Jlg 41AM (3120752) Service Manual User Manual

Service and Maintenance ManualModel(s)AM Series20AM25AM30AM36AM41AMP/N - 3120752April 2, 2013

ii – JLG Lift – 3120752TABLE OF CONTENTS Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3120752 – JLG Lift – iii TABLE OF CONTENTSMast Section 3 - Assembly (All Masts) . . . . . . . . . . . . . . . . . . . . . . . .

iv – JLG Lift – 3120752TABLE OF CONTENTS LIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. Hydraulic Pressure Setting - Adjustme

SECTION 1 - SPECIFICATIONS3120752 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESHydraulic Oil ReservoirAC Models – 5 qts. U.S. (4.7L)DC Mo

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 3120752Machine Height (Platform Stowed)20AM-AC & DC - 78 in. (2.0m)25AM-AC & DC - 78 in. (2.0m)30

SECTION 1 - SPECIFICATIONS3120752 – JLG Lift – 1-31.6 HYDRAULIC PRESSURE ADJUSTMENT(See Figure 1-1.)Adjust system pressure so that platform will raise

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3120752<--- START HERE - COPY AND PASTE1423Table 1-4. Model AM - Lubrication Intervals for Various Compo

SECTION 1 - SPECIFICATIONS3120752 – JLG Lift – 1-5Figure 1-2. Torque Chart (SAE Fasteners - Sheet 1 of 7)REFERENCE JLG ANEROBIC THREAD LOCKING COMPOU

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 3120752Figure 1-3. Torque Chart (SAE Fasteners - Sheet 2 of 7))Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS3120752 – JLG Lift – 1-7Figure 1-4. Torque Chart (SAE Fasteners - Sheet 3 of 7)Size TPI Bolt DiaTensile Stress AreaClamp Lo

NOTES:

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 3120752Figure 1-5. Torque Chart (SAE Fasteners - Sheet 4 of 7)Size TPI Bolt DiaTensile Stress AreaClamp Lo

SECTION 1 - SPECIFICATIONS3120752 – JLG Lift – 1-9Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 7))Size PITCHTensile Stress AreaClamp LoadT

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3120752Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 6 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 1 - SPECIFICATIONS3120752 – JLG Lift – 1-11Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 7 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3120752NOTES:

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-1SECTION 2. SERVICE PROCEDURES2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis se

SECTION 2 - SERVICE PROCEDURES2-2 – JLG Lift – 31207522.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE(See Table 2-2.)The preventive maintenance and

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-3Table 2-2. AM Model - Preventive Maintenance & Inspection Schedule.AREA ON MACHINEINTERVALPR

SECTION 2 - SERVICE PROCEDURES2-4 – JLG Lift – 3120752Footnotes:(1) Prior to use each day; or at each Operator change(2) Prior to each sale, lease,

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-52.3 SERVICING AND MAINTENANCE GUIDELINESGeneralThe following information is provided to assist y

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

SECTION 2 - SERVICE PROCEDURES2-6 – JLG Lift – 3120752Bolt Usage and Torque ApplicationUse bolts of proper length. A bolt which is too long willbottom

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-7a heavy application of oil (preferably a hot oil dip). Tapinside “walking” plates inward; if “wa

SECTION 2 - SERVICE PROCEDURES2-8 – JLG Lift – 31207522.4 LUBRICATION INFORMATIONHydraulic SystemThe primary enemy of a hydraulic system is contamina-

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-92.5 BATTERY CHARGER - ASSEMBLY AND DISASSEMBLYGeneral InformationDO NOT ATTEMPT TO DISASSEMBLE T

SECTION 2 - SERVICE PROCEDURES2-10 – JLG Lift – 3120752Transformer Replacement1. Disconnect the wiring connecting the transformer toother components w

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-11AC Circuit Breaker and Voltage Selection Switch Replacement1. Remove the wiring from the AC bre

SECTION 2 - SERVICE PROCEDURES2-12 – JLG Lift – 31207522.6 HYDRAULIC LIFT PUMP - SERVICINGRemove hydraulic pump from machine.FENNER BRAND PUMP - Brush

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-13Once brush housing has been removed, inspect the rotorcommutator for excessive wear before inst

SECTION 2 - SERVICE PROCEDURES2-14 – JLG Lift – 3120752MONARCH BRAND PUMP - Brush ReplacementMotor Assembly - Remove/Install - Reference MarksMotor/Br

