Jlg 41AM (3120872) Service Manual User Manual

Service and Maintenance ManualModel(s)AM Series20AM25AM30AM36AM41AMP/N - 3120872April 2, 2013

iv – JLG Lift – 3120872TABLE OF CONTENTS (Continued) LIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. Hydraulic Pressure Setting . . . . . . . . . .

SECTION 1 - SPECIFICATIONS3120872 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESHydraulic Oil ReservoirAC Models – 4.7 liters (5 qts. U.S

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 3120872Machine Height (Platform Stowed)20AM-AC & DC - 2.0m (78 in.)25AM-AC & DC - 2.0m (78 in.)30

SECTION 1 - SPECIFICATIONS3120872 – JLG Lift – 1-31.6 HYDRAULIC PRESSURE ADJUSTMENTAdjust system pressure so that platform will raise withrated capaci

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3120872Figure 1-2. Lubrication Locations (See Table below).1423Table 1-4. Lubrication Intervals for Variou

SECTION 1 - SPECIFICATIONS3120872 – JLG Lift – 1-51.9 TORQUE CHARTSFigure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 7)REFERENCE JLG ANEROBIC THRE

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 3120872Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7))Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS3120872 – JLG Lift – 1-7Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7)Size TPI Bolt DiaTensile Stress AreaClamp Lo

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 3120872Figure 1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7)Size TPI Bolt DiaTensile Stress AreaClamp Lo

SECTION 1 - SPECIFICATIONS3120872 – JLG Lift – 1-9Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 7))Size PITCHTensile Stress AreaClamp LoadT

NOTES:

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3120872Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 1 - SPECIFICATIONS3120872 – JLG Lift – 1-11Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3120872NOTES:

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-1SECTION 2. SERVICE PROCEDURES2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis se

SECTION 2 - SERVICE PROCEDURES2-2 – JLG Lift – 31208722.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE(See Table 2-2.)The preventive maintenance and

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-3Table 2-2. AM Model - Preventive Maintenance & Inspection Schedule.AREA ON MACHINEINTERVALP

SECTION 2 - SERVICE PROCEDURES2-4 – JLG Lift – 3120872Footnotes:(1) Prior to use each day; or at each Operator change(2) Prior to each sale, lease,

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-52.3 SERVICING AND MAINTENANCE GUIDELINESGeneralThe following information is provided to assist y

SECTION 2 - SERVICE PROCEDURES2-6 – JLG Lift – 3120872Bolt Usage and Torque ApplicationUse bolts of proper length. A bolt which is too long willbottom

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-7Protruding or Turned Pins: Chains operating with inade-quate lube generate tremendous friction b

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 PROCEDURES2-8 – JLG Lift – 3120872viscosities suited to the ambient temperatures in whichthe machine is operating, are recommended

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-9Cover Removal5. Remove the ten (10) screws on the sides and top ofthe charger cover and remove c

SECTION 2 - SERVICE PROCEDURES2-10 – JLG Lift – 3120872AC Circuit Breaker and Voltage Selection Switch Replacement1. Remove the wiring from the AC bre

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-112.6 HYDRAULIC LIFT PUMP - SERVICINGRemove hydraulic pump from machine.FENNER BRAND PUMP - Brush

SECTION 2 - SERVICE PROCEDURES2-12 – JLG Lift – 3120872Once brush housing has been removed, inspect the rotorcommutator for excessive wear before inst

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-13MONARCH BRAND PUMP - Brush ReplacementMotor Assembly - Remove/Install - Reference MarksMotor/Br

SECTION 2 - SERVICE PROCEDURES2-14 – JLG Lift – 3120872Brush Carrier Assembly - Remove/InstallBrush Assembly - Remove/InstallBrush Carrier Assembly -

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-15TANK AND PUMP REMOVAL - (All Pumps)Tank InstallationFilter Screen InstallationPump Installation

SECTION 2 - SERVICE PROCEDURES2-16 – JLG Lift – 3120872Pressure Adjust Valve Installation Pressure Check Valve InstallationPressure Adjust Valve Insta

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-172.7 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILDHYDRAULIC CYLINDERS ARE DESIGNED T

NOTES:

SECTION 2 - SERVICE PROCEDURES2-18 – JLG Lift – 3120872event that an unacceptable condition occurs, the headshould be replaced.PistonVisually inspect

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-19tom of the mast section-1. Shim to eliminate anyside clearance to prevent any strain on the sid

SECTION 2 - SERVICE PROCEDURES2-20 – JLG Lift – 31208722.8 MAST ASSEMBLY AND DISASSEMBLY PROCEDURESThe AM Series personnel lift mast sections are cont

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-21Platform Section Removal (All Masts)1. Remove chain adjust nuts from threaded ends ofchain atta

SECTION 2 - SERVICE PROCEDURES2-22 – JLG Lift – 312087220. Carefully slide mast section-4 out BOTTOM of sec-tion-3. Remove slide pads, shims and chain

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-23Figure 2-3. 20AM Mast Assembly Components. (5 Section)MASTSECTION - 5MASTSECTION - 4MASTSECTIO

SECTION 2 - SERVICE PROCEDURES2-24 – JLG Lift – 3120872Figure 2-4. 25AM & 36AM Mast Assembly Components. (6 Section)LIFTCYLINDERMASTSECTION - 1MA

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-25Figure 2-5. 30AM & 41AM Mast Assembly Components. (7 Section)LIFTCYLINDERMASTSECTION - 1MA

