MODEL 15ELI - JLG Industries Vertical Mas… · Service and Maintenance Manual ANSI MODEL 15ELI 3120779 August 5, 2002. CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts, terminals

Service and Maintenance Manual

ANSI

MODEL15ELI

3120779

August 5, 2002

CALIFORNIAN PROPOSITION 65

BATTERY WARNINGBattery posts,

terminals and relatedaccessories contain

lead and lead compounds,chemical known to the

State of Califormiato cause cancer andreproductive harm.

WASH HANDSAFTER HANDLING!

FOREWORD

The purpose of this manual is to provide users with the operating procedures essential for the promotion ofproper machine operation for its intended purpose. It is important to over-stress proper machine usage. Allinformation in this manual should be READ and UNDERSTOOD before any attempt is made to operate themachine. 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 ANDOPERATION, PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPER-ATING PERSONNEL.

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

THIS "SAFETY ALERT SYMBOL" IS USED TO CALL ATTENTION TO POTENTIAL HAZARDSWHICH 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:

JLG INDUSTRIES, INC. MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT. CONTACT JLG INDUS-TRIES, INC. OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLE-TINS WHICH MAY HAVE BEEN ISSUED FOR YOUR JLG PRODUCT. ALL ITEMS REQUIRED BY THE SAFETY RELATEDBULLETINS MUST BE COMPLETED ON THE AFFECTED JLG PRODUCT.

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.

DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUA-TION WHICH, IF NOT AVOIDED WILL RESULT IN SERIOUSINJURY OR DEATH.

CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUA-TION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR ORMODERATE INJURY. IT MAY ALSO BE USED TO ALERTAGAINST UNSAFE PRACTICES.

Also in this Manual "Notes:" are used to provide infor-mation of special interest.

WARNING INDICATES A POTENTIALLY HAZARDOUS SITU-ATION WHICH, IF NOT AVOIDED COULD RESULT IN SERI-OUS INJURY OR DEATH.

IMPORTANT OR INSTRUCTIONS PROCEDURES ESSENTIALFOR SAFE OPERATION AND WHICH, IF NOT FOLLOWEDMAY RESULT IN A MALFUNCTION OR DAMAGE TO THEMACHINE.

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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS


A. GENERAL

This section contains the general safety precautionswhich must be observed during maintenance of the aerialplatform. It is of utmost importance that maintenance per-sonnel pay strict attention to these warnings and precau-tions to avoid possible injury to themselves or others ordamage to the equipment. A maintenance program mustbe established by a qualified person and must be followedto ensure that the machine is safe to operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BYA RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEASTAS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA-TION.

The specific precautions to be observed during machinemaintenance are inserted at the appropriate point in themanual. These precautions are, for the most part, thosethat apply when servicing hydraulic and larger machinecomponent parts.

Your safety, and that of others, is the first considerationwhen engaging in the maintenance of equipment. Alwaysbe conscious of component weight and never attempt tomove 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 ade-quate support is provided.

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

B. HYDRAULIC SYSTEM SAFETY

1. It should be particularly noted that the machineshydraulic systems operate at extremely high andpotentially dangerous pressures. Every effort shouldbe made to relieve any system pressure prior to dis-connecting or removing any portion of the system.

2. Relieve system pressure by activating the lift DOWNcontrol with the platform completely lowered todirect any line pressure back into the return line tothe reservoir. Pressure feed lines to system compo-nents can then be disconnected with minimal fluidloss.

C. MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED INTHIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON-NEL INJURY OR DEATH AND IS A SAFETY VIOLATION.

• REMOVE ALL RINGS, WATCHES, AND JEWELRYWHEN PERFORMING ANY MAINTENANCE.

• DO NOT WEAR LONG HAIR UNRESTRAINED, ORLOOSE FITTING CLOTHING AND NECKTIES WHICHARE APT TO BECOME CAUGHT ON OR ENTANGLEDIN EQUIPMENT.

• OBSERVE AND OBEY ALL DANGER, WARNING, CAU-TION AND OTHER INSTRUCTIONS ON MACHINEAND IN SERVICE MANUAL.

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

• NEVER WORK UNDER AN ELEVATED PLATFORMUNTIL PLATFORM HAS BEEN SAFELY RESTRAINEDFROM ANY MOVEMENT BY BLOCKING OR OVER-HEAD SLING.

• BEFORE MAKING ADJUSTMENTS, LUBRICATING ORPERFORMING ANY OTHER MAINTENANCE, SHUTOFF ALL POWER CONTROLS.

• BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPO-NENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACH-MENTS STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANINGSOLVENTS.

3120779 – JLG Lift – a


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EFFECTIVITY PAGE

EFFECTIVITY CHANGES

June 15, 1999 - Original Issue of Manual

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

August 5, 2002 – Manual Revised

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EFFECTIVITY PAGE

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TABLE OF CONTENTS

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

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

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

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

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

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

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 COMPONENT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1Hydraulic Pump/Electric Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1Batteries – DC Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1Battery Charger – DC Models.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1Platform Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1Machine Weight (with Standard Platform). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1Machine Height (Platform Stowed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1Maximum Platform Height (Mast Extended) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1Maximum Working Height (Average person) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1Machine Overall Width and Length (Base) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1Machine Lift Up/Down Speeds (@ Max. Capacity). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

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

1.5 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

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

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

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

SECTION 2 - SERVICE PROCEDURES

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

2.2 SERVICING AND MAINTENANCE GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Mast Chain Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Mast Cable Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

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2.3 LUBRICATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

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

2.5 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Mast Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6Platform Section – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6Mast Section 3 – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Mast Section 2 – Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Mast Section 1 – Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.6 MAST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8Mast Section 1 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8Mast Section 2 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8Mast Section 3 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11Platform Mounting Section - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

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

2.8 MAST CHAINS/CABLES AND SEQUENCING CABLES ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 2-13Mast Chain/Cable Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13Sequencing Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2.9 SEQUENCE CABLE REPLACEMENT KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15Remove Old Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15Replacement Cable Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15Clamp Installation (Drum/Socket Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

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

SECTION 3 - TROUBLESHOOTING

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

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

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

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TABLE OF CONTENTS

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Hydraulic Pressure Setting - Adjustment Screw Located at Base of Pump Motor . . . . . . . . . . . .1-21-2. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-31-3. Lubrication Locations (See Table below). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-42-1. AC Junction Box - Internal Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52-2. Mast Section - Assembly/Disassembly Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62-3. 15ELI Mast Assembly Components. (4 Section - Chain/Cable or All Cable) . . . . . . . . . . . . . . . . .2-92-4. Mast Chain/Cable Routing Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-102-5. Mast Chain/Cable/Sequence Cable Adjustment Components. (Typical) . . . . . . . . . . . . . . . . . . .2-143-1. Hydraulic Schematic. (ELI) (2792491) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53-2. Electrical Diagram. (ELI - 12V-DC) (4933258-A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63-3. Electrical Diagram. (ELI - 120V-AC) (4933259-A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-83-4. Electrical Diagram. (ELI - 240V-AC) (4933260-A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-103-5. Electrical Diagram. (ELI - 100V-AC) (4933261-A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1. Hydraulic Oil Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21-2. Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21-3. Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21-4. Lubrication Intervals for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-42-1. Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22-2. AM Series Mast Component Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62-3. Preventive Maintenance & Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-183-1. AC Unit - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23-2. DC Unit - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

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SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

Hydraulic Oil Reservoir

AC Models – 5 qts. U.S. (4.7 ltr.)

