JLG 15ELI Service Manual

Service and Maintenance Manual

ANSI

MODEL

15ELI

3120779

August 5, 2002

CALIFORNIAN PROPOSITION 65

BATTERY WARNING

Battery posts,

terminals and related

accessories contain

lead and lead compounds,

chemical known to the

State of Califormia

to cause cancer and

reproductive harm.

WASH HANDS

AFTER HANDLING!

FOREWORD

The purpose of this manual is to provide users with the operating procedures essential for the promotion of
proper machine operation for its intended purpose. It is important to over-stress proper machine usage. All
information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the
machine. YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL - Keep it with the machine.

REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR.

BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND
OPERATION, PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPER­ATING PERSONNEL.

ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER
OPERATING CONDITIONS, WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN. ALTERATION AND/
OR MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN, WITHOUT WRITTEN APPROVAL
FROM JLG INDUSTRIES, PER OSHA REGULATIONS.

THIS "SAFETY ALERT SYMBOL" IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS
WHICH MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED.

Safety of personnel and proper use of the machine are of primary concern, DANGER, WARNING, CAUTION,
IMPORTANT, INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these areas.

They are defined as follows:

DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUA­TION WHICH, IF NOT AVOIDED WILL RESULT IN SERIOUS
INJURY OR DEATH.

CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUA­TION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR
MODERATE INJURY. IT MAY ALSO BE USED TO ALERT
AGAINST UNSAFE PRACTICES.

Also in this Manual "Notes:" are used to provide infor­mation of special interest.

JLG INDUSTRIES, INC. MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT. CONTACT JLG INDUS­TRIES, INC. OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLE­TINS 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.

WARNING INDICATES A POTENTIALLY HAZARDOUS SITU­ATION WHICH, IF NOT AVOIDED COULD RESULT IN SERI­OUS INJURY OR DEATH.

IMPORTANT OR INSTRUCTIONS PROCEDURES ESSENTIAL
FOR SAFE OPERATION AND WHICH, IF NOT FOLLOWED
MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE
MACHINE.

Due to the continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without
prior notification. Contact JLG Industries, Inc. for updated information.

This page left intentionally blank.

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A. GENERAL

This section contains the general safety precautions
which must be observed during maintenance of the aerial
platform. It is of utmost importance that maintenance per­sonnel pay strict attention to these warnings and precau­tions to avoid possible injury to themselves or others or
damage to the equipment. A maintenance program must
be established by a qualified person and must be followed
to ensure that the machine is safe to operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY
A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST
AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA­TION.

The specific precautions to be observed during machine
maintenance are inserted at the appropriate point in the
manual. These precautions are, for the most part, those
that apply when servicing hydraulic and larger machine
component parts.

Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of component weight and never attempt to
move heavy parts without the aid of a mechanical device.
Do not allow heavy objects to rest in an unstable position.
When raising a portion of the equipment, ensure that ade­quate support is provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON­TROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER/
OPERATOR.

C. MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON­NEL INJURY OR DEATH AND IS A SAFETY VIOLATION.

• REMOVE ALL RINGS, WATCHES, AND JEWELRY
WHEN PERFORMING ANY MAINTENANCE.

• DO NOT WEAR LONG HAIR UNRESTRAINED, OR
LOOSE FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.

• OBSERVE AND OBEY ALL DANGER, WARNING, CAU­TION AND OTHER INSTRUCTIONS ON MACHINE
AND IN SERVICE MANUAL.

• KEEP STANDING SURFACES AND HAND HOLDS
FREE OF OIL, GREASE, WATER, ETC.

• NEVER WORK UNDER AN ELEVATED PLATFORM
UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED
FROM ANY MOVEMENT BY BLOCKING OR OVER­HEAD SLING.

• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT
OFF ALL POWER CONTROLS.

•BATTERY SHOULD ALWAYS BE DISCONNECTED
DURING REPLACEMENT OF ELECTRICAL COMPO­NENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACH­MENTS STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.

B. HYDRAULIC SYSTEM SAFETY

1. It should be particularly noted that the machines
hydraulic systems operate at extremely high and
potentially dangerous pressures. Every effort should
be made to relieve any system pressure prior to dis­connecting or removing any portion of the system.

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 compo­nents can then be disconnected with minimal fluid
loss.

3120779 – JLG Lift – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

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b – JLG Lift – 3120779

EFFECTIVITY PAGE

EFFECTIVITY CHANGES

June 15, 1999 - Original Issue of Manual

November 28, 2000 - Manual Revised - Pages Affected;Section 2 - Page 2-8 and Pages 2-12 through 2-16.

August 5, 2002 – Manual Revised

3120779 – JLG Lift – c

EFFECTIVITY PAGE

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d – JLG Lift – 3120779

TABLE OF CONTENTS

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

INTRODUCTION -- MAINTENANCE SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

A GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

B HYDRAULIC SYSTEM SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

C MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

EFFECTIVITY CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 COMPONENT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Hydraulic Pump/Electric Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Batteries – DC Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Battery Charger – DC Models.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Platform Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Machine Weight (with Standard Platform). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Machine Height (Platform Stowed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Maximum Platform Height (Mast Extended) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Maximum Working Height (Average person) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Machine Overall Width and Length (Base) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Machine Lift Up/Down Speeds (@ Max. Capacity). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.4 TORQUE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.5 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.6 HYDRAULIC PRESSURE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.7 CYLINDER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.8 SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

SECTION 2 - SERVICE PROCEDURES

2.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 SERVICING AND MAINTENANCE GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Mast Chain Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Mast Cable Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

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TABLE OF CONTENTS

2.3 LUBRICATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.4 AC JUNCTION BOX COMPONENTS (AC POWERED MACHINES ONLY). . . . . . . . . . . . . . . . . . . 2-5

2.5 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Mast Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Platform Section – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Mast Section 3 – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Mast Section 2 – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Mast Section 1 – Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2.6 MAST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Mast Section 1 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Mast Section 2 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Mast Section 3 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

Platform Mounting Section - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.7 MAST TO BASE FRAME INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.8 MAST CHAINS/CABLES AND SEQUENCING CABLES ADJUSTMENT . . . . . . . . . . . . . . . . . . . .2-13

Mast Chain/Cable Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Sequencing Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.9 SEQUENCE CABLE REPLACEMENT KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Remove Old Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

Replacement Cable Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Clamp Installation (Drum/Socket Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.10 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

SECTION 3 - TROUBLESHOOTING

3.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 TROUBLESHOOTING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.3 ELECTRICAL AND HYDRAULIC CIRCUIT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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TABLE OF CONTENTS

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Hydraulic Pressure Setting - Adjustment Screw Located at Base of Pump Motor . . . . . . . . . . . . 1-2

1-2. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-3. Lubrication Locations (See Table below). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

2-1. AC Junction Box - Internal Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-2. Mast Section - Assembly/Disassembly Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3. 15ELI Mast Assembly Components. (4 Section - Chain/Cable or All Cable). . . . . . . . . . . . . . . . .2-9

2-4. Mast Chain/Cable Routing Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-5. Mast Chain/Cable/Sequence Cable Adjustment Components. (Typical) . . . . . . . . . . . . . . . . . . .2-14

3-1. Hydraulic Schematic. (ELI) (2792491) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-2. Electrical Diagram. (ELI - 12V-DC) (4933258-A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3-3. Electrical Diagram. (ELI - 120V-AC) (4933259-A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-4. Electrical Diagram. (ELI - 240V-AC) (4933260-A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-5. Electrical Diagram. (ELI - 100V-AC) (4933261-A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1. Hydraulic Oil Operating Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-2. Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-3. Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-4. Lubrication Intervals for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

2-1. Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2. AM Series Mast Component Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3. Preventive Maintenance & Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

3-1. AC Unit - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-2. DC Unit - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

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iv – JLG Lift – 3120779

SECTION 1. SPECIFICATIONS

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 Standard Duty

Pump Displacement – .098 cu. in./rev.(AFC 1.6 cc/rev.)

Pump Output – 1.65 GPM @ 800 PSI @ 11.7v-DC @

120 AMPS @ 45 Centistrokes (200 SSU)

Pressure Relief – Adjustable Range 1500 to 5000 PSI,

Set to 2800 PSI (193 bars) at factory

AC Models - 110 Volt AC motor/pump

Motor - 115/120v-AC, 1HP, 3450 RPM, 60Hz

Pump Displacement – .098 in./rev. (1.6 cc/rev.)

Pump Output – 1.4 GPM @ 800 PSI @ 15 AMPS @

115v-AC @ 45 Centistrokes (200 SSU)

Pressure Relief – Adjustable Range 1500 to 5000 PSI,

Set to 2800 PSI (193 bars) at factory

AC Models - 220 Volt AC motor/pump

Motor - 115/230v-AC, 1HP, 3450 RPM, 50/60Hz

Pump Displacement – .098 in./rev. (1.6 cc/rev.)

