JLG EcoLift50 Installation and user guide

Service and Maintenance Manual
Models
EcoLift50
SN P900004791 to Present
EcoLift70
SN P900004840to Present
31215861
January 15, 2020 - Rev A
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Discount-Equipment.com is your online resource for quality parts & equipment.
Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101
Need parts?
Click on this link: http://www.discount-equipment.com/category/5443-parts/ and
choose one of the options to help get the right parts and equipment you are looking
for. Please have the machine model and serial number available in order to help us
get you the correct parts. If you don’t find the part on the website or on once of the
online manuals, please fill out the request form and one of our experienced staff
members will get back to you with a quote for the right part that your machine needs.
We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,
Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,
Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack,
Lull, Skytrak, Tsurumi, Husquvarna Target, , Stow, Wacker, Sakai, Mi-T- M, Sullair, Basic,
Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti,
Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, Barreto, EZ Trench, Bil-
Jax, F.S. Curtis, Gehl Pavers, Heli, Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD,
Koshin, Rice, CH&E, General Equipment, ,AMida, Coleman, NAC, Gradall, Square Shooter,
Kent, Stanley, Tamco, Toku, Hatz, Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK,
Rol-Air, Small Line, Wanco, Yanmar

INTRODUCTION
31215861 A-1
SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A. GENERAL
This section contains the general safety precautions which
must be observed during maintenance of the Mobile Elevat-
ing Work Platform. It is of utmost importance that mainte-
nance personnel pay strict attention to these warnings and
precautions to avoid possible injury to themselves or others or
damage to the equipment. A maintenance program must be
established by a qualified person and must be followed to
ensure that the machine is safe to operate.
MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE
AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFAC-
TURED IS A SAFETY VIOLATION.
The specific precautions to be observed during machine main-
tenance are inserted at the appropriate point in the manual.
These precautions are, for the most part, those that apply
when servicing hydraulic and larger machine component
parts.
Your safety, and that of others, is the first consideration when
engaging in the maintenance of equipment. Always be con-
scious of component weight and never attempt to move
heavy parts without the aid of a mechanical device. Do not
allow heavy objects to rest in an unstable position. When rais-
ing a portion of the equipment, ensure that adequate support
is provided.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD
INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA IS THE RESPONSIBILITY
OF THE OWNER/OPERATOR.
B. HYDRAULIC SYSTEM SAFETY
1. It should be particularly noted that the machines
hydraulic systems operate at extremely high and poten-
tially dangerous pressures. Every effort should be made
to relieve any system pressure prior to disconnecting or
removing any portion of the system.
2. Relieve system pressure by lowering the platform com-
pletely to direct any line pressure back into the return
line to the reservoir. Pressure feed lines to system com-
ponents can then be disconnected with minimal fluid
loss.
C. MAINTENANCE
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION COULD
RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY
VIOLATION.
• REMOVE ALL RINGS, WATCHES, AND JEWELRY WHEN PER-
FORMING ANY MAINTENANCE.
• DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE FIT-
TING CLOTHING AND NECKTIES WHICH ARE APT TO
BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT.
• OBSERVE AND OBEY ALL DANGER, WARNING, CAUTION
AND OTHER INSTRUCTIONS ON MACHINE AND IN SERVICE
MANUAL.
• KEEP STANDING SURFACES AND HAND HOLDS FREE OF
OIL, GREASE, WATER, ETC.
• NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL
PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY
MOVEMENT BY BLOCKING OR OVERHEAD SLING.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PER-
FORMING ANY OTHER MAINTENANCE, SHUT OFF ALL
POWER CONTROLS.
• BATTERY SHOULD ALWAYS BE DISCONNECTED DURING
REPLACEMENT OF ELECTRICAL COMPONENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS
STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL-
VENTS.
• ENSURE REPLACEMENT PARTS OR COMPONENTS ARE
IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COM-
PONENTS.
