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JLG 25AM Service Manual

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1. a JI BLACK LAMP 78 8 79 RED 3 05 8e SRN 2 1 a 222115245 1 PLATFORM CONTROL BOX T 3 100 RED 3 22 le e 120 PLATFORM mU REMOVE WITH LSS OPTION 7 RED RED e e a ALARM gt BLK WIT BLI WAT J2 GREY es oll 20 LIFT 010 el la UP 09 20 WHITE WHITE 08 50 60 m LSS MODULE WEITE L OPTIONAL 155 RED J gt ENABLE INAL OPTIONAL n I ete AUXILLARY FOOT PEDAL CONTROL amp RED LIFT LIFT 74 1 DOWN UP n N Q 1 4 9 RED LIFT LE RED DOWN I gt I GREEN z la L lt 5 ee 5 Gm GREEN 12 3 CABLE GREEN 5 E O R O R CONTACTOR CONTACTOR YELLOW YELLOW Z k m aur POTTED RELAY SCHEMATIC aur 4 e 0 R 1 lt O R I ni amp o lt gt LED GREEN
2. 8 SEQUENCE CABLE ASSEMBLY CHAIN CABLE SHIELD 41AM ONLY 5 6 SECTION 2 MAST CHAIN CABLE SECTION 3 SHIELD 30AM 41AM MAST ANSI 92 3 SPEC MAST IJ SECTION 5 MAST SECTION 7 Geass ORIGINAL DESIGN UPPER LIFT SLIDE PAD CYLINDER MOUNTING AND atum TO SERIAL 142920 30AM 41AM UPPER lt SLIDE PAD SEQUENCE md AS OF CABLE NEW DESIGN LIFT CYLINDER SERIAL 142920 ASSEMBLY AND MOUNT Figure 2 5 30AM amp 41AM Mast Assembly Components 7 Section 3120752 JLG Lift 2 27 SECTION 2 SERVICE PROCEDURES MAST SECTIONS SECTION 5 SECTION 4 SECTION 3 SECTION 2 SECTION 1 CHAIN ASSY CHAIN ASSY CABLE ASSY CHAIN CABLE ASSY ANCHOR PLATES Figure 2 6 Mast Chain Cable Routing Diagram 2 28 JLG Lift 3120752 SECTION 2 SERVICE PROCEDURES 15 16 17 18 19 New Design Cylinder Install the mounting pin through the side mounting brackets and the cylinder valve body and through the mounting brackets on the other side of the mast Install the snap rings to each end of the mounting pin Insert hydraulic cylinder rod end into chai
3. WHITE 16 1 CROSSMEMBER 4321 32i 1111 pHo a Figure 3 9 Electrical Diagram AM Series 240V AC 3 16 Lift 3120752 SECTION 3 TROUBLESHOOTING 1 5 PRIMARY SECONDARY ls NI 13 7 GROUND CONTROL BOX LINE I WHITE NEUTRAL j GREEN GROUND INPUT 230 VOLTS menmi 4 RELAY it ac 2 3 4 12VDC 5 115 LINE 2 LIFT UP 6 115 NEUT 3 LIFT DOWN 1 680 4 EMER STOP 8 GRD T 8 8 8 a a 4 RELAY GREEN BLACK 2 VALVE LIFT DUMP VALVE 4933205_K Figure 3 5 Electrical Diagram AM Series 240V AC 3120752 JLG Lift SECTION 3 TROUBLESHOOTING
4. 3 20 JLG Lift 3120752 CALIFORNIA PROPOSITION 65 BATTERY WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Batteries also contain other harmful chemicals known to the State of California WASH HANDS AFTER HANDLING Oshkosh Corporation Company Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 JLG Worldwide Locations JLG Industries Australia Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 612 65 811111 61 2 65 813058 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil 55 193295 0407 55 19 3295 1025 USA 717 485 5161 amp 717 485 6417 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 44 0 161 654 1000 44 0 161 654 1001 3120752 JLG France 5 5 2 1 de Baulieu 47400 Fauillet France 38 33 0 5 53 88 31 70 33 0 5 53 88 31 79 A JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany 49 0 421 69 350 20 49 0 421 69 350 45 A Plataformas Elevadora
5. 115 VAC 6 OUTLET BOX a NI g OPTIONAL FOOT PEDAL CONTROL E LIFT Roe CREEN AE WHITE WHITE t te f 1 GREEN un CRED PLATFORM ENABLE ZS RED CRED lt RED LIFT Be OWN ferre IS Dr OPTIONAL AUX Em 1 LOWER ING RED RED BLK WHT eg SPIRAL CABLE REQ D ON 25 amp 36 FT MODELS GREEN WHT ORANGE ewercency GROUND CONTROL 1 STOP POWER r gt 1 amp gt gt 111 0 4 i YELLOW 1 19 5 5 2 5 REEN O R r ORs p 023 tp 0 8 2 SET SET SET LED
6. ADJUST NUT Note zi When chain fe is complete before JAM NUT Rs tightening the jam nut THREADED 72 against the adjust nut z apply Loctite 242 to the threads under the nut u J s e Figure 2 7 Mast Chain Cable Sequence Cable Adjustment Components Typical 3120752 JLG Lift 2 35 SECTION 2 SERVICE PROCEDURES NOTE Mast section 1 is fixed to the base and mast section 2 is attached to the lift cylinder these sections require no adjustment Adjust one mast section at a time starting from the back section 8 section 4 etc of the mast and work forward i e if three is OK then jump to four etc To adjust elevate the platform until the chain cable anchor adjust nuts are accessible at the front and bottom of each mast section A WARNI
7. A General ene TS ICD EE comes Hydraulic System 1 B Maintenance B EFFEGTIVITY CHANGES 5 t Lake ode t bd Eats Are SECTION 1 SPECIFICATIONS TA CAPACITIES etiem a antay e kanya aka yala tA xe ers d Td 1 1 Hydraulic Oil 1 1 1 2 Pe Dee a eed 1 1 Hydraulic Pump Electric Motor 1 1 Batteries 1 DC 1 1 1 Battery Charger DC 1 1 1 3 PERFORMANCE DATA y 1 hein ann CEOS ie pee tee 1 1 Platforiri Capacity catia EC UE b SERIES 1 1 Platform Cycle 1 1 Machine Weight with Standard 1 1 Machine Height Platform 1 2 Maximum Platform Height Mast 1 2 Maximum Working He
8. Figure 3 8 Electrical Diagram AM Series 120V AC JLG Lift 3120752 SECTION 3 TROUBLESHOOTING 1 5 PRIMARY SECONDARY l2 el ie Tij 4 8 GROUND CONTROL BOX 115 230V 12V0C RECTIFIER E A WEITE NEUTRAL GROUND 2 INPUT 115 VOLTS pu Al STARTER d RELAY t 1 24 11 H m GREEN 7 N 5 00000000N 1 paren 8 GREEN 81 I mm RED i 12voc 5 115 LINE 2 LIFT UP 6 115 NEUT Hia 3 LIFT DOWN 1 610 CORE 4 EMER STOP 8 GRD 1 8 3 T 3 1 2 7 1 4 7 B d JE B HER i 5 m 3 86 O R m ORANGE 062 DET P VALVE TIET uN VALVE 4933204_K Figure 3 4 Electrical Diagram AM Series 120V AC 3120752 JLG Lift 3 15 SECTION 3 TROUBLESHOOTING
9. E Ark Ra p B AER ERR UE age RUE dE 3 2 Continuity Measurement Over Long Distances 3 2 Requirements s rieni uu ie Este ERR 3 2 Procedure css Ue RR SOE EE u 3 2 3 5 ELECTRICAL SWITCH 2 3 5 Basic Check xi epa Eta di v pet 3 5 Limit Switches o o RR EDU ELM nen Be E ICE 3 5 Automatic SwItch6s oct ire cad yG See ee ES es e riot p M Ee RR 3 5 Switch Wiring Low Side High 1 3 5 3 6 OUTRIGGER INTERLOCK 3 8 Outrigger Socket and Outrigger Beam Interlock 3 8 Outrigger Socket Contactor Screw Mounting 3 8 Outrigger Beam Interlock Contactor Plate Mounting Instructions 3 8 Detent SCrewS Wee E eot Dr PR ED Gee AN RECO RR te Mee 3 10 3120752 JLG Lift iii TABLE CONTENTS LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Hydraulic Pressure Setting Adjustment Screw Located at Base of Pump Motor 1 3 1 2 Torque Chart psi ch eet IER EESTI eV EE mec ure ees 1 5 2 1 Lift Cylinder Internal Component Assembly Cross Section 2 19
10. 2 8 Hydraulic System oo oe FUE SN LIAE NN EIC UR 2 8 Hydraulic Oil Sasu u EV ANACO 2 8 Changing Hydraulic 1 2 8 Lubrication 1 2 2 8 2 5 BATTERY CHARGER ASSEMBLY AND 5 5 2 9 General Information ree ee a ee bade uy ee Hr eerie 2 9 Battery Charger Removal 2 9 Cover Removal dial wend pue hte ERG eme aer Me atr d DURO PUR ER AR Rud 2 9 Transformer 1 0 2 10 Printed Circuit Board 1 2 10 DC Circuit Breaker Replacement 2 10 AC Circuit Breaker and Voltage Selection Switch Replacement 2 11 Shunt Assembly Varistor and SCR Rectifier Replacement See lllustration 2 11 2 6 HYDRAULIC LIFT PUMP SERVICING 2 2 1 2 12 FENNER BRAND PUMP Brush Replacement 2 12 Motor Cap Motor 1 2 12 Motor Brush 2 III 2
11. n 9i E 99 OPTIONAL FOOT PEDAL CONTROL bm y 12 LINE 7 BLACK 7 BROWN CRED REMOVE WITH LSS OPTION aii ich LAMP JI BLACK ENABLE LIET e bom 65 86 lal lal wo 2 22 04 Es am o 120 12 GREY Oa EIE 0210 a 20 01030 5259 WHITE 6 GREEN LSS MODULE TED OPTIONAL LSS ee ORANGE SPIRAL CABLE REQ D ON 25 amp 36 FT MODELS USE ORANGE WIRE IN PLACE OF BLACK WHITE WIRE GROUND CONTROL STOP POWER Mc ON OFF c CD ei I 743 1 _ EN B S D pir 40 O R 2 SET LED LED LED LED CREEN 1 ORANGE I O R CONTACTOR CONTACTOR CONTACTOR CONTACTOR E u mu 1 L B I 3 4 2 OUTPUT RELAY REF
12. 4 2 1 2 2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE 2 2 2 3 SERVICING AND MAINTENANCE 2 5 General 2 5 Safety Workmanship 2 5 Cleanliness RA meh Da X n EO SEL RC 2 5 Components Removal and Installation 2 5 Component Disassembly and Reassembly 2 5 Pressure Fit Paits uu ne ee ee hak e due 2 5 eos eh eee a e emere paki ue dd bce ed 2 5 3120752 JLG Lift TABLE CONTENTS Gaskets vans atipana u ak Gide bn aka baat 2 5 Bolt Usage and Torque Application 2 6 Hydraulic Lines and Electrical 2 6 Hydraulic System xe 2 6 Lubrication and Servicing 2 6 Batteries Ee p v OM pue eR rte RUE Se neo 2 6 Mast Chain Inspection 2 6 Mast Cable Inspection 2 7 2 4 LUBRICATION INFORMATION
13. 3 16 3 10 Electrical Diagram AM Series 100 JAPAN 3 18 LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 Hydraulic Operating 1 2 1 2 Lubrication 1 4 4 1 2 1 3 Cylinder Specifications yu sy us 1 3 1 4 Model AM Lubrication Intervals for Various Components 1 4 2 1 Inspection and 1 4 2 2 2 2 AM Model Preventive Maintenance amp Inspection Schedule 2 3 2 3 Chain Stretch Tolerance s RR bees ae ea dees eee es 2 6 2 4 AM Series Mast Component Features 2 21 3 1 AC Unit 0 4 3 6 3 2 DC Unit 0 2 14 40 3 7 JLG Lift 3120752 SECTION 1 SPECIFICATIONS SECTION 1 SPECIFICATIONS 1 1 CAPACITIES Hydraulic Oil Reservoir AC Models 5 qts U S 4 71 DC Models 5 qts U S 4 71 1 2 COMPONENT DATA Hydraulic Pump Electric Motor Assembly DC Models 12 Volt DC Motor Pump Motor 12v DC Standard Duty Pump Displacement 049 cu in rev
14. i P GREEN 5 E m I gt ud 1 gt x ht h O R xr xr xr xz O R CONTACTOR mx mm gt YELLOW YELLOW BLUE BLUE O R O R 1169 GREEN GREEN GRND OUTPUT B WHITE 16 GREEN 16 GREEN RED 16 BLACK 4 CROSSMEMBER k 4321 3 LLLI 11 1352038 3 12 Figure 3 7 Electrical Diagram AM Series 12V DC JLG Lift 3120752 SECTION 3 TROUBLESHOOTING SPIRAL CABLE REQ D ON 25 4 36 FT MODELS BLACK WHITE BECOMES ORANGE RED BLK WHT WHITE L OPTINAL AUXILLARY WERING Mc GROUND CONTROL ro 1 NEUTRAL 7 WHITE 7 BLUE 16 5 CABLE LINE 7 BLACK 7 BROWN 12 3 GROUND 7 GREEN GREEN B GREEN B YEL 5 AMP FUSE ORANGE roi PUMP B MOTOR STARTER RELAY CBL BAT CBL A C INPUT BATTERY NEUTRAL WHITE BLUE CHARGER LINE BLACK BROWN GROUND GREEN 12700 BATTERY 4933203 D Figure 3 3 Electrical Diagram AM Series 12V DC 3120752 JLG Lift
15. s Siete astra Pinca ate fee cac 2 20 2 8 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES 2 21 Mast Disassembly 4 2 21 Platform Section Removal All 2 22 Mast Section 6 Removal 7 Section Mast 2 22 Mast Section 5 Removal 6 amp 7 Section 2 22 Mast Section 4 Removal All 2 22 Mast Section Removal All 2 23 Mast Section 2 Removal All 2 23 Mast Section 1 Disassembly All 2 23 2 9 ASSEMBLY du RAUS LR Panay ee SR aa Pur OVER UL ERE RPM 2 24 Mast Section 1 Assembly All 2 24 Mast Section 2 Assembly All 2 24 ii JLG Lift 3120752 TABLE CONTENTS Mast Section Assembly All Masts 2 29 Mast Section 4 Assembly All Masts 2 30 Mast Section 5 Assembly 25 30 36 41 ft 2 31 Mast Section 6 Assembly 30
16. 1 19 115 230V 16VDC 1 0 Wane 5 4 BLACK AR 19 8 6 2 20 6 1 5 1 4 ES T RECTIFIER 5 BLK BLACK L INE NEUTRAL E d 1 GROUND INPUT 100 VOLTS JE d 1 1 5 6 5 6 7 Gian RELAY 8 6 4 2 WHITE 123455786 e m I CRN 1 RED 4 1 12vDC 5 100VAC LINE en E 1 BLACK 2 LIFT UP 6 100VAC NEUT GREEN 2 3 LIFT DOWN 7 GRD 3 4 EMER STOP 8 GRD BLK WHT 1 8 21 21 3 7 47 1 4 J 8 n A 5 z BLK 4 5 E E M s T N WHITE 309 Pod 14 Tas aR WHT 12 YE 12 INTERLOCK YELLOW RELAY fi ani PUP N F 12 Com 15 MOTOR 1 1 gt I i it I I DE m e pes gt 52 GREEN GREEN ORANGE BLACK ORANGE 2 RED YEL 1 GREEN LIFT DM VALVE LIFT DOWN VALVE 4933206 C Figure 3 5 Electrical Diagram AM Series 100V AC JAPAN 3120752 JLG Lift 3 19 SECTION 3 TROUBLESHOOTING BS NOTES
17. 3 13 SECTION 3 TROUBLESHOOTING 115 VAC BOX m en iq 199 1 OPTIONAL FOOT PEDAL CONTROL RED SWITCH RED 3 7 1 LIFT LIFT DOWN L WHITE F RED GREEN 1 LIFT LAMP 155 option BLU 1 GRN 2 RED H PLATFORM ENABLE LIFT DOWN ENS 191719 pom RED N LSS MODULE OPTIONAL LSS 3 14 IONAL AUX LOWERING 9 H 8 8 OUTPUT POTTED RELAY REF RED BLACK ORANGE SPIRAL CABLE REQ D ON 25 4 36 FT MODELS USE ORANGE WIRE PLACE OF BLACK WHITE WIRE EMERGENCY GROUND CONTROL STOP POWER ON OFF alili D BI 3 we dir ORN 1 N 9 OIR 3 4 GREEN 1 O R O R O R SET SET SET SET LED LED LED LED GREEN BLACK DELI O R 0 6 O R 0 6 CONTACTOR CONTACTOR CONTACTOR CONTACTOR 1 DEF EN GREEN 15 1 GREEN BLACK r 1 i CROSSMEMBER
18. NEW DESIGN LIFT CYLINDER AND MOUNT Figure 2 3 20AM Mast Assembly Components 5 Section 3120752 JLG Lift 2 25 SECTION 2 SERVICE PROCEDURES tA b p 2 42 B UPPER MAST SECTION 5 SEQUENCE CABLE ASSEMBLY CHAIN CABLE SHIELD MAST 36AM ONLY HH SECTION 1 ANSI 92 3 SPEC MAST SECTION 2 CHAIN CABLE SHIELD pied SPEC MAST SECTION 4 MAST 2 ORIGINAL SECTION 6 B iow DESIGN LIFT SECTION 6 D CYLINDER UPPER SLIDE MOUNT MOUNTING POSITION PRIOR TO C4 al 142920 SECTION 6 OL UPPER bs SLIDE PAD e SEQUENCE e AS OF CABLE 9 142920 ASSEMBLY NEW DESIGN LIFT CYLINDER AND MOUNT Figure 2 4 25AM amp 36AM Mast Assembly Components 6 Section 2 26 JLG Lift 3120752 SECTION 2 SERVICE PROCEDURES
19. INTRODUCTION OPERATION SAFETY PRECAUTIONS 3120752 INTRODUCTION OPERATION SAFETY PRECAUTIONS All procedures herein are based on the use of the machine under proper operating conditions with no devi ations from original design intent as per OSHA regula READ amp HEED The ownership use service and or maintenance of this machine is subject to various federal state and local laws and regulations It is the responsibility of the owner user to be knowledgeable of these laws and regulations and to comply with them The most prevalent regulations of this type are the Federal OSHA Safety Regulations Listed below in abbreviated form are some of the requirements of Federal OSHA regulations in effect as of the date of publication of this handbook The listing of these requirements shall not relieve the owner user of the responsibility and obligation to deter mine all applicable laws and regulations and their exact wording and requirements and to comply with the requirements Nor shall the listing of these requirements constitute an assumption of responsibility of liability on the part of JLG Industries Inc 1 Only trained and authorized operators shall be per mitted to operate the aerial lift 2 A malfunctioning lift shall be shut down until repaired 3 The controls shall be plainly marked as to their func tion 4 The controls shall be tested each day prior to use to determine that they are in safe oper
20. Install cable on machine and adjust per instructions shown previously in Section 2 11 MAST CHAINS CABLES AND SEQUENCING CABLES ADJUST MENT 3120752 SECTION 3 TROUBLESHOOTING SECTION 3 TROUBLESHOOTING 3 1 GENERAL This section contains troubleshooting information to be used for locating and correcting most operating prob lems 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 3 HYDRAULIC CIRCUIT 5 The first reference for improper function of a hydraulic sys tem where the cause is not immediately apparent should be the Hydraulic Diagram Circuit The best place to begin the problem analysis is at the power source pump Once it is determined that the pump is serviceable then a sys tematic check of the circuit components would follow NOTE For aid in troubleshooting refer to Figure 3 6 for HYDRAULIC DIAGRAM circuit 3 4 ELECTRICAL SYSTEM MULTIMETER 3 2 TROUBLESHOOTING INFORMATION Troubleshooting procedures applicable to this machine 3120752 are listed and defined starting with Table 3 1 and Table 3 2 in this section of the manual Each malfunction within an individual group or system is followed by listing of probable causes which will enable determination of the applicable remedial action The prob able causes and the
21. 8 nylon washer onto contactor screw threads against insulating grommet Apply Loctite 242 to screw threads Install one 1 standard 8 brass nut and thread in against nylon washer until insulating grommet just starts to compress If necessary tighten nut further until top of contactor screw head measures 0 212 off floor of outrigger socket See Figure 3 5 Install wire end eyelet onto threaded end against previously installed brass nut Install second standard brass nut and thread tight against wire end eyelet While holding first brass nut jam tighten second brass nut against wire end eyelet 5 2001 DESIGN 1 3 8 Install insulating bushing into the holes the socket floor inside of outrigger sockets in base frame Place one 1 8 32UNC x 5 8 long contactor screw through each insulating grommet as shown in Fig ure 3 5 Install two 2 8 nylon washers onto contactor screw threads against insulating grommet on the underside of the outrigger socket gt Apply Loctite 242 to screw threads Install one 1 standard 8 brass nut and thread in against nylon washer until insulating grommet just starts to compress Install wire end eyelet onto threaded end against previously installed brass nut Install second standard brass nut and thread tight against wire end eyelet While holding first brass nut jam tighten second brass nut against wire end eyelet Outrigger Beam Interlock
22. 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 A CAUTION WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY 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 A WARNING NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT FORM 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 fil ters are provided to keep the wheel bearings mast sec tions and oil supply clean however these items must be maintained on a scheduled basis in order to function properly At any time when oil lines are disconnected clear adja cent area
