JLG 41EL Service Manual

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: [phone]
Fax: [phone]

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!

bATTERY

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
Poland
Phone: [phone]
Fax: [phone]

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

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 - OPERATION/SAFETY PRECAUTIONS

INTRODUCTION - OPERATION/SAFETY PRECAUTIONS

All procedures herein are based on the use of the
machine under proper operating conditions, with no devi­ations from original design intent ... as per OSHA regula­tions.

READ & HEED!

The ownership, use, service, and/or maintenance of this
machine is subject to various federal, state and local laws
and regulations. It is the responsibility of the owner/user to
be knowledgeable of these laws and regulations and to
comply with them. The most prevalent regulations of this
type are the Federal OSHA Safety Regulations*. Listed
below, in abbreviated form are some of the requirements
of Federal OSHA regulations in effect as of the date of
publication of this handbook.

The listing of these requirements shall not relieve the
owner/user of the responsibility and obligation to deter­mine all applicable laws and regulations and their exact
wording and requirements, and to comply with the
requirements. Nor shall the listing of these requirements
constitute an assumption of responsibility of liability on the
part of JLG Industries, Inc.

1. Only trained and authorized operators shall be per­mitted to operate the aerial lift.

2. A malfunctioning lift shall be shut down until
repaired.

3. The controls shall be plainly marked as to their func­tion.

4. The controls shall be tested each day prior to use to
determine that they are in safe operating condition.

5. Load limits specified by the manufacturer shall not
be exceeded.

6. Instruction and warning placards must be legible.

7. Aerial lifts may be "field modified" for uses other than
those intended by the manufacturer only if certified
in writing by the manufacturer or an equivalent
entity, such as a nationally recognized testing lab, to
be in conformity to applicable OSHA safety regula­tions and to be at least as safe as it was prior to
modification.

8. Aerial lifts shall not be used near electric power lines
unless the lines have been deenergized or adequate
clearance is maintained (see OSHA 29 CFR 1910.67
and 1926.400).

9. Employees using aerial lifts shall be instructed how
to recognize and avoid unsafe conditions and haz­ards.

10. Ground controls shall not be operated unless per­mission has been obtained from personnel in the
platform, except in case of an emergency.

11. Regular inspection of the job site and aerial lift shall
be performed by competent persons.

12. Personnel shall always stand on the floor of the plat­form, not on boxes, planks, railing or other devices
for a work position.

*Applicable Federal OSHA regulations, as of the date of
publication of this manual include, but are not limited to,
29 CFR 1910.67, 29 CFR 1926.20, 29 CFR 1926.21, 29
CFR 1926.28, 29 CFR 1926.400 and 29 CFR 1926.453.
Consult the current regulations for the exact wording and
full text of the requirements and contact the closest Fed­eral OSHA office for specific interpretations.

3120782 – JLG Lift – a

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.

b – JLG Lift – 3120782

EFFECTIVITY CHANGES

June 15, 1999 - Original Issue of Manual

November 21, 2000 - Revised - Pages Affected:Section 2 - Pages 2-11, 2-18 thru 2-21.

January 17, 2002 – Manual Revised

October 31, 2003 – Manual Revised

EFFECTIVITY PAGE

3120782 – JLG Lift – c

EFFECTIVITY PAGE

This Page Left Intentionally Blank

d – JLG Lift – 3120782

TABLE OF CONTENTS

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE NO.

INTRODUCTION -- OPERATION/SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

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

A GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

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

C MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

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 (1) – 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Platform Cycle Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Outrigger Footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Machine Overall Width and Length (Base) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.4 TORQUE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

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

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

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

1.6 HYDRAULIC PRESSURE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.7 CYLINDER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.8 SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

SECTION 2 - SERVICE PROCEDURES

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

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

Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2.3 SERVICING AND MAINTENANCE GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

3120782 – JLG Lift – i

TABLE OF CONTENTS (Continued)

Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Mast Chain Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Mast Cable Inspection Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2.4 LUBRICATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2.5 BATTERY CHARGER - ASSEMBLY AND DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Battery Charger Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Transformer Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Printed Circuit Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

DC Circuit Breaker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

AC Circuit Breaker and Voltage Selection Switch Replacement . . . . . . . . . . . . . . . . . . . . .2-10

Shunt Assembly, Varistor, and SCR Rectifier Replacement (See Illustration) . . . . . . . . . . . 2-11

2.6 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILD . . . . . . . . . . . . . . . . . . 2-12

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Lift Cylinder Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.7 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Mast Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

Platform Section Removal (All Masts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Mast Section 6 Removal (7 Section Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

Mast Section 5 Removal (6 & 7 Section Mast). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Mast Section 4 Removal (All Masts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Mast Section 3 Removal (All Masts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Mast Section 2 Removal (All Masts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Mast Section 1 Disassembly (All Masts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2.8 MAST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Mast Section 1 - Assembly (All Masts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Mast Section 2 - Assembly (All Masts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Mast Section 3 - Assembly (All Masts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Mast Section 4 - Assembly (All Masts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Mast Section 5 - Assembly (25/30/36/41 ft. Masts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24

Mast Section 6 - Assembly (30/41 ft. Masts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Platform Mounting Section - Assy. (All Masts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2.9 MAST TO BASE FRAME INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

2.10 MAST CHAINS/CABLES AND SEQUENCING CABLES ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 2-29

Mast Chain/Cable Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Sequencing Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2.11 SEQUENCE CABLE REPLACEMENT KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

Remove Old Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

Replacement Cable Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Clamp Installation (Drum/Socket Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

ii – JLG Lift – 3120782

TABLE OF CONTENTS

SECTION 3 - TROUBLESHOOTING

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

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

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

3.4 OUTRIGGER INTERLOCK CONTACTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Outrigger Socket and Outrigger Beam - Interlock Contacts. . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Outrigger Socket - Contactor Screw Mounting Instructions. . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Outrigger Beam - Interlock Contactor Plate Mounting Instructions . . . . . . . . . . . . . . . . . . . . 3-4

Detent Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Hydraulic Pressure Setting - Adjustment Screw Located at Base of Pump Motor . . . . . . . . . . . .1-3

1-2. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-3. Lubrication Locations (See Table below). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

2-1. Lift Cylinder Internal Component Assembly Cross-Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2-2. Mast Section - Assembly/Disassembly Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

2-3. 20EL Mast Assembly Components. (5 - Section). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19

2-4. 25EL & 36EL Mast Assembly Components. (6 - Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

2-5. 30EL & 41EL Mast Assembly Components. (7 - Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

2-6. Mast Chain/Cable Routing Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

2-7. Mast Chain/Cable/Sequence Cable Adjustment Components. (Typical) . . . . . . . . . . . . . . . . . . .2-29

3-1. Outrigger Socket Contactor Heads and Outrigger Beam - Contactor Plate

Mounting Hardware (ORIGINAL AND 5/2001 - DESIGN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-2. Hydraulic Schematic. (EL Series) (2792491_A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-3. Electrical Diagram. (EL Series - 12v-DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-4. Electrical Diagram. (EL Series - 120V-AC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-5. Electrical Diagram. (EL Series - 240V-AC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-4. Lubrication Intervals for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2-2 EL Model - Preventive Maintenance & Inspection Schedule.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2-3 Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-4 EL Series Mast Component Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

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

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

3120782 – JLG Lift – iii

TABLE OF CONTENTS (Continued)

This page intentionally l eft blank.

iv – JLG Lift – 3120782

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 – .049 cu. in./rev.(AFC 0.8 cc/rev.)

Pump Output – 0.43 GPM @ 3500 PSI @ 11.7v-DC @

150 AMPS @ 45 Centistrokes

Pressure Relief – Adjustable Range 1500 to 5000 PSI,

Set to 2800 PSI (193 bar) at factory

AC Models - 120 Volt AC motor/pump

Motor - 100/230v-AC, 1HP, 2850/3450 RPM, 50/60Hz

Pump Displacement – .049 in./rev. (0.8 cc/rev.)

Pump Output – 0.43 GPM @ 3500 PSI @ 16 AMPS @

115v-AC @ 45 Centistrokes

Pressure Relief – Adjustable Range 1500 to 5000 PSI,

Set to 2800 PSI (193 bar) at factory

AC Models - 240 Volt AC motor/pump

Motor - 100/230v-AC, 1HP, 2850/3450 RPM, 50/60Hz

Pump Displacement – .049 in./rev. (0.8 cc/rev.)

Pump Output – 0.43 GPM @ 3500 PSI @ 8 AMPS @

230v-AC @ 45 Centistrokes

Pressure Relief – Adjustable Range 1500 to 5000 PSI,

Set to 2800 PSI (193 bar) at factory

Batteries (1) – DC Models.

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

Battery Charger – DC Models.

Input - 120/240 Volts AC – 50/60 Hz - Voltage Selectable

Output - 12 volt, 10 Amp - DC

w/Auto Charge Sensing Circuit.

1.3 PERFORMANCE DATA

Platform Capacity

PLATFORM CAPACITY

MODEL

20EL

AC & DC

25EL

AC & DC

30EL

AC & DC

36EL

AC & DC

41EL

AC & DC

ANSI

(U.S.A.)

350 lb.

(160 kg)

350 lb.

(160 kg)

350 lb.

