Jlg 41EL Parts Manual User Manual

Illustrated Parts ManualModels20EL25EL30EL36EL41ELP/N - 3120783November 11, 2004

1-4 3120783SECTION 1 BASESECTION1BASE36 4740434 Washer, Nyl

8-2 3120783SECTION 8 DECALSSECTION8DECALSFIGURE 8-1.DECALS

3120783 8-3SECTION 8 DECALSSECTION8DECALSFIGURE 8-1. DECALS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0258499 DECAL INSTALLATION

8-4 3120783SECTION 8 DECALSSECTION8DECALSFIGURE 8-1. DECAL

3120783 9-1SECTION9RECOMMENDEDSERVICEPARTSSTOCKSECTION 9 RECOMMENDED SERVICE PARTS STOCKEL SERIESThe following list will service fleets of machines

9-2 3120783SECTION 9 RECOMMENDED SERVICE PARTS SECTION9RECOMME

3120783 10-1SECTION10SPECIALOPTIONSSECTION 10 SPECIAL OPTIONSNote: This list is to accomodate machines ordered with special equipment. Options may

10-2

3120783 1INDEXPART NUMBER INDEXMODEL 20/25/30/36/41ELP/N PAGE0100001 . . . . . . 1-50100011 . . . . . . 1-30100011 . . . . . . 1-40100011 . . . . .

2 3120783INDEXPART NUMBER INDEXMODEL 20/25/30/36/41EL0741606 . . . . .3-110741606 . . . . . .3-30741606 . . . . . .3-70741618 . . . . .3-1107508

3120783 3INDEXPART NUMBER INDEXMODEL 20/25/30/36/41EL2901605 . . . . . 3-132901606 . . . . . . 3-92901607 . . . . . 3-132901657 . . . . . . 8-329201

3120783 1-5SECTION1BASESECTION 1 BASE114 3900193 Screw, Countersunk #8-32NC x 3/4” 2115 4280291 Pad, Contact 1116 Beam, Outrigger Options: 14567601 20

4 3120783INDEXPART NUMBER INDEXMODEL 20/25/30/36/41EL3900200 . . . . .2-273900202 . . . . . .4-33900203 . . . . . .4-33900204 . . . . .4-1339002

3120783 5INDEXPART NUMBER INDEXMODEL 20/25/30/36/41EL4751400 . . . . . 3-174751400 . . . . . 3-184751400 . . . . . . 4-34751500 . . . . . 2-13475150

6 3120783INDEXPART NUMBER INDEXMODEL 20/25/30/36/41EL7020084 . . . . . .1-67020084 . . . . .3-177020084 . . . . .3-177020084 . . . . .3-18702008

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Fax: (717) 485-6417JLG Ind

1-6 3120783SECTION 1 BASESECTION1BASEFRONT WHEEL ASSEMBLIES

3120783 1-7SECTION1BASESECTION 1 BASEFIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1-8 3120783SECTION 1 BASESECTION1BASEFIGURE 1-2. TILTBACK I

3120783 1-9SECTION1BASESECTION 1 BASEFIGURE 1-2. TILTBACK INSTALLATION (36EL/41EL)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0258406 TILTBACK

1-10 3120783SECTION 1 BASESECTION1BASEFIGURE 1-2. TILTBACK

3120783 2-1SECTION2CONTROLSSECTION 2 CONTROLSTABLE OF CONTENTSFIGURE DESCRIPTION PAGE2-1 AC POWER COMPONENTS INSTALLATIONS . . . . . . . . . . . . . .