DC Models – 5 qts. U.S. (4.7 ltr.)

1.2 COMPONENT DATA

Hydraulic Pump/Electric Motor Assembly

DC Models - 12 Volt DC motor/pump

Motor - 12v - DC Standard Duty

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

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

120 AMPS @ 45 Centistrokes (200 SSU)

Pressure Relief – Adjustable Range 1500 to 5000 PSI,

Set to 2800 PSI (193 bars) at factory

AC Models - 110 Volt AC motor/pump

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

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

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

115v-AC @ 45 Centistrokes (200 SSU)



AC Models - 220 Volt AC motor/pump

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





Set to 2800 PSI (193 bars) at factoryACModels - 100 Volt AC motor/pump

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






Batteries – DC Models.

WET (Standard)

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

DRY (Option)

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

AGM (Absorption Gas Mat) (Option)

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

Battery Charger – DC Models.

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

12 Volt DC, 10 Amp - output

Automatic SCR Charger

Selectable Voltage

NOTE: A high output - 12Volt DC, 20 Amp output - SCRcharger is supplied with the AGM battery option.

1.3 PERFORMANCE DATA

Platform Capacity

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

Machine Weight (with Standard Platform)

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

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

Machine Height (Platform Stowed)

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

Maximum Platform Height (Mast Extended)

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

Maximum Working Height (Average person)

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

Machine Overall Width and Length (Base)

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

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

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

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

1.4 TORQUE REQUIREMENTSWhen maintenance becomes necessary or a fastener hasloosened, refer to the Torque Chart, Figure 1-2. to deter-mine proper torque value.

3120779 – JLG Lift – 1-1


1.5 LUBRICATION

Hydraulic Oil

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

For cold weather applications, i.e. when temperaturesremain consistently below +20°F (–7° C) JLG recom-mends using Mobil DTE 13 hydraulic oil.

Aside from JLG recommendations, it is not advisable tomix oils of different brands or types, as they may not con-tain the same required additives or be of comparable vis-cosities. If use of hydraulic oil other than Mobilfluid 424 isdesired, contact JLG Industries for proper recommenda-tions.

Lubrication Specifications

1.6 HYDRAULIC PRESSURE ADJUSTMENT(See Figure 1-1.)

Adjust system pressure so that platform will raise withrated capacity in platform.

Turning adjustment screw clockwise, increases systempressure, turning screw counterclockwise, decreasessystem pressure.

Do not adjust system pressure higher than required toraise the load. Make pressure adjustment with oil at nor-mal operating temperature. If pressure is set when oil is

cold, platform may not raise rated load after oil haswarmed.

1.7 CYLINDER SPECIFICATIONS

NOTE: All dimensions are given in inches (in), with the met-ric equivalent, centimeters (cm), given in parenthe-ses.

1.8 SERIAL NUMBER LOCATIONSFor machine identification, a serial number plate is affixedto the machine. The plate is located on the back of themast, just above the mast support bracket. In addition,should the serial number plate be damaged or missing,the machine serial is stamped on the mast and on thebase frame.

Table 1-1. Hydraulic Oil Operating Range

HYDRAULIC SYSTEM OPERATING TEMPERATURE RANGE

SAE VISCOSITYGRADE

0° F to +23° F(-18° C to -5° C)

10W

0° F to +210° F(-18° C to +99° C)

10W-20, 10W-30

50° F to 210° F(+10° C to +210° C)

20W-20

Table 1-2. Lubrication Specifications

KEY SPECIFICATIONS

MPG - Multipurpose Grease having a minimum dripping point of 350° F. Excellent water resistance and adhesive qual-ities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)

EPGL - Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or MIL-Spec MIL-L-2105.

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

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

(Remove Hex Head Cap as Shown)

Table 1-3. Cylinder Specifications

DESCRIPTION BOREin./(cm)

STROKEin./(cm)

ROD DIA.in./(cm)

Lift Cylinder - 15ELI - AC & DC

1.63(4.14)

56.50(143.50)

1.38(3.50)

PRESSUREADJUSTMENT

SCREW

HYDRAULICOIL TANK

GROUNDCONTROLSTATIONCOVER

ADJUSTMENTSCREW CAP

(SHOWN REMOVED)

1-2 – JLG Lift – 3120779


Figure 1-2. Torque Chart.

3120779 – JLG Lift – 1-3


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

2

1

3

Table 1-4. Lubrication Intervals for Various Components

ITEM COMPONENTNO/TYPE

LUBE POINTSLUBE/METHOD

INTERVAL HOURS

COMMENTS3 MOS.or

150 Hrs.

6 MOS.or

300 Hrs.

1 YR.or

600 Hrs.

2 YRS.or

1200 Hrs.

1 Hydraulic Oil Fill To Lineon Reservoir5 Qt. (4.3 L)Reservoir

HO - Check Hyd. Oil LevelHO - Change Hyd. Oil

✔

Check Hyd. Oil after every10 hrs. of operation.Change Hyd. Oil after every 1200 hrs. of operation.

2 Swivel Raceways 2 - Front Casters MPG - Pressure Gun ✔

3 Mast Chains * 2 - Per Section Chain Lube - Brush or Spray ✔

* Applies Only to Mast Sections with Chains.

Key to Lubricants: MPG - Multipurpose GreaseHO - Hydraulic Oil - See Table 7-1 in Service Manual. (JLG recommends using Mobilfluid 424 hydraulic oil.)

Notes: 1. Be certain to lubricate like items on each side of the machine.2. Recommended lubricating intervals are based on normal use. If machine is subjected to severe operating conditions,

such as a high number of cycles, location, corrosive/dirty environment, etc., user must adjust lubricating requirements accordingly.3. Lubricating intervals 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 to do so will

result in incorrect oil level reading on the hydraulic reservoir.

1-4 – JLG Lift – 3120779


SECTION 2. SERVICE PROCEDURES

2.1 GENERALThis section provides general information to assist in theperformance of maintenance on the personnel l ift.Descriptions, techniques and specific procedures aredesigned to provide the safest and most efficient mainte-nance for use by personnel responsible for ensuring thecorrect installation and operation of machine componentsand systems.

WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURESCONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THENOTED IRREGULARITY, WORK SHOULD BE STOPPED ANDTECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORKIS RESUMED.

2.2 SERVICING AND MAINTENANCE GUIDELINES

GeneralThe following information is provided to assist you in theuse and application of servicing and maintenance proce-dures contained in this chapter.

Safety and WorkmanshipYour safety, and that of others, is the first considerationwhen engaging in the maintenance of equipment. Alwaysbe conscious of component weight. Never attempt tomove 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 ade-quate support is provided.

NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT-FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENTBY BLOCKING OR OVERHEAD SLING.

CleanlinessThe most important single item in preserving the long ser-vice life of a machine is to keep dirt and foreign materialsout of the vital components. Precautions have been takento safeguard against this. Shields, covers, seals, and fil-ters are provided to keep the wheel bearings, mast sec-tions and oil supply clean; however, these items must bemaintained on a scheduled basis in order to functionproperly.

At any time when oil lines are disconnected, clear adja-cent areas as well as the openings and fittings them-selves. As soon as a line or component is disconnected,

cap or cover all openings to prevent entry of foreign mat-ter.

Clean and inspect all parts during servicing or mainte-nance, and assure that all passages and openings areunobstructed. Cover all parts to keep them clean. Be sureall parts are clean before they are installed. New partsshould remain in their containers until they are ready to beused.

Components Removal and Installation

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

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

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

Component Disassembly and Reassembly

When disassembling or reassembling a component, com-plete the procedural steps in sequence. Do not partiallydisassemble or assemble one part, then start on another.Always recheck your work to assure that nothing has beenoverlooked. Do not make any adjustments, other thanthose recommended, without obtaining proper approval.

Pressure-Fit Parts

When assembling pressure-fit parts, use an “anti-seize” ormolybdenum disulfide base compound to lubricate themating surface.

Bearings

When a bearing is removed, cover it to keep out dirt andabrasives. Clean bearings in nonflammable cleaning sol-vent and allow to drip dry. Compressed air can be usedbut do not spin the bearing.

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

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

Lubricate new or used serviceable bearings before instal-lation. When pressing a bearing into a retainer or bore,apply pressure to the outer race. If the bearing is to beinstalled on a shaft, apply pressure to the inner race.

3120779 – JLG Lift – 2-1


Gaskets

Check that holes in gaskets align with openings in themating parts. If it becomes necessary to hand-fabricate agasket, use gasket material or stock of equivalent materialand thickness. Be sure to cut holes in the right location, asblank gaskets can cause serious system damage.

Bolt Usage and Torque Application

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

Unless specific torque requirements are given within thetext, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in accordance withrecommended shop practices. (See Figure 1-1.)

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, aswell as their receptacles, when disconnecting or removingthem from the unit. This will assure that they are correctlyreinstalled.

Hydraulic System

Keep the system clean. If evidence of metal or rubber par-ticles is found in the hydraulic system, drain and flush theentire system.

Disassemble and reassemble parts on clean work sur-face. Clean all metal parts with non-flammable cleaningsolvent. Lubricate components, as required, to aid assem-bly.

Lubrication and Servicing

Components and assemblies requiring lubrication andservicing are shown in the Lubrication Chart, (See Figure1-2.). Service applicable components with the amount,type, and grade of lubricant recommended in this manual,at the specified intervals. When recommended lubricantsare not available, consult your local supplier for an equiva-lent that meets or exceeds the specifications listed.

Batteries

Clean batteries, using a non-metallic brush and a solutionof baking soda and water. Rinse with clean water. Aftercleaning, thoroughly dry batteries and coat terminals withan anti-corrosion compound.

Mast Chain Inspection Procedure

MAST CHAINS TO BE INSPECTED AND LUBRICATED EVERYTHREE MONTHS.

Inspect mast chains for the following conditions:

Wear: Always inspect that segment of chain that operatesover a sheave. As the chain flexes over the extend/retractsheaves, joints and plate edges wear very gradually.Chain “stretch” can be measured using a manufacturerswear scale or steel tape. When chains have elongated 3%they must be removed and replaced. Refer to Table 2-1 forproper chain specifications and allowable stretch toler-ances. Peening and wear of chain plate edges are causedby the chain sliding over a chain worn contact face of asheave, or unusually heavy loads. All of the above requirereplacement of the chain and correction of the cause.Chain side wear, noticeable when pin heads and outsideplates show a definite wear pattern, is caused by misalign-ment of the sheave/chain anchors and must be correctedpromptly. Do not repair chains; if a section of chain isdamaged, replace the entire chain set.

Rust and Corrosion: Rust and corrosion will cause amajor reduction in the load carrying capacity of the chain,because these are primary reasons for side plate crack-ing. The initial lubrication at the factory is applied in a hotdip tank to assure full penetration into the joint. Do notsteam clean or degrease chains. At time of chain installa-tion, factory lube must be supplemented by a mainte-nance program to provide a film of oil on the chains at alltimes. If chains are corroded, they must be inspected,especially the outside plates, for cracks in-line with thepins. If cracks are found, replace the chain; if no cracksare discovered, lubricate the chains by dipping in heatedoil, and reinstall on the machine. Keep chains lubricated.

Fatigue Cracks: Fatigue is a phenomenon that affectsmost metals, and is the most common cause of chainplate failures. Fatigue cracks are found through the linkholes, perpendicular (90 degrees) from the pin in-lineposition. Inspect chains carefully after long time use andheavy loading for this type of crack. If any cracks are dis-covered, replace all chains, as seemingly sound platesare on the verge of cracking. Fatigue and ultimatestrength failures on JLG Lifts are incurred as a result ofsevere abuse as design specs are well within the rated lift-ing capacity of these chains.

Table 2-1. Chain Stretch Tolerance

Chain SizePin to Pin

MeasurementAllowable Stretch

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

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

2-2 – JLG Lift – 3120779


Tight Joints: All joints in the leaf chain should flex freely.On leaf chains, tight joints are usually caused by rust/cor-rosion, or the inside plates “walking” off the bushing. Lim-ber up rusty/corroded chains (after inspecting carefully)with a heavy application of oil (preferably a hot oil dip). Tapinside “walking” plates inward; if “walking” persists,replace the chain. This type of problem is accelerated bypoor lubrication maintenance practice, and most tightjoint chains have been operated with little or no lubrica-tion. 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 peenedchain components. Keep chains lubricated.

Protruding or Turned Pins: Chains operating with inade-quate lube generate tremendous friction between the pinand plates (pin and bushing on leaf chain). In extremecases, this frictional torque can actually turn the pins inthe outside press-fit plates. Inspect for turned pins, whichcan be easily spotted as the “V” flats on the pin heads areno longer in line. Replace all chains showing evidence ofturned or protruding pins. Keep chains lubricated.