Pump Output – 1.4 GPM @ 800 PSI @ 15 AMPS @

115v-AC @ 45 Centistrokes (200 SSU)

Pressure Relief – Adjustable Range 1500 to 5000 PSI,

Set to 2800 PSI (193 bars) at factoryAC

Models - 100 Volt AC motor/pump

Motor - 100v-AC, 1HP, 3450 RPM, 50Hz

Pump Displacement – .098 in./rev. (1.6 cc/rev.)

Pump Output – 1.4 GPM @ 800 PSI @ 15 AMPS @

115v-AC @ 45 Centistrokes (200 SSU)

Pressure Relief – Adjustable Range 1500 to 5000 PSI,

Set to 2800 PSI (193 bars) at factory

Batteries – DC Models.

WET (Standard)

12 Volt – 165 Amp (min.) – Deep Cycle Marine - RV

DRY (Option)

12 Volt – 165 Amp (min.) – Deep Cycle Marine - RV

AGM (Absorption Gas Mat) (Option)

12Volt – 100 O.A.H. – M2 Marine Combination

Battery Charger – DC Models.

110/240 Volts AC, 50/60 Hz - input

12 Volt DC, 10 Amp - output

Automatic SCR Charger

Selectable Voltage

NOTE: A high output - 12Volt DC, 20 Amp output - SCR

charger is supplied with the AGM battery option.

1.3 PERFORMANCE DATA

Platform Capacity

15ELI - AC & DC - 350 lb. (159kg)

Machine Weight (with Standard Platform)

15ELI - AC - 900 lbs. (408kg)

15ELI - DC - 970 lbs. (440kg)

Machine Height (Platform Stowed)

15ELI - AC & DC - 78.25 in. (1.9 m)

Maximum Platform Height (Mast Extended)

15ELI - AC & DC - 15 ft. (4.57 m)

Maximum Working Height (Average person)

15ELI - AC & DC - 21 ft. (6.4 m)

Machine Overall Width and Length (Base)

15ELI Models - 29 in.(W) x 47 in.(L) (74 cm x 1.19 m)

Machine Lift Up/Down Speeds (@ Max. Capacity)

Lift UP Time - 30 sec. (from stowed to maximum extend)

Lift DOWN Time - 22-28 sec. (max. extend to stowed)

1.4 TORQUE REQUIREMENTS

When maintenance becomes necessary or a fastener has
loosened, refer to the Torque Chart, Figure 1-2. to deter­mine proper torque value.

3120779 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

1.5 LUBRICATION

Hydraulic Oil

Hydraulic oils must have anti-wear qualities at least to API
Service Classification GL-3, and sufficient chemical stabil­ity for mobile hydraulic system service. JLG Industries,
recommends Mobilfluid 424 hydraulic oil, which has an
SAE viscosity of 10W-30 and a viscosity index of 152.

For cold weather applications, i.e. when temperatures
remain consistently below +20°F (–7° C) JLG recom­mends using Mobil DTE 13 hydraulic oil.

Aside from JLG recommendations, it is not advisable to
mix oils of different brands or types, as they may not con­tain the same required additives or be of comparable vis­cosities. If use of hydraulic oil other than Mobilfluid 424 is
desired, contact JLG Industries for proper recommenda­tions.

Table 1-1. Hydraulic Oil Operating Range

HYDRAULIC SYSTEM OPERATING

TEMPERATURE RANGE

0 ° F t o +2 3 ° F

(-18° C to -5° C)

0° F to +210° F

(-18° C to +99° C)

5 0° F t o 2 1 0° F

(+10° C to +210° C)

SAE VISCOSITY

GRADE

10W

10W-20, 10W-30

20W-20

cold, platform may not raise rated load after oil has
warmed.

PRESSURE

ADJUSTMENT

ADJUSTMENT

SCREW CAP

(SHOWN REMOVED)

SCREW

HYDRAULIC

OIL TANK

GROUND

CONTROL

STATION

COVER

Figure 1-1. Hydraulic Pressure Setting - Adjustment

Screw Located at Base of Pump Motor

(Remove Hex Head Cap as Shown)

Lubrication Specifications

Table 1-2. Lubrication Specifications

KEY SPECIFICATIONS

MPG - Multipurpose Grease having a minimum dripping point

of 350° F. Excellent wa ter resistance and adhesive qual­ities, and being of extreme pressure type. (Timken OK
40 pounds minimum.)

EPGL - Extreme Pressure Gear Lube (oil) meeting API service

classification GL-5 or MIL-Spec MIL-L-2105.

HO - Hydraulic Oil. ISO-Vg grade 32, 46.

1.6 HYDRAULIC PRESSURE ADJUSTMENT

(See Figure 1-1.)

Adjust system pressure so that platform will raise with
rated capacity in platform.

Turning adjustment screw clockwise, increases system

pressure, turning screw counterclockwise, decreases
system pressure.

Do not adjust system pressure higher than required to
raise the load. Make pressure adjustment with oil at nor­mal operating temperature. If pressure is set when oil is

1.7 CYLINDER SPECIFICATIONS

NOTE: All dimensions are given in inches (in), with the met-

ric equivalent, centimeters (cm), given in parenthe­ses.

Table 1-3. Cylinder Specifications

DESCRIPTION

Lift Cylinder ­15ELI - AC & DC

BORE

in./(cm)

1.63

(4.14)

STROKE
in./(cm)

56.50

(143.50)

ROD DIA.

in./(cm)

1.38

(3.50)

1.8 SERIAL NUMBER LOCATIONS

For machine identification, a serial number plate is affixed
to the machine. The plate is located on the back of the
mast, just above the mast support bracket. In addition,
should the serial number plate be damaged or missing,
the machine serial is stamped on the mast and on the
base frame.

1-2 – JLG Lift – 3120779

SECTION 1 - SPECIFICATIONS

Figure 1-2. Torque Chart.

3120779 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

3

1

2

Figure 1-3. Lubrication Locations (See Table below).

Table 1-4. Lubrication Intervals for Various Components

INTERVAL HOURS

ITEM COMPONENT

1 Hydraulic Oil Fill To Line

2 Swivel Raceways 2 - Front Casters MPG - Pressure Gun

3 Mast Chains * 2 - Per Section Chain Lube - Bru sh or

* Applies Only to Mast Sections with Chains.

Key to Lubricants: MPG - Multipurp ose Grease

HO - Hydraulic Oil - See Table 7-1 in Service Manual. (JLG recommends using Mobilfluid 424 hydraulic oil.)

Notes: 1. Be cer tain to lubricate like items on each side of the machine.

2. Recommended lubricating intervals are based on normal use. If machine is subjected to severe operating conditions,

such as a high number of cycles, location, corrosive/dir ty environment, etc., user must adjust lubricating requirements accordingly.

3. Lubricating inter vals are calculated on 50 hours of machine operation a week.

4. Prior to checking hydraulic oil level, operate machine through one complete cycle of lift function (full up and down). Failur e t o do s o wi l l
result in incorrect oil level reading on the hydraulic reservoir.

NO/TYPE

LUBE POINTS

on Reservoir
5 Qt. (4.3 L)
Reservoir

LUBE/METHOD

HO - Check
H y d. O il L ev e l
HO - Change
H y d. O il

Spray

3 MOS.

or

150 Hrs.

✔

6 MOS.

or

300 Hrs.

✔

1 YR.

or

600 Hrs.

2 YRS.

or

1200 Hrs.

✔

COMMENTS

Check Hyd. Oil after every
10 hrs. of operation.
Change Hyd. Oil after ever y
1200 hrs. of operation.

1-4 – JLG Lift – 3120779

SECTION 2 - SERVICE PROCEDURES

SECTION 2. SERVICE PROCEDURES

2.1 GENERAL

This section provides general information to assist in the
performance of maintenance on the personnel lift.
Descriptions, techniques and specific procedures are
designed to provide the safest and most efficient mainte­nance for use by personnel responsible for ensuring the
correct installation and operation of machine components
and systems.

WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES
CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE
NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND
TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK
IS RESUMED.

2.2 SERVICING AND MAINTENANCE GUIDELINES

General

The following information is provided to assist you in the
use and application of servicing and maintenance proce­dures contained in this chapter.

Safety and Workmanship

Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of component weight. Never attempt to
move heavy parts without the aid of a mechanical device.
Do not allow heavy objects to rest in an unstable position.
When raising a portion of the equipment, ensure that ade­quate support is provided.

NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT­FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT
BY BLOCKING OR OVERHEAD SLING.

Cleanliness

The most important single item in preserving the long ser­vice life of a machine is to keep dirt and foreign materials
out of the vital components. Precautions have been taken
to safeguard against this. Shields, covers, seals, and fil­ters are provided to keep the wheel bearings, mast sec­tions and oil supply clean; however, these items must be
maintained on a scheduled basis in order to function
properly.

At any time when oil lines are disconnected, clear adja­cent areas as well as the openings and fittings them­selves. As soon as a line or component is disconnected,

cap or cover all openings to prevent entry of foreign mat­ter.

Clean and inspect all parts during servicing or mainte­nance, and assure that all passages and openings are
unobstructed. Cover all parts to keep them clean. Be sure
all parts are clean before they are installed. New parts
should remain in their containers until they are ready to be
used.