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-15Brush Carrier Assembly - Remove/InstallBrush Assembly - Remove/InstallBrush Carrier Assembly -

NOTES:

SECTION 2 - SERVICE PROCEDURES2-16 – JLG Lift – 3120752TANK AND PUMP REMOVAL - (All Pumps)Tank InstallationFilter Screen InstallationPump Installation

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-17Pressure Adjust Valve Installation Pressure Check Valve InstallationPressure Adjust Valve Insta

SECTION 2 - SERVICE PROCEDURES2-18 – JLG Lift – 31207522.7 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILDHYDRAULIC CYLINDERS ARE DESIGNED T

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-19event that an unacceptable condition occurs, the headshould be replaced.PistonVisually inspect

SECTION 2 - SERVICE PROCEDURES2-20 – JLG Lift – 3120752Cylinder Assembly(See Figure 2-1.)1. Rinse the inside of the tube with hydraulic fluid andallow

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-212.8 MAST ASSEMBLY AND DISASSEMBLY PROCEDURESThe AM Series personnel lift mast sections are con-

SECTION 2 - SERVICE PROCEDURES2-22 – JLG Lift – 3120752Platform Section Removal (All Masts)3. Remove cable adjust nuts from threaded ends ofcable atta

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-2322. Carefully slide mast section-4 out BOTTOM of sec-tion-3. Remove slide pads, shims and chain

SECTION 2 - SERVICE PROCEDURES2-24 – JLG Lift – 31207522.9 MAST ASSEMBLY(See Figure 2-3., Figure 2-4. or Figure 2-5.)Mast Section 1 - Assembly (All Ma

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-25Figure 2-3. 20AM Mast Assembly Components. (5 - Section)NEW DESIGN LIFT CYLINDERAND MOUNTORIGI

INTRODUCTION - OPERATION/SAFETY PRECAUTIONS3120752 – JLG Lift – aINTRODUCTION - OPERATION/SAFETY PRECAUTIONSAll procedures herein are based on the use

SECTION 2 - SERVICE PROCEDURES2-26 – JLG Lift – 3120752Figure 2-4. 25AM & 36AM Mast Assembly Components. (6 - Section)MASTSECTION-5MASTSECTION-6M

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-27Figure 2-5. 30AM & 41AM Mast Assembly Components. (7 - Section)MASTSECTION-5MASTSECTION-6M

SECTION 2 - SERVICE PROCEDURES2-28 – JLG Lift – 3120752Figure 2-6. Mast Chain/Cable Routing Diagram.

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-29New Design Cylinder: Install the mounting pinthrough the side mounting brackets and the cylinde

SECTION 2 - SERVICE PROCEDURES2-30 – JLG Lift – 312075229. Shim per instructions in step 7, Mast Section 2 -Assembly.30. Insert slide pads into the bo

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-31Mast Section 5 - Assembly (25/30/36/41 ft. Masts)NOTE: Steps 43 thru 56 apply to six (6) sectio

SECTION 2 - SERVICE PROCEDURES2-32 – JLG Lift – 3120752Mast Section 6 - Assembly (30/41 ft. Masts)NOTE: Steps 57 thru 69 install section-6 to a seven

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-33NOTE: The platform mounting section slide pads, areassembled differently than the slide pads fo

SECTION 2 - SERVICE PROCEDURES2-34 – JLG Lift – 31207522.10 MAST TO BASE FRAME INSTALLATION1. Using an overhead crane or suitable lifting devicecapabl

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-352.11 MAST CHAINS/CABLES AND SEQUENCING CABLES ADJUSTMENTMast Chain/Cable AdjustmentThe intentio

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSb – JLG Lift – 3120752INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSGeneralThis section contains the gener

SECTION 2 - SERVICE PROCEDURES2-36 – JLG Lift – 3120752NOTE: Mast section-1 is fixed to the base and mast section-2 is attached to the lift cylinder,

SECTION 2 - SERVICE PROCEDURES3120752 – JLG Lift – 2-372.12 SEQUENCE CABLE REPLACEMENT KITA sequence cable replacement kit is available from theJLG Pa