Chain Anchors and Sheaves: An inspection of the chainmust include a close examination of chain anchors andsheaves. Check chain anchors for wear, breakage andmisalignment. Anchors with worn or broken fingers shouldbe replaced. They should also be adjusted to eliminatetwisting the chain for an even load distribution.

Inspect the sheaves, sheave bearings, sheave groovesand pins for extreme wear, replace as necessary. A wornsheave 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 MONTHSOR MORE FREQUENTLY AS DESCRIBED FOLLOWING.

WEAR PROTECTIVE GLOVES TO PROTECT HANDS WHEN HAN-DLING CABLE.

The periodic inspection shall cover the entire length of thecable. The inspection frequency shall be based on suchfactors as expected cable life as determined by experi-ence on the particular application or similar installations,severity of environment, percentage of capacity lifts, fre-quency rates of operation, and exposure to shock loads.

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

Only the surface wires of the cable require inspection, donot attempt to open the cable. Any deterioration resultingin any loss of original strength, such as described below,shall be noted, and then a determination made if furtheruse would constitute a hazard.

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

Conditions such as the following shall be sufficient reasonfor questioning continual use of the [cable] or increasingthe frequency of inspection:

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

2. One outer wire broken at the point of contact withthe core of the rope which has worked its way out ofthe rope structure and protrudes or loops out fromthe rope structure. Additional inspection of this sec-tion is required.

3. Wear of one-third the original diameter of outsideindividual wires.

4. Kinking, crushing, birdcaging or any other damageresulting 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 andincluding 5/16th in. (8mm);

NOTE: A good indicator of a stretched extend/retract cableis if the adjusting nuts are bottomed out. If no adjust-ment remains, the cables have stretched and needreplacement.

Also check for cracked, bent, worn, severely corroded, orimproperly installed cable ends.

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

2.3 LUBRICATION INFORMATION

Hydraulic SystemThe primary enemy of a hydraulic system is contamina-tion. Contaminants enter the system by various means,e.g., using inadequate hydraulic oil, allowing moisture,grease, filings, sealing components, sand, etc., to enterwhen performing maintenance, or by permitting the pumpto cavitate due to insufficient system warm-up or leaks inthe pump supply.

The design and manufacturing tolerances of the compo-nent working parts are very close, therefore, even the

3120779 – JLG Lift – 2-3


smallest amount of dirt or foreign matter entering a systemcan cause wear or damage to the components and gener-ally results in faulty operation. Every precaution must betaken to keep hydraulic oil clean, including reserve oil instorage.

Cloudy oils indicate a high moisture content which per-mits organic growth, resulting in oxidation or corrosion. Ifthis 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 beof comparable viscosities. Good grade mineral oils, withviscosities suited to the ambient temperatures in whichthe machine is operating, are recommended for use.

NOTE: Metal particles may appear in the oil of newmachines due to the wear-in of meshing compo-nents.

Hydraulic OilFor best performance, JLG recommends the use of ISO-Vg grade 32, 46 oil with a viscosity range between 15-250SUS at 100 degrees F (32-54 cST at 40 degrees C). Referto Section 7 for recommended hydraulic oils.

Changing Hydraulic OilUse of any of the recommended hydraulic oils eliminatesthe need for changing the oil on a regular basis. If it is nec-essary to change the oil, use only those oils meeting orexceeding the specifications appearing in this manual. Ifunable to obtain the same type of oil supplied with themachine, consult local supplier for assistance in selectingthe proper equivalent. Avoid mixing petroleum and syn-thetic base oils. JLG Industries recommends changing thehydraulic oil annually.

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

While the unit is shut down, a good preventive mainte-nance measure is to make a thorough inspection of allhydraulic components, lines, fittings, etc., as well as afunctional check of each system, before placing themachine back in service.

Lubrication SpecificationsSpecified lubricants, as recommended by the componentmanufacturers, are always the best choice, however,multi-purpose greases usually have the qualities whichmeet a variety of single purpose grease requirements.Should any question arise regarding the use of greases inmaintenance stock, consult your local supplier for evalua-tion. Refer to Table 1-2. for an explanation of the lubricantkey designations appearing in the Lubrication Chart.

2-4 – JLG Lift – 3120779


2.4 AC JUNCTION BOX COMPONENTS(AC POWERED MACHINES ONLY)

HAZARD OF ELECTRIC SHOCK! ALWAYS DISCONNECT ELEC-TRICAL POWER TO THE JUNCTION BOX BEFORE ATTEMPTINGTO DISCONNECT ANY CIRCUITS OR WHEN REMOVING COMPO-NENTS.

WHEN TESTING CIRCUITS WITH ELECTRICAL POWER ON, USEONLY INSTRUMENTS WITH INSULATED TEST LEADS KEEPINGYOUR HANDS OUTSIDE THE BOX.

1. 12V-DC Starter Relay 5. Bridge Rectifier2. 115V or 230V AC Power Relay 6. Relay3. Terminal Strip 7. 120/240V-AC to 16V-DC Transformer4. Circuit Breaker (AC) (CE Qty.-2)

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

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

1

2

3

4

5

6

7

3120779 – JLG Lift – 2-5


2.5 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES

The AM Series personnel lift mast sections are contructedof extruded aluminum, protected with an anodized surfacefinish. The mast sections rails are interlocked into eachother when assembled and are guided by slide padsmounted at the top and bottom of the rails on both sidesof the mast section.

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

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

Mast Disassembly Procedure(See Figure 2-2.)

1. After the platform and other hardware have beenremoved from the mast, and mast has beenremoved from machine, lay mast assembly downwith the shortest mast section-4 on top and facingup.

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

Platform Section – Removal

3. Remove cable adjust nuts from threaded ends ofcable attached to the cable anchor plate on BOT-TOM end of mast section-4 (short, platform mountingsection). Push threaded ends of cable throughanchor plate

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

NOTE: When sliding mast sections apart, be careful not toscratch or score the anodized finish in the slide padchannels.

5. Carefully slide short mast section-4 out BOTTOM ofmast section-3 rails. Disassemble slide pads, shimsand cable anchor plate from mast section-4, if nec-essary.

Table 2-2. AM Series Mast Component Features

ModelNo. of Mast

SectionsExtend Device

15ELI 4 Chain & Cable

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)CLOSED RAIL

(REFERS TO CLOSED RAIL

BACK OF MAST SECTION)

OPEN RAIL(REFERS TO OPEN RAIL

FRONT OF MAST SECTION)

2-6 – JLG Lift – 3120779


Mast Section 3 – Removal

1. Remove chain adjust nuts from threaded ends ofchain attached to the chain anchor plate on BOT-TOM end of mast section-3. Push threaded ends ofcable through anchor plate.