Components Removal and Installation

Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains,
cables, etc.) should be parallel to each other and as near
perpendicular as possible to top of part being lifted.

Should it be necessary to remove a component on an
angle, keep in mind that the capacity of an eyebolt or sim­ilar bracket lessens, as the angle between the supporting
structure and the component becomes less than 90
degrees.

If a part resists removal, check to see whether all nuts,
bolts, cables, brackets, wiring, etc., have been removed
and that no adjacent parts are interfering.

Component Disassembly and Reassembly

When disassembling or reassembling a component, com­plete the procedural steps in sequence. Do not partially
disassemble or assemble one part, then start on another.
Always recheck your work to assure that nothing has been
overlooked. Do not make any adjustments, other than
those recommended, without obtaining proper approval.

Pressure-Fit Parts

When assembling pressure-fit parts, use an “anti-seize” or
molybdenum disulfide base compound to lubricate the
mating surface.

Bearings

When a bearing is removed, cover it to keep out dirt and
abrasives. Clean bearings in nonflammable cleaning sol­vent and allow to drip dry. Compressed air can be used
but do not spin the bearing.

Discard bearings if the races and balls (or rollers) are pit­ted, scored, or burned.

If bearing is found to be serviceable, apply a light coat of
oil and wrap it in clean (waxed) paper. Do not unwrap
reusable or new bearings until they are ready to install.

Lubricate new or used serviceable bearings before instal­lation. When pressing a bearing into a retainer or bore,
apply pressure to the outer race. If the bearing is to be
installed on a shaft, apply pressure to the inner race.

3120779 – JLG Lift – 2-1

SECTION 2 - SERVICE PROCEDURES

Gaskets

Check that holes in gaskets align with openings in the
mating parts. 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.

Bolt Usage and Torque Application

Use bolts of proper length. A bolt which is too long will
bottom before the head is tight against its related part. If a
bolt is too short, there will not be enough thread area to
engage and hold the part properly. When replacing bolts,
use only those having the same specifications of the origi­nal, or one which is equivalent.

Unless specific torque requirements are given within the
text, standard torque values should be used on heat­treated bolts, studs, and steel nuts, in accordance with
recommended shop practices. (See Figure 1-1.)

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as
well as their receptacles, when disconnecting or removing
them from the unit. This will assure that they are correctly
reinstalled.

Hydraulic System

Keep the system clean. If evidence of metal or rubber par­ticles is found in the hydraulic system, drain and flush the
entire system.

Disassemble and reassemble parts on clean work sur­face. Clean all metal parts with non-flammable cleaning
solvent. Lubricate components, as required, to aid assem­bly.

Mast Chain Inspection Procedure

MAST CHAINS TO BE INSPECTED AND LUBRICATED EVERY
THREE MONTHS.

Inspect mast chains for the following conditions:

Wear: Always inspect that segment of chain that operates
over a sheave. As the chain flexes over the extend/retract
sheaves, joints and plate edges wear very gradually.
Chain “stretch” can be measured using a manufacturers
wear scale or steel tape. When chains have elongated 3%
they must be removed and replaced. Refer to Table 2-1 for
proper chain specifications and allowable stretch toler­ances. Peening and wear of chain plate edges are caused
by the chain sliding over a chain worn contact face of a
sheave, or unusually heavy loads. All of the above require
replacement of the chain and correction of the cause.
Chain side wear, noticeable when pin heads and outside
plates show a definite wear pattern, is caused by misalign­ment of the sheave/chain anchors and must be corrected
promptly. Do not repair chains; if a section of chain is
damaged, replace the entire chain set.

Rust and Corrosion: Rust and corrosion will cause a
major reduction in the load carrying capacity of the chain,
because these are primary reasons for side plate crack­ing. The initial lubrication at the factory is applied in a hot
dip tank to assure full penetration into the joint. Do not
steam clean or degrease chains. At time of chain installa­tion, factory lube must be supplemented by a mainte­nance program to provide a film of oil on the chains at all
times. If chains are corroded, they must be inspected,
especially the outside plates, for cracks in-line with the
pins. If cracks are found, replace the chain; if no cracks
are discovered, lubricate the chains by dipping in heated
oil, and reinstall on the machine. Keep chains lubricated.

Table 2-1. Chain Stretch Tolerance

Lubrication and Servicing

Components and assemblies requiring lubrication and
servicing are shown in the Lubrication Chart, (See Figure
1-2.). Service applicable components with the amount,
type, and grade of lubricant recommended in this manual,
at the specified intervals. When recommended lubricants
are not available, consult your local supplier for an equiva­lent that meets or exceeds the specifications listed.

Batteries

Clean batteries, using a non-metallic brush and a solution
of baking soda and water. Rinse with clean water. After
cleaning, thoroughly dry batteries and coat terminals with
an anti-corrosion compound.

Chain Size

.50" pitch 12" or 24 pitches .24 in./12 in. span

.625 pitch 15" or 24 pitches .30 in./15 in. span

Fatigue Cracks: Fatigue is a phenomenon that affects
most metals, and is the most common cause of chain
plate failures. Fatigue cracks are found through the link
holes, perpendicular (90 degrees) from the pin in-line
position. Inspect chains carefully after long time use and
heavy loading for this type of crack. If any cracks are dis­covered, replace all chains, as seemingly sound plates
are on the verge of cracking. Fatigue and ultimate
strength failures on JLG Lifts are incurred as a result of
severe abuse as design specs are well within the rated lift­ing capacity of these chains.

Pin to Pin

Measurement

Allowable Stretch

2-2 – JLG Lift – 3120779

SECTION 2 - SERVICE PROCEDURES

Tight Joints: All joints in the leaf chain should flex freely.
On leaf chains, tight joints are usually caused by rust/cor­rosion, or the inside plates “walking” off the bushing. Lim­ber up rusty/corroded chains (after inspecting carefully)
with a heavy application of oil (preferably a hot oil dip). Tap
inside “ walking” plates inward; if “walking” persists,
replace the chain. This type of problem is accelerated by
poor lubrication maintenance practice, and most tight
joint chains have been operated with little or no lubrica­tion. Tight joints on leaf chain are generally caused by:

a. Bent pins or plates.

b. Rusty joints.

c. Peened plate edges.

Oil rusty chains, and replace chains with bent or peened
chain components. Keep chains lubricated.

Protruding or Turned Pins: Chains operating with inade­quate lube generate tremendous friction between the pin
and plates (pin and bushing on leaf chain). In extreme
cases, this frictional torque can actually turn the pins in
the outside press-fit plates. Inspect for turned pins, which
can be easily spotted as the “V” flats on the pin heads are
no longer in line. Replace all chains showing evidence of
turned or protruding pins. Keep chains lubricated.

Chain Anchors and Sheaves: An inspection of the chain
must include a close examination of chain anchors and
sheaves. Check chain anchors for wear, breakage and
misalignment. Anchors with worn or broken fingers should
be replaced. They should also be adjusted to eliminate
twisting the chain for an even load distribution.

Inspect the sheaves, sheave bearings, sheave grooves
and pins for extreme wear, replace as necessary. A worn
sheave can mean several problems, as follows:

a. Chains too tight.

b. Sheave bearings/pin bad.

c. Bent/misaligned chains.

Inspection should be more frequent as cables approach
the end of their useful lives.

Only the surface wires of the cable require inspection, do
not attempt to open the cable. Any deterioration resulting
in any loss of original strength, such as described below,
shall be noted, and then a determination made if further
use would constitute a hazard.

Mast cables must be replaced after machine has been in
service for five (5) years, regardless of cable condition, or
sooner if conditions dictate.

Conditions such as the following shall be sufficient reason
for questioning continual use of the [cable] or increasing
the frequency of inspection:

1. In running ropes, six randomly distributed broken
wires in one lay or three broken wires in one strand
in one lay.

2. One outer wire broken at the point of contact with
the core of the rope which has worked its way out of
the rope structure and protrudes or loops out from
the rope structure. Additional inspection of this sec­tion is required.

3. Wear of one-third the original diameter of outside
individual wires.

4. Kinking, crushing, birdcaging or any other damage
resulting in distortion of the rope structure.

5. Evidence of any heat damage from any cause.

6. Reductions from nominal diameter of more than;

a. 1/64th in. (0.4mm) for diameters up to and

including 5/16th in. (8mm);

NOTE: A good indicator of a stretched extend/retract cable

is if the adjusting nuts are bottomed out. If no adjust­ment remains, the cables have stretched and need
replacement.

Also check for cracked, bent, worn, severely corroded, or

Mast Cable Inspection Procedure

MAST CABLES ARE TO BE INSPECTED EVERY THREE MONTHS
OR MORE FREQUENTLY AS DESCRIBED FOLLOWING.

improperly installed cable ends.

Inspect sheaves, sheave grooves, and sheave pins for
excessive wear, replace as necessary.

2.3 LUBRICATION INFORMATION

Hydraulic System

WEAR PROTECTIVE GLOVES TO PROTECT HANDS WHEN HAN­DLING CABLE.