23. Battery Fluid Battery Charger HYDRAULIC ELECTRIC SYSTEM Hydraulic Pump 1 2 9 2 5 Hydraulic Pump Cover Hydraulic Cylinder 7 9 2 9 2 9 Cylinder Attachment Pins and Pin Retainers 1 2 Hydraulic Hoses Lines and Fittings 1 9 Hydraulic Reservoir Cap and Breather Hydraulic Filter 3120752 5 7 JLG Lift 5 7 5 7 SECTION 2 SERVICE PROCEDURES Table 2 2 AM Model Preventive Maintenance amp Inspection Schedule INTERVAL AREA ON MACHINE PRE START 1 WEEKLY 3 PRE DELIVERY 2 ANNUAL 4 INSPECTION PREVENTATIVE PREVENTATIVE ORFREQUENT 3 YEARLY MAINTENANCE MAINTENANCE INSPECTION INSPECTION Hydraulic Fluid 11 11 11 11 11 Electrical Connections 20 20 Outrigger Interlock Systems 1 2 5 5 GENERAL Operator and Safety Manuals in Storage Box 21 21 21 ANSI and EMI Manuals Handbooks Installed 21 21 21 Capacity Decals Installed Secure Legible 21 21 21 All Decals Placards Installed Secure Legible 21 21 21 Walk Around Inspection Performed 22 Annual Machine Inspection Due 21 No Unauthorized Modifications or Additions 21 21 All Relevant Safety Publications Incorporated 21 21 22 General Structural Condition and Welds 2 4 2 4 All Fasteners Pins Shields and Covers 1 2 Grease and Lubricate to Specifications 22 22 Function Test of All Systems 22 Pa
24. assemble cable sheaves to top of mast section 6 as follows a Locate remaining sheave pin Slide two 2 cable sheave wheels onto sheave pin and center b Place two 2 short spacer tubes on sheave pin one on each end of sheave pin to outside of sheave wheels c Place two 2 sheave pin attach bars one on each end of sheave pin to outside of short spacer tubes d Holding complete cable sheave wheel assem bly slide assembly into top of mast section 6 and align threaded holes in sheave pin attach bars with holes in mast rails e Attach to top of mast section 6 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 6 back into section 5 until ends are even Check to make sure cable set 67 NOTE 68 69 70 71 72 from top of section 4 is seating properly in cable sheave wheels attached to top of mast section 5 Mast sections 3 4 and 5 may need to be restrained to keep their slide pads from pushing out the bottom of mast sections 2 3 and 4 Insert slide pads into the top end mast rails between section 5 and 6 one on each side of the mast with beveled surface facing inward towards section 6 Before fastening and shimming the slide pad on the top left sid
25. post wires and static winding wires are positioned not to block the holes for the motor mounting bolts inside the motor housing After final assembly of the brush housing check that all brush terminal screws are tight and the brush springs are positioned properly before mounting the motor to the pump motor end head Brush Final Positioning NOTICE ONCE THE ROTOR ASSEMBLY IS IN PLACE REMEMBER TO PUSH EACH BRUSH DOWN UNTIL THE BRUSH FACE IS IN CONTACT WITH THE COMMUTATOR ON THE ROTOR SHAFT AND THE BRUSH SPRING IS PUSHING DOWN ON TOP OF THE BRUSH JLG Lift 2 13 SECTION 2 SERVICE PROCEDURES MONARCH BRAND PUMP Brush Replacement Motor Assembly Remove Install Reference Marks Pump Motor Removal Installation Reference Marks For reference when reassembling mark motor cover housing and valve body position before disassembling 1 Motor Top Cover 4 Housing Motor Valve Body 2 Cover Housing Reference Mark Reference Mark 5 Motor Valve Body 3 Motor Housing NP 1 5 5 n ras m i E NI Motor Brush Cover Removal Installation 1 Motor Brush Cover 3 Washers 5 Power Lead Clip Attach Screws 2 Cover Screws b 4 Power Leads to
26. 12 Brush Housing Final Assembly 2 13 MONARCH BRAND PUMP Brush 2 14 Motor Assembly Remove Install Reference 2 14 Motor Brush Cover 2 14 Brush Carrier Assembly 2 15 Brush Assembly 2 15 TANK AND PUMP REMOVAL Pumps 2 16 Tank ot Fed c E RR RE ee oe 2 16 Filter Screen Installation 2 2 16 Pump Installation ken 1 eta ua ped ed eee e etr 7 2 16 Pressure Adjust Valve 1 2 17 Pressure Check Valve 1 2 17 2 7 HYDRAULIC LIFT CYLINDER REMOVAL INSPECTION AND REBUILD 2 18 Cylinder Removal tato whe LE pact eared oa 2 18 Cylinder Disassembly 2 18 Lift Cylinder Component 2 18 Cylinder Assembly ur s eat aes Gadd eh eee hat Sed des 2 20 Installation
27. 14 109 148 1 7 18 0 6250 0 2560 16300 170 230 130 176 190 258 153 207 1 7 8 9 0 8750 0 4620 29400 430 583 320 434 475 646 386 523 08750 0500 32400 40 67 350 475 50 707 45 56 12 1 0000 0 6630 42200 700 949 530 719 735 1000 633 858 7 1 9 tei rm 11 4 1 2500 0 9690 53800 1120 1518 840 1189 1175 1598 1009 1368 12 12500 10730 59600 140 161 90 1247 1300 1768 118 1516 138 6 13750 1 1550 64100 140 199 100 141 155 204 1322 1792 12 13750 15150 73000 1680 2278 120 1708 1750 2380 1506 2042 112 6 1500 14050 78000 1940 2630 140 1979 205 274 1 5 2379 12 15000 15800 87700 2200 2983 160 224 2300 3128 1974 2676 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 3120752 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND 0100011 242 121 Medium Strength Blue 0100019 271 Vibra TITE 140 High Strength Red 0100071 262 Vibra TITE 131 Medium High Strength Red Figure 1 2 Torque Chart SAE Fasteners Sheet 1 of 7 JLG Lift 1 5 SECTION 1 SPECIFICATION
28. 2 2 Mast Section Assembly Disassembly Reference 2 21 2 3 20AM Mast Assembly Components 5 2 25 2 4 25AM amp 36AM Mast Assembly Components 6 2 26 2 5 30AM 41AM Mast Assembly Components 7 2 27 2 6 Mast Chain Cable Routing Diagram 2 28 2 7 Mast Chain Cable Sequence Cable Adjustment Components 2 36 3 1 Voltage Measurement 3 3 3 2 Resistance 1 3 3 3 3 Continuity 3 4 3 4 Current Measurement 3 4 3 5 Outrigger Socket Contactor Heads and Outrigger Beam Contactor Plate Mounting Hardware ORIGINAL AND 5 2001 DESIGN 3 9 3 6 Hydraulic Schematic AM Series 2792491 3 11 3 7 Electrical Diagram AM Series 12 3 12 3 8 Electrical Diagram AM Series 120 3 14 3 9 Electrical Diagram AM Series 240
29. 25 36 5 32 8 NI NN ee ee ee c Tia 2 wm ze 200 1 150 16 2 17 978 ss ET NETTO WARE F CNN DRE RN 20 25 245 1525 io sso 460 24 3 38 220 1065 960 800 561 2095 1885 1575 694 2855 2570 2140 3665 3300 2750 4s n ewo ses 5 4395 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED NJO Figure 1 7 Torque Chart Fasteners Sheet 6 of 7 1 10 JLG Lift 3120752 SECTION 1 SPECIFICATIONS Magni Coating Ref 4150701 CLASS 12 9 SOCKET HEAD CAP SCREWS M6 AND ABOVE i Tensile Dry or Loctite 2427 2717 Loctite 262 Size PITCH Stress OR Vibra TITE OR Vibra TITE i um or 140 M 15 678 78 8 78 36 60 115 12 5 18 0 22 8 36 1 52 5 as mm 4000 NO 500
30. 41 ft 2 32 Platform Mounting Section Assy All Masts 2 33 2 10 MAST TO BASE FRAME 4 1 2 34 2 11 MAST CHAINS CABLES AND SEQUENCING CABLES 2 35 Mast Chain Cable 2 35 Sequencing Cable 2 36 2 12 SEQUENCE CABLE REPLACEMENT 1 2 37 Remove Old 2 37 Replacement Cable 1 2 97 Clamp Installation Drum Socket Type 2 37 SECTION 3 TROUBLESHOOTING 31 GENERAL 3 1 3 2 TROUBLESHOOTING 2 2 3 1 3 8 HYDRAULIC CIRCUIT 1 0 4 3 1 3 4 ELECTRICAL SYSTEM MULTIMETER 3 1 Groundihg aE asi fes eset peret 3 1 Backprobing ee Sih est o ei RR dogs Leur ud tat 3 1 Maxi ot ite ae tts Motta wetter bu 3 1 Pol rity eet 3 2
31. Shim per instructions in step 7 Mast Section 2 Assembly Insert slide pads into the bottom end mast rails between section 2 and 3 one on each side of the mast with beveled surface facing out towards sec tion 2 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes on inside rail on bottom end of mast section 3 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Section 4 Assembly Masts When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Locate mast section 4 carefully slide section 4 closed rail into section 3 open rail Slide sections together until ends are even Locate one 1 of the chain cable anchor plates one with two threaded holes vertically aligned in center of bracket Attach through inner vertical set of holes at bottom of mast section 4 using two 2 1 4 20UNC x 3 4 long bolts place a flatwashers under head of each bolt Slide mast section 4 out the top of mast section 3 so the chain cable anchor plate on bottom of mast sec tion 4 is easily accessible at top end of mast section 3 Rest the top end of mast section 4 on a support while performing next step Insert threaded ends of chain assembly attached to anchor block on top mast section 2 through the cha
32. center of bracket Attach through inner vertical set of holes in bottom of mast section 5 6 7 with two 2 1 4 20UNC x 3 4 long bolts place a flatwasher under head of each bolt 3120752 SECTION 2 SERVICE PROCEDURES NOTE The platform mounting section slide pads are assembled differently than the slide pads for the other mast sections Mast section 5 6 7 slide pads may need to be assembled disassembled several times in order to determine the correct shim stock required for proper fit 75 Complete the following steps to determine shim stock thickness required for section 5 6 7 NOTE Always use the an even amount of shim material behind slide pads on both sides of the mast rails This will keep mast sections centered in rail chan nels and prevent any distortion of the section a Use two shim pieces per slide pad a thick one and a thin one b Start with a total thickness of approximately 035 and 075 thick shim stock c Attach shim stock and slide pads to both sides of mast section 5 6 7 using five 5 1 4 200 x 1 1 4 long hex head cap screws per side with flatwasher under each bolt head Assemble shim stock and slide pad to mast section rail with shim stock against rail and slide pad with bev eled side out NOTICE PRIOR TO SERIAL 142920 THE AM MAST INSTALLED TWO SHORT SLIDE PADS ON EACH SIDE OF THE PLATFORM MOUNT ING MAST SECTION AS OF SERIAL 142920 A LONGER SINGLE PAD IS INSTALL
33. mast has been removed from machine lay mast assembly down with the shortest mast section 5 6 7 on top and fac ing up 2 Remove sequencing retract cables from sides of mast assembly and the mini covers from the top of each mast section Also remove the latch bar assembly from BOTTOM of mast section 5 6 7 lt oP REFERS TO TOP END OF MAST SECTION END WITH COVER AND SHEAVE WHEELS ATTACHED BOTTOM OF MAST SECTION END WHICH SETS AT MACHINES BASE FRAME Figure 2 2 Mast Section Assembly Disassembly Reference JLG Lift 2 21 SECTION 2 SERVICE PROCEDURES Platform Section Removal Ail Masts 3 NOTE Remove cable adjust nuts from threaded ends of cable attached to the cable anchor plate on BOT TOM end of mast section 5 6 7 short platform mounting section Push threaded ends of cable through anchor plate At TOP of mast section 5 6 7 pull cables out and allow to hang loose When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide short mast section 5 6 7 out BOT TOM of mast section 4 5 6 rails Disassemble slide pads shims and cable anchor plate from mast sec tion 5 6 7 if necessary Mast Section 6 Removal 7 Section Mast NOTE NOTE 10 Steps 6 through 10 apply to removal of mast section 6 used on 30 amp 41 ft models which have seven 7
34. mast sections If disassembling a six 6 section 25 or 36 ft mast go to step 11 if disassembling a five 5 section 20 ft mast continue to step 17 Remove cable adjust nuts from threaded ends of cable attached to the cable anchor plate on bottom end of mast section 6 Push threaded ends of cable through anchor plate At top of mast section 6 pull cables out and allow to hang loose Slide mast section 6 out TOP of mast section 5 far enough to allow access to the cable sheave wheel assembly Remove countersunk flathead screws securing cable sheave wheel assembly attach bars on both side rails at top of mast 6 and remove sheave wheel assembly When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 6 out BOTTOM of sec tion 5 Remove slide pads shims and cable anchor plate if necessary Mast Section 5 Removal 6 amp 7 Section Mast NOTE 11 2 22 Steps 11 through 15 apply to removal of mast sec tion 5 used on 25 30 36 amp 41 ft models If servicing a 20 ft mast go to step 17 Remove cable adjust nuts from threaded ends of cable attached to the cable anchor plate on bottom 12 13 14 15 16 end of mast section 6 Push threaded ends of cable through anchor plate At top of mast section 5 pull cables out and allow to hang loose Slide mast section 5 out
35. of more than 3 months or when purchased used The frequency of this inspection must be increased as environment 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 The Annual Machine Inspection must be performed by a qualified JLG equipment mechanic on an annual basis no later than thirteen 13 months from the date of the prior Annual Machine Inspection JLG Industries Inc recog nizes a qualified JLG equipment mechanic as a person who has successfully completed the JLG Service Training School for the subject JLG product model Reference the machine Service and Maintenance Manual and appropri ate JLG inspection form for performance of this inspec tion 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 man ual 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 Industri
36. or 140 561 3 694 302 0 1990 1490 2090 14 23 0 7 8 78 3 82 34 6 8 6 1 2 874 n 79 12 19 125 3660 15 9 28 55 12 175 8430 367 88 66 97 154 241 331 469 22 303 639 24 353 811 27 459 1130 30 1530 33 36 42 5 4 817 355 5 2560 1920 2690 5 42 4 1120 487 0 4090 3070 4290 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED 3120752 Figure 1 6 Torque Chart METRIC Fasteners Sheet 5 of 7 JLG Lift SECTION 1 SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 10 9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12 9 SOCKET HEAD CAP SCREWS M5 Torque m Torque Lub OR Loctite amp Torque Dry or Loctite 24277 or 2711 OR Loctite 262 OR Size PITCH Stress TM TM Area 263 Vibra TITE 111 Vibra TITE 131 K 0 20 140 K 0 15 K 0 18 3 os 593 313 ECCE EE T a oz ez sa o spo p 0 8 25 2 22 7 18 9 1
37. or conditions and depend ing on the location and use of the machine 3120752 SECTION 2 SERVICE PROCEDURES Table 2 2 AM Model Preventive Maintenance amp Inspection Schedule AREA ON MACHINE INTERVAL PRE START 1 INSPECTION WEEKLY PREVENTATIVE MAINTENANCE 3 MONTH PREVENTATIVE MAINTENANCE PRE DELIVERY 2 OR FREQUENT 3 INSPECTION ANNUAL 4 YEARLY INSPECTION MAST ASSEMBLY 1 Mast Sections 2 5 Chain Systems 14 25 Sequence Cable Systems 1 2 3 Support Bars 1 2 Covers or Shields 1 Sheave Systems Bearings 1 2 1 2 Slide Pads 1 2 PLATFORM ASSEMBLY Platform Guard Rails 1 2 Gate 1 5 Floor Extension Deck Assembly Lanyard Anchorage Point CHASSIS ASSEMBLY Outrigger Beams Sockets and Locking Pins 1 2 5 7 Screw Jacks 1 2 5 Tires Wheels Caster Systems 1 2 Bubble Level 1 2 7 Cable Reel LiftMaster Winch and Winch Brake LiftMaster Only 1 2 5 FUNCTIONS CONTROLS Platform Controls Ground Controls 5 6 7 5 6 24 Function Control Locks Guards or Detents Function Enable System Emergency Stop Switches Ground amp Platform Function Limit or Cutout Switch Systems Manual Descent or Auxiliary Power POWERSYSTEM Batteries
38. plug driver and hammer to drive the plug into the sleeve while assuring that the strands are spaced somewhat equally around the plug Drive the plug until it is firmly seated and no more than 1 3 of the plug is visible from above the sleeve sss PLUG DRIVER INSERT PLUG 5 POSITION NOTE NOTE JLG Lift 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 SHAPE PLUG DRIVER STRANDS METAL TUBE AROUND OR PLIERS PLUG When assembling stainless steel parts all threads must be coated with a dry lubricant or an anti sieze lubricant to prevent seizing Coat the threads of the socket and sleeve with lubri cant and install the socket by twisting it over the strands of the cable and engage the threads of the sleeve with the socket Tighten until four threads or fewer are visible If more than four threads are visi ble proof load the cable and retighten the socket fit ting There is no specific requirement for torque INSPECTION INSTALL HOLE SOCKET AND TIGHTEN FOUR THREADS OR LESS SHOWING Inspect for proper assembly prior to loading the cable Strands visible through the inspection hole are your assurance of a proper assembly The end of the rope may not be visible in the inspec tion hole after loading
39. 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 recommended shop practices See Figure 1 2 Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacles when disconnecting or removing them from the unit This will assure that they are correctly reinstalled Hydraulic System Keep the system clean If evidence of metal or rubber par ticles is found in the hydraulic system drain and flush the entire system Disassemble and reassemble parts on clean work sur face Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assem bly Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown on the Lubrication Chart in Section 1 Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants are not available consult your local supplier for an equivalent that meets or exceeds the specifications listed Batteries Clean batteries using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroughl
40. sheave pin attach bars one each end of sheave pin to outside of space tubes d Holding complete sheave wheel assembly slide assembly into top of mast section 3 and align threaded holes in sheave pin attach bars with holes in mast rails e Attach to top of mast section 3 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 3 into section 2 until ends are even Check to make sure chain assembly wide chains are seating properly in chain anchor block chain sheave wheels attached to mast sec tion 2 Insert slide pads into the top end mast rails between section 2 and 3 one on each side of the mast with beveled surface facing inward towards section 3 Before fastening and shimming the slide pad on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in outside rail on top of mast section 2 and into the slide pad inserts Thread in enough to hold pad in place 2 29 SECTION 2 SERVICE PROCEDURES 29 30 31 32 Mast NOTE 33 34 35 36 NOTE 37 38 2 30
41. the new replacement cable to the top cable anchor bracket on the mast using the wash ers spring spring cap and lock nut previously dis assembled Thread the lock nut on until approximately 1 8 in 3mm of threads are exposed 3 Atthe bottom of the mast thread the loose end of the replacement cable through the proper sheave pulley and through the hole in the sheave pully anchor bracket on the mast section ahead of the sheave pulley 4 Grasp the cable and pull on the cable until the spring at the top of the cable is slightly compressed Use a black marker to mark the cable on the top side of the sheave pully anchor bracket This will determine where the clamp drum socket sleeve will be positioned on the cable NOTICE DO NOT CUT THE CABLE AT THE MARKED POINT ON THE CABLE THIS IS ONLY USED AS A REFERENCE FOR POSITIONING THE CABLE SLEEVE WHICH WILL REST AGAINST THE ANCHOR BRACKET ONCE INSTALLED 3120752 Clamp Installation Drum Socket Type THE MANUFACTURER OF THE DRUM SOCKET MENDS THE USE OF THEIR CABLE CLANP ASSEMBLY KIT JLG P N 7023275 TO ASSEMBLE THE CLAMP TO THE WIRE ROPE THE KIT CONSISTS OF VISE JAWS HOLD THE WIRE ROPE IN A VISE PROPERLY WITHOUT DAMAGING ANY ROPE STRANDS AND A PLUG DRIVER TO DRIVE THE PLUG INTO THE CENTER OF THE WIRE ROPE AND IS ALSO USED TO FORM THE STRANDS OF THE ROPE DURING ASSEMBLY NOTE The tools in the clamp assembly kit may be frabri cated if necessary Th
42. the rod port if visible to be sure they are not nicked or cut Install the head until the retaining ring seats in it s groove Installation 1 2 NOTE 10 11 12 13 14 15 16 JLG Lift Remove the plastic plugs from the cylinder Pull rod out of cylinder approximately 3 ft The following step is easier done with two people one to slide the cylinder into the mast the other to guide the rod into the cylinder block at the top of the mast Slide the cylinder into the mast and install the rod into the cylinder attach block Apply Loctite 222 purple to the setscrew securing the lift cylinder rod to the sheave wheel anchor block at the top of mast section 2 Install the setscrew in the cylinder attach block at the top of the mast coat the threads of the setscrew with Loctite RC 640 blue before tightening Original Design Cylinder Mount Install the cylin der mount and cylinder mounting plates into the bot tom of the mast section 1 Shim to eliminate any side clearance to prevent any strain on the sides of the mast when the bolts are tightened New Design Cylinder Mount Install the cylinder mounting plates at the bottom of the mast section 1 Mount plates two each side using the the 2 two long pass through bolts and nuts apply Loctite 242 to the bolt threads before tightening nuts Original Design Cylinder Clamp the cylinder in the mounting journal of the cylinder mount Apply Loc
43. tite 242 to the journal bolt threads and torque to 85 ft Ibs Align the hole in the mounting journal with the hole in the cylinder and Install the 1 5 16 bolt New Design Cylinder Install the mounting pin through the side mounting brackets and the cylinder valve body and through the mounting brackets on the other side of the mast Install the snap rings to each end of the mounting pin Connect the hydraulic fittings and lines new fittings should be used Slide the mast together stowed position from the top of the mast Stand machine upright on it s base wheels Connect the hydraulic line fittings at the pump Check oil level in the hydraulic oil reservoir add oil to fill line if necessary Install the ground station pump cover Set up machine for operation and cycle mast up and down approximately 3 ft to 4 ft a few times Check the hydraulic oil reservoir again add oil to the fill line 3120752 SECTION 2 SERVICE PROCEDURES 3120752 2 8 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES The AM Series personnel lift mast sections are con structed of extruded aluminum protected with an anod ized surface finish The mast sections rails are interlocked into each other when assembled and are guided by slide pads mounted at the top and bottom of the rails on both sides of the mast section The current AM model line mast assemblies have been designed with either five 5 six 6 or seven 7 mast sec ti
44. to contactor screw per Figure 3 5 and instructions in Section 3 6 Outrigger Interlock Contacts Replace contactor Replace LED Replace pull pin Unit lowers by itself Red emergency stop button is engaged PUSHED IN on either ground control station or on platform Control relay not functioning Motor start relay not functioning Unit wiring not properly grounded Disengage TURN CLOCKWISE red emergency button until it pops out Replace control relay Replace motor start relay Check all grounds in the wiring Unit leaking hydraulic oil Manual descent valve open Hydraulic hose and or fittings loose causing a hydraulic pressure leak Lift DOWN solenoid valve notfunction ing Close manual descent valve Tighten hydraulic hose and or fittings Replace Lift DOWN solenoid valve Unit lowers very slowly Hydraulic hose and or fittings loose Valve and or plug loose Breather cap on tank is saturated or clogged with oil Hydraulic oil tank over filled Tighten hydraulic hose and or fittings Tighten valve and or plug Replace breather cap on tank Lower oil levelto full mark on dipstick 3 6 Flow control valve not functioning JLG Lift Replace flow control valve 3120752 SECTION 3 TROUBLESHOOTING Table 3 2 DC Unit Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Outrigger LED light does notturn on Platform does n
45. 0059 J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 8 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 8 Torque Chart METRIC Fasteners Sheet 7 of 7 3120752 JLG Lift 1 11 SECTION 1 SPECIFICATIONS 27 NOTES JLG Lift 3120752 SECTION 2 SERVICE PROCEDURES SECTION 2 SERVICE PROCEDURES 2 1 MACHINE PREPARATION INSPECTION AND MAINTENANCE General 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 Preparation Inspection and Maintenance It is important to establish and conform to a comprehen sive inspection and preventive maintenance program The following table outlines the periodic machine inspec tions and maintenance recommended by JLG Industries Inc Cons
46. 10700 80 no 70 9 6 80 1 20 05000 01599 _ 14400 120 165 10 9 120 118 0 5625 02030 1850 170 230 155 210 130 175 5 8 1 0 6250 0 2260 20350 210 285 190 260 160 220 18 0 6250 0 2560 215 290 180 245 3 4 10 0 7500 0 3340 340 460 380 16 0 7500 0 3730 380 515 430 14 0 8750 0 5090 45800 670 910 600 815 500 680 112 100 0630 5900 95 1355 895 1215 745 1015 112 11250 0 8560 7700 1445 1965 1300 170 1085 1475 112 12500 1 0730 59600 2015 2740 1810 240 1510 2055 112 1370 13150 118100 2705 3680 2435 3310 2030 2760 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 5 Torque Chart SAE Fasteners Sheet 4 of 7 JLG Lift 3120752 SECTION 1 SPECIFICATIONS Tensile Stress Area Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 8 8 METRIC BOLTS CLASS 8 METRIC NUTS Torque Loctite amp Loctite 262 242 or 271 OR Vibra OR Vibra TITE 131 TITE 111
47. AFC 0 8 Pump Output 0 43 GPM 3500 PSI 11 7v DC 150 AMPS 45 Centistrokes Pressure Relief Adjustable Range 1500 to 5000 PSI Set to 2800 PSI 193 bar at factory AC Models 100 Volt AC Motor Pump Motor 100v AC 2 2850 3450 RPM 50 60Hz Pump Displacement 049 in rev 0 8 cc rev Pump Output 0 43 3500 PSI 16 AMPS 100v AC 45 Centistrokes Pressure Relief Adjustable Range 1500 to 5000 PSI Set to 2800 PSI 193 bar at factory AC Models 120 Volt AC Motor Pump Motor 100 230v AC 1HP 2850 3450 RPM 50 60Hz Pump Displacement 049 in rev 0 8 cc rev Pump Output 0 43 GPM 3500 PSI 16 AMPS 115v AC 9 45 Centistrokes Pressure Relief Adjustable Range 1500 to 5000 PSI Set to 2800 PSI 193 bar at factory AC Models 240 Volt AC Motor Pump Motor 100 230v AC 1 2850 3450 RPM 50 60Hz Pump Displacement 049 in rev 0 8 cc rev Pump Output 0 43 GPM 3500 PSI 8 AMPS 230v AC 45 Centistrokes Pressure Relief Adjustable Range 1500 to 5000 PSI Set to 2800 PSI 193 bar at factory 3120752 Batteries 1 DC Models 12 Volt 165 Amp min Deep Cycle Marine RV Battery Charger DC Models Input 120 240 Volts AC 50 60 Hz Voltage Selectable Output 12 volt 10 Amp DC w Auto Charge Sensing Circuit 1 3 PERFORMANCE DATA Platform Capacity PLATFORM C
48. APACITY MODEE ANSI C S A Brazil U S A Canada Japan 20AM AC amp DC 350lb 160kg 35010 160 160 0 3501 25AM AC amp DC 3501 160 0 3501 160 0 160 0 3501 30AM AC amp DC 3501b 160kg 35016 160 135kg 300 0 36AM AC amp DC 3001 135kg 3001b 135kg 135 0 3001 41AM AC amp DC 30015 135 0 3001b 135kg 135kg 300 Ib Platform Gycle Performance Lift Up cycle time from stowed to maximum platform height with maximum rated load Lift Down cycle time from maximum platform height to stowed position with maximum rated load MAXIMUM PLATFORM SPEEDS SECONDS 20AM 25AM 30AM 36AM 41AM Lift Down LiftUp 50 62 72 128 120 32 42 32 42 32 42 47 57 45 55 Machine Weight with Standard Platform 20AM AC 740 165 336kg 20AM DC 860 Ibs 390kg 25AM AC 825 Ibs 25AM DC 905 Ibs 30AM AC 890 Ibs 404kg 30AM DC 940 Ibs 427kg 36AM AC 1 060 Ibs 481kg 36AM DC 1 160 Ibs 526kg 41AM AC 1 100 Ibs 499kg 41AM DC 1 230 Ibs 558kg JLG Lift 374 411kg Sere SECTION 1 SPECIFICATIONS Machine Height Platform Stowed 20AM AC amp DC 78 in 2 0m 25AM AC amp DC 78 in 2 0m 30AM AC amp DC 78 in 2 0m 36AM AC amp DC 104 5 in 2 64m 75 5 in 1 9m 41AM AC amp DC 104 5 in 2 64m 77 5 in 2 0m In tilt back mode Maximum Platform Height Ma
49. Contactor Plate Mounting Instructions ORIGINAL DESIGN See Figure 3 5 1 Assemble insulating grommets into the screw holes in outrigger beam Locate contactor plate and insert two 2 brass 8 32UNC x 3 4 long countersunk flathead screws through the contactor plate and install two 2 nylon washers on each screw against contactor plate On outside of outrigger beam slide threads of brass screws of contactor plate assembly through insu lating grommets in outrigger beams until nylon washers rest against grommets and hold in place if necessary Install one 1 nylon washer on each screw inside of outrigger beam against insulating grommet Thread a brass 8 32UNC locknut onto each screw inside outrigger beam tighten screws until 175 height exists between bottom of plate and bot tom most edge of outrigger beam See Figure 3 5 5 2001 DESIGN See Figure 3 5 1 JLG Lift Assemble an insulating bushing into each of the screw holes in the floor of the outrigger beam Locate the contactor plate and insert two 2 brass 8 32UNC x 3 4 long countersunk flathead screws through the contactor plate Install one 1 o ring on one screw and stack two 2 on the other screw slide o rings in against contactor plate On the bottom of the outrigger beam slide the threads of brass screws with o rings and contactor plate assembly through the insulating bushings Install the screw with two 2 o rings
50. DIT METHODS TOLERANCE 10 8 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH SECTION 1 SPECIFICATIONS HEAD SCREWS Zinc Yellow Chromate Fasteners Ref 4150707 Torque Loctite amp 242 or 271 Torque o Semp ke Ed Loctite 262 Stress Area See Note 4 OR Vibra TITE 111 or or Vibra TITE 131 140 85 K 0 15 12 1 5000 1 5800 142200 3555 4835 3200 4350 2665 3625 PI K 0 18 o ose me mm oe mm os 4 40 0120 0064 j 01 D jJ T 6 32 01380 0009 j 0130 000015 j j j j 9 8 32 060 00400 J T T j O 16 01640 00474 j j AJ j 10 24 0190 A j j j j O _ 32 01900 0 02000 J j j j j O U 1 4 20 0250 0 0318 _ 2860 143 16 129 15 C 1 28 0250 0 0364 3280 164 19 m _ sr m Wm FF _____ 24 03125 0 0580 520 25 3 25 35 2 25 1 24 0350 0 0878 700 70 45 3 50 716 14 0435 0 1063 950 70 95 6 9 50 70 1 20 0437 0 1187 _
51. ED ON EACH SIDE ON MACHINES PRIOR TO SERIAL 142920 THE 41 MOUNTS THE SHORT UPPER SLIDE PAD IN THE UPPER SET OF SLIDE PAD MOUNTING HOLES THE 20AM 25AM 30AM AND 36AM MACHINES MOUNT THE UPPER SLIDE PAD IN THE LOWER SET OF SLIDE PAD MOUNTING HOLES SEE FIGURE 2 5 d Carefully thread the slide pad mounting bolts with flatwashers through slide pads and shim stock into threads in mast section 5 6 7 Be certain there are no air gaps between shims shim and mast or shim and slide pad when tight ened NOTE Mast section 5 6 7 into section 4 5 6 fit should be very snug but still be able to be pushed together by hand If too tight remove section 5 6 7 disassem ble slide pad and reduce thickness of shim stock e Begin sliding top of mast section 5 6 7 with closed rail down engaging the slide pads into slide pad channels at bottom of mast section 4 5 6 s open rail Continue to push section 5 6 7 into section 4 5 6 until BOTTOM ends of mast sections are even 3120752 76 77 78 79 80 f Check mast section for side play If play exists use thicker shims dividing thickness equally between both sides of mast 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 Slide mast section 5 6 7 to top of section 4 5 6 Insert threaded ends of ca
52. Fasteners Sheet 2 of 7 Lift 3120752 SECTION 1 SPECIFICATIONS HEAD SCREWS Magni Coating Ref 4150701 NOTES 1 THESE TORQUE VALUES DO NOT APPLY CADMIUM PLATED FASTENERS 3120752 CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 4 Torque Chart SAE Fasteners Sheet 3 of 7 JLG Lift Torque Si TPI Bolt Di Tensile Clamp Load Torque Loctite 262 07778 Stress Area See Note 4 Dry K 17 ORVibra TITE 111 or or Vibra TITE 131 140 OR Precoat 859 4 0120 00064 111 46 ooo J T T T T T e 32 01380 00099 a a Ses 8 32 0 1640 0 01400 10 24 0 1900 0 01750 32 01900 oo00 T T j 14 20 02500 00318 260 122 4 33 7 28 02050 0 0364 3280 139 16 131 75 5 16 18 0 3125 0 0524 4720 20 25 20 25 20 25 24 0 3125 0 0580 5220 3 8 16 0 3750 0 0775 7000 50 35 50 35 50 7116 1 2 9 16 5 8 34 78 9 085 04620 4160 515 70 45 4660 45 620 1 8 1000 06060 5150 70 95 65 90 645 875 1178 12 114 7 12 13 8 6 2300 3130 2165 2945 2030 2760 11 2 6 1 5000 1 4050 126500 2690 3660 2530 3440 2370 3225 NO 5000059 REV J 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AU
53. LED BO LED D GREEN e 5 5 ORANGE EI l 4 4 BLACK 5 5 3 MELZ OZR OZR O R O R CONTACTOR CONIACT R RED 1 YEL 1 YEL 1 Es m Es 6 l 1 m z T3 2 m uo POTTED RELAY REF WHITE 16 GREEN 16 GREEN 161 BLACK 1 CROSSMEMBER Figure 3 10 Electrical Diagram AM Series 100V AC JAPAN 3 18 JLG Lift 3120752 SECTION 3 TROUBLESHOOTING J PRINARY me 2
54. LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPO NENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACH MENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS 3120752 EFFECTIVITY PAGE EFFECTIVITY CHANGES June 1 1998 Original Issue of Manual December 2 1998 Manual Revised July 26 2000 Manual Revised September 22 2000 Manual Revised November 16 2000 Revised Pages Affected Section 2 Pages 2 11 2 18 thru 2 22 June 14 2001 Revised Pages Affected Section 2 Pages 2 4 thru 2 9 Section 3 Pages 3 3 thru 3 6 October 17 2001 Manual Revised Pages Affected Section 1 Page 1 1 Section 2 Pages 2 1 thru 2 4 October 31 2003 Manual Revised Pages Affected Section 1 Pages 1 1 1 2 and 1 5 Section 3 Pages 3 8 thru 3 15 March 23 2005 Manual Revised July 11 2006 Manual Revised January 30 2008 Manual Revised August 29 2012 Manual Revised 3120752 JLG Lift EFFECTIVITY 27 NOTES JLG Lift 3120752 TABLE CONTENTS TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE NO INTRODUCTION OPERATION SAFETY PRECAUTIONS A INTRODUCTION MAINTENANCE SAFETY
55. Lead Clips Soldered IMPORTANT REMOVE THE MOTOR COVER CAREFULLY THE SHORT POWER LEADS INSIDE THE COVER FROM THE POSTS SOL DERED TO ATTACH CLIPS WHICH ARE FASTENED TO THE BRUSH CARRIER ASSEMBLY WITH SCREWS ITEM 5 RAISE THE COVER STRAIGHT UP REMOVE THE SCREWS THEN HINGE THE COVER UP SEE CENTER ILLUSTRATION AND PRY THE CLIPS OFF OF THE BRUSH CARRIER ASSEMBLY TO COMPLETELY REMOVE THE MOTOR COVER NOTE a Once cover screws are removed you may need to tap lightly around the edge of the top cover to separate it from the motor housing Read the important note above before attempting to remove the cover b These steel screws are threaded into the aluminum valve body do not overtighten 2 14 JLG Lift 3120752 SECTION 2 SERVICE PROCEDURES Brush Carrier Assembly Remove Install 4 2 amp EE PE md ea 1 I V E INS L 2 3 28 TA i Sue Brush Carrier Assembly Remove Install 1 Stator Brush Carrier Screws Pump Rear 3 Mark Brush Carrier Position on Motor Housing 2 Stator Brush Carrier Screws Pump Front a 4 Brush Carrier Assembly NOTE a Removed previously with motor cover disassembly shown for
