Service and Maintenance Manual MODEL 15ELI 3120779 August 5, 2002 ANSI
CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemical known to the State of Califormia to cause cancer and reproductive harm.
FOREWORD The purpose of this manual is to provide users with the operating procedures essential for the promotion of proper machine operation for its intended purpose. It is important to over-stress proper machine usage. All information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the machine. YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL - Keep it with the machine. REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR.
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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A. GENERAL C. MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others or damage to the equipment.
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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.
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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 . . . . . . .
TABLE OF CONTENTS 2.3 LUBRICATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 2-1. 2-2. 2-3. 2-4. 2-5. 3-1. 3-2. 3-3. 3-4. 3-5. TITLE PAGE NO. Hydraulic Pressure Setting - Adjustment Screw Located at Base of Pump Motor . . . . . . . . . . . .1-2 Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Lubrication Locations (See Table below). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 DRY (Option) CAPACITIES 12 Volt – 165 Amp (min.) – Deep Cycle Marine - RV Hydraulic Oil Reservoir AGM (Absorption Gas Mat) (Option) 12Volt – 100 O.A.H. – M2 Marine Combination AC Models – 5 qts. U.S. (4.7 ltr.) DC Models – 5 qts. U.S. (4.7 ltr.) Battery Charger – DC Models. 110/240 Volts AC, 50/60 Hz - input 1.
SECTION 1 - SPECIFICATIONS 1.5 cold, platform may not raise rated load after oil has warmed. LUBRICATION Hydraulic Oil Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries, recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152. For cold weather applications, i.e.
SECTION 1 - SPECIFICATIONS Figure 1-2. Torque Chart.
SECTION 1 - SPECIFICATIONS 3 1 2 Figure 1-3. Lubrication Locations (See Table below). Table 1-4. Lubrication Intervals for Various Components INTERVAL HOURS ITEM 1 COMPONENT Hydraulic Oil NO/TYPE LUBE POINTS Fill To Line on Reservoir 5 Qt. (4.3 L) Reservoir LUBE/METHOD 6 MOS. or 300 Hrs. HO - Check Hyd. Oil Level HO - Change Hyd. Oil 2 Swivel Raceways 2 - Front Casters MPG - Pressure Gun 3 Mast Chains * Chain Lube - Brush or Spray 2 - Per Section 3 MOS. or 150 Hrs. 1 YR. or 600 Hrs.
SECTION 2 - SERVICE PROCEDURES SECTION 2. SERVICE PROCEDURES 2.1 cap or cover all openings to prevent entry of foreign matter. GENERAL This section provides general information to assist in the performance of maintenance on the personnel lift. Descriptions, techniques and specific procedures are designed to provide the safest and most efficient maintenance for use by personnel responsible for ensuring the correct installation and operation of machine components and systems.
SECTION 2 - SERVICE PROCEDURES Gaskets Mast Chain Inspection Procedure Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious system damage. MAST CHAINS TO BE INSPECTED AND LUBRICATED EVERY THREE MONTHS.
SECTION 2 - SERVICE PROCEDURES Tight Joints: All joints in the leaf chain should flex freely. On leaf chains, tight joints are usually caused by rust/corrosion, or the inside plates “walking” off the bushing. Limber up rusty/corroded chains (after inspecting carefully) with a heavy application of oil (preferably a hot oil dip). Tap inside “walking” plates inward; if “walking” persists, replace the chain.
SECTION 2 - SERVICE PROCEDURES smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage. Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil.
SECTION 2 - SERVICE PROCEDURES 2.4 AC JUNCTION BOX COMPONENTS (AC POWERED MACHINES ONLY) HAZARD OF ELECTRIC SHOCK! ALWAYS DISCONNECT ELECTRICAL POWER TO THE JUNCTION BOX BEFORE ATTEMPTING TO DISCONNECT ANY CIRCUITS OR WHEN REMOVING COMPONENTS. WHEN TESTING CIRCUITS WITH ELECTRICAL POWER ON, USE ONLY INSTRUMENTS WITH INSULATED TEST LEADS KEEPING YOUR HANDS OUTSIDE THE BOX. 1 2 7 6 3 5 4 1. 2. 3. 4. 12V-DC Starter Relay 115V or 230V AC Power Relay Terminal Strip Circuit Breaker (AC) (CE Qty.-2) 5.
SECTION 2 - SERVICE PROCEDURES 2.5 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES Mast Disassembly Procedure (See Figure 2-2.) 1. After the platform and other hardware have been removed from the mast, and mast has been removed from machine, lay mast assembly down with the shortest mast section-4 on top and facing up. The AM Series personnel lift mast sections are contructed of extruded aluminum, protected with an anodized surface finish.
SECTION 2 - SERVICE PROCEDURES Mast Section 3 – Removal 8. Remove countersunk-flathead screws securing chain anchor block/sheave wheel assembly attach bars on both side rails at TOP of mast section-2. 1. Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate on BOTTOM end of mast section-3. Push threaded ends of cable through anchor plate. 2.
