Jlg 41EL Service Manual User Manual

CORPORATE OFFICEJLG INDUSTRIES, INC.1 JLG DriveMcConnellsburg, PA.17233-9533USATelephone: (717) 485-5161Fax: (717) 485-6417Model20EL25EL30EL36EL41EL

ii – JLG Lift – 3120782TABLE OF CONTENTS (Continued) Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3120782 – JLG Lift – iii TABLE OF CONTENTSSECTION 3 - TROUBLESHOOTING3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . .

iv – JLG Lift – 3120782TABLE OF CONTENTS (Continued) This page intentionally left blank.

SECTION 1 - SPECIFICATIONS3120782 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESHydraulic Oil ReservoirAC Models – 5 qts. U.S. (4.7 ltr.)D

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 3120782Maximum Working Height (Average person)20EL-AC & DC - 26 ft. (7.92 m)25EL-AC & DC - 31 ft.

SECTION 1 - SPECIFICATIONS3120782 – JLG Lift – 1-31.6 HYDRAULIC PRESSURE ADJUSTMENT(See Figure 1-1.)Adjust system pressure so that platform will raise

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3120782Figure 1-2. Torque Chart.

SECTION 1 - SPECIFICATIONS3120782 – JLG Lift – 1-5Figure 1-3. Lubrication Locations (See Table below).1423Table 1-4. Lubrication Intervals for Vario

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 3120782This page left intentionally blank

SECTION 2 - SERVICE PROCEDURES3120782 – JLG Lift – 2-1SECTION 2. SERVICE PROCEDURES2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis se

JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444AustraliaPhone: (61) 2 65 811111Fax: (61) 2 65 810122JLG Industries (

SECTION 2 - SERVICE PROCEDURES2-2 – JLG Lift – 31207822.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE(See Table 2-2.)The preventive maintenance and

SECTION 2 - SERVICE PROCEDURES3120782 – JLG Lift – 2-3Table 2-2. EL Model - Preventive Maintenance & Inspection Schedule.AREA ON MACHINEINTERVALP

SECTION 2 - SERVICE PROCEDURES2-4 – JLG Lift – 3120782Footnotes:(1) Prior to use each day; or at each Operator change(2) Prior to each sale, lease,

SECTION 2 - SERVICE PROCEDURES3120782 – JLG Lift – 2-52.3 SERVICING AND MAINTENANCE GUIDELINESGeneralThe following information is provided to assist y

SECTION 2 - SERVICE PROCEDURES2-6 – JLG Lift – 3120782Bolt Usage and Torque ApplicationUse bolts of proper length. A bolt which is too long willbottom

SECTION 2 - SERVICE PROCEDURES3120782 – JLG Lift – 2-7Tight Joints: All joints in the leaf chain should flex freely.On leaf chain, tight joints are us

SECTION 2 - SERVICE PROCEDURES2-8 – JLG Lift – 31207822.4 LUBRICATION INFORMATIONHydraulic SystemThe primary enemy of a hydraulic system is contamina-

SECTION 2 - SERVICE PROCEDURES3120782 – JLG Lift – 2-92.5 BATTERY CHARGER - ASSEMBLY AND DISASSEMBLYGeneral InformationDO NOT ATTEMPT TO DISASSEMBLE T

SECTION 2 - SERVICE PROCEDURES2-10 – JLG Lift – 3120782Printed Circuit Board Replacement1. Disconnect the wide wiring connector from the endof the cir

SECTION 2 - SERVICE PROCEDURES3120782 – JLG Lift – 2-11Shunt Assembly, Varistor, and SCR Rectifier Replacement (See Illustration)Shunt Assembly (Item

FOREWORDThe purpose of this manual is to provide users with the operating procedures essential for the promotion ofproper machine operation for its in

SECTION 2 - SERVICE PROCEDURES2-12 – JLG Lift – 31207822.6 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILDHYDRAULIC CYLINDERS ARE DESIGNED T

SECTION 2 - SERVICE PROCEDURES3120782 – JLG Lift – 2-13cates uneven loading and when this occurs, the diametershould be checked for out-of-roundness.

SECTION 2 - SERVICE PROCEDURES2-14 – JLG Lift – 31207826. When the rod assembly is ready to be installed intothe tube, liberally apply an anti-seize l

SECTION 2 - SERVICE PROCEDURES3120782 – JLG Lift – 2-152.7 MAST ASSEMBLY AND DISASSEMBLY PROCEDURESThe EL Series personnel lift mast sections are cont

SECTION 2 - SERVICE PROCEDURES2-16 – JLG Lift – 3120782Platform Section Removal (All Masts)3. Remove cable adjust nuts from threaded ends ofcable atta

SECTION 2 - SERVICE PROCEDURES3120782 – JLG Lift – 2-1722. Carefully slide mast section-4 out BOTTOM of sec-tion-3. Remove slide pads, shims and chain

SECTION 2 - SERVICE PROCEDURES2-18 – JLG Lift – 31207822.8 MAST ASSEMBLY(See Figure 2-3., Figure 2-4. or Figure 2-5.)Mast Section 1 - Assembly (All Ma

SECTION 2 - SERVICE PROCEDURES3120782 – JLG Lift – 2-19Figure 2-3. 20EL Mast Assembly Components. (5 - Section)MASTSECTION-1UPPERSEQUENCECABLEASSEMBL

SECTION 2 - SERVICE PROCEDURES2-20 – JLG Lift – 3120782Figure 2-4. 25EL & 36EL Mast Assembly Components. (6 - Section)MASTSECTION-5MASTSECTION-6M