56. NG NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING 5 2 36 Start with the mast section which needs adjustment and loosen the bottom jam nut on each chain cable Tighten to raise mast section or loosen to lower mast section the adjusting nut against the anchor plate each chain cable Adjust the nut the amount required to raise or lower the top of the mast section to match the side profile shown in Figure 2 7 when the mast is retracted Be certain each chain cable pair is adjusted to equal tension The threaded end of the chain cable will need to be restrained while tightening the adjust nut to keep the chain cable from twisting Retract the mast all the way and check if the top of the mast sections appear as shown in Figure 2 7 Repeat steps 1 through 7 for remaining mast sec tions ENSURE THAT ALL CHAIN CABLE PAIRS HAVE EQUAL TENSION Once mast section adjustment is completed apply loctite 242 to the threads under the jam nuts that were loosened Then re tighten the loosened jam nuts until tight against the top adjust nut Chain cable should have slight tension but should not be taut Run mast through several cycles to verify cable chain adjustments and ensure no interference exists between chain anchor brackets and mast Sequencing Cable Adjustment 1 JLG Lift Retract mast completely and check e
57. RER HAS NO DIRECT CON TROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER OPERATOR Hydraulic System Safety 1 It should be particularly noted that the machines hydraulic systems operate at extremely high and potentially dangerous pressures Every effort should be made to relieve any system pressure prior to dis connecting or removing any portion of the system 2 Relieve system pressure by activating the lift DOWN control with the platform completely lowered to direct any line pressure back into the return line to the reservoir Pressure feed lines to system compo nents can then be disconnected with minimal fluid loss b JLG Lift Maintenance Safety WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION COULD RESULT IN MACHINE DAMAGE PERSON NEL INJURY OR DEATH AND IS A SAFETY VIOLATION REMOVE ALL RINGS WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE DO NOT WEAR LONG HAIR UNRESTRAINED OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT OBSERVE AND OBEY ALL DANGER WARNING CAU TION 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 OVER HEAD SLING BEFORE MAKING ADJUSTMENTS
58. S Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS Torque Torque orque 202 or Stress Area 0 OR Vibra TITE 111 or TITE 131 140 K 18 K 0 15 In Sq In LB N m IN LB N m IN LB N m 4 40 0 1120 0 00604 0 1120 0 00661 0 1380 0 00909 0 1380 0 01015 m 03640 001400 __ L T 0 1640 001474 13 0 24 0190 0017560 1580 0 7 T 0 1900 0 02000 1800 68 gt gt 14 20 02500 00318 2860 0 2500 0 0364 3280 eus m i 25 25 3 8 16 03750 0 0775 700 45 60 40 55 35 50 50 70 20 0435 0 1187 10700 80 10 70 95 60 80 12 13 110 120 155 8999 ees iro ae ps 288 EE 175 210 285 190 220 240 325 215 245 375 510 340 380 420 570 380 430 i 0 5090 45800 670 910 600 815 500 680 875 1015 1310 1475 1855 2055 2430 2760 3225 3625 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS NO 5000059 J 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER Figure 1 3 Torque Chart SAE
59. S SCR BATTERY CHARGER MANUAL INCLUDED WITH THE MACHINE FOR CHECKING THE INTERNAL AC AND DC CIRCUITS TO DETERMINE WHICH COMPONENT HAS FAILED COMPLETE WIRING DIAGRAMS PERTAINING TO YOUR MODEL CHARGER ARE ALSO INCLUDED IN THE MANUFACTUR ERS SCR BATTERY CHARGER MANUAL The AM Series dual AC input battery charger allows for replacement of the following internal components Con sult your Illustrated Parts Manual for part numbers of these components which are available from the JLG Parts Department Transformer Printed Circuit Board Shunt Assembly Interlock Relay SCR Rectifier AC Circuit Breaker DC Circuit Breaker Replacement and troubleshooting of these components requires removal of the battery charger from it s mounting on the charger battery box assembly 3120752 Battery Charger Removal 1 If plugged in unplug the AC voltage cord from AC receptacle and remove the charger battery box unit from the machine 2 Disconnect the RED and BLACK charging wires from the charger to the battery terminals in the lower battery compartment 3 Remove the four 4 mounting bolts and washers located on the back of the upper battery box sec tion securing the charger into the upper section 4 Remove the charger through the front opening while pulling the charging wires RED BLACK through the hole on the bottom of the upper battery box section Cover Removal 5 Remove the ten 10 screws on the sides an
60. STMENT See Figure 1 1 Adjust system pressure so that platform will raise with rated capacity in platform Turning adjustment screw clockwise increases system pressure turning screw counterclockwise decreases system pressure Do not adjust system pressure higher than required to raise the load Make pressure adjustment with oil at nor mal operating temperature If pressure is set when oil is cold platform may not raise rated load after oil has warmed PRESSURE ADJUSTIVENT E CER JA SCREW Figure 1 1 Pressure Setting Adjustment Screw Located at Base of Pump Motor Remove Hex Head Cap as Shown 1 7 CYLINDER SPECIFICATIONS NOTE All dimensions are given in inches in with met ric equivalent centimeters cm given in parenthe Ses Table 1 3 Cylinder Specifications DESCRIPTION BORE STROKE ROD DIA in cm in cm Lift Cylinder 1 63 56 50 1 38 20AM AC amp DC 4 14 143 50 3 50 Lift Cylinder 1 63 56 50 1 38 25AM AC amp DC 4 14 143 50 8 50 Lift Cylinder 1 63 56 50 1 38 30AM AC amp DC 4 14 143 50 8 50 Lift Cylinder 1 63 83 25 1 38 36AM AC amp DC 4 14 211 40 8 50 Lift Cylinder 1 63 78 25 1 38 41AM AC amp DC 4 14 198 75 8 50 1 8 SERIAL NUMBER LOCATIONS For machine identification a serial number plate is affixed to the machine The plate is locat
61. TICE INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these areas They are defined as follows A DANGER DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUA TION WHICH IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR DEATH A CAUTION CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUA TION WHICH IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES Also in this Manual Notes are used to provide infor mation of special interest A WARNING WARNING INDICATES A POTENTIALLY HAZARDOUS SITU ATION WHICH IF NOT AVOIDED COULD RESULT IN SERI OUS INJURY OR DEATH NOTICE IMPORTANT OR INSTRUCTIONS PROCEDURES ESSENTIAL FOR SAFE OPERATION AND WHICH IF NOT FOLLOWED MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE MACHINE JLG INDUSTRIES INC MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT CONTACT JLG INDUS TRIES INC OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLE TINS WHICH MAY HAVE BEEN ISSUED FOR YOUR JLG PRODUCT ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COMPLETED ON THE AFFECTED JLG PRODUCT Due to the continuous product improvements JLG Industries Inc reserves the right to make specification changes without prior notification Contact JLG Industries Inc for updated information BS NOTES
62. TOP of mast section 4 far enough to allow access to the cable sheave wheel assembly Remove countersunk flathead screws securing cable sheave wheel assembly attach bars on both side rails at top of mast section 6 and remove sheave wheel assembly Step 15 applies to removal of the cable assemblies used on mast section 5 of 30 amp 41 ft models If ser vicing a 25 or 36 ft mast go to step 16 While mast section 5 is still extended from section 4 remove the bolts attaching the two 2 cable assem bly anchor eyelets to the TOP of mast section 5 Remove cables When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 5 out BOTTOM of sec tion 4 Remove slide pads shims and cable anchor plate if necessary Mast Section 4 Removal Ail masts 17 18 19 20 21 NOTE JLG Lift Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate on BOT TOM end of mast section 4 Push threaded ends of cable through anchor plate At TOP of mast section 4 pull chains out and allow to hang loose be certain floor surface is clean and free of any metal chips or debris which may stick to lubricated chains or lay chains in a clean bucket Slide mast section 4 out TOP of mast section 3 far enough to allow access to the cable sheave wheel assembly Remove countersunk flathead screws securing cable
63. ach sequenc ing cable on outside of masts for excessive slack Adjust only to remove slack from cable Tighten nylock nut just enough to remove excessive slack from sequencing cable The springs should not be compressed more than 25 after adjusting 3120752 SECTION 2 SERVICE PROCEDURES 2 12 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 Remove the locking nut from the threaded end of the cable at the top of the mast and then remove the spring cap spring and spacer washers if installed 2 Slide the threaded top end out of the upper anchor bracket then at the bottom end pull the cable out though the sheave pulley anchor bracket until it is completely clear of the machine Replacement Cable Installation 1 Becertain the mast is completely retacted and at the bottom of travel Check the mast Side Profile at the top of the mast as shown in Figure 2 7 adjust mast sections to proper height if necessary 2 To determine where the clamp will be installed at the bottom of the replacement cable temporarily assemble
64. ad countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 4 back into section 3 until ends are even Check to make sure chain assembly narrow chains are seating properly in chain sheave wheels attached to top of mast sec tion 3 Insert slide pads into the top end mast rails between section 3 and 4 on each side of the mast with beveled surface facing inward towards section 4 Before fastening and shimming the slide pad on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in outside rail on top of mast section 3 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Insert slide pads into the bottom end mast rails between section 3 and 4 one on each side of the mast with beveled surface facing out towards sec tion 3 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes on inside rail on bottom end of mast section 4 and into the slide pad inserts Thread in enough to hold pad i
65. ain to the front crossmem ber of the base frame raise base frame Extend hydraulic cylinder out from bottom of mast assembly approximately one 1 foot Caps on extend and return ports will need to be removed to extend cylinder Catch any hydraulic fluid expelled from return port in a container to prevent spillage onto work area Bring base frame into position in front of mast assembly base frame and mast assembly must be held at 90 angle to each other Slide port end of hydraulic cylinder through hole in base frame cylinder mounting channel Return port tube side of cylinder must be on right side facing bottom of base and mast Align threaded hole in side of hydraulic cylinder head with hole in tab on bottom side of cylinder mounting channel Secure hydraulic cylinder to cyl inder mounting channel tab using a 5 16 18UNC x 5 8 long hex head bolt and flat washer 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 Attach mast to base using four 4 3 8 16UNC x 1 long hex head bolts flatwashers and nuts place a under bolt head mount with nuts on inside of frame Apply Loctite 242 to bolt threads before final tightening of nuts 8 10 11 12 13 Before setting machine upright on base install a short 90 elbow fitting flow control valve and another short 90 elbow
66. assembly When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Slide mast section 5 back into section 4 except for a foot or two of length Steps 48 applies to seven 7 section 30 and 41 ft masts only for six 6 section 25 and 36 ft masts continue to step 49 Locate two cable assemblies Attach the eyelet anchor end of each cable to the two inside holes near top of mast section 5 using 3 8 16UNC x 1 1 4 long hex head bolts nuts and flatwashers Place a flatwasher under bolt head and nut While mast section 5 is still extended from section 4 assemble cable sheaves to top of mast section 5 as follows a Locate remaining sheave pin Slide two 2 cable sheave wheels onto sheave pin and center b Place two 2 short spacer tubes on sheave pin one on each end of sheave pin to outside of sheave wheels NOTE 53 54 NOTE 55 56 57 58 59 JLG Lift c Place two 2 sheave pin attach bars one on each end of sheave pin to outside of short spacer tubes d Holding complete cable sheave wheel assem bly slide assembly into top of mast section 5 and align threaded holes in sheave pin attach bars with holes in mast rails e Attach to top of mast section 5 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten When sliding mast section
67. ating condition 5 Load limits specified by the manufacturer shall not be exceeded 6 Instruction and warning placards must be legible 7 Aerial lifts may be field modified for uses other than those intended by the manufacturer only if certified in writing by the manufacturer or an equivalent entity such as a nationally recognized testing lab to be in conformity to applicable OSHA safety regula tions and to be at least as safe as it was prior to modification 8 Aerial lifts shall not be used near electric power lines unless the lines have been deenergized or adequate clearance is maintained see OSHA 29 CFR 1910 67 and 1926 400 9 Employees using aerial lifts shall be instructed how to recognize and avoid unsafe conditions and haz ards 10 Ground controls shall not be operated unless per mission has been obtained from personnel in the platform except in case of an emergency 11 Regular inspection of the job site and aerial lift shall be performed by competent persons 12 Personnel shall always stand on the floor of the plat form not on boxes planks railing or other devices for a work position Applicable Federal OSHA regulations as of the date of publication of this manual include but are not limited to 29 CFR 1910 67 29 CFR 1926 20 29 CFR 1926 21 29 CFR 1926 28 29 CFR 1926 400 and 29 CFR 1926 453 Consult the current regulations for the exact wording and full text of the requirements and contact th
68. bad c Bent misaligned chains Mast Cable Inspection Procedure NOTICE MAST CABLES ARE TO BE INSPECTED EVERY THREE MONTHS OR MORE FREQUENTLY AS DESCRIBED FOLLOWING CAUTION WEAR PROTECTIVE GLOVES TO PROTECT HANDS WHEN HAN DLING CABLE The periodic inspection shall cover the entire length of the cable The inspection frequency shall be based on such factors as expected cable life as determined by experi ence on the particular application or similar installations severity of environment percentage of capacity lifts fre quency rates of operation and exposure to shock loads Inspection should be more frequent as cables approach the end of their useful lives Only the surface wires of the cable require inspection do not attempt to open the cable Any deterioration resulting in any loss of original strength such as described below shall be noted and then a determination made if further use would constitute a hazard Mast cables must be replaced after machine has been in service for five 5 years regardless of cable condition or sooner if conditions dictate Conditions such as the following shall be sufficient reason for questioning continual use of the cable or increasing the frequency of inspection 1 In running ropes six randomly distributed broken wires in one lay or three broken wires in one strand in one lay 2 One outer wire broken at the point of contact with the core of the rope which has worked
69. ble assembly attached to top of mast 3 4 5 through the cable anchor plate located on bottom of extended mast section 5 6 7 Loosely thread two 2 3 8 16UNC nuts onto stud threads on each chain Chains will be adjusted later in assembly Slide mast section 5 6 7 back into mast section 4 5 6 until bottom ends of masts are even Check to make sure cable set attached to top of section 3 4 5 is seating properly in cable sheave wheels attached to top of mast section 4 5 6 Mast sec tions 2 8 4 and 5 may need to be restrained to keep their slide pads from pushing out the bottom of mast sections 1 2 8 4 and 5 Adjust top and bottom ends of mast sections so they are all even with each other At bottom of mast assembly thread all chain cable adjusting nuts on threaded ends until they are snug against the anchor plates and all slack is removed from chains and cables Check that chains and cables are seated in their sheave wheels at top of mast assem bly Assemble the latch bar to mast section 5 6 7 the mini covers to the top of each mast section and the sequencing cables and hardware to the side of the mast assembly Mast assembly should now be complete JLG Lift 2 33 SECTION 2 SERVICE PROCEDURES 2 10 BASE FRAME INSTALLATION 1 2 34 Using an overhead crane or suitable lifting device capable of supporting the weight of base frame attach a sling strap or ch