The periodic inspection shall cover the entire length of the
cable. The inspection frequency shall be based on such
factors as expected cable life as determined by experi­ence on the particular application or similar installations,
severity of environment, percentage of capacity lifts, fre­quency rates of operation, and exposure to shock loads.

3120779 – JLG Lift – 2-3

The primary enemy of a hydraulic system is contamina­tion. Contaminants enter the system by various means,
e.g., using inadequate hydraulic oil, allowing moisture,
grease, filings, sealing components, sand, etc., to enter
when performing maintenance, or by permitting the pump
to cavitate due to insufficient system warm-up or leaks in
the pump supply.

The design and manufacturing tolerances of the compo­nent working parts are very close, therefore, even the

SECTION 2 - SERVICE PROCEDURES

smallest amount of dirt or foreign matter entering a system
can cause wear or damage to the components and gener­ally results in faulty operation. Every precaution must be
taken to keep hydraulic oil clean, including reserve oil in
storage.

Cloudy oils indicate a high moisture content which per­mits organic growth, resulting in oxidation or corrosion. If
this condition occurs, the system must be drained,
flushed, and refilled with clean oil.

It is not advisable to mix oils of different brands or types,
as they may not contain the same required additives or be
of comparable viscosities. Good grade mineral oils, with
viscosities suited to the ambient temperatures in which
the machine is operating, are recommended for use.

NOTE: Metal particles may appear in the oil of new

machines due to the wear-in of meshing compo­nents.

Hydraulic Oil

For best performance, JLG recommends the use of ISO­Vg 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.

Changing Hydraulic Oil

Use of any of the recommended hydraulic oils eliminates
the need for changing the oil on a regular basis. If it is nec­essary to change the oil, use only those oils meeting or
exceeding the specifications appearing in this manual. If
unable to obtain the same type of oil supplied with the
machine, consult local supplier for assistance in selecting
the proper equivalent. Avoid mixing petroleum and syn­thetic base oils. JLG Industries recommends changing the
hydraulic oil annually.

Use every precaution to keep the hydraulic oil clean. If the
oil must be poured from the original container into
another, be sure to clean all possible contaminants from
the service container.

While the unit is shut down, a good preventive mainte­nance measure is to make a thorough inspection of all
hydraulic components, lines, fittings, etc., as well as a
functional check of each system, before placing the
machine back in service.

Lubrication Specifications

Specified lubricants, as recommended by the component
manufacturers, are always the best choice, however,
multi-purpose greases usually have the qualities which
meet a variety of single purpose grease requirements.
Should any question arise regarding the use of greases in
maintenance stock, consult your local supplier for evalua­tion. Refer to Table 1-2. for an explanation of the lubricant
key designations appearing in the Lubrication Chart.

2-4 – JLG Lift – 3120779

2.4 AC JUNCTION BOX COMPONENTS

123

(AC POWERED MACHINES ONLY)

SECTION 2 - SERVICE PROCEDURES

HAZARD OF ELECTRIC SHOCK! ALWAYS DISCONNECT ELEC­TRICAL POWER TO THE JUNCTION BOX BEFORE ATTEMPTING
TO DISCONNECT ANY CIRCUITS OR WHEN REMOVING COMPO­NENTS.

7

6

WHEN TESTING CIRCUITS WITH ELECTRICAL POWER ON, USE
ONLY INSTRUMENTS WITH INSULATED TEST LEADS KEEPING
YOUR HANDS OUTSIDE THE BOX.

5

4

1. 12V-DC Starter Relay 5. Bridge Rectifier

2. 115V or 230V AC Power Relay 6. Relay

3. Termi n a l Strip 7. 120/240V-AC to 16V-DC Transformer

4. Circuit Breaker (AC) (CE Qty.-2)

Notes: See wiring diagrams in Section-3 of this manual for wiring instructions that apply to your model and machine voltage.

Figure 2-1. AC Junction Box - Internal Components.

3120779 – JLG Lift – 2-5

SECTION 2 - SERVICE PROCEDURES

2.5 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES

The AM Series personnel lift mast sections are contructed
of extruded aluminum, protected with an anodized surface
finish. The mast sections rails are interlocked into each
other when assembled and are guided by slide pads
mounted at the top and bottom of the rails on both sides
of the mast section.

The current ELI model mast assembly has been designed
with four (4) mast sections;

Table 2-2. AM Series Mast Component Features

Model

15ELI 4 Chain & Cable

When assembing mast sections carefully slide the mast
sections together from bottom until mast ends are even,
(when sliding mast sections together be careful not to
scratch the anodized surface in the slide pad channels).
Assemble the hardware to the bottom of mast section first,
then slide this section out the top of previous section and
assemble hardware to the top of mast, (See Figure 2-2.).
Always install slide pad shims with slide pads inserted into
the slide pad channels, (ends of mast sections even).

No. of Mast

Sections

Extend Device

Mast Disassembly Procedure

(See Figure 2-2.)

1. After the platform and other hardware have been
removed from the mast, and mast has been
removed from machine, lay mast assembly down
with the shortest mast section-4 on top and facing
up.

2. Remove sequencing retract cables from sides of
mast assembly and the mini covers from the top of
each mast section.

Platform Section – Removal

3. Remove cable adjust nuts from threaded ends of

cable attached to the cable anchor plate on BOT­TOM end of mast section-4 (short, platform mounting
section). Push threaded ends of cable through
anchor plate

4. At TOP of mast section-4, pull cables out and allow
to hang loose.

NOTE: When sliding mast sections apart, be careful not to

scratch or score the anodized finish in the slide pad
channels.

5. Carefully slide short mast section-4 out BOTTOM of
mast section-3 rails. Disassemble slide pads, shims
and cable anchor plate from mast section-4, if nec­essary.

OPEN RAIL

(REFERS TO OPEN RAIL

FRONT OF MAST SECTION)

TOP

(REFERS TO TOP END

OF MAST SECTION -

END WITH COVER

AND SHEAVE WHEELS

ATTACHED)

BOTTOM

(REFERS TO BOTTOM END

OF MAST SECTION -

CLOSED RAIL

(REFERS TO CLOSED RAIL

BACK OF MAST SECTION)

END WHICH SETS AT

MACHINES BASE FRAME)

Figure 2-2. Mast Section - Assembly/Disassembly Reference.

2-6 – JLG Lift – 3120779

SECTION 2 - SERVICE PROCEDURES

Mast Section 3 – Removal

1. Remove chain adjust nuts from threaded ends of

chain attached to the chain anchor plate on BOT­TOM end of mast section-3. Push threaded ends of
cable through anchor plate.

2. At TOP of mast section-3, pull chains out and allow
to hang loose, (be certain floor surface is clean and

free of any metal chips or debris which may stick to
lubricated chains or lay chains in a clean bucket).

3. Slide mast section-3 out TOP of mast section-2 far
enough to allow access to the chain sheave wheel
assembly.

4. Remove countersunk flathead screws securing
chain sheave wheel assembly attach bars on both
side rails at TOP of mast section-3 and remove
sheave wheel assembly.

5. While mast section-3 is still extended from section-2
remove the bolts attaching the two (2) chain assem­bly anchor blocks to the TOP of mast section-3.
Remove chains.

NOTE: When sliding mast sections apart, be careful not to

scratch or score the anodized finish in the slide pad
channels.

6. Carefully slide mast section-3 out BOTTOM of sec­tion-2. Remove slide pads, shims and chain anchor
plate, if necessary.

Mast Section 2 – Removal

7. Slide mast section-2 out TOP of mast section-1 far

enough to allow access to the chain anchor block/
sheave wheel assembly.

8. Remove countersunk-flathead screws securing
chain anchor block/sheave wheel assembly attach
bars on both side rails at TOP of mast section-2.

9. Slide the chain anchor block/sheave wheel assemby
and hydraulic cylinder out the TOP of mast section-2
far enough to allow removal of the sheave wheel
attach bars, sheave wheels and sheave pin from the
chain assembly anchor block.

10. Remove the setscrew holding the hydraulic cylinder
rod into the chain assembly anchor block. Lay chain
assembly to side.

11. Remove the hydraulic cylinder through the BOTTOM
of mast section-2, be careful not to nick or score cyl­inder rod surface while removing.

NOTE: When sliding mast sections apart, be careful not to

scratch or score the anodized finish in the slide pad
channels.

12. Carefully slide mast section-2 out BOTTOM of sec­tion-1. Remove slide pads and shims, if necessary.

Mast Section 1 – Disassembly

13. Slide the TOP of the remaining mast section-1 out

over edge of work surface and remove the bolts
attaching the anchor blocks of the two (2) chain
assemblies to mast section-1. Remove chain assem­blies from mast and lay aside.

14. Remove slide pads and shims from mast section-1,
is necessary.

Mast disassembly should now be complete.

3120779 – JLG Lift – 2-7

SECTION 2 - SERVICE PROCEDURES

2.6 MAST ASSEMBLY

(See Figure 2-2.)

