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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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)

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)

MONTH

MONTHS

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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