SECTION 2 - SERVICE PROCEDURES2-38 – JLG Lift – 31207523. Use a suitable tool and cut the cable as shown in theillustration following. For 1/8 in. cab

SECTION 3 - TROUBLESHOOTING3120752 – JLG Lift – 3-1SECTION 3. TROUBLESHOOTING3.1 GENERALThis section contains troubleshooting information to beused f

SECTION 3 - TROUBLESHOOTING3-2 – JLG Lift – 3120752PolarityFinding a negative voltage or current reading whenexpecting a positive reading frequently m

SECTION 3 - TROUBLESHOOTING3120752 – JLG Lift – 3-3 Voltage Measurement Resistance MeasurementFigure 3-1. Voltage Measurement (DC) Figure 3-2. Res

SECTION 3 - TROUBLESHOOTING3-4 – JLG Lift – 3120752 Continuity Measurement Current MeasurementFigure 3-3. Continuity Measurement Figure 3-4. Curr

SECTION 3 - TROUBLESHOOTING3120752 – JLG Lift – 3-53.5 ELECTRICAL SWITCH TESTINGBasic CheckThe following check determines if the switch is functioning

SECTION 3 - TROUBLESHOOTING3-6 – JLG Lift – 3120752Table 3-1. AC Unit - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYOutrigger LED light does not turn

SECTION 3 - TROUBLESHOOTING3120752 – JLG Lift – 3-7Table 3-2. DC Unit - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYOutrigger LED light does not turn

EFFECTIVITY PAGE 3120752 – JLG Lift – cEFFECTIVITY CHANGESJune 1, 1998 - Original Issue of ManualDecember 2, 1998 - Manual RevisedJuly 26, 2000 -

SECTION 3 - TROUBLESHOOTING3-8 – JLG Lift – 31207523.6 OUTRIGGER INTERLOCK CONTACTSOutrigger Socket and Outrigger Beam - Interlock ContactsIt is very

SECTION 3 - TROUBLESHOOTING3120752 – JLG Lift – 3-9Figure 3-5. Outrigger Socket Contactor Heads and Outrigger Beam - Contactor Plate Mounting Hardwar

SECTION 3 - TROUBLESHOOTING3-10 – JLG Lift – 31207525. On the inside of the outrigger beam, install twonylon washers on the screw with the two (2) o-r

SECTION 3 - TROUBLESHOOTING3120752 – JLG Lift – 3-11Figure 3-6. Hydraulic Schematic. (AM Series) (2792491_A)2792491_A

SECTION 3 - TROUBLESHOOTING3-12 – JLG Lift – 3120752Figure 3-7. Electrical Diagram. (AM Series - 12V-DC)4933203_D

SECTION 3 - TROUBLESHOOTING3120752 – JLG Lift – 3-13Figure 3-3. Electrical Diagram. (AM Series - 12V-DC)4933203_D

SECTION 3 - TROUBLESHOOTING3-14 – JLG Lift – 3120752Figure 3-8. Electrical Diagram. (AM Series - 120V-AC)4933204_K

SECTION 3 - TROUBLESHOOTING3120752 – JLG Lift – 3-15Figure 3-4. Electrical Diagram. (AM Series - 120V-AC)4933204_K

SECTION 3 - TROUBLESHOOTING3-16 – JLG Lift – 3120752Figure 3-9. Electrical Diagram. (AM Series - 240V-AC)4933205_K

SECTION 3 - TROUBLESHOOTING3120752 – JLG Lift – 3-17Figure 3-5. Electrical Diagram. (AM Series - 240V-AC)4933205_K

EFFECTIVITY PAGE d – JLG Lift – 3120752NOTES:

SECTION 3 - TROUBLESHOOTING3-18 – JLG Lift – 3120752Figure 3-10. Electrical Diagram. (AM Series - 100V-AC - JAPAN)4933206_C

SECTION 3 - TROUBLESHOOTING3120752 – JLG Lift – 3-19Figure 3-5. Electrical Diagram. (AM Series - 100V-AC - JAPAN)4933206_C

SECTION 3 - TROUBLESHOOTING3-20 – JLG Lift – 3120752NOTES:

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (

3120752 – JLG Lift – i TABLE OF CONTENTSTABLE OF CONTENTSSECTION - PARAGRAPH, SUBJECT PAGE NO.INTRODUCTION -- OPERATION/SAFETY PR