2. At TOP of mast section-3, pull chains out and allowto hang loose, (be certain floor surface is clean andfree of any metal chips or debris which may stick tolubricated chains or lay chains in a clean bucket).

3. Slide mast section-3 out TOP of mast section-2 farenough to allow access to the chain sheave wheelassembly.

4. Remove countersunk flathead screws securingchain sheave wheel assembly attach bars on bothside rails at TOP of mast section-3 and removesheave wheel assembly.

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


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

Mast Section 2 – Removal

7. Slide mast section-2 out TOP of mast section-1 farenough to allow access to the chain anchor block/sheave wheel assembly.

8. Remove countersunk-flathead screws securingchain anchor block/sheave wheel assembly attachbars on both side rails at TOP of mast section-2.

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

10. Remove the setscrew holding the hydraulic cylinderrod into the chain assembly anchor block. Lay chainassembly to side.

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


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

Mast Section 1 – Disassembly

13. Slide the TOP of the remaining mast section-1 outover edge of work surface and remove the boltsattaching the anchor blocks of the two (2) chainassemblies to mast section-1. Remove chain assem-blies from mast and lay aside.

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

Mast disassembly should now be complete.

3120779 – JLG Lift – 2-7


2.6 MAST ASSEMBLY

(See Figure 2-2.)

Mast Section 1 - Assembly

1. Place mast section-1, rail (open) side up (See Figure2-2.) on a clean, flat surface (preferably a table orwork bench capable of supporting the weight of theentire mast assembly). Slide mast out over end ofwork surface far enough to allow access to the chainanchor attach holes at top of mast.

2. Locate the two (2) single (wide) chain assemblies.Lay out each chain assembly with anchor block endtowards mast, and notched end of block down, (becertain floor surface is clean and free of any metalchips or debris which may stick to lubricated chainsor lay chains in a clean bucket).

3. Insert the block anchor end (with notched end onbottom) into the top of mast section-1 and secureusing two (2) 3/8"-16UNC x 2-1/2" long hex headbolts, flatwashers and nuts for each attach block.Place a flatwasher under bolt head and nut.


NOTE: When sliding mast sections together, be careful notto scratch or score the anodized finish in the slidepad channels.

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

5. Insert slide pads into the slide pad channels at bot-tom end of mast between section-1 and -2, (one oneach side of the mast), with beveled surface facingout towards section-1.

6. Thread slide pad attaching bolts, (two (2) 1/4"-20UNC x 3/8" long hex head bolts, place a flatwasher under head of each bolt), through holes inmast 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 materialbehind slide pads on both sides of the mast rails.This will keep mast sections centered in rail chan-nels and prevent any distortion of the mast section.

a. Start with a .036" thick shim and a .075" thickshim per side at each slide pad.

8. Slide shims into place between slide pad and mastrail. Tighten the slide pad mounting bolts, be surethere are no air gaps between shims, shim and mastor shim and slide pad when tightened.

a. Check mast section for side play. If play existsadd .015" shims dividing the thickness equallybetween both sides of mast. Insert shims untilthe shims cannot be inserted halfway by handwith the mast pulled to the opposite side.

b. When mast slide pads are shimmed properly,there should be no side to side movement ofslide pad in rail channel. Mast sections shouldbe snug in channels but still be able to slide inchannel by hand.

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

NOTE: Before fastening and shimming the slide pad on thetop left side of the mast, install a sequence cablebracket against the mast under the flatwasher.

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

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

NOTE: If hydraulic cylinder needs to be extended, the pro-tective caps on the extend and return ports will needto be temporarily removed. Be careful not to nick orscour rod surface when extending, also catch any oildraining out of cylinder to avoid spillage onto workarea.

12. Locate the hydraulic lift cylinder, slide the lift cylinderinto the closed rail side of mast section-2 with rodend to top and port end to bottom of mast. Cylindershould extend out of mast on both ends. Returntube should be on right side when facing bottom ofmast assembly.

13. Insert hydraulic cylinder rod end into chain assem-bly anchor block. Secure cylinder rod to anchorblock with a 1/4"-28UNF x .50" long - Type C set-screw. Coat threads with blue Loctite # 242 beforeassembly.

14. Locate chain assembly (single anchor block withtwo narrow chains). Lay out chain assembly withanchor block end towards mast, (be certain floorsurface is clean and free of any metal chip or debriswhich may stick to lubricated chains or lay chains ina clean bucket).

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

2-8 – JLG Lift – 3120779


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

MASTSECTION-1

MASTSECTION-2

LIFTCYLINDER

MASTSECTION-3

MASTSECTION-4

3120779 – JLG Lift – 2-9


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

2-10 – JLG Lift – 3120779


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

a. Insert sheave pin through anchor block on cylin-der rod end.

b. Place sheave wheels (for wide chain) on sheavepin, one each side of anchor block.

c. On outside of each sheave wheel, place asheave pin attach bar, (rectangular plate withthreaded holes on each side of pin bore hole).

d. Slide the whole anchor block assembly withsheave pin, wheels and pin attach bars into topof mast section-2. (Position anchor block withnarrow 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-countersunk-flathead cap screws each side. Coat threadswith Loctite #171 and tighten.

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



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

19. Locate one (1) of the chain/cable anchor plates (onewith threaded holes horizontally aligned to outside ofbracket). Attach using outer set of holes in bottom ofmast section-3 with two (2) 1/4"-20UNC x 3/4" longbolts, place a flatwasher under head of each bolt.

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

21. Insert threaded ends of chain assembly (attached totop of mast section-1), through holes in anchor plateattached to bottom of mast section-3. Looselythread two (2) 3/8"-16UNC nuts onto stud threads oneach chain. Chains will be adjusted later in assem-bly.

22. Locate two cable assemblies. Attach the eyeletanchor end of each cable to the outside holes neartop of mast section-3 using 3/8"-16UNC x 1-1/4" longhex head bolts, nuts and flatwashers. Place a flat-washer under bolt head and nut.

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

a. Locate the two (2) narrow chain sheave wheelsand slide onto sheave pin.

b. Slide two (2) short spacer tubes onto sheavepin, one each end of sheave pin to outside ofsheave wheels.

c. Place two (2) sheave pin attach bars, one eachend of sheave pin to outside of space tubes.

d. Holding complete sheave wheel assembly, slideassembly into top of mast section-3 and alignthreaded holes in sheave pin attach bars withholes in mast rails.

e. Attach to top of mast section-3 using two (2) 3/8"-16UNC x 1/2" long socket head-countersunk-flathead cap screws, each side. Coat threadswith Loctite #171 and tighten.


24. Carefully slide mast section-3 into section-2 untilends are even. Check to make sure chain assembly(wide chains) are seating properly in chain anchorblock chain sheave wheels attached to mast sec-tion-2.