Mast Section 1 - Assembly

1. Place mast section-1, rail (open) side up (See Figure

2-2.) on a clean, flat surface (preferably a table or
work bench capable of supporting the weight of the
entire mast assembly). Slide mast out over end of

work surface far enough to allow access to the chain
anchor attach holes at top of mast.

2. Locate the two (2) single (wide) chain assemblies.
Lay out each chain assembly with anchor block end
towards mast, and notched end of block down, (be

certain floor surface is clean and free of any metal
chips or debris which may stick to lubricated chains
or lay chains in a clean bucket).

3. Insert the block anchor end (with notched end on
bottom) into the top of mast section-1 and secure

using two (2) 3/8"-16UNC x 2-1/2" long hex head
bolts, flatwashers and nuts for each attach block.
Place a flatwasher under bolt head and nut.

Mast Section 2 - Assembly

a. Check mast section for side play. If play exists

add .015" shims dividing the thickness equally
between both sides of mast. Insert shims until
the shims cannot be inserted halfway by hand
with the mast pulled to the opposite side.

b. When mast slide pads are shimmed properly,

there should be no side to side movement of
slide pad in rail channel. Mast sections should
be snug in channels but still be able to slide in
channel by hand.

9. Insert slide pads into the slide pad channels (top of
mast) between section-1 and -2, (one on each side
of the mast), with beveled surface facing in towards

section-2.

NOTE: Before fastening and shimming the slide pad on the

top left side of the mast, install a sequence cable
bracket against the mast under the flatwasher.

10. Thread slide pad attaching bolts, two (2) 1/4"­20UNC x 3/8" long hex head bolts, place a flat
washer under head of each bolt, through holes in
mast section-1 outside rail (top of mast) and into the
slide pad inserts. Thread in enough to hold pad in
place.

NOTE: When sliding mast sections together, be careful not

to scratch or score the anodized finish in the slide
pad channels.

4. Locate mast section-2, carefully slide mast section-2
closed rail into section-1 open rail. Slide sections
together until ends are even.

5. Insert slide pads into the slide pad channels at bot­tom end of mast between section-1 and -2, (one on
each side of the mast), with beveled surface facing
out towards section-1.

6. Thread slide pad attaching bolts, (two (2) 1/4"­20UNC x 3/8" long hex head bolts, place a flat
washer under head of each bolt), through holes in
mast section-2 inside rail, into the slide pad inserts.
Thread in enough to hold pad in place.

7. Shim slide pads using the following steps:

NOTE: Always use the an even amount of shim material

behind slide pads on both sides of the mast rails.
This will keep mast sections centered in rail chan­nels and prevent any distortion of the mast section.

a. Start with a .036" thick shim and a .075" thick

shim per side at each slide pad.

8. Slide shims into place between slide pad and mast
rail. Tighten the slide pad mounting bolts, be sure
there are no air gaps between shims, shim and mast

or shim and slide pad when tightened.

11. Shim per instructions in step 7, Mast Section 2 ­Assembly.

NOTE: If hydraulic cylinder needs to be extended, the pro-

tective caps on the extend and return ports will need
to be temporarily removed. Be careful not to nick or
scour rod surface when extending, also catch any oil
draining out of cylinder to avoid spillage onto work
area.

12. Locate the hydraulic lift cylinder, slide the lift cylinder
into the closed rail side of mast section-2 with rod
end to top and port end to bottom of mast. Cylinder
should extend out of mast on both ends. Return
tube should be on right side when facing bottom of
mast assembly.

13. Insert hydraulic cylinder rod end into chain assem­bly anchor block. Secure cylinder rod to anchor
block with a 1/4"-28UNF x .50" long - Type C set­screw. Coat threads with blue Loctite # 242 before
assembly.

14. Locate chain assembly (single anchor block with
two narrow chains). Lay out chain assembly with
anchor block end towards mast, (be certain floor
surface is clean and free of any metal chip or debris
which may stick to lubricated chains or lay chains in
a clean bucket).

15. Slide mast section-2 out of mast section-1 approxi­mately one foot.

2-8 – JLG Lift – 3120779

SECTION-1

SECTION-2

MAST

SECTION-3

SECTION 2 - SERVICE PROCEDURES

MAST

MAST

SECTION-4

LIFT

CYLINDER

MAST

Figure 2-3. 15ELI Mast Assembly Components. (4 Section - Chain/Cable or All Cable)

3120779 – JLG Lift – 2-9

SECTION 2 - SERVICE PROCEDURES

Figure 2-4. Mast Chain/Cable Routing Diagram.

2-10 – JLG Lift – 3120779

SECTION 2 - SERVICE PROCEDURES

16. Assemble chain sheaves on chain assembly anchor
block (attached to cylinder rod end) and attach to
mast section-2 using following steps;

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 a

sheave pin attach bar, (rectangular plate with
threaded holes on each side of pin bore hole).

d. Slide the whole anchor block assembly with

sheave pin, wheels and pin attach bars into top
of mast section-2. (Position anchor block with
narrow chains facing mast section-3).

e. Attach to top of mast section-2 using two (2) 3/

8"-16UNC x 1/2" long socket head-countersunk­flathead cap screws each side. Coat threads
with Loctite #171 and tighten.

17. Slide mast section-2 back into section-1 until end
are even.

Mast Section 3 - Assembly

NOTE: When sliding mast sections together, be careful not

to scratch or score the anodized finish in the slide
pad channels.

18. Locate mast section-3, carefully slide section-3
closed rail into section-2 open rail. Slide sections
together until ends are even.

19. Locate one (1) of the chain/cable anchor plates (one
with threaded holes horizontally aligned to outside of
bracket). Attach using outer set of holes in bottom of

mast section-3 with two (2) 1/4"-20UNC x 3/4" long
bolts, place a flatwasher under head of each bolt.

20. Slide mast section-3, approximately two feet out of
the top of mast section-2.

21. Insert threaded ends of chain assembly (attached to
top of mast section-1), through holes in anchor plate

attached to bottom of mast section-3. Loosely
thread two (2) 3/8"-16UNC nuts onto stud threads on
each chain. Chains will be adjusted later in assem­bly.

22. Locate two cable assemblies. Attach the eyelet
anchor end of each cable to the outside holes near
top of mast section-3 using 3/8"-16UNC x 1-1/4" long
hex head bolts, nuts and flatwashers. Place a flat­washer under bolt head and nut.

23. Assemble chain sheaves (for narrow chain assem-
bly) to top of mast section-3 as follows;

b. Slide two (2) short spacer tubes onto sheave

pin, one each end of sheave pin to outside of
sheave wheels.

c. Place two (2) sheave pin attach bars, one each

end of sheave pin to outside of space tubes.

d. Holding complete sheave wheel assembly, slide

assembly into top of mast section-3 and align
threaded holes in sheave pin attach bars with
holes in mast rails.

e. Attach to top of mast section-3 using two (2) 3/

8"-16UNC x 1/2" long socket head-countersunk­flathead cap screws, each side. Coat threads
with Loctite #171 and tighten.

NOTE: When sliding mast sections together, be careful not

to scratch or score the anodized finish in the slide
pad channels.

24. Carefully slide mast section-3 into section-2 until
ends are even. Check to make sure chain assembly
(wide chains) are seating properly in chain anchor
block chain sheave wheels attached to mast sec­tion-2.

25. Insert slide pads into the top end mast rails between
section-2 and -3, (one on each side of the mast),
with beveled surface facing inward towards section-

3.

NOTE: Before fastening and shimming the slide pad on the

top left side of the mast, install a sequence cable
bracket against the mast under the flatwasher.

26. Thread slide pad attaching bolts, two (2) 1/4"­20UNC x 3/8" long hex head bolts, place a flat
washer under head of each bolt, through holes in
outside rail, on top of mast section-2 and into the
slide pad inserts. Thread in enough to hold pad in
place.

27. Shim per instructions in step 7, Mast Section 2 ­Assembly.

28. Insert slide pads into the bottom end mast rails
between section-2 and -3, (one on each side of the
mast), with beveled surface facing out towards sec­tion-2.

29. Thread slide pad attaching bolts, two (2) 1/4"­20UNC x 3/8" long hex head bolts, place a flat
washer under head of each bolt, through holes on
inside rail, on bottom end of mast section-3 and into
the slide pad inserts. Thread in enough to hold pad
in place.

30. Shim per instructions in step 7, Mast Section 2 ­Assembly.

a. Locate the two (2) narrow chain sheave wheels

and slide onto sheave pin.

3120779 – JLG Lift – 2-11

SECTION 2 - SERVICE PROCEDURES

Platform Mounting Section - Assembly

1. Locate the remaing mast section-4 (platform mount-

ing - mast section). Lay mast section on flat stable
surface.

2. Attach the remaining chain/cable anchor plate (one

with threaded holes vertically aligned in center of
bracket). Attach through inner (vertical) set of holes

in bottom of mast section-5/-6/-7 with two (2) 1/4"­20UNC x 3/4" long bolts, place a flatwasher under
head of each bolt.