(160 kg)

300 lb.

(135 kg)

300 lb.

(135 kg)

C.S.A.

(Canada)

300 lb.

(135 kg)

300 lb.

(135 kg)

250 lb.

(113 kg)

250 lb.

(113 kg)

250 lb.

(113 kg)

Brazil/
Japan

160 kg

(350 lb.)

160 kg

(350 lb.)

135 kg

(300 lb.)

135 kg

(300 lb.)

135 kg

(300 lb.)

Machine Weight (with Standard Platform)

20EL-AC - 740 lbs. (336kg)

20EL-DC - 860 lbs. (390kg)

25EL-AC - 825 lbs. (374kg)

25EL-DC - 904 lbs. (411kg)

30EL-AC - 890 lbs. (404kg)

30EL-DC - 940 lbs. (427kg)

36EL-AC - 1,060 lbs. (481kg)

36EL-DC - 1,160 lbs. (526kg)

41EL-AC - 1,100 lbs. (499kg)

41EL-DC - 1,260 lbs. (572kg)

Machine Height (Platform Stowed)

20EL-AC & DC - 77.3 in. (2.0 m)

25EL-AC & DC - 77.3 in. (2.0 m)

30EL-AC & DC - 77.3 in. (2.0 m)

36EL-AC & DC - 104.3 in. (2.64 m) *77 in. (2.0 m)

41EL-AC & DC - 104.3 in. (2.64 m) *77 in. (2.0 m)

* In tilt-back mode.

Maximum Platform Height (Mast Extended)

20EL-AC & DC - 20 ft. (6.09 m)

25EL-AC & DC - 25 ft. (7.62 m)

30EL-AC & DC - 30 ft. (9.14 m)

36EL-AC & DC - 36 ft. (11 m)

41EL-AC & DC - 41 in. (12.42 m)

3120782 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

Maximum Working Height (Average person)

20EL-AC & DC - 26 ft. (7.92 m)

25EL-AC & DC - 31 ft. (9.45 m)

30EL-AC & DC - 36 ft. (11 m)

36EL-AC & DC - 42 ft. (12.80 m)

41EL-AC & DC - 47 ft. (14.33 m)

Platform Cycle Performance

Lift Up cycle time - from stowed to maximum platform
height with maximum rated load.

Lift Down cycle time - from maximum platform height to
stowed position with maximum rated load.

Maximum Platform
Speeds: (in seconds)

Lift Up: 50 62 72 128 120

Lift Down: 32-42 32-42 32-42 47-57 45-55

20EL 25EL 30EL 36EL 41EL

Outrigger Footprint

20/25EL Models - 62 in. x 54 in. (1.57 m x 1.37 m)

30EL Models - 68 in. x 62 in. (1.72 m x 1.57 m)

36EL Models - 79 in. x 79 in. (2.0 m x 2.0 m)

41EL Models - 79 in. x 79 in. (2.0 m x 2.0 m)

Machine Overall Width and Length (Base)

20EL Models - 29 in.(W) x 47 in.(L) (74 cm x 1.19 m)

25EL Models - 29 in.(W) x 49 in.(L) (74 cm x 1.24 m)

30EL Models - 29 in.(W) x 52 in.(L) (74 cm x 1.32 m)

36EL Models - 29 in.(W) x 54.5 in.(L) (74 cm x 1.38 m)

41EL Models - 29 in.(W) x 57.5 in.(L) (74 cm x 1.46 m)

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.

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, or
as an alternate, Kendall Hyken 052 hydraulic oil, which
has an SAE viscosity of 10W-20 and a viscosity index of

152. Mobilfluid 424 and Kendall Hyken 052 are fully com­patible, and can be mixed as necessary.

When temperatures remain consistently below -20° F (-7°
C) an amount of No. 2 diesel fuel, not to exceed 20% of
system capacity, may be added to the hydraulic oil reser­voir. This diesel fuel will "thin" the hydraulic oil for easier
cold weather operation, and will almost completely dissi­pate from the hydraulic system over a several month
period of time. When cold weather is past, it may be nec­essary to drain and refill the hydraulic system to rid the
system of any remaining diesel fuel.

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 or
Kendall Hyken 052 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

( -1 8 ° C t o +9 9 ° C )

50° F to 210° F

(+10° C to +210° C)

SAE VISCOSITY

GRADE

10W

10W-20, 10W-30

20W-20

Lubrication Specifications

Table 1-2. Lubrication Specifications

KEY SPECIFICATIONS

MPG - Multipurpose Grease having a minimum dripping point

of 350° F. Excellen t water resistance and adhe sive qual­ities, and being of extreme pressure type. (Timken OK
40 poun ds 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.

1-2 – JLG Lift – 3120782

SECTION 1 - SPECIFICATIONS

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

PRESSURE

ADJUSTMENT

ADJUSTMENT

SCREW CAP

(SHOWN REMOVED)

SCREW

HYDRAULIC

OIL TANK

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 ­20EL-AC & DC

Lift Cylinder ­25EL-AC & DC

Lift Cylinder ­30EL-AC & DC

Lift Cylinder ­36EL-AC & DC

Lift Cylinder ­41EL-AC & DC

BORE

in./(cm)

1.63

(4.14)

1.63

(4.14)

1.63

(4.14)

1.63

(4.14)

1.63

(4.14)

STROKE

in./(cm)

56.50

(143.50)

56.50

(143.50)

56.50

(143.50)

83.25

(211.40)

78.25

(198.75)

ROD DIA.

in./(cm)

1.38

(3.50)

1.38

(3.50)

1.38

(3.50)

1.38

(3.50)

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.

GROUND

CONTROL

STATION

COVER

Figure 1-1. Hydraulic Pressure Setting - Adjustment

Screw Located at Base of Pump Motor

(Remove Hex Head Cap as Shown)

3120782 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

Figure 1-2. Torque Chart.

1-4 – JLG Lift – 3120782

SECTION 1 - SPECIFICATIONS

4

1

3

2

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

Table 1-4. Lubrication Intervals for Various Components

INTERVAL HOURS

ITEM COMPONTENT

Hydraulic Oil Fill To Line

1

Swivel Raceways 2 - Front Casters MPG - Pressure Gun

2

Leveling Jack

3

Screws

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

4

* Applies Only to Mast Sections with Chains.

Key to Lubricants: M PG - Multipurpose Grease

HO - Hydraulic Oil - See Table 7-1 in Service Manual.

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

2. Recommended lubricating intervals are ba sed 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). Failure t o do s o w i ll
result in incorrect oil level reading on the hydraulic reservoir.

NO/TYPE

LUBE POINTS

on Reservoir
5 Qt. (4.3 L)
Reservoir

4 - Jack Threads MPG - Brush

LUBE/METHOD

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

Spray

3

MONTHS

150 Hrs.

6

MONTHS

300 Hrs.

✔

✔

✔

1

YEAR

600 Hrs.

2

YEARS

1200 Hrs.

✔

COMMENTS

Check oil level every day.
Change hydraulic oil every
2 years.

Inspect , lubricate if drying or
rusting.

3120782 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

This page left intentionally blank

1-6 – JLG Lift – 3120782

SECTION 2 - SERVICE PROCEDURES

SECTION 2. SERVICE PROCEDURES

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness and maintain its safe
operating condition. For maximum service life and safe
operation, ensure that all the necessary inspections and
maintenance have been completed before placing the
machine into service.

Preparation, Inspection, and Maintenance

It is important to establish and conform to a comprehen­sive inspection and preventive maintenance program.
The following table outlines the periodic machine inspec­tions and maintenance recommended by JLG Industries,
Inc. Consult your national, regional, or local regulations
for further requirements for aerial work platforms. The fre­quency of inspections and maintenance must be
increased as environment, severity and frequency of
usage requires.

Pre-Start Inspection

It is the User’s or Operator’s primary responsibility to per­form a Pre-Start Inspection of the machine prior to use
daily or at each change of operator. Reference the Opera­tor’s and Safety Manual for completion procedures for the
Pre-Start Inspection. The Operator and Safety Manual
must be read in its entirety and understood prior to per­forming the Pre-Start Inspection.

Pre-Delivery Inspection and Frequent Inspection

The Pre-Delivery Inspection and Frequent Inspection shall
be performed by a qualified JLG equipment mechanic.
JLG Industries, Inc. recognizes a qualified JLG equipment
mechanic as a person who, by possession of a recog­nized degree, certificate, extensive knowledge, training, or
experience, has successfully demonstrated the ability and
proficiency to service, repair, and maintain the subject
JLG product model.

The Pre-Delivery Inspection and Frequent Inspection pro­cedures are performed in the same manner, but at differ­ent times. The Pre-Delivery Inspection shall be performed
prior to each sale, lease, or rental delivery. The Frequent
Inspection shall be accomplished for each machine in ser­vice for 3 months or 150 hours (whichever comes first);
out of service for a period of more than 3 months; or when
purchased used. The frequency of this inspection must be

increased as environment, severity and frequency of
usage requires.

Reference the JLG Pre-Delivery and Frequent Inspection
Form and the Inspection and Preventative Maintenance
Schedule for items requiring inspection during the perfor­mance of these inspections. Reference the appropriate
areas of this manual for servicing and maintenance proce­dures.