25. Insert slide pads into the top end mast rails betweensection-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 thetop left side of the mast, install a sequence cablebracket against the mast under the flatwasher.

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


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

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


3120779 – JLG Lift – 2-11


Platform Mounting Section - Assembly

1. Locate the remaing mast section-4 (platform mount-ing - mast section). Lay mast section on flat stablesurface.

2. Attach the remaining chain/cable anchor plate (onewith threaded holes vertically aligned in center ofbracket). Attach through inner (vertical) set of holesin bottom of mast section-5/-6/-7 with two (2) 1/4"-20UNC x 3/4" long bolts, place a flatwasher underhead of each bolt.

NOTE: The platform mounting section slide pads, areassembled differently than the slide pads for theother mast sections. Mast section-4 slide pads mayneed to be assembled/disassembled several times inorder to determine the correct shim stock requiredfor proper fit.

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

NOTE: Always use the an even amount of shim materialbehind slide pads on both sides of the mast rails.This will keep mast sections centered in rail chan-nels and prevent any distortion of the section.

a. Use two shim pieces per slide pad, a thick oneand 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 sidesof mast section-5/-6/-7 using five (5) 1/4"-20UNCx 1-1/4" long, hex head cap screws per side, withflatwasher under each bolt head. (Assembleshim stock and slide pad to mast section rail withshim stock against rail and slide pad with bev-eled side out).

d. Carefully thread the slide pad mounting boltswith flatwashers through slide pads and shimstock into threads in mast section-4. Be certainthere are no air gaps between shims, shim andmast or shim and slide pad when tightened.

NOTE: Mast section-4 into section-3 fit should be very snugbut still be able to be pushed together by hand. If tootight, remove section-4, disassemble slide pad andreduce thickness of shim stock.

e. Begin sliding top of mast section-4 with closedrail down engaging the slide pads into slide padchannels at bottom of mast section-3’s open rail.Continue to push section-4 into section-3 untilBOTTOM ends of mast sections are even.

f. Check mast section for side play. If play existsuse thicker shims dividing thickness equallybetween both sides of mast.

g. When mast slide pads are shimmed properly,there should be no side to side movement ofslide pad in rail channel. Mast sections shouldbe very snug in channels but still be able to slidein channel by hand.

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

5. Insert threaded ends of cable assembly (attached totop of mast section-2) through the cable anchorplate located on bottom of extended mast section-4.Loosely thread two (2) 3/8"-16UNC nuts onto studthreads on each chain. Chains will be adjusted laterin assembly.

6. Slide mast section-4 back into mast section-3 untilbottom ends of masts are even. Check to make surecable set attached to top of section-2 is seatingproperly in cable sheave wheels attached to top ofmast section-3. (Mast section-2 may need to berestrained to keep it’s slide pads from pushing outthe bottom of mast sections-1).

7. Adjust top and bottom ends of mast sections so theyare all even with each other. At bottom of mastassembly, thread all chain/cable adjusting nuts onthreaded ends until they are snug against theanchor plates and all slack is removed from chainsand cables. Check that chains and cables areseated in their sheave wheels at top of mast assem-bly.

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

Mast assembly should now be complete.

2.7 MAST TO BASE FRAME INSTALLATION

1. Using an overhead crane or suitable lifting devicecapable of supporting the weight of base frame,attach a sling strap or chain to the front crossmem-ber of the base frame, raise base frame.

2. Extend hydraulic cylinder out from bottom of mastassembly approximately one (1) foot. (Caps onextend and return ports will need to be removed toextend cylinder. Catch any hydraulic fluid expelledfrom return port in a container to prevent spillageonto work area).

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

4. Slide port end of hydraulic cylinder through hole inbase frame cylinder mounting channel. (Return port(tube side) of cylinder must be on right side facingbottom of base and mast).

2-12 – JLG Lift – 3120779


5. Align threaded hole in side of hydraulic cylinderhead with hole in tab on bottom side of cylindermounting channel. Secure hydraulic cylinder to cyl-inder mounting channel tab using a 5/16"-18UNC x5/8" long hex head bolt and flat washer.

6. Carefully push mast assembly and base assemblytogether until the four (4) holes on bottom rear ofmast align with holes in the base frame mast supportcrossmember.

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 andmount with nuts on inside of frame).

8. Locate the two (2) mast support braces, attach tosides of base frame using a 3/8"-16UNC x 1" longhex head bolt, nut and flatwashers each brace,(place a flatwasher under bolt head and nut andmount with nuts on inside of frame. Use access holein bottom of frame to attach nut inside frame).

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

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

11. Locate the mast support bracket. Attach mast sup-port bracket to mounting holes halfway up back ofmast using four (4) 3/8"-16UNC x 2-3/4" long hexhead bolts, locknuts and flatwashers. (Place a flat-washer under bolt head and nut and mount with nutson 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 supportbraces, (bolted to base), to the mast supportbracket, (bolted to mast), using 3/8"-16UNC x 2-3/4"long hex head bolts, nuts and flatwashers. (Place aflatwasher under bolt head and nut and mount withnuts on inside of bracket).

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

Mast installation should now be complete.

2.8 MAST CHAINS/CABLES AND SEQUENCING CABLES ADJUSTMENT

Mast Chain/Cable Adjustment

The intention of this procedure is to assure equal load dis-tribution between the individual chains/cables of a mastsection chain/cable set.

Adjust using the following procedure;

1. With mast retracted, step into the platform andbounce your weight up and down a few times to becertain platform is at the bottom of travel. Be certainall chain/cable sets are seated in their sheaves prop-erly at the top of each mast section.

2. Then with no load in the platform check the side pro-file of the top of the mast for the amount of adjust-ment necessary to step the mast sections 7/16 in.(12mm) for mast sections-3 and up. (See Figure 2-5.)

NOTE: Mast section-1 is fixed to the base and mast section-2 is attached to the lift cylinder, these sectionsrequire no adjustment.

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

4. Elevate the platform until the chain/cable anchoradjust nuts are accessible at the front and bottom ofeach mast section.

NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT-FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENTBY BLOCKING OR OVERHEAD SLING.

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

6. Tighten (to raise mast section), or loosen (to lowermast section) the adjusting nut against the anchorplate on each chain/cable. Adjust the nut theamount required to raise or lower the top of the mastsection to match the side profile shown in Figure 2-5. when the mast is retracted. Be certain each chain/cable pair is adjusted to equal tension. (Thethreaded end of the chain/cable will need to berestrained while tightening the adjust nut to keep thechain/cable from twisting.)