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31215861 1
TABLE OF CONTENTS
SECTION 1 - MACHINE SPECIFICATIONS
1.1 General Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Serial Number Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 Torque Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SAE Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SECTION 2 - GENERAL SERVICE INFORMATION
2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Servicing and Maintenance Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Components Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
SECTION 3 - COMPONENT SERVICING
3.1 Frame Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
EcoLift50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
EcoLift70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Tool Tray Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
EcoLift50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
EcoLift70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Platform Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 Castor Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
EcoLift50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
EcoLift70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5 Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.6 Flywheel Crank Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.7 Mast Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Mast Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Mast Re-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Gas Cylinder Pressurizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Flywheel Rotation Force - Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
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231215861
TABLE OF CONTENTS
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SECTION 1 - MACHINE SPECIFICATIONS
31215861 1-1
SECTION 1. MACHINE SPECIFICATIONS
1.1 GENERAL SPECIFICATIONS
1.2 DIMENSIONS 1.3 SERIAL NUMBER IDENTIFICATION
The serial number plate is attached to the mast frame on the
front of the machine.
DESCRIPTION EcoLift50 EcoLift70
Maximum Working Height 10.9 ft (3.32 m) 13.21 ft (4.03 m)
Maximum Platform Height 4.9 ft (1.50 m) 7.21 ft (2.20 m)
Platform Dimensions 28.3 in (L) x 23.6 in (W)
(720 mm (L) x 600 mm (W))
33.4 in (L) x 25.3 in (W)
(850 mm (L) x 644 mm (W))
Working Footprint 38.8 in x 28.3 in
(985 mm x 700 mm)
50.3 in x 29.1 in
(1280 mm x 740 mm)
Maximum Platform Capacity
(Platform and Tool Tray Combined)
330 lb (150 kg)
(1 person + tools)
Maximum Tool Tray Capacity 33 lb (15 kg)
Maximum Manual Side Force 45 lb (200 N)
Maximum Gradient for Operation 0 degrees
Maximum Wind Force Indoor use only
Maximum Wheel Load 260 lb (118 kg) 320 lb (145 kg)
Maximum Ground Bearing Pressure 168 psi (11.81 kg/cm2) 171 psi (12 kg/cm2)
DESCRIPTION EcoLift50 EcoLift70
Length 38.8 in (985 mm) 50.3 in (1280 mm)
Width 28.3 in (700 mm) 29.1in (740 mm)
Height 61 in (1550 mm) 76.77 in (1950 mm)
Weight 397 lb (180 kg) 672 lb (305 kg)
OAR00360
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SECTION 1 - MACHINE SPECIFICATIONS
1-2 31215861
1.4 OPERATING SPECIFICATIONS
EcoLift50 EcoLift70
OAR00590
13 ft
(4 m)
9.8 ft
(3 m)
6.5 ft
(2 m)
3.3 ft
(1 m)
00
14 ft
(4.2 m)
9.84 ft
(3 m)
6.5 ft
(2 m)
3.28 ft
(1 m)
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SECTION 1 - MACHINE SPECIFICATIONS
31215861 1-3
1.5 LUBRICATION INTERVALS
ITEM COMPONENT LUBE POINTS LUBE TYPE/METHOD *
INTERVAL (a)
1
MONTH
6
MONTHS
1
YEAR
1Mast Flywheel Flywheel Crank - Drive Gears OGG - Inspect and lubricate. Do not use standard gear grease. 
Lubrication Types:
• OGG - Open Gear Grease, Omega 73 - Grade 2, Harsh Environment Grease
NOTE: Recommended lubricating intervals are based on normal use. If machine is subjected to severe operating conditions (i.e., high number of cycles, harsh environment, corrosive/
dirty environment, etc.), lubricating requirements must be adjusted accordingly.
OAR00390
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SECTION 1 - MACHINE SPECIFICATIONS
1-4 31215861
1.6 TORQUE CHARTS
In the event of maintenance or a loose fastener, use the following torque charts to determine proper torque value.
SAE Fasteners
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SECTION 1 - MACHINE SPECIFICATIONS
31215861 1-5
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SECTION 1 - MACHINE SPECIFICATIONS
1-6 31215861
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SECTION 1 - MACHINE SPECIFICATIONS
31215861 1-7
Metric Fasteners
Go to Discount-Equipment.com to order your parts

Discount-Equipment.com is your online resource for quality parts & equipment.
Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101
Need parts?