Annual Machine Inspection

The Annual Machine Inspection must be performed by a
qualified JLG equipment mechanic on an annual basis, no
later than thirteen (13) months from the date of the prior
Annual Machine Inspection. JLG Industries, Inc. recog­nizes a qualified JLG equipment mechanic as a person
who has successfully completed the JLG Service Training
School for the subject JLG product model. Reference the
machine Service and Maintenance Manual and appropri­ate JLG inspection form for performance of this inspec­tion.

Reference the JLG Annual Machine Inspection Form and
the Inspection and Preventative Maintenance Schedule for
items requiring inspection during the performance of this
inspection. Reference the appropriate areas of this man­ual for servicing and maintenance procedures.

For the purpose of receiving safety-related bulletins, it is
important that JLG Industries, Inc. has updated ownership
information for each machine. When performing each
Annual Machine Inspection, notify JLG Industries, Inc. of
the current machine ownership.

Preventative Maintenance

In conjunction with the specified inspections, mainte­nance shall be performed by a qualified JLG equipment
mechanic. JLG Industries, Inc. recognizes a qualified JLG
equipment mechanic as a person who, by possession of a
recognized degree, certificate, extensive knowledge, train­ing, or experience, has successfully demonstrated the
ability and proficiency to service, repair, and maintain the
subject JLG product model.

Reference Table 2-2, EL Model - Preventive Maintenance
& Inspection Schedule., and the appropriate areas of this
manual for servicing and maintenance procedures. The
frequency of service and maintenance must be increased
as environment, severity and frequency of usage requires.

3120782 – JLG Lift – 2-1

SECTION 2 - SERVICE PROCEDURES

Table 2-1. Inspection and Maintenance

Type Frequency

Pre-Start
Inspection

Pre-Delivery
Inspection

Frequent
Inspection

Annual
Machine
Inspection

Preventative
Maintenance

Prior to use each day; or
At each Operator change.

Prior to each sale, lease, or
rental delivery.

In service for 3 months or 150 hours, which­ever comes first; or Out of service for a
period of more than 3 months; or Pu r­chased used.

Annually, no later than 13 months from the
date of the prior inspection.

At intervals as specified in the Service and
Maintenance Manual.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Qualified JLG

Service

Qualification

Mechanic

Mechanic

Mechanic

Mechanic

Reference

Service and Maintenance Man­ual and applicable JLG inspec­tion form.

Service and Maintenance Man­ual and applicable JLG inspec­tion form.

Service and Maintenance Man­ual and applicable JLG inspec­tion form.

Service and Maintenance Man­ual

2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

(See Table 2-2.)

The preventive maintenance and inspection checks are
listed and defined in the following table. 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.

2-2 – JLG Lift – 3120782

SECTION 2 - SERVICE PROCEDURES

Table 2-2. EL Model - Preventive Maintenance & Inspection Schedule.

INTERVAL

AREA ON MACHINE

PRE-START (1)

INSPECTION

WEEKLY

PREVENTATIVE

MAINTENANCE

MAST ASSEMBLY 1

Mast Sections 2, 5
Chain Systems 14 3, 14 14, 25
Sequence Cable Systems 31, 2, 3
Support Bars 1, 2
Covers or Shields 1
Sheave Systems 1, 2 1, 2
Bearings 1, 2
Slide Pads 1, 2

PLATFORM ASSEMBLY 1
Platform 11
Guard Rails 1, 2 2
Gate 1, 5 5
Floor 2
Extension Deck Assembly 1, 5
Lanyard Anchorage Point 1

CHASSIS ASSE MBLY 1
Outrigger Beams, Sockets, and Locking P ins 1, 2, 5, 7 1, 2, 5, 7
Outrigger Screw Jacks 51, 2, 5
Tires/Wheels/Caster Systems 1, 2 1, 2
Bubble Level 1, 2, 7 1, 2, 7
Cable Reel (LiftMaster Only) 55
Winch and Winch Brake (LiftMaster Only) 1, 2, 5

FUNCTIONS/CONTROLS 1
Platform Controls 55, 6, 7
Ground Controls 5 5, 6, 24
Function Control Locks, Guards, or Detents 5 5
Function Enable System 5
Emergency Stop Switches (Ground & Platform) 5 5
Function Limit or Cutout Switch Systems
Manual Descent or Auxiliary Power 5 5

POWER SYSTEM

Batteries 19 9
Battery Fluid 11 11
Battery Charger 5

HYDRAULIC/ELECTRIC SYS TEM 1
Hydraulic Pump 9 1, 2, 9 2, 5
Hydraulic Pump Cover 1
Hydraulic Cylinder 7, 9 2, 9 2, 9
Cylinder Attachment Pins and Pin Retainers 1, 2
Hydraulic Hoses, Lines, and Fittings 9 1, 9
Hydraulic Reservoir, Cap, and Breather 5, 7 5, 7 5, 7
Hydraulic Filter

3 MONTH
PREVENTATIVE
MAINTENANCE

PRE-DELIVERY (2)
OR FREQUENT (3)

INSPECTION

ANNUAL (4)

(YEARLY)

INSPECTION

3120782 – JLG Lift – 2-3

SECTION 2 - SERVICE PROCEDURES

Table 2-2. EL Model - Preventive Maintenance & Inspection Schedule.

INTERVAL

AREA ON MACHINE

PRE-START (1)

INSPECTION

WEEKLY

PREVENTATIVE

MAINTENANCE

Hydraulic Fluid * 11 11 11 11 11
Electrical Connections 20 20
Outrigger Interlock Systems 1, 2, 5 5

GENERAL

Operator and Safety Manuals in Storage Box 21 21 21
ANSI and EMI Manuals/Handbooks Installed 21 21 21
Capacity Decals Installed, Secure, Legibl e 21 21 21
All Decals/Placards Installed, Secure, Legible 21 21 21
"Walk-Around" Inspection Performed 22
Annual Machine Inspection Due 21
No Unauthorized Modifications or Additions 21 21
All Relevant Safety Publications Incorporated 21 21, 22
General Structural Condition and Welds 2, 4 2, 4
All Fasteners, Pins, Shields, and Covers 1, 2
Grease and Lubricate to Specifications 22 22
Function Test of All Systems 22
Paint and Appearance 77
Stamp Inspection Date on Frame 22
Notify JLG of Machine Ownership 22

3 MONTH
PREVENTATIVE
MAINTENANCE

PRE-DELIVERY (2)
OR FREQUENT (3)

INSPECTION

ANNUAL (4)

(YEARLY)

INSPECTION

Footnotes:

(1) Prior to use each day; or at each Operator change

(2) Prior to each sale, lease, or delivery

(3) In service for 3 months or 150 hours; or Out of service
for 3 months or more; or Purchased used

(4) Annually, no later than 13 months from the date of the
prior inspection

Inspection and Maintenance Codes:

1. Check for proper and secure installation.

2. Visual inspection for damage, cracks, distortion, or

excessive wear.

3. Check for proper adjustment.

4. Check for cracked or broken welds.

5. Operates properly.

6. Returns to neutral or "off" position when released.

7. Clean and free of debris.

8. Interlocks function properly.

9. Check for signs of leakage.

10. Decals installed and legible.

11. Check for proper fluid level.

12. Check for chafing and proper routing.

13. Check for proper tolerances.

14. Properly lubricated.

15. Torqued to proper specification.

16. No gouges, excessive wear, or cords showing.

17. Properly inflated and seated around rim.

18. Proper and authorized components.

19. Fully charged.

20. No loose connections, corrosion, or abrasions.

21. Verify.

22. Perform.

23. Sealed properly.

24. Overrides Platform controls.

25. Inspected per Service and Maintenance Manual.

2-4 – JLG Lift – 3120782

SECTION 2 - SERVICE PROCEDURES

2.3 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.

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.

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.

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.

3120782 – JLG Lift – 2-5

SECTION 2 - SERVICE PROCEDURES

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.

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.

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 very gradually wear.
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 8-1 for
proper chain specifications and allowable stretch toler­ances. Peening and wear of chain plate edges are caused
by 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 2-3. Chain Stretch Tolerance

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

2-6 – JLG Lift – 3120782

SECTION 2 - SERVICE PROCEDURES

Tight Joints: All joints in the leaf chain should flex freely.
On leaf chain, tight joints are usually caused by rust/corro­sion, or the inside plates “walking” off the bushing. Limber
up rusty/corroded chains (after inspecting care fully) 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.

Mast Cable Inspection Procedure

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

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
improperly installed cable ends.

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

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.

3120782 – JLG Lift – 2-7

SECTION 2 - SERVICE PROCEDURES

2.4 LUBRICATION INFORMATION

Hydraulic System

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
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.

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.

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.

2-8 – JLG Lift – 3120782

SECTION 2 - SERVICE PROCEDURES

2.5 BATTERY CHARGER - ASSEMBLY AND DISASSEMBLY

General Information

DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGER
IF MACHINE IS STILL UNDER WARRANTY. OPENING THE BAT­TERY CHARGER WHILE THE MACHINE IS UNDER WARRANTY
WILL VOID THE CHARGER WARRANTY. IF UNDER WARRANTY
REQUEST A REPLACEMENT CHARGER FROM THE FACTORY.