70. btract this value from the measured resistance of the wires to get a more accu rate measurement Consult the circuit schematic to determine which wires to use in addition to wire under test here called wire 1 and wire 2 and how to isolate these wires These wires should appear in the same connectors as the wire under test or are within reach of the jumper 1 Disconnect all connections associated with the wire under test and the two additional wires If harness is not completely isolated disconnect battery terminals also as a precaution 2 Measure continuity between all three wires the wire under test wire 1 and wire 2 These should be open If not repair the shorted wires or replace the harness 3 On one side jumper from contact of wire 1 and wire 2 4 Measure continuity between wire 1 and wire 2 If there is continuity both wires are good and can be used for this test If there is not continuity either wire could be bad Check connections and measurement setup Redo measurement If still no continuity repair wires or consult schematic for other wires to use for test 5 Jumper from wire under test to wire 1 6 Measure continuity If there is continuity the wire under test is good Resistance of a wire increases as the length increases and as the diameter decreases One can find the continuity of two wires here 1 and 2 at once by following steps 1 through 4 If there is a prob lem the third wire is
71. cles embedded in the seal surface It is nor mal to cut the static seal on the retaining ring groove upon disassembly Remove the rod seal static o ring and backup and rod wiper Damage to the seal grooves par ticularly on the sealing surfaces is unacceptable In the 3120752 SECTION 2 SERVICE PROCEDURES 3120752 IN THIS AREA ONLY Figure 2 1 Lift Cylinder Internal Component Assembly Cross Section event that an unacceptable condition occurs the head should be replaced Piston Visually inspect the outside surface for scratches or pol ishing Deep scratches are unacceptable Polishing indi cates uneven loading and when this occurs the diameter should be checked for out of roundness If out of round ness exceeds 0 007 this is unacceptable Check the con dition of the dynamic seals and bearings looking particularly for metallic particles embedded in the bearing and in the piston seal surface Remove the seals and bearings Damage to the seal grooves particularly on the sealing surfaces is unacceptable In the event that an unacceptable condition occurs the piston should be replaced Tube Assembly Visually inspect the inside bore for scratches and pits There should be no scratches or pits deep enough to catch the fingernail Scratches that catch the fingernail but are less than 0 5 inch long and primarily in the circumfer ential direction are acceptable provided they cannot cut the piston seal The roughne
72. cratch or score the anodized finish in the slide pad channels Locate mast section 2 carefully slide mast section 2 closed rail into section 1 open rail Slide sections together until ends are even Insert slide pads into the slide pad channels at bot tom end of mast between section 1 and 2 one on each side of the mast with beveled surface facing out towards section 1 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in mast section 2 inside rail into the slide pad inserts Thread in enough to hold pad in place Shim slide pads using the following steps Always use an even amount of shim material behind slide pads on both sides of the mast rails This will keep mast sections centered in rail channels and prevent any distortion of the mast section a Start with a 036 thick shim and a 075 thick shim per side at each slide pad b Slide shims into place between slide pad and mast rail Tighten the slide pad mounting bolts be sure there are no air gaps between shims shim and mast or shim and slide pad when tight ened NOTE 10 NOTE 11 12 13 14 JLG Lift c 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 d W
73. ctive mast cylinder hydraulic line cover plate from the base frame under the mast Use a container to catch the hydraulic oil from cylin der and hydraulic lines in next step discard oil Remove the hydraulic lines from the mast cylinder Original Design Cylinder Remove the one 1 5 16 bolt securing the cylinder to the cylinder mount and the four 4 1 2 bolts securing the cylinder mount to the mast section 1 side rails New Design Cylinder Remove the snap ring from either end of the cylinder mount pin running through the cylinder valve block While supporting the cylin der remove the mounting pin In the following step the mast cylinder mount will be shimmed tight in the mast Remove the cylinder mast mount from the mast In the following step the mast cylinder may be tight in the cylinder attach block at the top of the mast Pull the mast cylinder out of the mast JLG Lift Cylinder Disassembly 1 Before disassembling the cylinder clean away all dirt and foreign substances from openings particu larly the head area NOTE Always protect the chrome surface of the cylinder rod during assembly and disassembly Any damage to this surface will require replacement of the rod 2 Extend the rod until the piston bottoms out against the cylinder head 3 Compress the head retraining ring enough to allow the the cylinder head to be removed 4 Carefully slide the head rod piston assembly out of the cyl
74. d top of the charger cover and remove cover JLG Lift 2 9 SECTION 2 SERVICE PROCEDURES Transformer Replacement 1 Disconnect the wiring connecting the transformer to other components within the charger assembly 2 Remove the four nuts from the cap screws securing the transformer brackets to the base of the charger chassis 3 Remove transformer S S 2 10 Lift Printed Circuit Board Replacement 1 Disconnect the wide wiring connector from the end of the circuit board 2 Remove the four 4 screw attaching the card to the front face of the charger chassis 3 Remove the circuit board DC Circuit Breaker Replacement 1 Remove the wiring from the breaker terminals 2 Remove the bolt nut and washer from each side of the breaker remove the breaker from the housing 3120752 SECTION 2 SERVICE PROCEDURES Circuit Breaker and Voltage Selection Switch Replacement 1 3120752 Remove the wiring from the AC breaker or Voltage Selection Switch terminals To remove the breaker or switch from the front face of the charger on the inside of the charger front face push in on the tabs located on the sides of the breaker switch assembly and remove the assembly out the front of the charger lt 4 S
75. e closest Fed eral OSHA office for specific interpretations JLG Lift a INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS General This section contains the general safety precautions which must be observed during maintenance of the aerial platform It is of utmost importance that maintenance per sonnel pay strict attention to these warnings and precau tions 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 A WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA TION The specific precautions to be observed during machine maintenance 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 conscious 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 raising a portion of the equipment ensure that ade quate support is provided A WARNING SINCE THE MACHINE MANUFACTU
76. e of ferrous metal physically similar to it The switch state in the control system diagnostics should change 5 When reinstalling or replacing switch be sure to fol low mounting instructions and properly set the gap between the switch and object sensed Automatic Switches If the switch is actuated automatically by temperature or pressure for example find a way to manually actuate the switch to test it Do this either by applying heat or pres sure for example to the switch These switches may need to be energized to actuate 1 Connect instrumentation to monitor and or control the parameter the switch is measuring 2 Observe switch state in control system with the Ana lyzer See vehicle or control system documentation on how to do this 3 Operate system such that the switch actuates This could be going over a certain pressure or tempera ture for example The state indicated in the control system should change Switch Wiring Low Side High Side When controlling a load a switch can be wired between the positive side of the power source and the load This switch is called a high side switch The switch supplies the power to the load When a switch is wired between the negative side of the power source and the load it is a low side switch The switch provides the ground to the load A low side switch will allow voltage to be present on the load No power is applied because the switch is stopping current flow Th
77. e of the mast install a sequence cable bracket against the mast under the flatwasher Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in outside rail on top of mast section 5 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Insert slide pads into the bottom end mast rails between section 5 and 6 one on each side of the mast with beveled surface facing out towards sec tion 5 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes on inside rail on bottom end of mast section 4 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Platform Mounting Section Assy Masts NOTE 73 74 JLG Lift Reference to mast sections 5 6 7 made following is dependent on which model machine you are servic ing since the 20 ft machines use five 5 mast sec tions the 25 and 36 ft models use six 6 mast sections the 30 and 41 ft models use seven 7 mast sections Locate the remaing mast section 5 6 7 platform mounting mast section Lay mast section on flat stable surface Attach the remaining chain cable anchor plate one with threaded holes vertically aligned in
78. e vise clamp consists of vise jaws with a hole 1 32 in smaller than the diameter of the wire rope you are working with i e 1 8 in rope 3 32 in hole The plug driver is a metal tube with a hole in the bot tom to allow the strands of the wire rope to be shaped after the plug has been tapped into the cen ter of the wire rope 1 Using the recommended vise jaws clamp the wire rope into a vise with the bottom edge of the black mark made on the wire rope resting just above the vise jaws CABLE RECOMMENDED VISE JAWS MARK ON CABLE 2 Twist the sleeve from the clamp kit onto the rope until it is flat against the vise jaws at the mark made made on the wire rope SLEEVE INSTALLED JLG Lift 2 37 SECTION 2 SERVICE PROCEDURES 3 2 38 Use a suitable tool and cut the cable as shown in the illustration following For 1 8 in cable the recom mended length is 5 8 in past the end of the sleeve Unlay the cable strands by gently forcing a screw driver between the outer strands to unlay the cable When done properly the outer strands will form a symmetrical basket Do not straighten out the spiral lay of the strands unlay any wires that make up the strand or allow the strands to cross each other inside the sleeve STRANDS UNLAYED Install the plug supplied with the kit by placing the plug in the center of the strands starting with the small tapered end of the plug Use a metal tube
79. ed on the back of the mast just above the mast support bracket 3120752 JLG Lift 1 3 SECTION 1 SPECIFICATIONS Table 1 4 Model AM Lubrication Intervals for Various Components INTERVAL HOURS NO TYPE COMPONENT LUBE METHOD 3 6 1 2 COMMENTS LUBE POINTS MONTHS MONTHS YEAR YEARS 150 Hrs 300 Hrs 600 Hrs 1200 Hrs 1 Hydraulic Oil Fill To Line HO Check Check oil level every day on Reservoir Hyd Oil Level v Change hydraulic oil every 2 years 5 Qt 4 3L Change Reservoir Hyd Oil 2 SwivelRaceways 2 FrontCasters MPG Pressure Gun v 3 Leveling Jack 4 JackThreads Brush v Screws 4 M MastChains 2 Per Section CL Brush or Spray Inspect lubricate if drying or rusting Applies Only to Mast Sections with Chains Keyto Lubricants MPG Multipurpose Grease HO Hydraulic Oil ISO Vg grade 32 46 CL Chain Lube Use a good quality chain lubricant Notes 1 lubricate like items on each side of the machine 2 Recommended lubricating intervals are based on normal use If machine is subjected to severe operating conditions such as a high number of cycles location corrosive dirty environment etc user must adjust lubricating requirements accordingly 3 Lubricating intervals are calculated on 50 hours of machine operation a week 4 Priorto checking hydraulic oil level operate machine through one complete cycle
80. erably a hot oil dip Tap inside walking plates inward if walking persists replace the chain This type of problem is accelerated by poor lubrication maintenance practice and most tight joint chains have been operated with little or no lubrica tion Tight joints on leaf chain are generally caused by a Bent pins or plates b Rusty joints c Peened plate edges Oil rusty chains and replace chains with bent or peened chain components Keep chains lubricated Protruding or Turned Pins Chains operating with inade quate lube generate tremendous friction between the pin and plates pin and bushing on leaf chain In extreme cases this frictional torque can actually turn the pins in the outside press fit plates Inspect for turned pins which can be easily spotted as the V flats on the pin heads are no longer in line Replace all chains showing evidence of turned or protruding pins Keep chains lubricated Chain Anchors and Sheaves An inspection of the chain must include a close examination of chain anchors and sheaves Check chain anchors for wear breakage and misalignment Anchors with worn or broken fingers should be replaced They should also be adjusted to eliminate twisting the chain for an even load distribution Inspect the sheaves sheave bearings sheave grooves and pins for extreme wear replace as necessary A worn sheave can mean several problems as follows a Chains too tight b Sheave bearings pin
81. es 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 ability and proficiency to service repair and maintain the subject JLG product model Reference Table 2 2 AM Model Preventive Maintenance amp Inspection Schedule and the appropriate areas of this manual for servicing and maintenance procedures The frequency of service and maintenance must be increased as environment severity and frequency of usage requires 3120752 JLG Lift 2 1 SECTION 2 SERVICE PROCEDURES Table 2 1 Inspection and Maintenance PRIMARY SERVICE RESPONSIBILITY QUALIFICATION Pre Start Priorto use each day or Useror 0perator 0perator Operator Safety Manual Inspection Ateach Operator change Pre Delivery Priorto each sale lease or Owner Dealer or User Qualified JLG Service and Maintenance Man Inspection rental delivery Mechanic ual and applicable JLG inspec tion form Frequent In service for 3 months or 150 hours Owner Dealer or User Qualified JLG Service and Maintenance Man Inspection whichever comes first or Out of service Mecha
82. ew heads in the bottom of the outrigger socket can make contact to complete the inter lock circuit The purpose of this design is to assure the proper size outrigger beams are used with their specific AM model to assure machine stability i e the shorter outrigger beams of the 20AM 25AM and 30AM models cannot be mistak enly used on higher reaching 36AM or 41AM models JLG Lift 3120752 SECTION 3 TROUBLESHOOTING CYLINDER PRES COMPENSATED FLOW VALVE SOLENOID POSITION TWO WAY DUMP VALVE FILTER SCREEN LIFT CYLINDER MANIFOLD EXTEND HOSE ENDHEAD oo Doo e TWO POSITION TWO WAY DUMP VALVE gt 5 AD RELIEF VALVE CHECK VALVE gu ___ FILTER SCREEN 2792491 A Figure 3 6 Hydraulic Schematic AM Series 2792491 A 3120752 JLG Lift 3 11 SECTION 3 TROUBLESHOOTING
83. fL An Oshkosh Truck Corporation Company Service and Maintenance Manual Model s AM Series 20AM 25AM 30AM 36AM 41AM P N 3120752 August 29 2012 NOTES 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 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 BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPER ATING PERSONNEL ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER OPERATING CONDITIONS WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN ALTERATION AND OR MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN WITHOUT WRITTEN APPROVAL FROM JLG INDUSTRIES PER OSHA REGULATIONS THIS SAFETY ALERT SYMBOL IS USED CALL ATTENTION TO POTENTIAL HAZARDS WHICH MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED Safety of personnel and proper use of the machine are of primary concern DANGER WARNING CAUTION NO