Click on this link: http://www.discount-equipment.com/category/5443-parts/ and
choose one of the options to help get the right parts and equipment you are looking
for. Please have the machine model and serial number available in order to help us
get you the correct parts. If you don’t find the part on the website or on once of the
online manuals, please fill out the request form and one of our experienced staff
members will get back to you with a quote for the right part that your machine needs.
We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,
Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,
Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack,
Lull, Skytrak, Tsurumi, Husquvarna Target, , Stow, Wacker, Sakai, Mi-T- M, Sullair, Basic,
Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti,
Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, Barreto, EZ Trench, Bil-
Jax, F.S. Curtis, Gehl Pavers, Heli, Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD,
Koshin, Rice, CH&E, General Equipment, ,AMida, Coleman, NAC, Gradall, Square Shooter,
Kent, Stanley, Tamco, Toku, Hatz, Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK,
Rol-Air, Small Line, Wanco, Yanmar

SECTION 2 - GENERAL SERVICE INFORMATION
31215861 2-1
SECTION 2. GENERAL SERVICE INFORMATION
2.1 MACHINE PREPARATION, INSPECTION, AND
MAINTENANCE
This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness and maintain its safe
operating condition. For maximum service life and safe
operation, ensure that all the necessary inspections and
maintenance have been completed before placing the
machine into service. With proper care, maintenance, and
inspections performed per JLG’s recommendations with
any and all discrepancies corrected, this product will be fit
for continued use.
Preparation, Inspection, and Maintenance
It is important to establish and conform to a comprehen-
sive inspection and preventive maintenance program. The
Preventive Maintenance and Inspection Schedule (Section
2.2) outlines the periodic machine inspections and main-
tenance recommended by JLG Industries, Inc. Consult
your national, regional, or local regulations for further
requirements for Mobile Elevating Work Platforms
(MEWP). The frequency of inspections and maintenance
must be increased as environment, severity and frequency
of usage requires.
Pre-Start Inspection
It is the User’s or Operator’s primary responsibility to per-
form a Pre-Start Inspection of the machine prior to use
daily or at each change of operator. Reference the Opera-
tion and Safety Manual for completion procedures for the
Pre-Start Inspection. The Operation and Safety Manual
must be read in its entirety and understood prior to per-
forming the Pre-Start Inspection.
Pre-Delivery Inspection and Frequent Inspection
The Pre-Delivery Inspection and Frequent Inspection shall
be performed by a qualified JLG equipment mechanic. JLG
Industries, Inc. recognizes a qualified JLG equipment
mechanic as a person who, by possession of a recognized
degree, certificate, extensive knowledge, training, or expe-
rience, has successfully demonstrated the ability and pro-
ficiency to service, repair, and maintain the subject JLG
product model.
The Pre-Delivery Inspection and Frequent Inspection pro-
cedures are performed in the same manner, but at differ-
ent times. The Pre-Delivery Inspection shall be performed
prior to each sale, lease, or rental delivery. The Frequent
Inspection shall be accomplished for each machine in ser-
vice for 3 months or 150 hours; out of service for a period
of more than 3 months; or when purchased used. The fre-
quency of this inspection must be increased as environ-
ment, severity and frequency of usage requires.
Reference the JLG Pre-Delivery and Frequent Inspection
Form and the Inspection and Preventative Maintenance
Schedule for items requiring inspection during the perfor-
mance of these inspections. Reference the appropriate
areas of this manual for servicing and maintenance proce-
dures.
Annual Machine Inspection
JLG recommends that the Annual Machine Inspection be
performed by a Factory-Trained Service Technician on an
annual basis, no later than thirteen (13) months from the
date of the prior Annual Machine Inspection. JLG Indus-
tries, Inc. recognizes a Factory-Trained Service Technician
as a person who has successfully completed the JLG Ser-
vice Training School for the subject JLG product model.
Reference the machine Service and Maintenance Manual
and appropriate JLG inspection form for performance of
this inspection.
Reference the JLG Annual Machine Inspection Form and
the Inspection and Preventative Maintenance Schedule
for items requiring inspection during the performance of
this inspection. Reference the appropriate areas of this
manual for servicing and maintenance procedures.