NOTE: The platform mounting section slide pads, are

assembled differently than the slide pads for the
other mast sections. Mast section-4 slide pads may
need to be assembled/disassembled several times in
order to determine the correct shim stock required
for proper fit.

3. Complete the following steps to determine shim
stock thickness required for section-4;

NOTE: Always use the an even amount of shim material

behind slide pads on both sides of the mast rails.
This will keep mast sections centered in rail chan­nels and prevent any distortion of the section.

a. Use two shim pieces per slide pad, a thick one

and a thin one.

b. Start with a total thickness of approximately

.035" and .075" thick shim stock.

c. Attach shim stock and slide pads to both sides

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

shim stock and slide pad to mast section rail with
shim stock against rail and slide pad with bev­eled side out).

d. Carefully thread the slide pad mounting bolts

with flatwashers through slide pads and shim
stock into threads in mast section-4. Be certain
there are no air gaps between shims, shim and
mast or shim and slide pad when tightened.

NOTE: Mast section-4 into section-3 fit should be very snug

but still be able to be pushed together by hand. If too
tight, remove section-4, disassemble slide pad and
reduce thickness of shim stock.

e. Begin sliding top of mast section-4 with closed

rail down engaging the slide pads into slide pad
channels at bottom of mast section-3’s open rail.
Continue to push section-4 into section-3 until
BOTTOM ends of mast sections are even.

f. Check mast section for side play. If play exists

use thicker shims dividing thickness equally
between both sides of mast.

g. When mast slide pads are shimmed properly,

there should be no side to side movement of
slide pad in rail channel. Mast sections should
be very snug in channels but still be able to slide
in channel by hand.

4. Slide mast section-4 out to top of section-3.

5. Insert threaded ends of cable assembly (attached to

top of mast section-2) through the cable anchor
plate located on bottom of extended mast section-4.
Loosely thread two (2) 3/8"-16UNC nuts onto stud
threads on each chain. Chains will be adjusted later
in assembly.

6. Slide mast section-4 back into mast section-3 until
bottom ends of masts are even. Check to make sure
cable set attached to top of section-2 is seating
properly in cable sheave wheels attached to top of
mast section-3. (Mast section-2 may need to be

restrained to keep it’s slide pads from pushing out
the bottom of mast sections-1).

7. Adjust top and bottom ends of mast sections so they
are all even with each other. At bottom of mast
assembly, thread all chain/cable adjusting nuts on
threaded ends until they are snug against the
anchor plates and all slack is removed from chains
and cables. Check that chains and cables are
seated in their sheave wheels at top of mast assem­bly.

8. Assemble the mini covers to the top of each mast
section and the sequencing cables and hardware to
the side of the mast assembly.

Mast assembly should now be complete.

2.7 MAST TO BASE FRAME INSTALLATION

1. Using an overhead crane or suitable lifting device

capable of supporting the weight of base frame,
attach a sling strap or chain to the front crossmem­ber of the base frame, raise base frame.

2. Extend hydraulic cylinder out from bottom of mast
assembly approximately one (1) foot. (Caps on

extend and return ports will need to be removed to
extend cylinder. Catch any hydraulic fluid expelled
from return port in a container to prevent spillage
onto work area).

3. Bring base frame into position in front of mast
assembly, (base frame and mast assembly must be
held at 90° angle to each other).

4. Slide port end of hydraulic cylinder through hole in
base frame cylinder mounting channel. (Return port

(tube side) of cylinder must be on right side facing
bottom of base and mast).

2-12 – JLG Lift – 3120779

SECTION 2 - SERVICE PROCEDURES

5. Align threaded hole in side of hydraulic cylinder
head with hole in tab on bottom side of cylinder
mounting channel. Secure hydraulic cylinder to cyl­inder mounting channel tab using a 5/16"-18UNC x
5/8" long hex head bolt and flat washer.

6. Carefully push mast assembly and base assembly
together until the four (4) holes on bottom rear of
mast align with holes in the base frame mast support
crossmember.

7. Attach mast to base using four (4) 3/8"-16UNC x 1"
long hex head bolts, locknuts and flatwashers,

(place a flatwasher under bolt head and nut and
mount with nuts on inside of frame).

8. Locate the two (2) mast support braces, attach to
sides of base frame using a 3/8"-16UNC x 1" long
hex head bolt, nut and flatwashers each brace,

(place a flatwasher under bolt head and nut and
mount with nuts on inside of frame. Use access hole
in bottom of frame to attach nut inside frame).

9. Before setting machine upright on base, install a
short 90° elbow fitting, flow control valve and
another short 90° elbow fitting on the end of the flow
control valve in the extend (left) port on bottom of
hydraulic cylinder. Install a long 90° elbow fitting on
return (right) port. Use sealant tape on fitting
threads. Cap ports until hydraulic lines are installed.

10. Carefully set machine in an upright position on its
base frame wheels.

11. Locate the mast support bracket. Attach mast sup­port bracket to mounting holes halfway up back of
mast using four (4) 3/8"-16UNC x 2-3/4" long hex
head bolts, locknuts and flatwashers. (Place a flat-

washer under bolt head and nut and mount with nuts
on inside of frame).

12. Using a 4 ft. level, ensure mast is set to vertical
(plumb) on the base frame.

13. When mast is vertical (plumb), attach support
braces, (bolted to base), to the mast support
bracket, (bolted to mast), using 3/8"-16UNC x 2-3/4"
long hex head bolts, nuts and flatwashers. (Place a

flatwasher under bolt head and nut and mount with
nuts on inside of bracket).

14. After securing mast to base frame, using 4 ft. level
again check that mast is vertical (plumb) on base
frame.

Mast installation should now be complete.

2.8 MAST CHAINS/CABLES AND SEQUENCING CABLES ADJUSTMENT

Mast Chain/Cable Adjustment

The intention of this procedure is to assure equal load dis­tribution between the individual chains/cables of a mast
section chain/cable set.

Adjust using the following procedure;

1. With mast retracted, step into the platform and
bounce your weight up and down a few times to be
certain platform is at the bottom of travel. Be certain
all chain/cable sets are seated in their sheaves prop­erly at the top of each mast section.

2. Then with no load in the platform check the side pro­file of the top of the mast for the amount of adjust­ment necessary to step the mast sections 7/16 in.
(12mm) for mast sections-3 and up. (See Figure 2-

5.)

NOTE: Mast section-1 is fixed to the base and mast section-

2 is attached to the lift cylinder, these sections
require no adjustment.

3. Adjust one mast section at a time starting from the
back (section-3, section-4, etc.) of the mast and
work forward. (i.e.. if three is OK, then jump to four,
etc.)

4. Elevate the platform until the chain/cable anchor
adjust nuts are accessible at the front and bottom of
each mast section.

NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT­FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT
BY BLOCKING OR OVERHEAD SLING.

5. Start with the mast section which needs adjustment
and loosen the bottom (jam) nut on each chain/
cable.

6. Tighten (to raise mast section), or loosen (to lower
mast section) the adjusting nut against the anchor

plate on each chain/cable. Adjust the nut the
amount required to raise or lower the top of the mast
section to match the side profile shown in Figure 2-

5. when the mast is retracted. Be certain each chain/
cable pair is adjusted to equal tension. (The

threaded end of the chain/cable will need to be
restrained while tightening the adjust nut to keep the
chain/cable from twisting.)

7. Retract the mast all the way and check if the top of
the mast sections appear as shown in Figure 2-5.

8. Repeat steps (1) through (7) for remaining mast sec­tions. ENSURE THAT ALL CHAIN/CABLE PAIRS
HAVE EQUAL TENSION.

3120779 – JLG Lift – 2-13

SECTION 2 - SERVICE PROCEDURES

S

p

MAST SIDE PROFILE

CHECK IF OVERALL HEIGHT

OF MACHINE FROM

FLOOR TO TOP OF MAST

IS WITHIN SPECIFICATION

MAST CHAIN/CABLE ADJUSTER

STEP APPROXIMATELY

7/16 in. (12mm)

SEQUENCE CABLE

ADJUST NUT

SECTION-1

FIXED

TO BASE

SECTION-2

EXTENDED BY

CYLINDER

SECTION-3

EXTENDED BY

CHAIN

SECTION-4
EXTENDED BY
CHAIN/CABLE

SECTION-5

(PLATFORM

HEADER SECTION)

EXTENDED BY

CHAIN/CABLE

Note: When

is complete, before

tightening the jam nut

against the adjust nut,

a

ply Loctite #242 to the

threads under the jam nut.

Figure 2-5. Mast Chain/Cable/Sequence Cable Adjustment Components. (Typical)

9. Once mast section adjustment is completed, apply

loctite #242 to the threads under the (jam) nuts that
were loosened. Then re-tighten the loosened (jam)
nuts until tight against the top (adjust) nut. Chain/
cable should have slight tension but should not be
taut.

CHAIN/CABLE

ANCHOR PLATE

ADJUST NUT

chain adjustment

.

JAM NUT

THREADED

CHAIN/CABLE

END

Sequencing Cable Adjustment

1. Retract mast completely, and check each sequenc-

ing cable on outside of masts for excessive slack.
Adjust only to remove slack from cable.