84. fitting on the end of the flow control valve in the extend left port on bottom of hydraulic cylinder Install a long 90 elbow fitting on return right port Use sealant tape on fitting threads Cap ports until hydraulic lines are installed Carefully set machine in an upright position on its base frame wheels Locate the mast support bracket Attach mast sup port bracket to mounting holes halfway up back of mast using four 4 3 8 16UNC x 2 3 4 long hex head bolts locknuts and flatwashers Place a flat washer under bolt head and nut and mount with nuts on inside of frame Using a 4 ft level ensure mast is set to vertical plumb on the base frame When mast is vertical plumb attach mast support braces bolted to base and mast support bracket using 3 8 16UNC x 1 long hex head bolts and lock nuts After securing mast to base frame using 4 ft level again check that mast is vertical plumb on base frame Mast installation should now be complete JLG Lift 3120752 SECTION 2 SERVICE PROCEDURES 2 11 MAST CHAINS CABLES AND Adjust using the following procedure SEQUENCING CABLES ADJUSTMENT 1 With mast retracted step into the platform and bounce your weight up and down a few times to be Mast Chain Cable Adjustment certain platform is at the bottom of travel Be certain all chai
85. he cylin der mount and cylinder mounting plates into the bot tom of the mast section 1 Shim to eliminate any side clearance to prevent any strain on the sides of the mast when the bolts are tightened New Design Cylinder Mount Install the cylinder mounting plates at the bottom of the mast section 1 Mount plates two each side using the the 2 two long pass through bolts and nuts apply Loctite 242 to the bolt threads before tightening nuts Original Design Cylinder Clamp the cylinder in the mounting journal of the cylinder mount Apply Loc tite 242 to the journal bolt threads and torque to 85 ft Ibs Align the hole in the mounting journal with the hole in the cylinder and Install the 1 5 16 bolt 3120752 SECTION 2 SERVICE PROCEDURES SECTION 4 CHAIN CABLE SHIELD ANSI 92 3 UPPER SPEC SEQUENCE CABLE ASSEMBLY C mast w SECTION 1 T mast SECTION 3 MAST Hes SECTION 5 4 lE SECTION 2 SECTION 5 IU UPPER SLIDEPAD MOUNTING POSITION PRIOR o 11 ORIGINAL TO Va DESIGN 142920 a YR LIFT gt B CYLINDER Ex MOUNT EB SECTION 5 y UPPER SLIDE PAD AS OF C 142920 gt
86. hen mast slide pads are shimmed properly there should be no side to side movement of slide pad in rail channel Mast sections should be snug in channels but still be able to slide in channel by hand Insert slide pads into the slide pad channels top of between section 1 and 2 one on each side of the mast with beveled surface facing in towards section 2 Before fastening and shimming the slide pad on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in mast section 1 outside rail top of mast and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly If hydraulic cylinder needs to be extended the pro tective caps on the extend and return ports will need to be removed Be careful not to nick or scour rod surface when extending also catch any oil draining out of cylinder to avoid spillage onto work area Locate the hydraulic lift cylinder slide the lift cylinder into the closed rail side of mast section 2 with rod end to top and port end to bottom of mast Cylinder should extend out of mast on both ends Mount the cylinder with the manual descent valve assemby fac ing the back of the mast towards mast section 1 Original Design Cylinder Mount Install t
87. his section shows diagrams of a common digital VOM con figured for several different circuit measurements Instruc tions for your VOM may vary Please consult the meter operator s manual for more information Grounding Grounding the meter means to take the black lead which is connected to the COM common or negative port and touch it to a good path to the negative side of the voltage source Backprobing To backprobe means to take the measurement by accessing a connector s contact on the same side as the wires the back of the connector Readings can be done while maintaining circuit continuity this way If the connec tor is the sealed type great care must be taken to avoid damaging the seal around the wire It is best to use probes or probe tips specifically designed for this tech nique especially on sealed connectors Whenever possi ble insert probes into the side of the connector such that the test also checks both terminals of the connection It is possible to inspect a connection within a closed connec tor by backprobing both sides of a connector terminal and measuring resistance Do this after giving each wire a gentle pull to ensure the wires are still attached to the con tact and contacts are seated in the connector Min Max Use of the Min Max recording feature of some meters can help when taking measurements of intermittent condi tions while alone For example you can read the voltage applied to a soleno
88. hunt Assembly Varistor and SCR Rectifier Replacement See Illustration Shunt Assembly Item 71 1 Carefully remove the screw from the end of the shunt assembly The white insulator may need to be restrained to keep it from turning while removing the shunt assembly fasteners Also make note of the position of each washer nut and wire connector when removing for later assembly SCR Rectifier Replacement Item 2 1 2 3 Remove the wiring from the SCR Rectifier Remove the nut securing the rectifier to the insulated aluminum chassis bracket Remove the SCR Rectifier Varistor Replacement Item 3 1 JLG Lift Remove the fasteners securing the varistor to the aluminum angle bracket see illustration below One through the rear panel of the base with a short white spacer and one at the long white insulator attaching the shunt assembly to the bracket Remove the varistor from it s mount 2 11 SECTION 2 SERVICE PROCEDURES 2 6 HYDRAULIC LIFT SERVICING Remove hydraulic pump from machine Motor Brush Installation FENNER BRAND PUMP Brush Replacement Motor Cap Motor Installation Brush Housing Installation Motor Cap Installation 1 Brush Housing 1 Cap Assembly Screws 2 Cap Assembly 2 Brush Housing Screws 3 Mark Front of Motor and Brush Housing for reference when reassembling Brush Assembly Connectio
89. id when it is only operational while a switch far from the solenoid and meter is held down JLG Lift 3 4 SECTION 3 TROUBLESHOOTING Polarity Finding a negative voltage or current reading when expecting a positive reading frequently means the leads are reversed Check what reading is expected the loca tion of the signal and that the leads are connected to the device under test correctly Also check that the lead on the port goes to the ground or negative side of the sig nal and the lead on the other port goes to the positive side of the signal Scale M Mega 1 000 000 Displayed Number kilo 1 000 Displayed Number m milli Displayed Number 1 000 micro Displayed Number 1 000 000 Example 1 2 1200 Q Example 50 mA 0 05 A Continuity Measurement Over Long Distances When trying to determine continuity of a harness or wire longer than the reach of standard instrument leads is possible to perform the check without excessively long leads Using the other wires in the harness one can deter mine the condition of a particular wire in the harness Requirements Harness with at least three separate wires including the wire under test These wires must be able to be isolated from other wires etc Jumper or method to connect contacts on one side of harness Meter that can measure resistance or continuity Procedure Test multimeter leads resistance Su
90. ight Average 1 2 Machine Overall Width and Length 1 2 Outrigger Footprint s here EE UR ug 1 2 Outrigger Machine Leveling 1 2 1 4 TORQUE REQUIREMENTS 1 2 1 5 LUBRICATION msec erret rettet de Cic er vade Cs Wapa qa edt dede 1 2 Hydraulic Oil FIO s 2643 S Ut vUa DEL e ND 1 2 1 6 HYDRAULIC PRESSURE 1 8 1 7 CYLINDER SPECIFICATIONS 1 4 2 1 8 1 8 SERIAL NUMBER LOCATIONS 1 1 8 SECTION 2 SERVICE PROCEDURES 2 1 MACHINE PREPARATION INSPECTION AND 2 1 exei viaa Saa aaa aches es aw ss 2 1 Preparation Inspection and 2 1 Pre Start Inspection ora uiu bi were qtue 2 1 Pre Delivery Inspection and Frequent 2 1 Annual Machine 1 2 1 Preventative
91. ign matter entering a system can cause wear or damage to the components and gener ally 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 per mits organic growth resulting in oxidation or corrosion If this condition occurs the system must be drained flushed and refilled with clean oil It is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities Good grade mineral oils with viscosities suited to the ambient temperatures in which the machine is operating are recommended 1 use NOTE Metal particles may appear in the of new machines due to the wear in of meshing compo nents Hydraulic Oil For best performance JLG recommends the use of ISO Vg grade 32 46 oil with a viscosity range between 15 250 SUS at 100 degrees F 32 54 cST at 40 degrees C Refer to Section 7 for recommended hydraulic oils 2 8 JLG Lift Changing Hydraulic Oil Use of any of the recommended hydraulic oils eliminates the need for changing the oil on a regular basis If it is nec essary to change the oil use only those oils meeting or exceeding the specifications appearing in this manual If unable to obtain the same type of oil supplied with the machine consult local supplier for assistance in selecting the proper equivalent A
92. il on the chains at all times If chains are corroded they must be inspected especially the outside plates for cracks in line with the pins If cracks are found replace the chain if no cracks are discovered lubricate the chains by dipping in heated oil and reinstall on the machine Keep chains lubricated Table 2 3 Chain Stretch Tolerance Chain Size Pinto Allowable Stretch Measurement 50 pitch 12 or 24 pitches 24 12 625 pitch 15 or 24 pitches 30 15 span Fatigue Cracks Fatigue is a phenomenon that affects most metals and is the most common cause of chain plate failures Fatigue cracks are found through the link holes perpendicular 90 degrees from the pin in line position Inspect chains carefully after long time use and heavy loading for this type of crack If any cracks are dis covered replace all chains as seemingly sound plates are on the verge of cracking Fatigue and ultimate strength failures on JLG Lifts are incurred as a result of severe abuse as design specs are well within the rated lift ing capacity of these chains Tight Joints joints in the leaf chain should flex freely On leaf chain tight joints are usually caused by rust corro sion or the inside plates walking off the bushing Limber up rusty corroded chains after inspecting care fully with 2 6 JLG Lift 3120752 SECTION 2 SERVICE PROCEDURES a heavy application of oil pref
93. in cable anchor plate located on bottom of extended mast section 4 Loosely thread two 2 3 8 16UNC nuts onto stud threads on each chain Chains will be adjusted later in assembly Step 34 applies to 25 and 36 ft six 6 section masts and amp 41 ft seven 7 section masts only For five 5 section 20 1 masts skip to step 35 While mast section 4 is still extended from section 3 locate two cable assemblies Attach the eyelet anchor end of each cable to the inside set of holes near top of mast section 4 using 3 8 16UNC x 1 1 4 long hex head bolts nuts and flatwashers Place a flatwasher under bolt head and nut While mast section 4 is still extended from section 3 assemble cable sheaves to top of mast section 4 as follows NOTE 39 40 NOTE 41 42 43 44 45 JLG Lift a Locate the wide tube spacer and slide onto sheave pin b Slide two 2 cable sheave wheels onto sheave pin one each end of sheave pin to outside of tube spacer c Place two 2 large flat washers one each end of sheave pin to outside of cable sheave wheels d Place two 2 sheave pin attach bars one each end of sheave pin to outside of large flatwash ers e Holding complete cable sheave wheel assem bly slide assembly into top of mast section 4 and align threaded holes in sheave pin attach bars with holes in mast rails f Attach to top of mast section 4 using two 2 3 8 16UNC x 1 2 long socket he
94. inder tube A gentle tap on the head assembly may be required to remove the head from the cylin der tube 5 Place the head rod piston assembly on a surface that will not damage the chrome 6 Remove the piston locknut and separate the piston from the rod 7 Slide the head off the rod from the piston end NOTE When removing the old seals use only blunt tools be sure there are no sharp edges that may damage the seal grooves during removal Scratching the groove may cause by pass 8 Remove and discard all old seals Lift Cylinder Component Inspection Cylinder Rod There should be no scratches or pits deep enough to catch the fingernail Pits that go to the base metal are unacceptable Scratches that catch the fingernail but are not to the base metal less than 0 5 inch long and primarily in the circumferential direction are acceptable provided they cannot cut the rod seal Chrome should be present over the entire surface of the rod and the lack thereof is unacceptable In the event that an unacceptable condition occurs the rod should be repaired or replaced Cylinder Head Visually inspect the inside bore for scratches or polishing Deep scratches are unacceptable Polishing indicates uneven loading and when this occurs the bore should be checked for out of roundness If out of roundness exceed 0 007 this is unacceptable Check the condition of the dynamic seals wiper rod seals looking particulary for metallic parti
95. int and Appearance 7 7 Stamp Inspection Date on Frame 22 Notify JLG of Machine Ownership 22 Change per Lubrication Chart in Section 1 of this Service Manual Footnotes 9 Check for signs of leakage 1 Prior to use each day or at each Operator change 10 Decals installed and legible 2 Prior to each sale lease or delivery 11 Check proper fluid level 3 In service for 3 months or 150 hours or Out of service 12 Check for chafing and proper routing for 3 months or more or Purchased used 13 Check for proper tolerances 4 Annually no later than 13 months from the date of the 14 Properly lubricated prior inspection 15 Torqued to proper specification 16 No gouges excessive wear or cords showing Inspection and Maintenance Codes 17 inflated seated around Check proper secure installation 1e Proper and anihorizsd componen Visual inspection for damage cracks distortion or 19 Fully charged excessive wear 3 Check for proper adjustment 20 No loose connections corrosion or abrasions 4 Check for cracked or broken welds Es Veny 5 225 Perform 6 Returns to neutral or off position when released 23 Sealed properly 7 Clean and free of debris 24 Overrides Platform controls 8 Interlocks function properly 25 Inspected per Service and Maintenance Manual 2 4 Lift 3120752 SECTION 2 SERVICE PROCEDURES
96. is voltage can be seen if the measurement is taken with one test lead on the load and the other on the battery negative side or grounded to the vehicle What is actually being measured is the voltage drop across the switch This could mislead a technician into thinking the load is receiving power but not operating To produce an accurate picture of power or voltage applied to the load measure voltage across the load s power terminals Also the technician can measure the voltage at both power ter minals with respect to battery ground The difference between those two measurements is the voltage applied to the load JLG Lift 3 5 SECTION 3 TROUBLESHOOTING Table 3 1 AC Unit Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Outrigger LED light does notturn on Outriggers are not properly inserted in outrigger sockets Power source is OFF Fuse s blown Checkfor loose wire s on contactor screws under outrigger sockets caus ing an open circuit Contactor damaged LED burnt out Pull pin on outrigger socket is dam aged Platform does not rise when the four LED s are ON and motor does not start Check all outriggers for proper instal lation in outrigger sockets Check power source Check all insulating grommets on inter lock contactors in base frame outrigger sockets and contactor plates on outrigger beams Replace damaged grommet s and replace blown fuse Properly reinstall wire
