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