2. Tighten nylock-nut just enough to remove excessive
slack from sequencing cable. The springs should
not be compressed more than 25% after adjusting.

3. Run mast through several cycles to verify cable/
chain adjustments and ensure no interference exists
between chain anchor brackets and mast.

2-14 – JLG Lift – 3120779

SECTION 2 - SERVICE PROCEDURES

2.9 SEQUENCE CABLE REPLACEMENT KIT

A sequence cable replacement kit is available from the
JLG Parts Department to service broken or worn
sequence cables. This kit consists of a replacement
sequence cable with the threaded (top) end attached
same as the top end of the factory cable. Also included is
a clamp (drum/socket type) to secure the bottom end of
the cable. Use the following procedure to install the
replacement cable and clamp kit.

Remove Old Cable

1. Remove the locking nut from the threaded end of

the cable at the top of the mast and then remove the
spring cap, spring, and spacer washers if installed.

2. Slide the threaded top end out of the upper anchor
bracket, then at the bottom end pull the cable out
though the sheave pulley/anchor bracket until it is
completely clear of the machine.

Replacement Cable Installation

1. Be certain the mast is completely retacted and at the

bottom of travel. Check the mast "Side Profile" at the
top of the mast as shown in Figure 2-5., adjust mast
sections to proper height if necessary.

Clamp Installation (Drum/Socket Type)

THE MANUFACTURER OF THE DRUM/SOCKET CLAMP RECOM­MENDS 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
A VISE PROPERLY WITHOUT DAMAGING ANY ROPE STRANDS
AND A PLUG DRIVER TO DRIVE THE PLUG INTO THE CENTER OF
THE WIRE ROPE AND IS ALSO USED TO FORM THE STRANDS OF
THE ROPE DURING ASSEMBLY.

NOTE: The tools in the clamp assembly kit may be frabri-

cated if necessary. The vise clamp consists of vise
jaws with a hole drilled 1/32 in. smaller than the
diameter of the wire rope you are working with (i.e.
1/8 in. rope - 3/32 in. hole.)
The plug driver is a metal tube with a hole in the bot­tom to allow the strands of the wire rope to be
shaped after the plug has been tapped into the cen­ter of the wire rope.

1. Using the recommended vise jaws, clamp the wire
rope into a vise with the bottom edge of the black
mark made on the wire rope resting just above the
vise jaws.

2. To determine where the clamp will be installed at the
bottom of the replacement cable, temporarily
assemble the new replacement cable to the top
cable anchor bracket on the mast using the wash­ers, spring, spring cap and lock nut previously dis­assembled. Thread the lock nut on until
approximately 1/8 in. (3mm) of threads are exposed.

3. At the bottom of the mast, thread the loose end of
the replacement cable through the proper sheave
pulley and through the hole in the sheave pully/
anchor bracket on the mast section ahead of the
sheave pulley.

4. Grasp the cable and pull on the cable until the
spring at the top of the cable is slightly compressed.
Use a black marker to mark the cable on the top
side of the sheave pully/anchor bracket. This will
determine where the clamp (drum/socket) sleeve will
be positioned on the cable.

DO NOT CUT THE CABLE AT THE MARKED POINT ON THE
CABLE THIS IS ONLY USED AS A REFERENCE FOR POSITIONING
THE CABLE SLEEVE WHICH WILL REST AGAINST THE ANCHOR
BRACKET ONCE INSTALLED.

2. Twist the sleeve from the clamp kit onto the rope
until it is flat against the vise jaws at the mark made
made on the wire rope.

3120779 – JLG Lift – 2-15

SECTION 2 - SERVICE PROCEDURES

3. Use a suitable tool and cut the cable as shown in the
illustration following. For 1/8 in. cable the recom­mended length is 5/8 in. past the end of the sleeve.

4. Unlay the cable strands by gently forcing a screw­driver between the outer strands to unlay the cable.
When done properly the outer strands will form a
symmetrical basket. Do not straighten out the spiral
lay of the strands, unlay any wires that make up the
strand, or allow the strands to cross each other
inside the sleeve.

6. Reclamp the assembly in the vise on the flats of the
sleeve. Using the plug driver, a metal tube or pliers,
bend the outer strands toward the center strands
enough that the socket can be slipped over all the
strands.

NOTE: When assembling stainless steel parts all threads

must be coated with a dry lubricant or an anti-sieze
lubricant to prevent seizing.

7. Coat the threads of the socket and sleeve with lubri­cant and install the socket by twisting it over the
strands of the cable and engage the threads of the
sleeve with the socket. Tighten until four threads or
fewer are visible. If more than four threads are visi­ble, proof load the cable and retighten the socket fit­ting. (There is no specific requirement for torque.)

5. Install the plug supplied with the kit by placing the
plug in the center of the strands starting with the
small tapered end of the plug. Use a metal tube
(plug driver) and hammer to drive the plug into the
sleeve while assuring that the strands are spaced
somewhat equally around the plug. Drive the plug
until it is firmly seated and no more than 1/3 of the
plug is visible from above the sleeve.

8. Inspect for proper assembly prior to loading the
cable. Strands visible through the inspection hole
are your assurance of a proper assembly.

NOTE: The end of the rope may not be visible in the inspec-

tion hole after loading.

9. Install cable on machine and adjust per instructions
shown previously in Section 2.8, MAST CHAINS/
CABLES AND SEQUENCING CABLES ADJUST­MENT.

2-16 – JLG Lift – 3120779

SECTION 2 - SERVICE PROCEDURES

2.10 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

(See Table 2-3.)

The preventive maintenance and inspection checks are
listed and defined in the following table (See Table 2-3.).
This table is divided into two basic parts, the “AREA” to be
inspected and the “INTERVAL” at which the inspection is
to take place. Under the “AREA” portion of the table, the
various systems along with the components that make up
that system are listed. The “INTERVAL” portion of the table
is divided into five columns representing the various
inspection time periods. The numbers listed within the
interval column represent the applicable inspection code
for which that component is to be checked.

The checks and services listed in this schedule are not
intended to replace any local or regional regulations that
may pertain to this type of equipment nor should the lists
be considered as all inclusive. Variances in interval times
may occur due to climate and/or conditions and depend­ing on the location and use of the machine.

JLG Industries requires that a complete annual inspection
be performed in accordance with the “Annual Machine
Inspection Report” form. Forms are supplied with each
new machine and are also available from JLG Customer
Service. Form must be completed and returned to JLG
Industries.

JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL
INSPECTION BE PERFORMED IN ACCORDANCE WITH THE
“ANNUAL MACHINE INSPECTION REPORT” FORM.

3120779 – JLG Lift – 2-17

SECTION 2 - SERVICE PROCEDURES

Table 2-3. Preventive Maintenance & Inspection Schedule.

AREA ON MACHINE INTERVAL

PLATFORM

Control Switches 1,11

Placards and De cals 1,2

Control Tags 1,2

Electrical Cables 1,8

Handrail and Bar Gate 1,4

MAST

Mast Chains/Cables /and all component parts 1,4,7,9

Mast Section s 1,4,7

Mast Sequencing Cables 1,4,7,9

BASE FRAME

Batteries (DC Mode ls) 1,3 5 12

Battery Charger ( DC Models) 1

Power Cable (AC Models) 1,8

Electric Motor/Hyd raulic Pump Unit 1 5

Hydraulic Hoses and Fittings 1 5

Hydraulic Oil Reservoir * 3 5 4

Hydraulic Oil Re servoir Breather 6,14

Manual Descent Valve 1,7

Lift Cylinder 1 5,6,13 4

Floor Brake Assembl y 1,6,7,8 12

Placards and De cals 1,2

Wheels and Caste rs 1 8,9 12

Wheel Bearings 8 12

Power Switch (Ground Con trol Box) 1,11

Control Tags 1,2

Placards and De cals 1,2

Hoses and Cables 1,8

(10 HRS.)

DAILY

(50 HRS.)

WEEKLY

(200 HRS.)
MONTHLY

(500 HRS.)
3 MONTHS

(1000 HRS.)

6 MONTHS

(2000 HRS.)

1 YEAR

The inspection and maintenance code numbers are as fol­lows:

1. Check for proper and secure installation.

2. Check for visible damage and legibility.

3. Check for proper fluid level.

4. Check for any structural damage; cracked or broken

welds; bent/warped surface; broken cable strands.

5. Check for leakage.

6. Check for presence of excessive dirt or foreign

material.

7. Check for proper operation and freedom of move­ment.

8. Check for excessive wear or damage.

9. Check for proper tightness and adjustment.

10. Drain, clean and refill.

11. Check for proper operation while pump/motor is

running.

12. Check for proper lubrication.

13. Check for evidence of scratches, nicks or rust and

for straightness of rod.

14. Check for condition of element; replace as neces­sary.

2-18 – JLG Lift – 3120779

SECTION 3 - TROUBLESHOOTING

SECTION 3. TROUBLESHOOTING

3.1 GENERAL

This section contains troubleshooting information to be
used for locating and correcting most of the operating
problems which may develop in the aerial platform. If a
problem should develop which is not presented in this
section or which is not corrected by listed corrective
actions, technically qualified guidance should be obtained
before proceeding with any maintenance.