ALSO BEFORE REPLACING ANY COMPONENT, USE THE
CHARGER MANUFACTURERS (SCR) BATTERY CHARGER MAN­UAL INCLUDED WITH THE MACHINE FOR CHECKING THE INTER­NAL AC AND DC CIRCUITS TO DETERMINE WHICH COMPONENT
HAS FAILED. COMPLETE WIRING DIAGRAMS PERTAINING TO
YOUR MODEL CHARGER ARE ALSO INCLUDED IN THE MANU­FACTURERS (SCR) BATTERY CHARGER MANUAL.

The EL Series dual AC input battery charger allows for
replacement of the following internal components. Con­sult your Illustrated Parts Manual for part numbers of
these components which are available from the JLG Parts
Department:

• Trans former

• Printed Circuit Board

• Shunt Assembly

• Interlock Relay

• SCR Rectifier

• AC Circuit Breaker

Cover Removal

5. Remove the ten (10) screws on the sides and top of

the charger cover and remove cover.

Transformer Replacement

1. Disconnect the wiring connecting the transformer to

other components within the charger assembly.

2. Remove the four nuts from the cap screws securing
the transformer brackets to the base of the charger
chassis.

3. Remove transformer.

• DC Circuit Breaker

Replacement and troubleshooting of these components
requires removal of the battery charger from it’s mounting
on the charger/battery box assembly.

Battery Charger Removal

1. If plugged in, unplug the AC voltage cord from AC

receptacle and remove the charger/battery box unit
from the machine.

2. Disconnect the + (RED) and – (BLACK) charging
wires from the charger to the battery terminals in the
lower battery compartment.

3. Remove the four (4) mounting bolts and washers
located on the back of the upper battery box sec­tion, securing the charger into the upper section.

4. Remove the charger through the front opening while
pulling the charging wires (RED/BLACK) through the
hole on the bottom of the upper battery box section.

3120782 – JLG Lift – 2-9

SECTION 2 - SERVICE PROCEDURES

Printed Circuit Board Replacement

1. Disconnect the wide wiring connector from the end

of the circuit board.

2. Remove the four (4) screw attaching the card to the
front face of the charger chassis.

3. Remove the circuit board.

AC Circuit Breaker and Voltage Selection Switch Replacement

1. Remove the wiring from the AC breaker or Voltage

Selection Switch terminals.

2. To remove the breaker or switch from the front face
of the charger, on the inside of the charger front
face, push in on the tabs located on the sides of the
breaker/switch assembly and remove the assembly
out the front of the charger

DC Circuit Breaker Replacement

1. Remove the wiring from the breaker terminals.

2. Remove the bolt, nut and washer from each side of

the breaker, remove the breaker from the housing.

2-10 – JLG Lift – 3120782

SECTION 2 - SERVICE PROCEDURES

Shunt Assembly, Varistor, and SCR Rectifier Replacement (See Illustration)

Shunt Assembly (Item #1)

1. Carefully remove the screw from the end of the

shunt assembly. The white insulator may need to be
restrained to keep it from turning while removing the
shunt assembly fasteners. Also make note of the
position of each washer, nut and wire connector
when removing for later assembly.

SCR Rectifier Replacement (Item #2)

1. Remove the wiring from the SCR Rectifier.

2. Remove the nut securing the rectifier to the insulated

aluminum chassis bracket.

3. Remove the SCR Rectifier.

1

Varistor Replacement (Item #3)

1. Remove the fasteners securing the varistor to the

aluminum angle bracket (see illustration below). One
through the rear panel of the base with a short white
spacer and one at the long white insulator attaching
the shunt assembly to the bracket.

2. Remove the varistor from it’s mount.

3

2

3120782 – JLG Lift – 2-11

SECTION 2 - SERVICE PROCEDURES

2.6 HYDRAULIC LIFT CYLINDER ­REMOVAL, INSPECTION AND REBUILD

HYDRAULIC CYLINDERS ARE DESIGNED TO HOLD HYDRAULIC
FLUID UNDER HIGH PRESSURE. BE SURE ALL APPROPRIATE
MEASURES ARE TAKEN TO RELIEVE RESIDUAL PRESSURE IN
THE CYLINDER BEFORE DISCONNECTING LINES.

Disassembly

1. Disconnect power source. (Remove the DC power

pack/charger assembly from back of mast, if so
equipped).

2. Remove ground control (pump) cover.

3. Disconnect the hydraulic lines at the pump.

4. Using suitable lifting equipment, lay machine down

horizontal onto the back of mast to allow access to
the bottom of the machine. (Preferably on an ele-

vated work surface capable of supporting the full
weight of the machine).

5. Slide (extend) the mast out the top about 2 ft. to 3 ft.
to allow access to the cylinder attach setscrew on
the attach block at the top of mast section-2.

6. Remove the cylinder attach setscrew from the attach
block on top of mast section-2. (Lowest set of
sheaves).

7. Remove the protective mast cylinder/hydraulic line
cover plate from the base frame under the mast.

NOTE: (Use a container to catch the hydraulic oil from cylin-

der and hydraulic lines in next step, discard oil).

8. Remove the hydraulic lines from the mast cylinder.

9. Remove the one (1) 5/16" bolt securing the cylinder

to the cylinder mount and the four (4) 1/2" bolts
securing the cylinder mount to the mast section-1
side rails.

NOTE: In the following step the mast cylinder mount will be

shimmed tight in the mast.

10. Remove the cylinder mast mount from the mast.

NOTE: In the f ollow ing st ep the ma st cy linder m ay be ti ght in

the cylinder attach block at the top of the mast.

11. Pull the mast cylinder out of the mast.

Cylinder Disassembly

12. Before disassembling the cylinder, clean away all

dirt and foreign substances from openings, particu­larly the head area.

NOTE: Always protect the chrome surface of the cylinder

rod during assembly and disassembly. Any damage
to this surface will require replacement of the rod.

13. Extend the rod until the piston bottoms out against
the cylinder head.

14. Compress the head retraining ring enough to allow
the the cylinder head to be removed.

15. Carefully slide the head/rod/piston assembly out of
the cylinder tube. A gentle tap on the head assembly
may be required to remove the head from the cylin­der tube.

16. Place the head/rod/piston assembly on a surface
that will not damage the chrome.

17. Remove the piston locknut and separate the piston
from the rod.

18. Slide the head off the rod from the piston end.

NOTE: When removing the old seals use only blunt tools, be

sure there are no sharp edges that may damage the
seal grooves during removal. Scratching the groove
may cause by-pass.

19. Remove and discard all old seals.

Lift Cylinder Component Inspection

Cylinder Rod

There should be no scratches or pits deep enough to
catch the fingernail. Pits that go to the base metal are
unacceptable. Scratches that catch the fingernail but are
not to the base metal, less than 0.5 inch long and primarily
in the circumferential direction are acceptable provided
they cannot cut the rod seal. Chrome should be present
over the entire surface of the rod and the lack thereof is
unacceptable. In the event that an unacceptable condition
occurs, the rod should be repaired or replaced.

Cylinder Head

Visually inspect the inside bore for scratches or polishing.
Deep scratches are unacceptable. Polishing indicates
uneven loading and when this occurs, the bore should be
checked for out-of-roundness. If out-of-roundness exceed

0.007", this is unacceptable. Check the condition of the
dynamic seals (wiper, rod seals) looking particulary for
metallic particles embedded in the seal surface. It is nor­mal to cut the static seal on the retaining ring groove upon
disassembly. Remove the rod seal, static o-ring and
backup and rod wiper. Damage to the seal grooves, par­ticularly on the sealing surfaces, is unacceptable. In the
event that an unacceptable condition occurs, the head
should be replaced.

Piston

Visually inspect the outside surface for scratches or pol­ishing. Deep scratches are unacceptable. Polishing indi-

2-12 – JLG Lift – 3120782

SECTION 2 - SERVICE PROCEDURES

LOCKNUT

(Torque

S

cates uneven loading and when this occurs, the diameter
should be checked for out-of-roundness. If out-of-round­ness exceeds 0.007", this is unacceptable. Check the con­dition of the dynamic seals and bearings looking
particularly for metallic particles embedded in the bearing
and in the piston seal surface. Remove the seals and
bearings. Damage to the seal grooves, particularly on the
sealing surfaces, is unacceptable. In the event that an
unacceptable condition occurs, the piston should be
replaced.

Tube A sse m b ly

Visually inspect the inside bore for scratches and pits.
There should be no scratches or pits deep enough to
catch the fingernail. Scratches that catch the fingernail but
are less than 0.5 inch long and primarily in the circumfer­ential direction are acceptable provided they cannot cut
the piston seal. The roughness of the bore should be
between 10 and 20 µ inches RMS. Significant variation
(greater than 8 µ inches difference) are unacceptable. In
the event that an unacceptable condition occurs, the tube
assembly should be repaired or replaced.

Cylinder Assembly

(See Figure 2-1.)

1. Rinse the inside of the tube with hydraulic fluid and
allow to drain. A high-pressure rinse followed by a
wipe with a lint-free rag is preferable. Clean all inter­nal components of any foreign material.