For the purpose of receiving safety-related bulletins, it is
important that JLG Industries, Inc. has updated ownership
information for each machine. When performing each
Annual Machine Inspection, notify JLG Industries, Inc. of
the current machine ownership.
Preventative Maintenance
In conjunction with the specified inspections, mainte-
nance shall be performed by a qualified JLG equipment
mechanic. JLG Industries, Inc. recognizes a qualified JLG
equipment mechanic as a person who, by possession of a
recognized degree, certificate, extensive knowledge, train-
ing, or experience, has successfully demonstrated the abil-
ity and proficiency to service, repair, and maintain the
subject JLG product model.
Refer to the Preventive Maintenance and Inspection
Schedule and the appropriate areas of this manual for ser-
vicing and maintenance procedures. The frequency of ser-
vice and maintenance must be increased as environment,
severity and frequency of usage requires.
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SECTION 2 - GENERAL SERVICE INFORMATION
2-2 31215861
Inspection and Maintenance Table
TYPE FREQUENCY PRIMARY
RESPONSIBILITY
SERVICE
QUALIFICATION REFERENCE
Pre-Start
Inspection
Prior to use each day; or
At each Operator change. User or Operator User or Operator Operator and Safety Manual
Pre-Delivery
Inspection
Prior to each sale, lease, or
rental delivery.
Owner, Dealer, or
User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
Frequent
Inspection
In service for 3 months; or Out of service for a
period of more than 3 months; or Purchased
used.
Owner, Dealer, or
User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
Annual
Machine
Inspection
Annually, no later than 13 months from the
date of the prior inspection.
Owner, Dealer, or
User
JLG Factory-Trained
Service Technician
(Recommended)
Service and Maintenance Manual
and applicable JLG inspection form.
Preventative
Maintenance
At intervals as specified in the Service and
Maintenance Manual.
Owner, Dealer, or
User Qualified JLG Mechanic Service and Maintenance Manual
JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING
SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.
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SECTION 2 - GENERAL SERVICE INFORMATION
31215861 2-3
2.2 PREVENTIVE MAINTENANCE AND INSPECTION
SCHEDULE
The preventive maintenance and inspection checks are
listed and defined in the following table. This table is
divided into two basic parts, the “AREA” to be inspected
and the “INTERVAL” at which the inspection is to take
place. Under the “AREA” portion of the table, the various
systems along with the components that make up that
system are listed. The “INTERVAL” portion of the table is
divided into two columns representing the various inspec-
tion time periods. The numbers listed within the interval
column represent the applicable inspection code for
which that component is to be checked.
The checks and services listed in this schedule are not
intended to replace any local or regional regulations that
may pertain to this type of equipment nor should the lists
be considered as all inclusive. Variances in interval times
may occur due to climate and or conditions and depend-
ing on the location and use of the machine.
AREA ON MACHINE
INTERVAL
Pre-Delivery1 or Frequent 2
(Quarterly)
Inspection
Annual3
(Yearly)
Inspection
MAST ASSEMBLY AND PLATFORM ASSEMBLY
Mast Sections 2, 3 2, 3
Belt System 1, 2, 3 1, 2, 3
Slide Pads 1, 2 1, 2
Platform, Platform Gate, and Latches 1, 3 1, 3
Guard Rails 1, 2 1, 2
Covers and Shields 1, 5 1, 5
Floor 1, 2 1, 2
Lanyard Anchorage Point 1, 2, 6 1, 2, 6
Flywheel Crank Assembly 1, 3 1, 3, 4
Tool Tray 1 1
CHASSIS AND BASE ASSEMBLY
Brake Release 3 3
Wheel Locking Nut 150 150
Covers and Shields 1, 5 1, 5
Static Strap 1 1
Wheel and Tire Assemblies 1, 2 1, 2
Bubble Level 1 1
Emergency Lowering Tool 1, 3 1, 3
GENERAL
No Unauthorized Modifications or Additions 9 9
General Structural Condition and Welds 2 2
Paint and Appearance 5 5
Notify JLG of Machine Ownership 9 9
Annual Machine Inspection Due - 9
All Relevant Safety Publications Incorporated 9 9
All Decals/Placards Installed, Secure, Legible 9 9
All Fasteners, Pins, Shields, and Covers 1,2 1,2
Function Test of All Systems 9 9
Stamp Inspection Date on Frame - 9
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SECTION 2 - GENERAL SERVICE INFORMATION
2-4 31215861
Footnotes:
1 Prior to each sale, lease, or delivery
2 In service for 3 months; Out of service for 3 months or more; Purchased used
3 Annually, no later than 13 months from the date of the prior inspection, Includes all daily and quarterly inspections, mandated by