2-2 3120783SECTION 2 CONTROLSSECTION2CONTROLSFIGURE 2-1. AC PO

3120783 2-3SECTION 2 CONTROLSSECTION2CONTROLS.FIGURE 2-1. AC POWER COMPONENTS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.POWERPACK

2-4 3120783SECTION 2 CONTROLSSECTION2CONTROLS0641608 Bolt 3/8”

3120783 2-5SECTION 2 CONTROLSSECTION2CONTROLSFIGURE 2-1. AC POWER COMPONENTS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2-6 3120783SECTION 2 CONTROLSSECTION2CONTROLSFIGURE 2-2. AC JU

3120783 2-7SECTION 2 CONTROLSSECTION2CONTROLS.FIGURE 2-2. AC JUNCTION BOX ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.JUNCTION BOX ASSE

2-8 3120783SECTION 2 CONTROLSSECTION2CONTROLSFIGURE 2-3. AC MO

3120783 2-9SECTION 2 CONTROLSSECTION2CONTROLS.FIGURE 2-3. AC MOTOR/PUMP ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.MOTOR/PUMP ASSEMBLY

2-10 3120783SECTION 2 CONTROLSSECTION2CONTROLS27 Tank Options:

3120783 2-11SECTION 2 CONTROLSSECTION2CONTROLSFIGURE 2-3. AC MOTOR/PUMP ASSEMBLY (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2-12 3120783SECTION 2 CONTROLSSECTION2CONTROLSFIGURE 2-4. DC P

3120783 2-13SECTION 2 CONTROLSSECTION2CONTROLS.FIGURE 2-4. DC POWER COMPONENTS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.POWER PA

REVISION LOG3120783 AMay 10, 1999 - Original Issue Of ManualNovember 15, 1999 - Revised (Manual edited to 0010555 Revision 19)June 30, 2000 - Revised

2-14 3120783SECTION 2 CONTROLSSECTION2CONTROLS23 0641404 Bolt

3120783 2-15SECTION 2 CONTROLSSECTION2CONTROLS0271373 FLOOR BRAKE ALARM INSTALLATION Ref. A401 0100011 Loctite #242 (Not Shown) A/R402 0140022 Alarm,

2-16 3120783SECTION 2 CONTROLSSECTION2CONTROLSFIGURE 2-5. DC P

3120783 2-17SECTION 2 CONTROLSSECTION2CONTROLS.FIGURE 2-5. DC POWER PACK INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0400223 BATTER

2-18 3120783SECTION 2 CONTROLSSECTION2CONTROLSFIGURE 2-6. BATT

3120783 2-19SECTION 2 CONTROLSSECTION2CONTROLS.FIGURE 2-6. BATTERY CHARGER ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0400176 BATTERY

2-20 3120783SECTION 2 CONTROLSSECTION2CONTROLSFIGURE 2-7. DC M

3120783 2-21SECTION 2 CONTROLSSECTION2CONTROLS.FIGURE 2-7. DC MOTOR/PUMP ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.DC MOTOR/PUMP ASSE

2-22 3120783SECTION 2 CONTROLSSECTION2CONTROLS37 Tube, Return

3120783 2-23SECTION 2 CONTROLSSECTION2CONTROLSFIGURE 2-7. DC MOTOR/PUMP ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

REVISION LOGB 3120783

2-24 3120783SECTION 2 CONTROLSSECTION2CONTROLSFIGURE 2-8. CABL

3120783 2-25SECTION 2 CONTROLSSECTION2CONTROLS.FIGURE 2-8. CABLES AND CONTROLS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.CABLES A

2-26 3120783SECTION 2 CONTROLSSECTION2CONTROLS30 4751500 Flatw

3120783 2-27SECTION 2 CONTROLSSECTION2CONTROLS30EL (DC Machines)36.5ft/11.1m30EL (AC Machines)37.5ft/11.4m36EL (DC Machines)29ft/8.8m36EL (AC Machines

2-28 3120783SECTION 2 CONTROLSSECTION2CONTROLS0258482 AUXILIAR

3120783 2-29SECTION 2 CONTROLSSECTION2CONTROLS1060565 16/4 (Retractile) (25EL/36EL) .5ft/.15m306 Clamp, Hose Options:1320149 (20EL/30EL/41EL) (Not Sho

2-30 3120783SECTION 2 CONTROLSSECTION2CONTROLSFIGURE 2-8. CAB

3120783 3-1SECTION3MASTSECTION 3 MASTTABLE OF CONTENTSFIGURE DESCRIPTION PAGE3-1 MAST ASSEMBLY - 20EL . . . . . . . . . . . . . . . . . . . . . . . .