2. Lubricate the head and all seals with hydraulic fluid
prior to installation. Install the seal, wiper, o-ring,
back-up ring, and retraining ring to the cylinder
head.

3. Lubricate the piston and all components with
hydraulic fluid. Install the seal and wear ring to the
piston.

NOTE: Re-check that seals are not twisted or pinched and

are properly seated.

4. Place the rod on a clean table. Install the static o­ring seal into the groove on the piston end of the
rod.

5. Install the head followed by the piston onto the rod
noting the proper orientation of each component.
Torque the piston nut to 175-200 ft. lbs.

CYLINDER

TUBE

ASSEMBLY

RETAINING RING

175-200 Ft. Lb.)

GROOVE

PISTON

WEAR

RING

PISTON

SEAL

WHEN ASSEMBLING

CYLINDER

APPLY ANTI-SEIZE

COMPOUND

AROUND THE HEAD

IN THI

AREA ONLY

O-RING

O-RING

CYLINDER

HEAD

BACKUP

RING

CYLINDER

HEAD

RETAINING

RING

ROD

SEAL

CYLINDER

ROD

ROD

WIPER

Figure 2-1. Lift Cylinder Internal Component Assembly Cross-Section.

3120782 – JLG Lift – 2-13

SECTION 2 - SERVICE PROCEDURES

6. When the rod assembly is ready to be installed into
the tube, liberally apply an anti-seize lubricant to the
head outer surface, especially the static seal.

7. Next dip the entire rod assembly into hydraulic fluid
and stuff this assembly into the tube. Watch the
seals as they pass over the rod port (if visible) to be
sure they are not nicked or cut.

8. Install the head until the retaining ring seats in it’s
groove.

Installation

1. Remove the plastic plugs from the cylinder.

2. Pull rod out of cylinder approximately 3 ft.

NOTE: The following step is easier done with two people,

one to slide the cylinder into the mast, the other to
guide the rod into the cylinder block at the top of the
mast.

3. Slide the cylinder into the mast and install the rod
into the cylinder attach block.

4. Apply Loctite #222 (purple) to the setscrew securing
the lift cylinder rod to the sheave wheel anchor block
at the top of mast section-2.

6. Install the cylinder mount at the bottom of the mast
using the four (4) 1/2" bolts. Re-shim to eliminate
any side clearance to prevent any strain on the sides
of the mast when the bolts are tightened.

7. Install the one (1) 5/16" bolt, securing the mast cylin­der to the cylinder mount.

8. Connect the hydraulic fittings and lines, (new fittings
should be used).

9. Slide the mast together (stowed position) from the
top of the mast.

10. Stand machine upright on it’s base wheels.

11. Connect the hydraulic line fittings at the pump.

12. Check oil level in the hydraulic oil reservoir, add oil

to fill line, if necessary.

13. Install the ground station (pump) cover.

14. Set-up machine for operation and cycle mast (up

and down) approximately 3 ft. to 4 ft. a few times.

15. Check the hydraulic oil reservoir again, add oil to the
fill line.

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

2-14 – JLG Lift – 3120782

SECTION 2 - SERVICE PROCEDURES

2.7 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES

The EL 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 EL model line mast assemblies have been
designed with either five (5), six (6) or seven (7) mast sec­tions as shown following;

Table 2-4. EL Series Mast Component Features

Model

20EL 5Chain & Cable

25EL / 36EL 6Chain & Cable

30EL / 41EL 7Chain & Cable

Assembly procedures for all mast assemblies is basically
the same, carefully slide the mast sections together from
bottom until mast ends are even, (when sliding mast sec-

tions together be careful not to scratch the anodized sur­face in the slide pad channels). Assemble the hardware to

No. of Mast

Sections

Extend Device

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).

Mast Disassembly Procedure

(See Figure 2-2.)

NOTE: Referen ce t o ma st sec tio ns -5/-6 /-7 m ade fol low i ng i s

dependent on which model machine you are servic­ing since the 20 ft. machines use five (5) mast sec­tions, the 25 and 36 ft. models use six (6) mast
sections, the 30 and 41 ft. models use seven (7)
mast sections .

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-5/-6/-7 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. Also, remove the latch bar
assembly from BOTTOM of mast section-5/-6/-7.

OPEN RAIL

(REFERS TO OPEN RAIL

FRONT OF MAST SECTION)

CLOSED RAIL

(REFERS TO CLOSED RAIL

BACK OF MAST SECTION)

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

TOP

(REFERS TO TOP END

OF MAST SECTION -

END WITH COVER

AND SHEAVE WHEELS

ATTACHED)

BOTTOM

(REFERS TO BOTTOM END

OF MAST SECTION -

END WHICH SETS AT

MACHINES BASE FRAME)

3120782 – JLG Lift – 2-15

SECTION 2 - SERVICE PROCEDURES

Platform Section Removal (All Masts)

3. Remove cable adjust nuts from threaded ends of

cable attached to the cable anchor plate on BOT­TOM end of mast section-5/-6/-7 (short, platform
mounting section). Push threaded ends of cable
through anchor plate

4. At TOP of mast section-5/-6/-7, 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-5/-6/-7 out BOT­TOM of mast section-4/-5/-6 rails. Disassemble slide
pads, shims and cable anchor plate from mast sec­tion-5/-6/-7, if necessary.

Mast Section 6 Removal (7 Section Mast)

NOTE: Steps 6 th rou gh 10 ap ply to removal of mas t s ec tio n-

6 used on 30 & 41 ft. models which have seven (7)
mast sections. If disassembl ing a six (6) se ction 25
or 36 ft. mast, go to step 11, if disassembling a five
(5) section 20 ft. mast continue to step 17.

6. Remove cable adjust nuts from threaded ends of
cable attached to the cable anchor plate on bottom
end of mast section-6. Push threaded ends of cable
through anchor plate.

7. At top of mast section-6, pull cables out and allow to
hang loose.

8. Slide mast section-6 out TOP of mast section-5 far
enough to allow access to the cable sheave wheel
assembly.

9. Remove countersunk-flathead screws securing
cable sheave wheel assembly attach bars on both
side rails at top of mast section-6 and remove
sheave wheel assembly.

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

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

10. Carefully slide mast section-6 out BOTTOM of sec­tion-5. Remove slide pads, shims and cable anchor
plate, if necessary.

Mast Section 5 Removal (6 & 7 Section Mast)

NOTE: Steps 11 through 15 apply to removal of mast sec-

tion-5 used on 25, 30 , 36 & 4 1 ft. mo dels. If servicing
a 20 ft. mast, go to step 17.

11. Remove cable adjust nuts from threaded ends of
cable attached to the cable anchor plate on bottom

end of mast section-6. Push threaded ends of cable
through anchor plate.

12. At top of mast section-5, pull cables out and allow to
hang loose.

13. Slide mast section-5 out TOP of mast section-4 far
enough to allow access to the cable sheave wheel
assembly.

14. Remove countersunk-flathead screws securing
cable sheave wheel assembly attach bars on both
side rails at top of mast section-6 and remove
sheave wheel assembly.

NOTE: Step 15 applies to r emoval of th e cable asse mblies

used on mast section-5 of 30 & 41 ft. models. If ser­vicing a 25 or 36 ft. mast, go to step 16.

15. While mast section-5 is still extended from section-4
remove the bolts attaching the two (2) cable assem­bly anchor eyelets to the TOP of mast section-5.
Remove cables.

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

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

16. Carefully slide mast section-5 out BOTTOM of sec­tion-4. Remove slide pads, shims and cable anchor
plate, if necessary.

Mast Section 4 Removal (All Masts)

17. Remove chain adjust nuts from threaded ends of

chain attached to the chain anchor plate on BOT­TOM end of mast section-4. Push threaded ends of
cable through anchor plate.

18. At TOP of mast section-4, 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).

19. Slide mast section-4 out TOP of mast section-3 far
enough to allow access to the cable sheave wheel
assembly.

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

21. While mast section-4 is still extended from section-3
remove the bolts attaching the two (2) cable assem­bly anchor eyelets to the TOP of mast section-4.
Remove cables.

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

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

2-16 – JLG Lift – 3120782

SECTION 2 - SERVICE PROCEDURES

22. Carefully slide mast section-4 out BOTTOM of sec­tion-3. Remove slide pads, shims and chain anchor
plate, if necessary.

Mast Section 3 Removal (All Masts)

23. 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.

24. 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).

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

26. 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.

27. 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.

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

Mast Section 1 Disassembly (All Masts)

35. 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.

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

Mast disassembly should now be complete.

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

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

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

Mast Section 2 Removal (All Masts)

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

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

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

31. 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.

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

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

3120782 – JLG Lift – 2-17

SECTION 2 - SERVICE PROCEDURES

2.8 MAST ASSEMBLY

(See Figure 2-3., Figure 2-4. or Figure 2-5.)

Mast Section 1 - Assembly (All Masts)

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

2-1.) 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 (All Masts)

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.

b. 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.

c. 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.

d. 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.

8. 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.

9. 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.

10. 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 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.

11. 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.

12. 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.

13. 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).