regulating body
50 Indicates a 50 hour interval required to perform task after initial use of machine. This only occurs once in machine life
Performance Codes:
1 - Check for proper and secure: installation, adjustment, or torque
2 - Visual inspection for damage: (cracks, corrosion, abrasions, distortion, excessive wear, broken welds, gouges, chafing and
threads showing)
3 - Proper operation
4 - Check for proper sealing, signs of leakage and fluid level
5 - Clean and free of debris
6 - Decals installed and legible
7 - Check for proper tolerances, routing, and lubrication
8 - Fully Charged
9 - Verify/Perform
AREA ON MACHINE
INTERVAL
Pre-Delivery1 or Frequent 2
(Quarterly)
Inspection
Annual3
(Yearly)
Inspection
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SECTION 2 - GENERAL SERVICE INFORMATION
31215861 2-5
2.3 SERVICING AND MAINTENANCE GUIDELINES
General
The following information is provided to assist you in the
use and application of servicing and maintenance proce-
dures contained in this chapter.
WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CON-
TAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGU-
LARITY, WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED
GUIDANCE OBTAINED BEFORE WORK IS RESUMED.
Safety and Workmanship
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of component weight. Never attempt to
move heavy parts without the aid of a mechanical device.
Do not allow heavy objects to rest in an unstable position.
When raising a portion of the equipment, ensure that ade-
quate support is provided.
NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS
BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR
OVERHEAD SLING.
Cleanliness
The most important single item in preserving the long ser-
vice life of a machine is to keep dirt and foreign materials
out of the vital components. Precautions have been taken
to safeguard against this. Shields, covers, seals, and filters
are provided to keep the wheel bearings, mast sections
and oil supply clean; however, these items must be main-
tained on a scheduled basis in order to function properly.
At any time when oil lines are disconnected, clear adjacent
areas as well as the openings and fittings themselves. As
soon as a line or component is disconnected, cap or cover
all openings to prevent entry of foreign matter.
Clean and inspect all parts during servicing or mainte-
nance, and assure that all passages and openings are
unobstructed. Cover all parts to keep them clean. Be sure
all parts are clean before they are installed. New parts
should remain in their containers until they are ready to be
used.
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SECTION 2 - GENERAL SERVICE INFORMATION
2-6 31215861
Components Removal and Installation
Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains, cables,
etc.) should be parallel to each other and as near perpen-
dicular as possible to top of part being lifted.
Should it be necessary to remove a component on an
angle, keep in mind that the capacity of an eyebolt or sim-
ilar bracket lessens, as the angle between the supporting
structure and the component becomes less than 90
degrees.
If a part resists removal, check to see whether all nuts,
bolts, cables, brackets, wiring, etc., have been removed
and 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 partially
disassemble or assemble one part, then start on another.
Always recheck your work to assure that nothing has been
overlooked. Do not make any adjustments, other than
those recommended, without obtaining proper approval.
Pressure-Fit Parts
When assembling pressure-fit parts, use an “anti-seize” or
molybdenum disulfide base compound to lubricate the
mating surface.
Bearings
When a bearing is removed, cover it to keep out dirt and
abrasives. Clean bearings in nonflammable cleaning sol-
vent and allow to drip dry. Compressed air can be used
but 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 of
oil and wrap it in clean (waxed) paper. Do not unwrap
reusable 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 be
installed on a shaft, apply pressure to the inner race.
Gaskets
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.
Bolt Usage and Torque Application
Use bolts of proper length. A bolt which is too long will
bottom before the head is tight against its related part. If a
bolt is too short, there will not be enough thread area to
engage 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 the
text, standard torque values should be used on heat-
treated bolts, studs, and steel nuts, in accordance with rec-
ommended shop practices.
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