SECTION 2 - SERVICE PROCEDURES2-26 – JLG Lift – 31208722.9 MAST ASSEMBLY(See Figure 2-3., Figure 2-4. or Figure 2-5.)Mast Section 1 - Assembly (All Ma

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-27New Design Cylinder: Install the mounting pinthrough the side mounting brackets and the cylinde

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS3120872 – JLG Lift – aINTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSGENERALThis section contains the gener

SECTION 2 - SERVICE PROCEDURES2-28 – JLG Lift – 312087229. Shim per instructions in step 7, Mast Section 2 -Assembly.30. Insert slide pads into the bo

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-2945. Shim per instructions in step 7, Mast Section 2 -Assembly.Mast Section 5 - Assembly (25/30/

SECTION 2 - SERVICE PROCEDURES2-30 – JLG Lift – 3120872Mast Section 6 - Assembly (30/41 ft. Masts)NOTE: Steps 57 thru 69 install section-6 to a seven

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-31other mast sections. Mast section-5/-6/-7 slide padsmay need to be assembled/disassembled sever

SECTION 2 - SERVICE PROCEDURES2-32 – JLG Lift – 31208725. Align threaded hole in side of hydraulic cylinderhead with hole in tab on bottom side of cyl

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-33one side or the other.The threaded end of the chain/cable may need to berestrained while tighte

SECTION 2 - SERVICE PROCEDURES2-34 – JLG Lift – 31208722.12 SEQUENCE CABLE REPLACEMENT KITA sequence cable replacement kit is available from theJLG Pa

SECTION 2 - SERVICE PROCEDURES3120872 – JLG Lift – 2-353. Use a suitable tool and cut the cable as shown in theillustration following. For 1/8 in. cab

SECTION 2 - SERVICE PROCEDURES2-36 – JLG Lift – 3120872NOTES:

SECTION 3 - TROUBLESHOOTING3120872 – JLG Lift – 3-1SECTION 3. TROUBLESHOOTING3.1 GENERALThis section contains troubleshooting information to beused f

EFFECTIVITY CHANGESb – JLG Lift – 3120872EFFECTIVITY CHANGESNovember 5, 1998- Original Issue of ManualJuly 26, 2000 - Manual RevisedSeptember 22, 20

SECTION 3 - TROUBLESHOOTING3-2 – JLG Lift – 3120872PolarityFinding a negative voltage or current reading whenexpecting a positive reading frequently m

SECTION 3 - TROUBLESHOOTING3120872 – JLG Lift – 3-3 Voltage Measurement Resistance MeasurementFigure 3-1. Voltage Measurement (DC) Figure 3-2. Res

SECTION 3 - TROUBLESHOOTING3-4 – JLG Lift – 3120872 Continuity Measurement Current MeasurementFigure 3-3. Continuity Measurement Figure 3-4. Curr

SECTION 3 - TROUBLESHOOTING3120872 – JLG Lift – 3-53.5 ELECTRICAL SWITCH TESTINGBasic CheckThe following check determines if the switch is functioning

SECTION 3 - TROUBLESHOOTING3-6 – JLG Lift – 3120872Table 3-1. AC Unit - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYOutrigger LED light does not turn

SECTION 3 - TROUBLESHOOTING3120872 – JLG Lift – 3-7Table 3-2. DC Unit - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYOutrigger LED light does not turn

SECTION 3 - TROUBLESHOOTING3-8 – JLG Lift – 31208723.6 OUTRIGGER INTERLOCK CONTACTSOutrigger Socket and Outrigger Beam - Interlock ContactsIt is very

SECTION 3 - TROUBLESHOOTING3120872 – JLG Lift – 3-9Figure 3-5. Outrigger Socket Contactor Heads and Outrigger Beam - Contactor Plate Mounting Hardwar

SECTION 3 - TROUBLESHOOTING3-10 – JLG Lift – 31208725. On the inside of the outrigger beam, install twonylon washers on the screw with the two (2) o-r

SECTION 3 - TROUBLESHOOTING3120872 – JLG Lift – 3-11Figure 3-6. Hydraulic Schematic. (AM Series)2792491_A

3120872 – JLG Lift – i TABLE OF CONTENTSTABLE OF CONTENTSSECTION - PARAGRAPH, SUBJECT PAGE NO.INTRODUCTION -- MAINTENANCE SAFETY

SECTION 3 - TROUBLESHOOTING3-12 – JLG Lift – 3120872Figure 3-7. Electrical Diagram. (AM Series - 12v-DC)4933203_D

SECTION 3 - TROUBLESHOOTING3120872 – JLG Lift – 3-13Figure 3-3. Electrical Diagram. (AM Series - 12v-DC)4933203_D

SECTION 3 - TROUBLESHOOTING3-14 – JLG Lift – 3120872Figure 3-8. Electrical Diagram. (AM Series - 240V-AC)4933205_K

SECTION 3 - TROUBLESHOOTING3120872 – JLG Lift – 3-15Figure 3-4. Electrical Diagram. (AM Series - 240V-AC)4933205_K

SECTION 3 - TROUBLESHOOTING3-16 – JLG Lift – 3120872NOTES:

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

ii – JLG Lift – 3120872TABLE OF CONTENTS (Continued) Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3120872 – JLG Lift – iii TABLE OF CONTENTSMast Section 3 - Assembly (All Masts) . . . . . . . . . . . . . . . . . . . . . . . .