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

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

2-18 – JLG Lift – 3120782

3

MAST

SECTION-4

SECTION 2 - SERVICE PROCEDURES

UPPER

SEQUENCE

CABLE

ASSEMBLY

MAST

SECTION-1

MAST

SECTION-5

SECTION-5

UPPER

SLIDE PAD

MOUNTING

POSITION

PRIOR

TO C#

142920

SECTION-5

UPPER

SLIDE PAD

AS OF

C# 142920

MAST

SECTION-

MAST

SECTION-2

LOWER

SEQUENCE

CABLE

ASSEMBLY

Figure 2-3. 20EL Mast Assembly Components. (5 - Section)

3120782 – JLG Lift – 2-19

SECTION 2 - SERVICE PROCEDURES

SECTION-1

SECTION-2

SECTION-3

SECTION-4

SEQUENCE

ASSEMBLY

MAST
SECTION-5

UPPER

CABLE

MAST

MAST

MAST
SECTION-6

SECTION-6

UPPER

SLIDE PAD

MOUNTING

POSITION

PRIOR
TO C#

142920

SECTION-6

UPPER

SLIDE PAD

AS OF

C# 142920

MAST

MAST

LOWER

SEQUENCE

CABLE

ASSEMBLY

Figure 2-4. 25EL & 36EL Mast Assembly Components. (6 - Section)

2-20 – JLG Lift – 3120782

SECTION 2 - SERVICE PROCEDURES

MAST

SECTION-5

SECTION-4

SECTION-3

SECTION-2

SECTION-1

SEQUENCE

ASSEMBLY

SEQUENCE

ASSEMBLY

UPPER

CABLE

MAST

MAST

SECTION-7

IMPORTANT

UPPER

SLIDE PAD

MOUNTING

POSITION

PRIOR

TO C#

142920

41AM

30AM

MAST

MAST

SECTION-6

MAST

MAST

LOWER

CABLE

SECTION-7

UPPER

SLIDE PAD

AS OF

C# 142920

Figure 2-5. 30EL & 41EL Mast Assembly Components. (7 - Section)

3120782 – JLG Lift – 2-21

SECTION 2 - SERVICE PROCEDURES

MAST SECTIONS

SECTION 2

SECTION 1

HYD.

CYL.
LIFTS
HERE

CHAIN ASSY.

SECTION 5

SECTION 4

SECTION 3

CHAIN ASSY.

CABLE ASSY.

CHAIN / CABLE ASSY. ANCHOR PLATES

Figure 2-6. Mast Chain/Cable Routing Diagram.

2-22 – JLG Lift – 3120782

SECTION 2 - SERVICE PROCEDURES

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.

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

Mast Section 3 - Assembly (All Masts)

NOTE: When sliding mast sections together, be careful not

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

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

18. 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.

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

20. 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.

21. 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.

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

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

and slide onto sheave pin.

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.

23. 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.

24. 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.

25. 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.

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

27. 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.

28. 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.

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

Mast Section 4 - Assembly (All Masts)

NOTE: When sliding mast sections together, be careful not

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

3120782 – JLG Lift – 2-23

SECTION 2 - SERVICE PROCEDURES

30. Locate mast section-4, carefully slide section-4
closed rail into section-3 open rail. Slide sections
together until ends are even.

31. Locate one (1) of the chain/cable anchor plates (one
with two threaded holes vertically aligned in center of
bracket). Attach through inner (vertical) set of holes

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

32. Slide mast section-4 out the top of mast section-3 so
the chain/cable anchor plate on bottom of mast sec­tion-4 is easily accessible at top end of mast section-

3. Rest the top end of mast section-4 on a support
while performing next step.

33. Insert threaded ends of chain assembly (attached to
anchor block on top mast section-2) through the

chain/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.

NOTE: Step 34 applies to 25 and 36 ft., six (6) section masts

and 30 & 41 ft., s even (7) s ectio n masts only. For five
(5) section 20 ft. masts skip to step 35.

34. While mast section-4 is still extended from section-3;
locate two cable assemblies. Attach the eyelet
anchor end of each cable to the inside set of holes
near top of mast section-4 using 3/8"-16UNC x 1-1/4"
long hex head bolts, nuts and flatwashers. Place a
flatwasher under bolt head and nut.

35. While mast section-4 is still extended from section-3,
assemble cable sheaves to top of mast section-4 as
follows;

a. Locate the wide tube spacer and slide onto

sheave pin.

b. Slide two (2) cable sheave wheels onto sheave

pin, one each end of sheave pin to outside of
tube spacer.

c. Place two (2) large flat washers, one each end of

sheave pin to outside of cable sheave wheels.

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

end of sheave pin to outside of large flatwash­ers.

e. Holding complete cable sheave wheel assem-

bly, slide assembly into top of mast section-4
and align threaded holes in sheave pin attach
bars with holes in mast rails.

f. Attach to top of mast section-4 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.

36. Carefully slide mast section-4 back into section-3
until ends are even. Check to make sure chain
assembly (narrow chains) are seating properly in
chain sheave wheels attached to top of mast sec­tion-3.

37. Insert slide pads into the top end mast rails between
section-3 and -4, (one on each side of the mast),
with beveled surface facing inward towards section-

4.

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.

38. 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-3 and into the
slide pad inserts. Thread in enough to hold pad in
place.

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

40. Insert slide pads into the bottom end mast rails
between section-3 and -4, (one on each side of the
mast), with beveled surface facing out towards sec­tion-3.

41. 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-4 and into
the slide pad inserts. Thread in enough to hold pad
in place.

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

Mast Section 5 - Assembly (25/30/36/41 ft. Masts)

NOTE: Steps 43 thru 56 ap ply to si x (6) s ec tio n 2 5 a nd 36 ft.

and seven (7) section 30 and 41 ft. masts only. For
five (5) section 20 ft. masts continue to step 70.

NOTE: When sliding mast sections together, be careful not

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

43. Locate mast section-5, carefully slide section-5
closed rail into section-4 open rail. Slide sections
together until ends are even.

44. Locate one (1) of the chain/cable anchor plates (one
with threaded holes horizontally aligned to outside
edges of bracket). Attach through outer set of holes
in bottom of mast section-5 with two (2) 1/4"-20UNC

2-24 – JLG Lift – 3120782

SECTION 2 - SERVICE PROCEDURES

x 3/4" long bolts, place a flatwasher under head of
each bolt.

45. Slide mast section-5 out the top of mast section-4 so
the chain/cable anchor plate on bottom of mast sec­tion-5 is easily accessible near top end of mast sec­tion-4. Rest the top end of mast section-5 on a
support while performing next step.

46. Insert threaded ends of cable assembly (attached to
top of mast section-3) through the chain/cable

anchor plate located on bottom of extended mast
section-5. Loosely thread two (2) 3/8"-16UNC nuts
onto stud threads on each chain. Chains will be
adjusted later in assembly.

NOTE: When sliding mast sections together, be careful not

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

47. Slide mast section-5 back into section-4 except for a
foot or two of length.

NOTE: Steps 48 applies to seven (7) section 30 and 41 ft.

masts only for six (6) section 25 and 36 ft. masts
continue to step 49.

48. Locate two cable assemblies. Attach the eyelet
anchor end of each cable to the two inside holes
near top of mast section-5 using 3/8"-16UNC x 1-1/4"
long hex head bolts, nuts and flatwashers. Place a
flatwasher under bolt head and nut.

49. While mast section-5 is still extended from section-4,
assemble cable sheaves to top of mast section-5 as
follows;

a. Locate remaining sheave pin. Slide two (2) cable

sheave wheels onto sheave pin and center.

b. Place two (2) short spacer tubes on sheave pin,

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

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

each end of sheave pin to outside of short
spacer tubes.

d. Holding complete cable sheave wheel assem-

bly, slide assembly into top of mast section-5
and align threaded holes in sheave pin attach
bars with holes in mast rails.

e. Attach to top of mast section-5 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.

50. Carefully slide mast section-5 back into section-4
until ends are even. Check to make sure cable set
from top of section-3 is seating properly in cable

sheave wheels attached to top of mast section-4.

(Mast sections-2, -3 and -4 may need to be
restrained to keep their slide pads from pushing out
the bottom of mast sections-1, -2 and -3).

51. Insert slide pads into the top end mast rails between
section-4 and -5, (one on each side of the mast),
with beveled surface facing inward towards section-

5.

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.

52. 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-4 and into the
slide pad inserts. Thread in enough to hold pad in
place.

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

54. Insert slide pads into the bottom end mast rails
between section-4 and -5, (one on each side of the
mast), with beveled surface facing out towards sec­tion-4.

55. 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-4 and into
the slide pad inserts. Thread in enough to hold pad
in place.

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

Mast Section 6 - Assembly (30/41 ft. Masts)

NOTE: Steps 57 thru 69 install section-6 to a seven (7) sec-

tion 30 and 41 ft. mast. If assembling a six (6) sec­tion 25 or 36 ft. mast, skip to step 70.

57. Locate mast section-6, carefully slide section-6
closed rail into section-5 open rail. Slide sections
together until ends are even.

58. Locate one (1) of the chain/cable anchor plates (one
with threaded holes horizontally aligned to outside
edges of bracket). Attach through outer set of holes

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

59. Slide mast section-6 out the top of mast section-5 so
the chain/cable anchor plate on bottom of mast sec­tion-6 is easily accessible near top end of mast sec­tion-5. Rest the top end of mast section-6 on a
support while performing next step.