3-2 3120783SECTION 3 MASTSECTION3MASTFIGURE 3-1. MAST ASSEMB

3120783 3-3SECTION 3 MASTSECTION3MAST.FIGURE 3-1. MAST ASSEMBLY - 20EL FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.MAST ASSEMBLY - 20EL OPTIONS

3120783 iFIGURE NO. TITLE PAGE NO.TABLE OF CONTENTSSECTION 1 - BASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4 3120783SECTION 3 MASTSECTION3MAST38 3580217 Sheave, Cabl

3120783 3-5SECTION 3 MASTSECTION3MAST1260329 CHAIN ASSEMBLY - #466 CHAIN Ref. C101 0100062 Loctite #RC/640 (Not Shown) A/R102 Block Options: 10561150

3-6 3120783SECTION 3 MASTSECTION3MASTFIGURE 3-2. MAST ASSEMB

3120783 3-7SECTION 3 MASTSECTION3MAST.FIGURE 3-2. MAST ASSEMBLY - 25EL & 36ELFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.MAST ASSEMBLIES OP

3-8 3120783SECTION 3 MASTSECTION3MAST27 Channel, Mast #6 Opt

3120783 3-9SECTION 3 MASTSECTION3MAST62 4712600 Flatwasher, 1” Narrow 1463 4740414 Cup Washer 864 4750800 Flatwasher, 8” Wide 1065 4751600 Flatwasher,

3-10 3120783SECTION 3 MASTSECTION3MASTFIGURE 3-3. MAST ASSEM

3120783 3-11SECTION 3 MASTSECTION3MAST.FIGURE 3-3. MAST ASSEMBLY - 30EL & 41ELFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.MAST ASSEMBLIES O

3-12 3120783SECTION 3 MASTSECTION3MAST1271395 41EL 28 Channe

3120783 3-13SECTION 3 MASTSECTION3MAST60 4567492 Tube, Spacer 161 4711400 Flatwasher, 1/4” Narrow 8062 4711500 Flatwasher, 5/16” Narrow 563 4711800 Fl

ii 3120783TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO.

3-14 3120783SECTION 3 MASTSECTION3MAST206 3422722 Pin 2207 3

3120783 3-15SECTION 3 MASTSECTION3MASTFIGURE 3-3. MAST ASSEMBLY - 30EL & 41EL (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3-16 3120783SECTION 3 MASTSECTION3MASTFIGURE 3-4. MAST MOUNT

3120783 3-17SECTION 3 MASTSECTION3MAST.FIGURE 3-4. MAST MOUNTED COMPONENTS INSTALLATIONSFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0258741 LOA

3-18 3120783SECTION 3 MASTSECTION3MAST0258965 LOADING HARDWA

3120783 3-19SECTION 3 MASTSECTION3MAST203 3311605 Locknut 3/8”-16NC 4204 4711600 Washer 3/8” 8205 4845717 Stowage Rack Weldment (Left Side) 1206 48457

3-20 3120783SECTION 3 MASTSECTION3MASTFIGURE 3-4. MAST MOUN

3120783 4-1SECTION4PLATFORMSECTION 4 PLATFORMTABLE OF CONTENTSFIGURE DESCRIPTION PAGE4-1 STEP-IN MOLDED PLATFORM INSTALLATION . . . . . . . . . . .

4-2 3120783SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-1.STEP-IN MOL

3120783 4-3SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-1. STEP-IN MOLDED PLATFORM INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.025847

3120783 1-1SECTION1BASESECTION 1 BASETABLE OF CONTENTSFIGURE DESCRIPTION PAGE1-1 BASE MOUNTED COMPONENTS INSTALLATION . . . . . . . . . . . . . . . .