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

8. Repeat steps (1) through (7) for remaining mast sec-tions. ENSURE THAT ALL CHAIN/CABLE PAIRSHAVE EQUAL TENSION.

3120779 – JLG Lift – 2-13


9. Once mast section adjustment is completed, applyloctite #242 to the threads under the (jam) nuts thatwere loosened. Then re-tighten the loosened (jam)nuts until tight against the top (adjust) nut. Chain/cable should have slight tension but should not betaut.

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 excessiveslack from sequencing cable. The springs shouldnot be compressed more than 25% after adjusting.

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

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

SECTION-1FIXED

TO BASE

SEQUENCE CABLEADJUST NUT

CHECK IF OVERALL HEIGHTOF MACHINE FROM

FLOOR TO TOP OF MAST IS WITHIN SPECIFICATION

SECTION-2EXTENDED BY

CYLINDER

SECTION-5(PLATFORM

HEADER SECTION)EXTENDED BYCHAIN/CABLE

CHAIN/CABLEANCHOR PLATE

ADJUST NUT

JAM NUT

THREADEDCHAIN/CABLE

END

SECTION-4EXTENDED BYCHAIN/CABLE

SECTION-3EXTENDED BY

CHAIN

STEP APPROXIMATELY7/16 in. (12mm)

MAST SIDE PROFILE MAST CHAIN/CABLE ADJUSTERS

Note: When

pply Loctite #242 to the

threads under the jam nut.

.

chain adjustment

is complete, before

tightening the jam nutagainst the adjust nut,

a

2-14 – JLG Lift – 3120779


2.9 SEQUENCE CABLE REPLACEMENT KIT

A sequence cable replacement kit is available from theJLG Parts Department to service broken or wornsequence cables. This kit consists of a replacementsequence cable with the threaded (top) end attachedsame as the top end of the factory cable. Also included isa clamp (drum/socket type) to secure the bottom end ofthe cable. Use the following procedure to install thereplacement cable and clamp kit.

Remove Old Cable

1. Remove the locking nut from the threaded end ofthe cable at the top of the mast and then remove thespring cap, spring, and spacer washers if installed.

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

Replacement Cable Installation

1. Be certain the mast is completely retacted and at thebottom of travel. Check the mast "Side Profile" at thetop of the mast as shown in Figure 2-5., adjust mastsections to proper height if necessary.

2. To determine where the clamp will be installed at thebottom of the replacement cable, temporarilyassemble the new replacement cable to the topcable anchor bracket on the mast using the wash-ers, spring, spring cap and lock nut previously dis-assembled. Thread the lock nut on untilapproximately 1/8 in. (3mm) of threads are exposed.

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

4. Grasp the cable and pull on the cable until thespring at the top of the cable is slightly compressed.Use a black marker to mark the cable on the topside of the sheave pully/anchor bracket. This willdetermine where the clamp (drum/socket) sleeve willbe positioned on the cable.

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

Clamp Installation (Drum/Socket Type)

THE MANUFACTURER OF THE DRUM/SOCKET CLAMP RECOM-MENDS THE USE OF THEIR CABLE CLAMP ASSEMBLY KIT (JLGP/N - 7023275) TO ASSEMBLE THE CLAMP TO THE WIRE ROPE.THE KIT CONSISTS OF VISE JAWS TO HOLD THE WIRE ROPE INA VISE PROPERLY WITHOUT DAMAGING ANY ROPE STRANDSAND A PLUG DRIVER TO DRIVE THE PLUG INTO THE CENTER OFTHE WIRE ROPE AND IS ALSO USED TO FORM THE STRANDS OFTHE ROPE DURING ASSEMBLY.

NOTE: The tools in the clamp assembly kit may be frabri-cated if necessary. The vise clamp consists of visejaws with a hole drilled 1/32 in. smaller than thediameter 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 bot-tom to allow the strands of the wire rope to beshaped after the plug has been tapped into the cen-ter of the wire rope.

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

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

3120779 – JLG Lift – 2-15


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

4. Unlay the cable strands by gently forcing a screw-driver between the outer strands to unlay the cable.When done properly the outer strands will form asymmetrical basket. Do not straighten out the spirallay of the strands, unlay any wires that make up thestrand, or allow the strands to cross each otherinside the sleeve.

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

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

NOTE: When assembling stainless steel parts all threadsmust be coated with a dry lubricant or an anti-siezelubricant to prevent seizing.

7. Coat the threads of the socket and sleeve with lubri-cant and install the socket by twisting it over thestrands of the cable and engage the threads of thesleeve with the socket. Tighten until four threads orfewer are visible. If more than four threads are visi-ble, proof load the cable and retighten the socket fit-ting. (There is no specific requirement for torque.)

8. Inspect for proper assembly prior to loading thecable. Strands visible through the inspection holeare 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 instructionsshown previously in Section 2.8, MAST CHAINS/CABLES AND SEQUENCING CABLES ADJUST-MENT.

2-16 – JLG Lift – 3120779


2.10 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

(See Table 2-3.)

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

The checks and services listed in this schedule are notintended to replace any local or regional regulations thatmay pertain to this type of equipment nor should the listsbe considered as all inclusive. Variances in interval timesmay occur due to climate and/or conditions and depend-ing on the location and use of the machine.

JLG Industries requires that a complete annual inspectionbe performed in accordance with the “Annual MachineInspection Report” form. Forms are supplied with eachnew machine and are also available from JLG CustomerService. Form must be completed and returned to JLGIndustries.

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

3120779 – JLG Lift – 2-17


The inspection and maintenance code numbers are as fol-lows:

1. Check for proper and secure installation.2. Check for visible damage and legibility.3. Check for proper fluid level.4. Check for any structural damage; cracked or broken

welds; bent/warped surface; broken cable strands.5. Check for leakage.6. Check for presence of excessive dirt or foreign

material.7. Check for proper operation and freedom of move-

ment.

8. Check for excessive wear or damage.9. Check for proper tightness and adjustment.

10. Drain, clean and refill.11. Check for proper operation while pump/motor is

running.12. Check for proper lubrication.13. Check for evidence of scratches, nicks or rust and

for straightness of rod.14. Check for condition of element; replace as neces-

sary.

Table 2-3. Preventive Maintenance & Inspection Schedule.

AREA ON MACHINE INTERVAL

PLATFORM(10 HRS.)