3120782 – JLG Lift – 2-25

SECTION 2 - SERVICE PROCEDURES

60. Insert threaded ends of cable assembly (attached to
top of mast section-4) through the chain/cable

anchor plate located on bottom of extended mast
section-6. Loosely thread two (2) 3/8"-16UNC nuts
onto stud threads on each chain. Chains will be
adjusted later in assembly.

61. Slide mast section-6 back into section-5 except for a
foot or two of length.

62. While mast section-6 is still extended from section-5,
assemble cable sheaves to top of mast section-6 as
follows;

a. Locate remaining sheave pin. Slide two (2) cable

sheave wheels onto sheave pin and center.

b. Place two (2) short spacer tubes on sheave pin,

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

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

each end of sheave pin to outside of short
spacer tubes.

d. Holding complete cable sheave wheel assem-

bly, slide assembly into top of mast section-6
and align threaded holes in sheave pin attach
bars with holes in mast rails.

e. Attach to top of mast section-6 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.

63. Carefully slide mast section-6 back into section-5
until ends are even. Check to make sure cable set
from top of section-4 is seating properly in cable
sheave wheels attached to top of mast section-5.

(Mast sections-3, -4 and -5 may need to be
restrained to keep their slide pads from pushing out
the bottom of mast sections-2, -3 and -4).

64. Insert slide pads into the top end mast rails between
section-5 and -6, (one on each side of the mast),
with beveled surface facing inward towards section-

6.

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.

65. 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-5 and into the
slide pad inserts. Thread in enough to hold pad in
place.

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

67. Insert slide pads into the bottom end mast rails
between section-5 and -6, (one on each side of the
mast), with beveled surface facing out towards sec­tion-5.

68. 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-4 and into
the slide pad inserts. Thread in enough to hold pad
in place.

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

Platform Mounting Section - Assy. (All Masts)

NOTE: Referen ce t o ma st sec tio ns -5/-6 /-7 m ade fol low i ng i s

dependent on which model machine you are servic­ing since the 20 ft. machines use five (5) mast sec­tions, the 25 and 36 ft. models use six (6) mast
sections, the 30 and 41 ft. models use seven (7)
mast sections .

70. Locate the remaing mast section-5/-6/-7 (platform
mounting - mast section). Lay mast section on flat

stable surface.

71. 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-5/-6/-7 slide pads
may need to be assembled/disassembled several
times in order to determine the correct shim stock
required for proper fit.

72. Complete the following steps to determine shim
stock thickness required for section-5/-6/-7;

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

2-26 – JLG Lift – 3120782

SECTION 2 - SERVICE PROCEDURES

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

PRIOR TO C# 142920 THE EL MAST INSTALLED TWO SHORT
SLIDE PADS ON EACH SIDE OF THE PLATFORM MOUNTING
MAST SECTION. AS OF C# 142920 A LONGER SINGLE PAD IS
INSTALLED ON EACH SIDE.
ON MACHINES PRIOR TO C# 142920 THE 41EL MOUNTS THE
(SHORT) UPPER SLIDE PAD IN THE UPPER SET OF SLIDE PAD
MOUNTING HOLES. THE 20EL, 25EL, 30EL AND 36EL MACHINES
MOUNT THE UPPER SLIDE PAD IN THE LOWER SET OF SLIDE
PAD MOUNTING HOLES. (SEE FIGURE 2-5.)

d. Carefully thread the slide pad mounting bolts

with flatwashers through slide pads and shim
stock into threads in mast section-5/-6/-7. Be
certain there are no air gaps between shims,
shim and mast or shim and slide pad when tight­ened.

NOTE: Mast section-5/-6/-7 into section-4/-5/-6 fit should be

very snug but still be able to be pushed together by
hand. If too tight, remove section-5/-6/-7, disassem­ble slide pad and reduce thickness of shim stock.

e. Begin sliding top of mast section-5/-6/-7 with

closed rail down engaging the slide pads into
slide pad channels at bottom of mast section-4/­5/-6’s open rail. Continue to push section-5/-6/-7
into section-4/-5/-6 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.

73. Slide mast section-5/-6/-7 to top of section-4/-5/-6.

74. Insert threaded ends of cable assembly (attached to

top of mast section-3/-4/-5) through the cable anchor
plate located on bottom of extended mast section-5/

-6/-7. Loosely thread two (2) 3/8"-16UNC nuts onto
stud threads on each chain. Chains will be adjusted
later in assembly.

75. Slide mast section-5/-6/-7 back into mast section-4/­5/-6 until bottom ends of masts are even. Check to
make sure cable set attached to top of section-3/-4/­5 is seating properly in cable sheave wheels
attached to top of mast section-4/-5/-6. (Mast sec-

tions-2, -3, -4 and -5 may need to be restrained to
keep their slide pads from pushing out the bottom of
mast sections-1, -2, -3, -4 and -5).

76. 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.

77. Assemble the latch bar to mast section-5/-6/-7, 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.

3120782 – JLG Lift – 2-27

SECTION 2 - SERVICE PROCEDURES

2.9 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).

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.

2-28 – JLG Lift – 3120782

SECTION 2 - SERVICE PROCEDURES

S

p

2.10 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. Also to step each front mast sec­tion up approximately 1/4 in. (6.5mm) from the section
behind it to allow clearance for the individual mast section
covers.

MAST SIDE PROFILE

STEP APPROXIMATELY

1/4 in. (6.5mm)

CHECK IF OVERALL HEIGHT

OF MACHINE FROM

FLOOR TO TOP OF MAST

IS WITHIN SPECIFICATION

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 obtain the 1/4 in. (6.5mm) step
for mast sections-3 and up. (See Figure 2-7.)

MAST CHAIN/CABLE ADJUSTER

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

chain adjustment

is complete, before
tightening the jam nut
against the adjust nut,

ply Loctite #242 to the

a

threads under the jam nut.

.

CHAIN/CABLE

ANCHOR PLATE

ADJUST NUT

JAM NUT

THREADED

CHAIN/CABLE

END

Figure 2-7. Mast Chain/Cable/Sequence Cable Adjustment Components. (Typical)

3120782 – JLG Lift – 2-29

SECTION 2 - SERVICE PROCEDURES

NOTE: Mast sect i on-1 is fix ed to the ba se and m as t sec tio n-

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. To adjust, 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-

7. 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 2-7.

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

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.

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.

2.11 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 2-7., adjust mast
sections to proper height if necessary.

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.

2-30 – JLG Lift – 3120782

SECTION 2 - SERVICE PROCEDURES

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.

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.

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.

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.

3120782 – JLG Lift – 2-31

SECTION 2 - SERVICE PROCEDURES

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.)

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 2.10, MAST CHAINS/
CABLES AND SEQUENCING CABLES ADJUST­MENT.

2-32 – JLG Lift – 3120782

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 HYDRAULIC CIRCUIT CHECKS

(See Figure 3-2.)

The first reference for improper function of a 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

3-2. HYDRAULIC Schematic at the end of this sec­tion. For ELECTRICAL Diagrams refer to Figures 3-

3., 3-4. & 3-5. also at the end of this chapter.

3120782 – JLG Lift – 3-1

SECTION 3 - TROUBLESHOOTING

Table 3-1. AC Unit - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Outrigger LED light does not turn on.

Outriggers are not properly inserted in
outrigger sockets.

Power source is OFF. Check power source.

Fuse(s) blown. Check all insulating grommets on

Check for loose wire(s) on contactor
screws under outrigger sockets (caus­ing an open circuit).

Contactor damaged. Replace contactor.

LED burnt out. Replace LED.

Pull pin on outrigger socket is dam­aged.

Platform does not rise when the four LED’s are ON and motor does not start.

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

Control relay not functioning. Replace control relay.

Motor start relay not functioning. Replace motor start relay.

Unit wiring not properly grounded. Check all grounds in the wiring.

Unit lowers by itself.

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.

Unit leaking hydraulic oil.

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.

Unit lowers very slowly.

Flow control valve not functioning. Replace flow control valve.

Check all outriggers for proper instal­lation in outrigger sockets

inter-lock contactors in base frame
outrigger sockets and contactor
plates on outrigger beams. Replace
damaged grommet(s) and replace
blown fuse.

Properly reinstall wire to contactor
screw per Figure 3-1. and instructions
in Section 3.4, Outrigger Interlock
Contacts.

Replace pull pin.

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

Tighten hydraulic hose and/or fittings.

Replace Lift DOWN solenoid valve.

Replace breather cap on tank.

3-2 – JLG Lift – 3120782

Table 3-2. DC Unit - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Outrigger LED light does not turn on.

Outriggers are not properly inserted in
outrigger sockets.

Power source is OFF. Check power source.

Fuse(s) blown. Check all insulating grommets on

Check for loose wire(s) on contactor
screws under outrigger sockets (caus­ing an open circuit).

Contactor damaged. Replace contactor.

LED burnt out. Replace LED.

Pull pin on outrigger socket is dam­aged.

Platform does not rise when the four LED’s are ON and motor does not start.

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

Control relay not functioning. Replace control relay.

Motor start relay not functioning. Replace motor start relay.

Unit wiring not properly grounded. Check all grounds in the wiring.