3.2 TROUBLESHOOTING INFORMATION

The troubleshooting procedures applicable to the aerial
platform are listed and defined in Table 3-1., AC Unit Trou­bleshooting and Table 3-2., DC Unit Troubleshooting.

Each malfunction within an individual group or system is
followed by a listing of probable causes which will enable
determination of the applicable remedial action. The prob­able causes and the remedial action should, where possi­ble, be checked in the order listed in the tables.

It should be noted that there is no substitute for a thor­ough knowledge of the equipment and related systems.

It should be recognized that the majority of the problems
arising in the machine will be centered in the hydraulic
and electrical systems. For this reason, every effort has
been made to ensure that all likely problems in these
areas are given the fullest possible treatment. In the
remaining machine groups, only those problems which
are symptomatic of greater problems which have more
than one probable cause and remedy are included. This
means that problems for which the probable cause and
remedy may be immediately obvious are not listed in this
section.

The first rule for troubleshooting any circuit that is hydrau­lically operated and electrically controlled is to determine
if the circuit is lacking hydraulic oil and electrical control
power. 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.

3.3 ELECTRICAL AND HYDRAULIC CIRCUIT CHECKS

(See Figure 3-1., 3-2., 3-3., 3-4. & 3-5.)

The first reference for improper function of a electrical/
hydraulic system, where the cause is not immediately
apparent, should be the Troubleshooting Chart. The best
place to begin the problem analysis is at the power source
(pump). Once it is determined that the pump is service­able, then a systematic check of the circuit components,
beginning with the control, would follow.

NOTE: For aid in Hydraulic troubleshooting, refer to Figure

3-1. HYDRAULIC Schematic at the end of this sec­tion. For ELECTRICAL Diagrams refer to Figure 3-2.,
3-3., 3-4. & 3-5., also at the end of this chapter.

3120779 – JLG Lift – 3-1

SECTION 3 - TROUBLESHOOTING

Table 3-1. AC Unit - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Platform does not rise.

Platform lowers by itself.

Unit leaking hydraulic oil.

Unit lowers very slowly.

Power source is OFF or unplugged). Check power source or Ground Sta-

tion Key Switch.

Red emergency stop button is
engaged (PUSHED IN) on either
ground control station or on platform.

Foot Brake is not engaged. Engage Foot Brake at front of

Control relay not functioning. Replace control relay.

Motor start relay not functioning. Replace motor start relay.

Fuse(s) blown. Replace blown fuse. If fuse blows

Unit wiring not properly ground ed. Check all grounds in the wiring.

Check for loose wire(s) on Floor Brake
Limit Switch (causing an open circuit).

Manual descent valve open. Close manual descent valve.

Hydraulic hose and/or fittings loose
causing a hydraulic pressure leak.

Lift DOWN solenoid valve not function­ing.

Hydraulic hose and/or fittings loose. Tighten hydraulic hose and/or fittings.

Valve and/or plug loose. Tighten valve and/or plug.

Breather cap on tank is saturated or
clogged with oil.

Hydraulic oil tank over-filled. Lower oil level to full mark on dipstick.

Flow control valve not functioning. Replace flow control valve.

Disengage (TURN CLOCKWISE) red
emergency button until it pops out.

machine.

again check electrical circuit for short
circuit.

Properly reinstall wire to limit switch.

Tighten hydraulic hose and/or fittings.

Replace Lift DOWN solenoid valve.

Replace breather cap on tank.

3-2 – JLG Lift – 3120779

TROUBLE PROBABLE CAUSE REMEDY

Platform does not rise.

Platform lowers by itself.

Unit leaking hydraulic oil.

Unit lowers very slowly.

SECTION 3 - TROUBLESHOOTING

Table 3-2. DC Unit - Troubleshooting

Power source is OFF or unplugged. Check power source or Ground Sta-

tion Key Switch.

Red emergency stop button is
engaged (PUSHED IN) on either
ground control station or on platform.

Foot Brake is not engaged. Engage Foot Brake at front of

Control relay not functioning. Replace control relay.

Motor start relay not functioning. Replace motor start relay.

Fuse(s) blown. Replace blown fuse. If fuse blows

Unit wiring not properly ground ed. Check all grounds in the wiring.

Check for loose wire(s) on Floor Brake
Limit Switch (causing an open circuit).

Manual descent valve open. Close manual descent valve.

Hydraulic hose and/or fittings loose
causing a hydraulic pressure leak.

Lift DOWN solenoid valve not function­ing.

Hydraulic hose and/or fittings loose. Tighten hydraulic hose and/or fittings.

Valve and/or plug loose. Tighten valve and/or plug.

Breather cap on tank is saturated or
clogged with oil.

Hydraulic oil tank over-filled. Lower oil level to full mark on dipstick.

Flow control valve not functioning. Replace flow control valve.

Disengage (TURN CLOCKWISE) red
emergency button until it pops out.

machine.

again check electrical circuit for short
circuit.

Properly reinstall wire to limit switch.

Tighten hydraulic hose and/or fittings.

Replace Lift DOWN solenoid valve.

Replace breather cap on tank.

3120779 – JLG Lift – 3-3

SECTION 3 - TROUBLESHOOTING

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3-4 – JLG Lift – 3120779

SECTION 3 - TROUBLESHOOTING

2792491_A

Figure 3-1. Hydraulic Schematic. (AM Series) (2792491)

3120779 – JLG Lift – 3-5

SECTION 3 - TROUBLESHOOTING

A

4933258_

Figure 3-2. Electrical Diagram. (ELI - 12V-DC) (4933258-A)

3-6 – JLG Lift – 3120779

SECTION 3 - TROUBLESHOOTING

A

4933258_

Figure 3-2. Electrical Diagram. (ELI - 12V-DC) (4933258-A)

3120779 – JLG Lift – 3-7

SECTION 3 - TROUBLESHOOTING

4933259_A

Figure 3-3. Electrical Diagram. (ELI - 120V-AC) (4933259-A)

3-8 – JLG Lift – 3120779

SECTION 3 - TROUBLESHOOTING

4933259_A

Figure 3-3. Electrical Diagram. (ELI - 120V-AC) (4933259-A)

3120779 – JLG Lift – 3-9

SECTION 3 - TROUBLESHOOTING

4933260_A

Figure 3-4. Electrical Diagram. (ELI - 240V-AC) (4933260-A)

3-10 – JLG Lift – 3120779

SECTION 3 - TROUBLESHOOTING

4933260_A

Figure 3-4. Electrical Diagram. (ELI - 240V-AC) (4933260-A)

3120779 – JLG Lift – 3-11

SECTION 3 - TROUBLESHOOTING

4933261_A

Figure 3-5. Electrical Diagram. (ELI - 100V-AC) (4933261-A)

3-12 – JLG Lift – 3120779

SECTION 3 - TROUBLESHOOTING

4933261_A

Figure 3-4. Electrical Diagram. (ELI - 100V-AC) (4933261-A)

3120779 – JLG Lift – 3-13

SECTION 3 - TROUBLESHOOTING

This page left intentionally blank.

3-14 – JLG Lift – 3120779

McConnellsburg PA. 17233-9533

JLG Worldwide Locations

Corporate Office

JLG Industries, Inc.

1 JLG Drive

USA

Phone: [phone]

Fax: [phone]

JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
Phone: [phone]
Fax: [phone]

JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
Phone: [phone]
Fax: [phone]

JLG Industries (Europe)
Kilmartin Place,
Tannochside Park
Uddingston G71 5PH
Scotland
Phone: [phone]
Fax: [phone]

JLG Industries (UK)
Unit 12, Southside
Bredbury Park Industrial Estate
Bredbury
Stockport
SK6 2sP
England
Phone: [phone]
Fax: [phone]

JLG Europe B.V.
Jupiterstraat 234
2132 HJ Foofddorp
The Netherlands
Phone: [phone]
Fax: [phone]

JLG Industries (Pty) Ltd.
Unit 1, 24 Industrial Complex
Herman Street
Meadowdale
Germiston
South Africa
Phone: [phone]
Fax: [phone]

JLG Deutschland GmbH
Max Planck Strasse 21
D-27721 Ritterhude/lhlpohl
Bei Bremen
Germany
Phone: [phone]
Fax: [phone]

JLG Industries (Norge AS)
Sofeimyrveien 12
N-1412 Sofienyr
Norway
Phone: [phone]
Fax: [phone]

Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755Castellbisbal
Spain
Phone: [phone]
Fax: [phone]

JLG Industries (Italia)
Via Po. 22
20010 Pregnana Milanese - MI
Italy
Phone: [phone]
Fax: [phone]

JLG Polska
UI. Krolewska
00-060 Warsawa
Pol an d
Phone: [phone]
Fax: [phone]

JLG Industries (Sweden)
Enkopingsvagen 150
Box 704
SE - 175 27 Jarfalla
Sweden
Phone: [phone]
Fax: [phone]