SECTION 2 - SERVICE PROCEDURES 2.6 a. Check mast section for side play. If play exists add .015" shims dividing the thickness equally between both sides of mast. Insert shims until the shims cannot be inserted halfway by hand with the mast pulled to the opposite side. MAST ASSEMBLY (See Figure 2-2.) Mast Section 1 - Assembly b. When mast slide pads are shimmed properly, there should be no side to side movement of slide pad in rail channel.
SECTION 2 - SERVICE PROCEDURES MAST SECTION-3 MAST SECTION-1 LIFT CYLINDER MAST SECTION-2 MAST SECTION-4 Figure 2-3. 15ELI Mast Assembly Components.
SECTION 2 - SERVICE PROCEDURES Figure 2-4. Mast Chain/Cable Routing Diagram.
SECTION 2 - SERVICE PROCEDURES 16. Assemble chain sheaves on chain assembly anchor block (attached to cylinder rod end) and attach to mast section-2 using following steps; b. Slide two (2) short spacer tubes onto sheave pin, one each end of sheave pin to outside of sheave wheels. a. Insert sheave pin through anchor block on cylinder rod end. c. Place two (2) sheave pin attach bars, one each end of sheave pin to outside of space tubes. b.
SECTION 2 - SERVICE PROCEDURES Platform Mounting Section - Assembly g. When mast slide pads are shimmed properly, there should be no side to side movement of slide pad in rail channel. Mast sections should be very snug in channels but still be able to slide in channel by hand. 1. Locate the remaing mast section-4 (platform mounting - mast section). Lay mast section on flat stable surface. 4. Slide mast section-4 out to top of section-3. 2.
SECTION 2 - SERVICE PROCEDURES 5. Align threaded hole in side of hydraulic cylinder head with hole in tab on bottom side of cylinder mounting channel. Secure hydraulic cylinder to cylinder mounting channel tab using a 5/16"-18UNC x 5/8" long hex head bolt and flat washer. 6. Carefully push mast assembly and base assembly together until the four (4) holes on bottom rear of mast align with holes in the base frame mast support crossmember. 2.
SECTION 2 - SERVICE PROCEDURES MAST SIDE PROFILE MAST CHAIN/CABLE ADJUSTERS STEP APPROXIMATELY 7/16 in.
SECTION 2 - SERVICE PROCEDURES 2.9 SEQUENCE CABLE REPLACEMENT KIT A sequence cable replacement kit is available from the JLG Parts Department to service broken or worn sequence cables. This kit consists of a replacement sequence cable with the threaded (top) end attached same as the top end of the factory cable. Also included is a clamp (drum/socket type) to secure the bottom end of the cable. Use the following procedure to install the replacement cable and clamp kit. Remove Old Cable 1.
SECTION 2 - SERVICE PROCEDURES 6. Reclamp the assembly in the vise on the flats of the sleeve. Using the plug driver, a metal tube or pliers, bend the outer strands toward the center strands enough that the socket can be slipped over all the strands. 3. Use a suitable tool and cut the cable as shown in the illustration following. For 1/8 in. cable the recommended length is 5/8 in. past the end of the sleeve. 4.
SECTION 2 - SERVICE PROCEDURES 2.10 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE (See Table 2-3.) The preventive maintenance and inspection checks are listed and defined in the following table (See Table 2-3.). This table is divided into two basic parts, the “AREA” to be inspected and the “INTERVAL” at which the inspection is to take place. Under the “AREA” portion of the table, the various systems along with the components that make up that system are listed.
SECTION 2 - SERVICE PROCEDURES Table 2-3. Preventive Maintenance & Inspection Schedule. AREA ON MACHINE PLATFORM INTERVAL (10 HRS.) DAILY Control Switches 1,11 Placards and Decals 1,2 Control Tags 1,2 Electrical Cables 1,8 Handrail and Bar Gate 1,4 (50 HRS.) WEEKLY (200 HRS.) MONTHLY (500 HRS.) 3 MONTHS (1000 HRS.) 6 MONTHS (2000 HRS.
SECTION 3 - TROUBLESHOOTING SECTION 3. TROUBLESHOOTING 3.1 GENERAL 3.3 This section contains troubleshooting information to be used for locating and correcting most of the operating problems which may develop in the aerial platform. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance. 3.
SECTION 3 - TROUBLESHOOTING 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 Station 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.
SECTION 3 - TROUBLESHOOTING 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 Station 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.
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SECTION 3 - TROUBLESHOOTING 2792491_A Figure 3-1. Hydraulic Schematic.
SECTION 3 - TROUBLESHOOTING 4933258_A Figure 3-2. Electrical Diagram.
SECTION 3 - TROUBLESHOOTING 4933258_A Figure 3-2. Electrical Diagram.
SECTION 3 - TROUBLESHOOTING 4933259_A Figure 3-3. Electrical Diagram.
SECTION 3 - TROUBLESHOOTING 4933259_A Figure 3-3. Electrical Diagram.
SECTION 3 - TROUBLESHOOTING 4933260_A Figure 3-4. Electrical Diagram.
SECTION 3 - TROUBLESHOOTING 4933260_A Figure 3-4. Electrical Diagram.
SECTION 3 - TROUBLESHOOTING 4933261_A Figure 3-5. Electrical Diagram.
SECTION 3 - TROUBLESHOOTING 4933261_A Figure 3-4. Electrical Diagram.
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Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.