SECTION 2 - SERVICE PROCEDURES3120782 – JLG Lift – 2-21Figure 2-5. 30EL & 41EL Mast Assembly Components. (7 - Section)MASTSECTION-5MASTSECTION-6M

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SECTION 2 - SERVICE PROCEDURES2-22 – JLG Lift – 3120782Figure 2-6. Mast Chain/Cable Routing Diagram.HYD.CYL.LIFTSHERESECTION 1SECTION 2SECTION 3SECTI

SECTION 2 - SERVICE PROCEDURES3120782 – JLG Lift – 2-23a. Insert sheave pin through anchor block on cylin-der rod end.b. Place sheave wheels (for wide

SECTION 2 - SERVICE PROCEDURES2-24 – JLG Lift – 312078230. Locate mast section-4, carefully slide section-4closed rail into section-3 open rail. Slide

SECTION 2 - SERVICE PROCEDURES3120782 – JLG Lift – 2-25x 3/4" long bolts, place a flatwasher under head ofeach bolt.45. Slide mast section-5 out

SECTION 2 - SERVICE PROCEDURES2-26 – JLG Lift – 312078260. Insert threaded ends of cable assembly (attached totop of mast section-4) through the chain

SECTION 2 - SERVICE PROCEDURES3120782 – JLG Lift – 2-27shim stock and slide pad to mast section rail withshim stock against rail and slide pad with be

SECTION 2 - SERVICE PROCEDURES2-28 – JLG Lift – 31207822.9 MAST TO BASE FRAME INSTALLATION1. Using an overhead crane or suitable lifting devicecapable

SECTION 2 - SERVICE PROCEDURES3120782 – JLG Lift – 2-292.10 MAST CHAINS/CABLES AND SEQUENCING CABLES ADJUSTMENTMast Chain/Cable AdjustmentThe intentio

SECTION 2 - SERVICE PROCEDURES2-30 – JLG Lift – 3120782NOTE: Mast section-1 is fixed to the base and mast section-2 is attached to the lift cylinder,

SECTION 2 - SERVICE PROCEDURES3120782 – JLG Lift – 2-31Clamp Installation (Drum/Socket Type)THE MANUFACTURER OF THE DRUM/SOCKET CLAMP RECOM-MENDS THE

INTRODUCTION - OPERATION/SAFETY PRECAUTIONS3120782 – JLG Lift – aINTRODUCTION - OPERATION/SAFETY PRECAUTIONSAll procedures herein are based on the use

SECTION 2 - SERVICE PROCEDURES2-32 – JLG Lift – 31207826. Reclamp the assembly in the vise on the flats of thesleeve. Using the plug driver, a metal t

SECTION 3 - TROUBLESHOOTING3120782 – JLG Lift – 3-1SECTION 3. TROUBLESHOOTING3.1 GENERALThis section contains troubleshooting information to beused f

SECTION 3 - TROUBLESHOOTING3-2 – JLG Lift – 3120782Table 3-1. AC Unit - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYOutrigger LED light does not tur

SECTION 3 - TROUBLESHOOTING3120782 – JLG Lift – 3-3Table 3-2. DC Unit - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYOutrigger LED light does not tur

SECTION 3 - TROUBLESHOOTING3-4 – JLG Lift – 31207823.4 OUTRIGGER INTERLOCK CONTACTSOutrigger Socket and Outrigger Beam - Interlock ContactsIt is very

SECTION 3 - TROUBLESHOOTING3120782 – JLG Lift – 3-5Figure 3-1. Outrigger Socket Contactor Heads and Outrigger Beam - Contactor Plate Mounting Hardwar

SECTION 3 - TROUBLESHOOTING3-6 – JLG Lift – 31207825. On the inside of the outrigger beam, install twonylon washers on the screw with the two (2) o-ri

SECTION 3 - TROUBLESHOOTING3120782 – JLG Lift – 3-7Figure 3-2. Hydraulic Schematic. (EL Series) (2792491_A)2792491_A

SECTION 3 - TROUBLESHOOTING3-8 – JLG Lift – 3120782Figure 3-3. Electrical Diagram. (EL Series - 12v-DC)4933203_C

SECTION 3 - TROUBLESHOOTING3120782 – JLG Lift – 3-9Figure 3-3. Electrical Diagram. (EL Series - 12v-DC)4933203_C

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSb – JLG Lift – 3120782INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA. GENERALThis section contains the ge

SECTION 3 - TROUBLESHOOTING3-10 – JLG Lift – 3120782Figure 3-4. Electrical Diagram. (EL Series - 120V-AC)4933204_H

SECTION 3 - TROUBLESHOOTING3120782 – JLG Lift – 3-11Figure 3-4. Electrical Diagram. (EL Series - 120V-AC)4933204_H

SECTION 3 - TROUBLESHOOTING3-12 – JLG Lift – 3120782Figure 3-5. Electrical Diagram. (EL Series - 240V-AC)4933205_H

SECTION 3 - TROUBLESHOOTING3120782 – JLG Lift – 3-13Figure 3-5. Electrical Diagram. (EL Series - 240V-AC)4933205_H

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EFFECTIVITY PAGE 3120782 – JLG Lift – cEFFECTIVITY CHANGESJune 15, 1999 - Original Issue of ManualNovember 21, 2000 - Revised - Pages Affected:Secti

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3120782 – JLG Lift – i TABLE OF CONTENTSTABLE OF CONTENTSSECTION - PARAGRAPH, SUBJECT PAGE NO.INTRODUCTION -- OPERATION/SAFETY PR