97. its way out of the rope structure and protrudes or loops out from the rope structure Additional inspection of this sec tion is required 3 Wear of one third the original diameter of outside individual wires 4 Kinking crushing birdcaging or any other damage resulting in distortion of the rope structure 5 Evidence of any heat damage from any cause 6 Reductions from nominal diameter of more than a 1 64th in 0 4mm for diameters up to and including 5 16th in 8mm NOTE A good indicator of a stretched extend retract cable is if the adjusting nuts are bottomed out If no adjust ment remains the cables have stretched and need replacement Also check for cracked bent worn severely corroded or improperly installed cable ends Inspect sheaves sheave grooves and sheave pins for excessive wear replace as necessary 3120752 JLG Lift 2 7 SECTION 2 SERVICE PROCEDURES 2 4 LUBRICATION INFORMATION Hydraulic System The primary enemy of a hydraulic system is contamina tion Contaminants enter the system by various means e g using inadequate hydraulic oil allowing moisture grease filings sealing components sand etc to enter when performing maintenance or by permitting the pump to cavitate due to insufficient system warm up or leaks in the pump supply The design and manufacturing tolerances of the compo nent working parts are very close therefore even the smallest amount of dirt or fore
98. lenoid valve Unit lowers very slowly Hydraulic hose and or fittings loose Valve and or plug loose Breather cap on tank is saturated or clogged with oil Hydraulic oil tank over filled Tighten hydraulic hose and or fittings Tighten valve and or plug Replace breather cap on tank Lower oil levelto full mark on dipstick 3120752 Flow control valve not functioning JLG Lift Replace flow control valve 3 7 SECTION 3 TROUBLESHOOTING 3 6 OUTRIGGER INTERLOCK CONTACTS Outrigger Socket and Outrigger Beam Interlock Contacts It is very important that the outrigger interlock contacts located on the bottom surface inside the outrigger sockets of the base frame and the contactor plate on the bottom of each outrigger beam are installed correctly These parts when installed properly will be insulated from negative ground Read the following steps and see Figure 3 5 for correct installation Also see Troubleshooting Tables 3 1 amp 3 2 for any reference to possible problems with interlock contacts Outrigger Socket Contactor Screw Mounting Instructions See Figure 3 5 ORIGINAL DESIGN 1 Install insulating grommets into holes on the socket floor inside of outrigger sockets in base frame Assemble two 2 8 32UNC x 5 8 long contactor screws with two 2 8 nylon washers under head and insert screw through insulating grommet as shown in Figure 9 1 Install one 1
99. lve Installation 1 Adjust Valve Cap 4 Valve Ball 1 Check Valve Assembly 5 Check Valve Port 3 Valve Spring 6 Extend Pressure Port 3 O Ring Seal 7 Return Port Shown Plugged 4 Backing Ring Note Adjust pressure per specification shown in Section 1 of this Note Extend Pressure and Return Ports Shown Plugged Service Manual 3120752 JLG Lift 2 17 SECTION 2 SERVICE PROCEDURES 2 7 HYDRAULIC LIFT CYLINDER REMOVAL INSPECTION AND REBUILD A WARNING HYDRAULIC CYLINDERS ARE DESIGNED TO HOLD HYDRAULIC FLUID UNDER HIGH PRESSURE BE SURE ALL APPROPRIATE MEASURES ARE TAKEN TO RELIEVE RESIDUAL PRESSURE IN THE CYLINDER BEFORE DISCONNECTING LINES Cylinder Removal 1 NOTE NOTE 10 NOTE 11 2 18 Disconnect power source Remove the DC power assembly from back of mast if so equipped Remove ground control pump cover Disconnect the hydraulic lines at the pump Using suitable lifting equipment lay machine down horizontal onto the back of mast to allow access to the bottom of the machine Preferably on an ele vated work surface capable of supporting the full weight of the machine Slide extend the mast out the top about 2 ft to 3 ft to allow access to the cylinder attach setscrew on the attach block at the top of mast section 2 Remove the cylinder attach setscrew from the attach block on top of mast section 2 Lowest set of sheaves Remove the prote
100. n assem bly anchor block Secure cylinder rod to anchor block with a 1 4 28UNF x 50 long Type C set screw Coat threads with blue Loctite 242 before assembly Locate chain assembly single block with two narrow chains Lay out chain assembly with anchor block end towards mast be certain floor surface is clean and free of any metal chip or debris which may stick to lubricated chains or lay chains in a clean bucket Slide mast section 2 out of mast section 1 approxi mately one foot Assemble chain sheaves on chain assembly anchor block attached to cylinder rod end and attach to mast section 2 using following steps a Insert sheave pin through anchor block on cylin der rod end b Place sheave wheels for wide chain on sheave pin one each side of anchor block c On outside of each sheave wheel place a sheave pin attach bar rectangular plate with threaded holes on each side of pin bore hole d Slide the whole anchor block assembly with sheave pin wheels and pin attach bars into top of mast section 2 Position anchor block with narrow chains facing mast section 3 e Attach to top of mast section 2 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten Slide mast section 2 back into section 1 until end are even Mast Section 3 Assembly Masts NOTE When sliding mast sections together be careful n
101. n cable sets are seated in their sheaves prop The intention of this procedure is to assure equal load dis erly at the top of each mast section tribution between the individual chains cables of a mast section chain cable set Also to step each front mast sec 2 Then with no load in the platform check the side tion up approximately 1 4 in 6 5mm from the section of the top of the mast for the amount of adjust behind it to allow clearance for the individual mast section ment necessary to obtain the 1 4 in 6 5mm step covers for mast sections 3 and up See Figure 2 7 MAST SIDE PROFILE MAST CHAIN CABLE ADJUSTERS STEP APPROXIMATELY 1 4 6 5 EE SEQUENCE CABLE R ADJUST NUT 0 T 419 CHECK IF OVERALL HEIGHT T SECTION 1 FLOOR TO TOP MAST FIXED IS WITHIN SPECIFICATION TO BASE SECTION 2 EXTENDED BY CYLINDER SECTION 3 JL Nl EXTENDED CHAIN SECTION 4 EXTENDED BY CHAIN CABLE SECTION 5 PLATFORM HEADER SECTION EXTENDED CHAIN CABLE PLATE
102. n place Shim per instructions in step 7 Mast Section 2 Assembly 3120752 SECTION 2 SERVICE PROCEDURES Mast Section 5 Assembly 25 30 36 41 ft Masts NOTE NOTE 46 47 48 49 NOTE 50 NOTE 51 52 3120752 Steps 43 thru 56 apply to six 6 section 25 36 ft and seven 7 section 30 and 41 ft masts only For five 5 section 20 ft masts continue to step 70 When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Locate mast section 5 carefully slide section 5 closed rail into section 4 open rail Slide sections together until ends are even Locate one 1 of the chain cable anchor plates one with threaded holes horizontally aligned to outside edges of bracket Attach through outer set of holes in bottom of mast section 5 with two 2 1 4 20UNC x 3 4 long bolts place a flatwasher under head of each bolt Slide mast section 5 out the top of mast section 4 so the chain cable anchor plate on bottom of mast sec tion 5 is easily accessible near top end of mast sec tion 4 Rest the top end of mast section 5 on a support while performing next step Insert threaded ends of cable assembly attached to top of mast section 3 through the chain cable anchor plate located on bottom of extended mast section 5 Loosely thread two 2 3 8 16UNC nuts onto stud threads on each chain Chains will be adjusted later in
103. nd sufficient chemical stabil ity 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 when temperatures remain consistently below 20 F 7 JLG recom mends using Mobil DTE 13 hydraulic oil Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not con tain the same required additives or be of comparable vis cosities If use of hydraulic oil other than Mobilfluid 424 is desired contact JLG Industries for proper recommenda tions Table 1 1 Hydraulic Oil Operating Range HYDRAULIC SYSTEM OPERATING SAE VISCOSITY TEMPERATURE RANGE GRADE 0 Fto 180 F 10W 18 Cto 83 C 0 Fto 210 F 18 Cto 99 C 50 Fto 210 F 20W 20 10 Cto 99 C 10W 20 10W 30 Table 1 2 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 F Excellent water resistance and adhesive qual ities and being of extreme pressure type Timken OK 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API service classification GL 5 or MIL Spec MIL L 2105 HO Hydraulic Oil ISO Vg grade 32 46 CL Chain Lube Use a good quality chain lubricant JLG Lift 3120752 SECTION 1 SPECIFICATIONS 1 6 HYDRAULIC PRESSURE ADJU
104. ng the anchor blocks of the two 2 chain assemblies to mast section 1 Remove chain assem blies from mast and lay aside Remove the hydraulic lift cylinder from it s mount attached to mast section 1 if necessary Remove slide pads and shims from mast section 1 is necessary Mast disassembly should now be complete JLG Lift 2 23 SECTION 2 SERVICE PROCEDURES 2 9 ASSEMBLY See Figure 2 3 Figure 2 4 Figure 2 5 Mast Section 1 Assembly Masts 1 Place mast section 1 open side up See Figure 2 2 on a clean flat surface preferably a table or work bench capable of supporting the weight of the entire mast assembly Slide mast out over end of work surface far enough to allow access to the chain anchor attach holes at top of mast Locate the two 2 single wide chain assemblies Lay out each chain assembly with anchor block end towards mast and notched end of block down be certain floor surface is clean and free of any metal chips or debris which may stick to lubricated chains or lay chains in a clean bucket Insert the block anchor end with notched end on bottom into the top of mast section 1 and secure using two 2 3 8 16UNC x 2 1 2 long hex head bolts flatwashers and nuts for each attach block Place a flatwasher under bolt head and nut Mast Section 2 Assembly Aii Masts NOTE NOTE 2 24 When sliding mast sections together be careful not to s
105. nic ual and applicable JLG inspec for a period of more than months or Pur tion form chased used Annual Annually no later than 13 months fromthe Owner Dealer or User Qualified JLG Service and Maintenance Man Machine date of the prior inspection Mechanic ual and applicable JLG inspec Inspection tion form Preventative Atintervals as specified in the Service and Owner Dealer or User Qualified JLG Service and Maintenance Man Maintenance Maintenance Manual Mechanic ual 2 2 JLG Lift 2 2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE See Table 2 2 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 five 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
106. ning 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 JLG Lift 2 5 SECTION 2 SERVICE PROCEDURES 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
107. ns 1 Negative Post 3 Brush Assemblies 1 Motor Assembly 3 Pump End Head 2 Positive Post 4 Spring Washer i L SENS Note Length of wires to brush assemblies shown exaggerated for illustrative purposes 2 12 JLG Lift 3120752 SECTION 2 SERVICE PROCEDURES Once brush housing has been removed inspect the rotor commutator for excessive wear before installing a new brush set The rotor commutator surface when new is approximately 1 8 in 3mm in thickness 7 2 AS By AE New Brush Installation 1 Brush Terminal Screw 4 Brush Spring 2 Brush 5 See Installation Note Below 3 Brush Holder Installation the same for all four 4 brush assemblies Note Using a clean towel push each brush 2 up into it s holder 3 slide the spring 4 over the side of the brush This will hold each brush in place and allow them to clear the rotor commutator during reassembly Clean the rotor commutator with a non conductive electrical cleaner before assembling the brush housing to the motor hous ing 3120752 Brush Housing Final Assembly Tips It is easier to install the brush housing assembly by sliding the rotor assembly completely out of the other end of the motor housing then attach the brush housing first After the brush housing is installed look into the motor housing from the opposite end to check that the positive
108. of lift function full up and down Failure to do so will result in incorrect oil level reading on the hydraulic reservoir lt START HERE COPY AND PASTE 1 4 JLG Lift 3120752 SECTION 1 SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 5 BOLTS amp GRADE 2 NUTS Torque j 7 Tensile Torque Torque Loctite 242 or 271 sico reu o TUNE 0990 Dry Lubricated OR Vibra TITE 111 or Oe 5 72574 4 40 0 1120 0 00604 380 8 0 9 6 48 01120 0 00661 40 7 uns 40 0 1380 0 01015 610 18 2 0 13 1 5 8 32 01640 0 01400 90 30 34 2 25 36 0160 0014 7 90 35 23 26 10 24 01900 001750 1120 43 48 2 35 32 0190 0 02000 1285 49 5 36 4 j I E E E 28 0 2500 0 0364 2320 120 13 5 86 10 135 15 Lo m san FB Nm Fri Nm Fr Nm Fr Nm or 3 8 16 0 3750 0 0775 4940 30 41 2 1 35 48 28 38 24 0350 0088 500 35 47 25 3 404 54 3 43 20 0 4375 0 1187 7550 55 75 40 60 82 50 68 v2 13 05000 0 1419 90500 75 102 5 75 85 16 6 92 9 16 12 0 5625 0 1820 11600 110 149 80 108 120 163 98 133 18 0565 02030 12950 120 163 90 12 135
109. ons as shown following Table 2 4 AM Series Mast Component Features Model No Device Sections 20 5 Chain 8 Cable 25 6 Chain amp Cable 30AM 41AM 7 Chain amp Cable Assembly procedures for all mast assemblies is basically the same carefully slide the mast sections together from bottom until mast ends are even when sliding mast sec tions together be careful not to scratch the anodized sur face in the slide pad channels Assemble the hardware to gt CLOSED RAIL REFERS TO CLOSED RAIL BACK OF MAST SECTION OPEN RAIL f REFERS TO OPEN RAIL 4 FRONT MAST SECTION the bottom of mast section first then slide this section out the top of previous section and assemble hardware to the top of mast See Figure 2 2 Always install slide pad shims with slide pads inserted into the slide pad channels ends of mast sections even Shim slide pads so that all side to side section movement is eliminated but section can still slide in mast by hand Mast Disassembly Procedure See Figure 2 2 NOTE Reference to mast sections 5 6 7 made following is dependent on which model machine you are servic ing since the 20 ft machines use five 5 mast sec tions the 25 and 36 ft models use six 6 mast sections the 30 and 41 ft models use seven 7 mast sections 1 After the platform and other hardware have been removed from the mast and
110. ot 20 21 3120752 to scratch or score the anodized finish in the slide pad channels Locate mast section 3 carefully slide section 3 closed rail into section 2 open rail Slide sections together until ends are even Locate one 1 of the chain cable anchor plates one with threaded holes horizontally aligned to outside of bracket Attach using outer set of holes in bottom of mast section 3 with two 2 1 4 20UNC x 3 4 long bolts place a flatwasher under head of each bolt 22 23 24 25 NOTE 26 27 28 JLG Lift Slide mast section 3 approximately two feet out of the top of mast section 2 Insert threaded ends of chain assembly attached to top of mast section 1 through holes in anchor plate attached to bottom of mast section 3 Loosely thread two 2 3 8 16UNC nuts onto stud threads on each chain Chains will be adjusted later in assem bly Locate two cable assemblies Attach the eyelet anchor end of each cable to the outside holes near top of mast section 3 using 3 8 16UNC x 1 1 4 long hex head bolts nuts and flatwashers Place a flat washer under bolt head and nut Assemble chain sheaves for narrow chain assem bly to top of mast section 3 as follows a Locate the two 2 narrow chain sheave wheels and slide onto sheave pin b Slide two 2 short spacer tubes onto sheave pin one each end of sheave pin to outside of sheave wheels c Place two 2
111. ot rise when the four LED s are ON and motor does not start Outriggers are not properly inserted in outrigger sockets Power source is OFF Fuse s blown Checkfor loose wire s on contactor screws under outrigger sockets caus ing an open circuit Contactor damaged LED burnt out Pull pin on outrigger socket is dam aged Check all outriggers for proper instal lation in outrigger sockets Check power source Check all insulating grommets on inter lock contactors in base frame outrigger sockets and contactor plates on outrigger beams Replace damaged grommet s and replace blown fuse Properly reinstall wire to contactor screw per Figure 3 5 and instructions in Section 3 6 Outrigger Interlock Contacts Replace contactor Replace LED Replace pull pin Unit lowers by itself Red emergency button is engaged PUSHED IN on either ground control station or on platform Control relay notfunctioning Motor start relay not functioning Unit wiring not properly grounded Disengage TURN CLOCKWISE red emergency button until it pops out Replace control relay Replace motor start relay Check all grounds the wiring Unit leaking hydraulic oil Manual descent valve open Hydraulic hose and or fittings loose causing a hydraulic pressure leak Lift DOWN solenoid valve notfunction ing Close manual descent valve Tighten hydraulic hose and or fittings Replace Lift DOWN so
