast Section 4 Removal (All Masts)
34
Mast Section 3 Removal (All Masts)
35
Mast Section 2 Removal (All Masts)
35
Mast Section 1 Disassembly (All Masts)
35
Mast Assembly
36
Mast Section 1 - Assembly (All Masts)
36
Mast Section 2 - Assembly (All Masts)
36
20EL Mast Assembly Components. (5 - Section)
37
25EL & 36EL Mast Assembly Components. (6 - Section)
38
30EL & 41EL Mast Assembly Components. (7 - Section)
39
Mast Chain/Cable Routing Diagram
40
Mast Section 3 - Assembly (All Masts)
41
Mast Section 4 - Assembly (All Masts)
41
Mast Section 5 - Assembly (25/30/36/41 Ft. Masts)
42
Mast Section 6 - Assembly (30/41 Ft. Masts)
43
Platform Mounting Section - Assy. (All Masts)
44
Mast to Base Frame Installation
46
Mast Chains/Cables and Sequencing Cables Adjustment
47
Mast Chain/Cable Adjustment
47
Mast Chain/Cable/Sequence Cable Adjustment Components. (Typical)
47
Sequencing Cable Adjustment
48
Sequence Cable Replacement Kit
48
Remove Old Cable
48
Replacement Cable Installation
48
Clamp Installation (Drum/Socket Type)
49
Section 3. Troubleshooting
51
General
51
Troubleshooting Information
51
Hydraulic Circuit Checks
51
Outrigger Interlock Contacts
54
Outrigger Socket and Outrigger Beam - Interlock Contacts
54
Outrigger Socket - Contactor Screw Mounting Instructions
54
Outrigger Beam - Interlock Contactor Plate Mounting Instructions
54
Outrigger Socket Contactor Heads and Outrigger Beam - Contactor Plate Mounting Hardware (ORIGINAL and 5/2001 - DESIGN)
55
Detent Screws
56
Hydraulic Schematic. (el Series) (2792491_A)
57
Electrical Diagram. (el Series - 12V-DC)
58

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