Unit lowers by itself.

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.

Unit leaking hydraulic oil.

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.

Unit lowers very slowly.

Flow control valve not functioning. Replace flow control valve.

SECTION 3 - TROUBLESHOOTING

Check all outriggers for proper instal­lation in outrigger sockets

inter-lock contactors in base frame
outrigger sockets and contactor
plates on outrigger beams. Replace
damaged grommet(s) and replace
blown fuse.

Properly reinstall wire to contactor
screw per Figure 3-1. and instructions
in Section 3.4, Outrigger Interlock
Contacts."

Replace pull pin.

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

Tighten hydraulic hose and/or fittings.

Replace Lift DOWN solenoid valve.

Replace breather cap on tank.

3120782 – JLG Lift – 3-3

SECTION 3 - TROUBLESHOOTING

3.4 OUTRIGGER INTERLOCK CONTACTS

Outrigger Socket and Outrigger Beam ­Interlock Contacts

It is very important that the outrigger interlock contacts
located on the bottom surface inside the outrigger sockets
of the base frame, and the contactor plate on the bottom
of each outrigger beam are installed correctly. These parts
when installed properly will be insulated from (–) negative
ground. Read the following steps and see Figure 3-1. for
correct installation. Also see Troubleshooting Tables 3-1 &
3-2. for any reference to possible problems with interlock
contacts.

Outrigger Socket - Contactor Screw Mounting Instructions

(See Figure 3-1.)

ORIGINAL DESIGN

1. Install insulating grommets into holes (on the socket

floor) inside of outrigger sockets in base frame.

2. Assemble two (2) #8-32UNC x 5/8" long contactor
screws with two (2) #8 nylon washers under head
and insert screw through insulating grommet as
shown in Figure 9-1.

3. Install one (1) #8 nylon washer onto contactor
screw threads against insulating grommet.

4. Apply Loctite #242 to screw threads.

5. Install one (1) standard #8 brass nut and thread in

against nylon washer until insulating grommet just
starts to compress. If necessary tighten nut further
until top of contactor screw head measures 0.212"
off floor of outrigger socket. (See Figure 3-1.)

6. Install wire end eyelet onto threaded end against
previously installed brass nut.

7. Install second standard brass nut and thread tight
against wire end eyelet.

8. While holding first brass nut, jam (tighten) second
brass nut against wire end eyelet.

5/2001 - DESIGN

1. Install an insulating bushing into the holes (on the

socket floor) inside of outrigger sockets in base
frame.

2. Place one (1) #8-32UNC x 5/8" long contactor screw
through each insulating grommet as shown in Fig­ure 3-1.

3. Install two (2) #8 nylon washers onto contactor
screw threads against insulating grommet, on the
underside of the outrigger socket.

4. Apply Loctite #242 to screw threads.

5. Install one (1) standard #8 brass nut and thread in

against nylon washer until insulating grommet just
starts to compress.

6. Install wire end eyelet onto threaded end against
previously installed brass nut.

7. Install second standard brass nut and thread tight
against wire end eyelet.

8. While holding first brass nut, jam (tighten) second
brass nut against wire end eyelet.

Outrigger Beam - Interlock Contactor Plate Mounting Instructions

ORIGINAL DESIGN

(See Figure 3-1.)

1. Assemble insulating grommets into the screw holes
in outrigger beam.

2. Locate contactor plate and insert two (2) brass #8 ­32UNC x 3/4" long countersunk flathead screws
through the contactor plate and install two (2) nylon
washers on each screw against contactor plate.

3. On outside of outrigger beam slide threads of brass
screws (of contactor plate assembly) through insu-
lating grommets in outrigger beams until nylon
washers rest against grommets and hold in place if
necessary.

4. Install one (1) nylon washer on each screw inside of
outrigger beam, against insulating grommet.

5. Thread a brass #8 - 32UNC locknut onto each
screw inside outrigger beam, tighten screws until
.175" height exists between bottom of plate and bot­tom most edge of outrigger beam. (See Figure 3-1.)

5/2001 - DESIGN

(See Figure 3-1.)

1. Assemble an insulating bushing into each of the
screw holes in the floor of the outrigger beam.

2. Locate the contactor plate and insert two (2) brass
#8 - 32UNC x 3/4" long countersunk flathead screws
through the contactor plate.

3. Install one (1) o-ring on one screw and stack two (2)
on the other screw, slide o-rings in against contactor
plate.

4. On the bottom of the outrigger beam slide the
threads of brass screws (with o-rings and contactor
plate assembly) through the insulating bushings.
Install the screw with two (2) o-rings towards jack
end of outrigger beam. Hold in place if necessary.

3-4 – JLG Lift – 3120782

(USE TO ADJUST PLATE

ORIGINAL DESIGN

OUTRIGGER SOCKET

OUTRIGGER SOCKET

ROUND HEAD SCREW

INSULATOR BUSHING

APPLY LOCTITE #242

S

APPLY LOCTITE #222

SECTION 3 - TROUBLESHOOTING

TYPICAL

SAFETY DETENT

(BUTTON HEAD SCREW)

ARRANGEMENT
ON AM MODELS

(SEE SUB-SECTION

BELOW - "SAFETY

DETENT SCREWS")

OUTRIGGER

BEAM ASSEMBLY

CONTACTOR SCREW

HEIGHT ADJ.

FLOOR OF

OUTRIGGER SOCKET

0.175"

0.212"

RELAY WIRE &

ATTACHING EYELET

5/2001 - DESIGN

PLATE HEIGHT

ADJUSTMENT

BRASS COUNTERSUNK

FLAT HEAD SCREW

BRASS LOCKNUT

HEIGHT WHEN TIGHTENING)

NYLON WASHER

INSULATING GROMMET

NYLON WASHERS

OUTRIGGER BEAM

CONTACTOR PLATE

O/R SOCKET

CONTACTOR SCREW HEAD

NYLON WASHERS

INSULATING GROMMET

NYLON WASHER

STANDARD BRASS NUTS

APPLY LOCTITE #242

TO THREADS

OUTRIGGER BEAM

JACK END OF

OUTRIGGER BEAM

(FLOOR)

OPEN END OF

NYLON

WASHERS

ACORN NUT

TO THREAD

BRASS

FLAT HEAD SCREW

INSULATOR

BUSHING

O-RINGS

TO THREADS

CONTACTOR

PLATE

NYLON WASHERS

NUT

Figure 3-1. Outrigger Socket Contactor Heads and Outrigger Beam - Contactor Plate Mounting Hardware

(ORIGINAL AND 5/2001 - DESIGN).

3120782 – JLG Lift – 3-5

SECTION 3 - TROUBLESHOOTING

5. On the inside of the outrigger beam, install two
nylon washers on the screw with the two (2) o-rings
installed (one towards jack end) and three (3) nylon
washers on the the other screw (towards open end
of beam).

6. Coat the threads of the screws with Loctite #222
and thread the steel acorn nuts onto each screw.
Hold the acorn nuts and tighten the screws using a
cordless screw driver set at the #1 torque setting.

Detent Screws

(See Figure 3-1.)

OUTRIGGER BEAMS are manufactured with a series of
holes drilled around the CONTACTOR PLATE assembly.

OUTRIGGER SOCKETS are equipped with button head
screws (detent screws) mounted around the CONTAC­TOR SCREW HEADS on the floor of the outrigger socket.
The detent screws must align with the holes in the outrig­ger socket before the contactor plate on the outrigger
beam, and the contactor screw heads in the bottom of the
outrigger socket can make contact to complete the inter­lock circuit.

The purpose of this design is to assure the proper size
outrigger beams are used with their specific EL model to
assure machine stability, i.e. the shorter outrigger beams
of the 20EL, 25EL and 30EL models cannot be mistakenly
used on higher reaching 36EL or 41EL models.

3-6 – JLG Lift – 3120782

SECTION 3 - TROUBLESHOOTING

2792491_A

Figure 3-2. Hydraulic Schematic. (EL Series) (2792491_A)

3120782 – JLG Lift – 3-7

SECTION 3 - TROUBLESHOOTING

4933203_C

Figure 3-3. Electrical Diagram. (EL Series - 12v-DC)

3-8 – JLG Lift – 3120782

SECTION 3 - TROUBLESHOOTING

4933203_C

Figure 3-3. Electrical Diagram. (EL Series - 12v-DC)

3120782 – JLG Lift – 3-9

SECTION 3 - TROUBLESHOOTING

4933204_H

Figure 3-4. Electrical Diagram. (EL Series - 120V-AC)

3-10 – JLG Lift – 3120782

SECTION 3 - TROUBLESHOOTING

4933204_H

Figure 3-4. Electrical Diagram. (EL Series - 120V-AC)

3120782 – JLG Lift – 3-11

SECTION 3 - TROUBLESHOOTING

4933205_H

Figure 3-5. Electrical Diagram. (EL Series - 240V-AC)

3-12 – JLG Lift – 3120782

SECTION 3 - TROUBLESHOOTING

4933205_H

Figure 3-5. Electrical Diagram. (EL Series - 240V-AC)

3120782 – JLG Lift – 3-13

SECTION 3 - TROUBLESHOOTING

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3-14 – JLG Lift – 3120782