4-4 3120783SECTION 4 PLATFORMSECTION4PLATFORM132 Not Used133 382002

3120783 4-5SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-1. STEP-IN MOLDED PLATFORM INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY

4-6 3120783SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-2.QUICK-CHANG

3120783 4-7SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-2. QUICK-CHANGE PLATFORM INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.PLATFORM

4-8 3120783SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-3.QUICK-CHANG

3120783 4-9SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-3. QUICK-CHANGE PLATFORM INSTALLATION WITH GULLWING GATEFIG & ITEM # PART NUMBER DESCRIPTIO

4-10 3120783SECTION 4 PLATFORMSECTION4PLATFORM119 Not Used120 33110

3120783 4-11SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-3. QUICK-CHANGE PLATFORM INSTALLATION WITH GULLWING GATE (CONTINUED)FIG & ITEM # PART NUMB

4-12 3120783SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-4.OPTIONAL P

3120783 4-13SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-4. OPTIONAL PLATFORM COMPONENT INSTALLATIONSFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1-2 3120783SECTION 1 BASESECTION1BASEFIGURE 1-1. BASE MOUNT

4-14 3120783SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-4. OPTIONAL

3120783 5-1SECTION5CYLINDERSECTION 5 CYLINDERTABLE OF CONTENTSFIGURE DESCRIPTION PAGE5-1 LIFT CYLINDER ASSEMBLY (PRIOR TO S/N 17519). . . . . . . .

5-2 3120783SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-1.LIFT C

3120783 5-3SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-1. LIFT CYLINDER ASSEMBLY (PRIOR TO S/N 17519)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV

5-4 3120783SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-2.LIFT C

3120783 5-5SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-2. LIFT CYLINDER ASSEMBLY (S/N 17519 TO PRESENT)FIG & ITEM # PART NUMBER DESCRIPTION QTY. R

5-6 3120783SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-2. LIFT

3120783 6-1SECTION6HYDRAULICSECTION 6 HYDRAULICTABLE OF CONTENTSFIGURE DESCRIPTION PAGE6-1 HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . .

6-2 3120783SECTION 6 HYDRAULICSECTION6HYDRAULICFIGURE 6-1.HYDRA

3120783 6-3SECTION 6 HYDRAULICSECTION6HYDRAULICFIGURE 6-1. HYDRAULIC DIAGRAMFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.HYDRAULIC DIAGRAMS OPTI

3120783 1-3SECTION1BASESECTION 1 BASE.FIGURE 1-1. BASE MOUNTED COMPONENTS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.BASE ASSEMBLI

6-4 3120783SECTION 6 HYDRAULICSECTION6HYDRAULICFIGURE 6-1. HYD

3120783 7-1SECTION7ELECTRICALSECTION 7 ELECTRICALTABLE OF CONTENTSFIGURE DESCRIPTION PAGE7-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . .

7-2 3120783SECTION 7 ELECTRICALSECTION7ELECTRICAL FIGURE 7

3120783 7-3SECTION 7 ELECTRICALSECTION7ELECTRICALFIGURE 7-1.ELECTRICAL DIAGRAM LISTFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

7-4 3120783SECTION 7 ELECTRICALSECTION7ELECTRICALFIGURE 7-2.

3120783 7-5SECTION 7 ELECTRICALSECTION7ELECTRICAL

7-6 3120783SECTION 7 ELECTRICALSECTION7ELECTRICALFIGURE 7-3.

3120783 7-7SECTION 7 ELECTRICALSECTION7ELECTRICAL

7-8 3120783SECTION 7 ELECTRICALSECTION7ELECTRICAL “TH

3120783 8-1SECTION8DECALSSECTION 8 DECALSTABLE OF CONTENTSFIGURE DESCRIPTION PAGE8-1 DECALS INSTALLATION . . . . . . . . . . . . . . . . . .