DAILY(50 HRS.)WEEKLY

(200 HRS.)MONTHLY

(500 HRS.)3 MONTHS

(1000 HRS.)6 MONTHS

(2000 HRS.)1 YEAR

Control Switches 1,11

Placards and Decals 1,2

Control Tags 1,2

Electrical Cables 1,8

Handrail and Bar Gate 1,4

MAST

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

Mast Sections 1,4,7

Mast Sequencing Cables 1,4,7,9

BASE FRAME

Batteries (DC Models) 1,3 5 12

Battery Charger (DC Models) 1

Power Cable (AC Models) 1,8

Electric Motor/Hydraulic Pump Unit 1 5

Hydraulic Hoses and Fittings 1 5

Hydraulic Oil Reservoir * 3 5 4

Hydraulic Oil Reservoir Breather 6,14

Manual Descent Valve 1,7

Lift Cylinder 1 5,6,13 4

Floor Brake Assembly 1,6,7,8 12


Wheels and Casters 1 8,9 12

Wheel Bearings 8 12

Power Switch (Ground Control Box) 1,11

Control Tags 1,2


Hoses and Cables 1,8

2-18 – JLG Lift – 3120779


SECTION 3. TROUBLESHOOTING

3.1 GENERALThis section contains troubleshooting information to beused for locating and correcting most of the operatingproblems which may develop in the aerial platform. If aproblem should develop which is not presented in thissection or which is not corrected by listed correctiveactions, technically qualified guidance should be obtainedbefore proceeding with any maintenance.

3.2 TROUBLESHOOTING INFORMATIONThe troubleshooting procedures applicable to the aerialplatform are listed and defined in Table 3-1., AC Unit Trou-bleshooting and Table 3-2., DC Unit Troubleshooting.

Each malfunction within an individual group or system isfollowed by a listing of probable causes which will enabledetermination of the applicable remedial action. The prob-able causes and the remedial action should, where possi-ble, be checked in the order listed in the tables.

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

It should be recognized that the majority of the problemsarising in the machine will be centered in the hydraulicand electrical systems. For this reason, every effort hasbeen made to ensure that all likely problems in theseareas are given the fullest possible treatment. In theremaining machine groups, only those problems whichare symptomatic of greater problems which have morethan one probable cause and remedy are included. Thismeans that problems for which the probable cause andremedy may be immediately obvious are not listed in thissection.

The first rule for troubleshooting any circuit that is hydrau-lically operated and electrically controlled is to determineif the circuit is lacking hydraulic oil and electrical controlpower. This can be ascertained by overriding the bypassvalve (mechanically or electrically) so that oil is availableto the function valve, then overriding the function valvemechanically. If the function performs satisfactorily, theproblem exists with the control circuit.

3.3 ELECTRICAL AND HYDRAULIC CIRCUIT CHECKS

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

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

NOTE: For aid in Hydraulic troubleshooting, refer to Figure3-1. HYDRAULIC Schematic at the end of this sec-tion. For ELECTRICAL Diagrams refer to Figure 3-2.,3-3., 3-4. & 3-5., also at the end of this chapter.

3120779 – JLG Lift – 3-1


Table 3-1. AC Unit - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Platform does not rise.

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

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

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

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

Control relay not functioning. Replace control relay.

Motor start relay not functioning. Replace motor start relay.

Fuse(s) blown. Replace blown fuse. If fuse blows again check electrical circuit for short circuit.

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

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

Properly reinstall wire to limit switch.

Platform lowers by itself.

Manual descent valve open. Close manual descent valve.

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

Tighten hydraulic hose and/or fittings.

Lift DOWN solenoid valve not function-ing.

Replace Lift DOWN solenoid valve.

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.

Replace breather cap on tank.

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.

3-2 – JLG Lift – 3120779


Table 3-2. DC Unit - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Platform does not rise.

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

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

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

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

Control relay not functioning. Replace control relay.

Motor start relay not functioning. Replace motor start relay.

Fuse(s) blown. Replace blown fuse. If fuse blows again check electrical circuit for short circuit.

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

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

Properly reinstall wire to limit switch.

Platform lowers by itself.

Manual descent valve open. Close manual descent valve.

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

Tighten hydraulic hose and/or fittings.

Lift DOWN solenoid valve not function-ing.

Replace Lift DOWN solenoid valve.

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.

Replace breather cap on tank.

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.

3120779 – JLG Lift – 3-3



3-4 – JLG Lift – 3120779


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

2792491_A

3120779 – JLG Lift – 3-5


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

4933258_A

3-6 – JLG Lift – 3120779


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

4933258_A

3120779 – JLG Lift – 3-7


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

4933259_A

3-8 – JLG Lift – 3120779



4933259_A

3120779 – JLG Lift – 3-9



4933260_A

3-10 – JLG Lift – 3120779



4933260_A

3120779 – JLG Lift – 3-11



4933261_A

3-12 – JLG Lift – 3120779



4933261_A

3120779 – JLG Lift – 3-13



3-14 – JLG Lift – 3120779

JLG Worldwide Locations

Corporate Office

JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-9533

USA

Phone: (717) 485-5161

Fax: (717) 485-6417

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

JLG Industries (UK)Unit 12, SouthsideBredbury Park Industrial EstateBredburyStockportSK6 2sPEnglandPhone: (44) 870 200 7700Fax: (44) 870 200 7711

JLG Deutschland GmbHMax Planck Strasse 21D-27721 Ritterhude/lhlpohlBei BremenGermanyPhone: (49) 421 693 500Fax: (49) 421 693 5035

JLG Industries (Italia)Via Po. 2220010 Pregnana Milanese - MIItalyPhone: (39) 02 9359 5210Fax: (39) 02 9359 5845

JLG Latino Americana Ltda.Rua Eng. Carlos Stevenson,80-Suite 7113092-310 Campinas-SPBrazilPhone: (55) 19 3295 0407Fax: (55) 19 3295 1025

JLG Europe B.V.Jupiterstraat 2342132 HJ FoofddorpThe NetherlandsPhone: (31) 23 565 5665Fax: (31) 23 557 2493

JLG Industries (Norge AS)Sofeimyrveien 12N-1412 SofienyrNorwayPhone: (47) 6682 2000Fax: (47) 6682 2001

JLG PolskaUI. Krolewska00-060 WarsawaPolandPhone: (48) 91 4320 245Fax: (48) 91 4358 200

JLG Industries (Europe)Kilmartin Place, Tannochside ParkUddingston G71 5PHScotlandPhone: (44) 1 698 811005Fax: (44) 1 698 811055

JLG Industries (Pty) Ltd.Unit 1, 24 Industrial ComplexHerman StreetMeadowdaleGermistonSouth AfricaPhone: (27) 11 453 1334Fax: (27) 11 453 1342

Plataformas Elevadoras JLG Iberica, S.L.Trapadella, 2P.I. Castellbisbal Sur08755CastellbisbalSpainPhone: (34) 93 77 24700Fax: (34) 93 77 11762

JLG Industries (Sweden)Enkopingsvagen 150Box 704SE - 175 27 JarfallaSwedenPhone: (46) 8 506 59500Fax: (46) 8 506 59534

Documents

MODEL 15ELI - JLG Industries Vertical Mas… · Service and Maintenance Manual ANSI MODEL 15ELI 3120779 August 5, 2002. CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts, terminals