112. reference only Brush Assembly Remove Install az Brush Assembly Remove Install 1 Brush Assembly a 4 Brush Terminal Screw 2 Brush Carrier Socket 5 Brush Attach Terminal 3 Brush Tab Slot NOTE a Slide brush assembly into socket until tab is in slot at rear of socket 3120752 JLG Lift 2 15 SECTION 2 SERVICE PROCEDURES TANK AND PUMP REMOVAL All Pumps Tank Installation Pump Installation Tank Installation 1 Tank Assembly 3 O Ring Seal 2 Tank Screws 4 4 Use Screwdriver to pry tank away from pump head Filter Screen Installation 22 1 Pump Assembly 2 Pump Assembly Screws Filter Screen Installation Pump Installation 3 Pump Shaft Seal 4 Pump End Head 1 Filter Screen 2 Pump Pick Up Tube 1 Pump Assembly 2 16 Lift Pump 0 Ring Installation 2 0 Ring Seal 3 0 Ring Seal 3120752 SECTION 2 SERVICE PROCEDURES Pressure Adjust Valve Installation Pressure Check Valve Installation 6 m S amp S NS 2 Se 1 ANY ML j Pressure Adjust Valve Installation Pressure Check Va
113. remedial action should where possi ble be checked in the order listed in the troubleshooting tables It should be noted that there is no substitute for a thor ough knowledge of the equipment and related systems It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electrical systems For this reason every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment In the remaining machine groups only those problems which are symptomatic of greater problems which have more than one probable cause and remedy are included This means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section The first rule for troubleshooting any circuit that is hydrau lically operated and electrically controlled is to determine if the circuit is lacking hydraulic oil and electrical control power This can be ascertained by overriding the bypass valve mechanically or electrically so that oil is available to the function valve then overriding the function valve mechanically If the function performs satisfactorily the problem exists with the control circuit BASICS A wide variety of multimeters or Volt Ohm Meters VOM can be used for troubleshooting your equipment A digital meter with reasonable accuracy within 796 is recom mended for the measurements in these procedures T
114. s JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755 Castellbisbal Barcelona Spain 34937724700 34 93 771 1762 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Sverige Enkopingsvagen 150 704 SE 176 27 Jarfalla Sweden 46 0 850 659 500 446 0 850 659 534 A JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI taly 39 029 359 5210 39 029 359 5845 B www jlg com Oshkosh JLG Singapore Technology Equipment Pte Ltd 29 Tuas Ave 4 Jurong Industrial Estate 639379 Singapore 65 6591 9030 65 6591 9031
115. s as well as the openings and fittings them selves As soon as a line or component is disconnected cap or cover all openings to prevent entry of foreign mat ter 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 3120752 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 perpendicular 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 obtai
116. s together be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 5 back into section 4 until ends are even Check to make sure cable set from top of section 3 is seating properly in cable sheave wheels attached to top of mast section 4 Mast sections 2 3 and 4 may need to be restrained to keep their slide pads from pushing out the bottom of mast sections 1 2 and 3 Insert slide pads into the top end mast rails between section 4 and 5 one on each side of the mast with beveled surface facing inward towards section 5 Before fastening and shimming the slide pad on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in outside rail on top of mast section 4 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Insert slide pads into the bottom end mast rails between section 4 and 5 one on each side of the mast with beveled surface facing out towards sec tion 4 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes on inside rail on bottom end of mast section 4 and into the slide pad inserts Thread in eno
117. sheave wheel assembly attach bars on both side rails at TOP of mast 4 and remove sheave wheel assembly While mast section 4 is still extended from section 3 remove the bolts attaching the two 2 cable assem bly anchor eyelets to the TOP of mast section 4 Remove cables When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels 3120752 SECTION 2 SERVICE PROCEDURES 22 Mast 23 24 25 26 27 NOTE 28 Carefully slide mast section 4 out BOTTOM of sec tion 3 Remove slide pads shims and chain anchor plate if necessary Section 3 Removal Ail Masts Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate on BOT TOM end of mast section 3 Push threaded ends of cable through anchor plate At TOP of mast section 3 pull chains out and allow to hang loose be certain floor surface is clean and free of any metal chips or debris which may stick to lubricated chains or lay chains in a clean bucket Slide mast section 3 out TOP of mast section 2 far enough to allow access to the chain sheave wheel assembly Remove countersunk flathead screws securing chain sheave wheel assembly attach bars on both side rails at TOP of mast section 3 and remove sheave wheel assembly While mast section 3 is still extended from section 2 remove the bolts attaching the two 2 chain assem bly anchor blocks to
118. ss of the bore should be between 10 and 20 inches RMS Significant variation greater than 8 inches difference are unacceptable In the event that an unacceptable condition occurs the tube assembly should be repaired or replaced JLG Lift 2 19 SECTION 2 SERVICE PROCEDURES Cylinder Assembly See Figure 2 1 1 NOTE 2 20 Rinse the inside of the tube with hydraulic fluid and allow to drain A high pressure rinse followed by a wipe with a lint free rag is preferable Clean all inter nal components of any foreign material Lubricate the head and all seals with hydraulic fluid prior to installation Install the seal wiper o ring back up ring and retraining ring to the cylinder head Lubricate the piston components with hydraulic fluid Install the seal and wear ring to the piston Re check that seals are not twisted or pinched and are properly seated Place the rod on a clean table Install the static o ring seal into the groove on the piston end of the rod Install the head followed by the piston onto the rod noting the proper orientation of each component Torque the piston nut to 175 200 ft 165 When the rod assembly is ready to be installed into the tube liberally apply an anti seize lubricant to the head outer surface especially the static seal Next dip the entire rod assembly into hydraulic fluid and stuff this assembly into the tube Watch the seals as they pass over
119. st Extended 20AM AC amp DC 20 ft 6 09m 25AM AC amp DC 25 ft 7 62m 30AM AC amp DC 30 ft 9 14m 36AM AC amp DC 36 ft 11m 41AM AC amp DC 41 in 12 42m Maximum Working Height Average Person 20AM AC amp DC 26 ft 7 92m 25AM AC amp DC 31 ft 9 45m 30AM AC amp DC 36 ft 11m 36AM AC amp DC 42 ft 12 80m 41AM AC amp DC 47 ft 14 33m Machine Overall Width and Length Base 20AM Models 29 in W x 47 in L 74cm x 1 19m 25AM Models 29 in W x 49 in L 74cm x 1 24m 30AM Models 29 in W x 52 in L 74cm x 1 32m 36AM Models 29 in W Outrigger Footprint 20 25AM Models 62 in x 54 in 1 57m x 1 37m 30AM Models 68 in x 62 in 1 72m x 1 57m 36AM Models 79 in x 79 in 2 0m x 2 0m 41AM Models 79 in x 79 in 2 0m x 2 0m Outrigger Machine Leveling Capahility x 54 5 in L 74cm x 1 38m 41AM Models 29 in W x 57 5 in L 74cm x 1 46m MAXIMUM GRADE MODEL OUTRIGGERS CAN LEVEL MACHINE ON FRONT TO BACK SIDE TO SIDE 20AM 10 11 5 25 10 11 5 30 9 8 5 8 3 7 2 41AM 8 7 1 1 4 TORQUE REQUIREMENTS When maintenance becomes necessary or a fastener has loosened refer to the Torque Chart Figure 1 2 on page 1 5 to determine proper torque value 1 5 LUBRICATION Hydraulic Oil HO Hydraulic oils must have anti wear qualities at least to Service Classification GL 3 a
120. tch connects the two terminals and open otherwise c Ifthe switch has more than one common contact repeat the process for that circuit Limit Switches Limit switches are used to control movement or indicate position Mechanical limit switches are just like manually operated switches except that the moving object operates the switch These switches can be tested the same way as a standard switch by manually operating the sensing arm Another type of limit switch used by JLG is the inductive proximity switch also referred to as a prox switch Induc tive proximity switches are actuated only by ferrous metal metal that contains Iron such as steel near the switch They do not require contact and must be energized to actuate These types of switches can be used to detect boom or platform position for example These switches have a sensing face where the switch can detect ferrous metal close to it To find the sensing face take note how the switch is mounted and how the mechanisms meet the switch Test this type of switch as follows 1 Remove prox switch from its mount 2 Reconnect harness if it was disconnected for step 1 and turn on machine 3 Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer See vehicle or control system documenta tion on how to do this 4 Place sensing face of switch on the object to be sensed by the switch If that is not available use a piec
121. the TOP of mast section 3 Remove chains When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 3 out BOTTOM of sec tion 2 Remove slide pads shims and chain anchor plate if necessary Mast Section 2 Removal Ail Masts 29 30 31 32 NOTE 3120752 Slide mast section 2 out TOP of mast section 1 far enough to allow access to the chain anchor block sheave wheel assembly Remove countersunk flathead screws securing chain anchor block sheave wheel assembly attach bars on both side rails at TOP of mast section 2 Extend the chain anchor block sheave wheel assemby and hydraulic cylinder rod out the TOP of mast section 2 far enough to allow removal of the sheave wheel attach bars sheave wheels and sheave pin from the chain assembly anchor block Remove the setscrew holding the hydraulic cylinder rod into the chain assembly anchor block Lay chain assembly to side When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels 33 Carefully slide mast section 2 out the TOP of sec tion 1 be careful not to nick or score cylinder rod surface while removing Remove slide pads and shims if necessary Mast Section 1 Disassembly Aii Masts 34 35 36 Slide the TOP of the remaining mast section 1 out over edge of work surface and remove the bolts attachi
122. towards jack end of outrigger beam Hold in place if necessary 3120752 SECTION 3 TROUBLESHOOTING ORIGINAL DESIGN OPEN END OF OUTRIGGER SOCKET APPLY LOCTITE 242 TO THREADS Figure 3 5 Outrigger Socket Contactor Heads and Outrigger Beam Contactor Plate Mounting Hardware ORIGINAL AND 5 2001 DESIGN 3120752 JLG Lift 3 9 SECTION 3 TROUBLESHOOTING 3 10 On the inside of the outrigger beam install two nylon washers on the screw with the two 2 o rings installed one towards jack end and three 3 nylon washers on the the other screw towards open end of beam Coat the threads of the screws with Loctite 222 and thread the steel acorn nuts onto each screw Hold the acorn nuts and tighten the screws using a cordless screw driver set at the 1 torque setting Detent Screws See Figure 3 5 OUTRIGGER BEAMS are manufactured with a series of holes drilled around the CONTACTOR PLATE assembly OUTRIGGER SOCKETS are equipped with button head screws detent screws mounted around the CONTAC TOR SCREW HEADS on the floor of the outrigger socket The detent screws must align with the holes in the outrig ger socket before the contactor plate on the outrigger beam and the contactor scr
123. ugh to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly 2 31 SECTION 2 SERVICE PROCEDURES Mast Section 6 Assembly 30 41 ft Masts NOTE 60 61 62 63 64 65 NOTE 66 2 32 Steps 57 thru 69 install section 6 to a seven 7 sec tion 30 and 41 1 mast If assembling a six 6 sec tion 25 or 36 ft mast skip to step 70 Locate mast section 6 carefully slide section 6 closed rail into section 5 open rail Slide sections together until ends are even Locate one 1 of the chain cable anchor plates one with threaded holes horizontally aligned to outside edges of bracket Attach through outer set of holes in bottom of mast section 6 with two 2 1 4 20UNC x 3 4 long bolts place a flatwasher under head of each bolt Slide mast section 6 out the top of mast section 5 so the chain cable anchor plate on bottom of mast sec tion 6 is easily accessible near top end of mast sec tion 5 Rest the top end of mast section 6 on a support while performing next step Insert threaded ends of cable assembly attached to top of mast section 4 through the chain cable anchor plate located on bottom of extended mast section 6 Loosely thread two 2 3 8 16UNC nuts onto stud threads on each chain Chains will be adjusted later in assembly Slide mast section 6 back into section 5 except for a foot or two of length While mast section 6 is still extended from section 5
124. ult your national regional or local regulations for further requirements for aerial work platforms The fre quency 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 tor s and Safety Manual for completion procedures for the Pre Start Inspection The Operator 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 recog nized degree certificate extensive knowledge training or experience has successfully demonstrated the ability and proficiency 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 whichever comes first out of service for a period
125. urned OFF before testing con Use firm contact with meter leads Use firm contact with meter leads First test meter and leads by touching leads together Meter should produce an audible alarm indicating continuity 3 4 JLG Lift 3120752 SECTION 3 TROUBLESHOOTING 3120752 3 5 ELECTRICAL SWITCH TESTING Basic The following check determines if the switch is functioning properly not the circuit in which the switch is placed A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected 1 De energize the circuit 2 Isolate the switch from the rest of the circuit if possi ble If not possible keep in mind it may affect read ings 3 Access the terminals to the switch 4 the switch has two terminals a Measure resistance across the terminals b Change the switch position c Measure resistance again with the leads in the same positions If the meter was reading short it should read an open If the meter was reading open it should read short 5 the switch has more than two terminals consult the schematic or switch diagram to determine what terminals will be connected The test is similar to testing a switch with two terminals a Place one meter lead on the common contact and the other on a different contact in the same circuit b Cycle through all positions of the switch meter should read short only when the swi
126. used to troubleshoot the other wires To find the problem start at step 1 and use the entire pro cedure 3 2 JLG Lift 3120752 SECTION 3 TROUBLESHOOTING Voltage Measurement Resistance Measurement Figure 3 1 Voltage Measurement DC Figure 3 2 Resistance Measurement f meter is not auto ranging set it to the correct range First test meter and leads by touching leads together See multimeter s operation manual Resistance should read a short circuit very low resis Use firm contact with meter leads tance Circuit power must be turned OFF before testing resistance Disconnect component from circuit before testing f meter is not auto ranging set it to the correct range See multimeter s operation manual Use firm contact with meter leads 3120752 JLG Lift 3 3 SECTION 3 TROUBLESHOOTING Continuity Measurement Current Measurement 77 Sie a Figure 3 3 Continuity Measurement Figure 3 4 Current Measurement DC Set up the meter for the expected current range Be sure to connect the meter leads to the correct jacks for the current range you have selected If meter is not auto ranging set it to the correct range tinuity Disconnect component from circuit before testing See multi meter s operation manual Some meters require a separate button press to enable audible continuity testing Circuit power must be t
127. void mixing petroleum and syn thetic base oils JLG Industries recommends changing the hydraulic oil annually Use every precaution to keep the hydraulic oil clean If the oil must be poured from the original container into another be sure to clean all possible contaminants from the service container While the unit is shut down a good preventive mainte nance measure is to make a thorough inspection of all hydraulic components lines fittings etc as well asa functional check of each system before placing the machine back in service Lubrication Specifications Specified lubricants as recommended by the component manufacturers are always the best choice however multi purpose greases usually have the qualities which meet a variety of single purpose grease requirements Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion Refer to Table 1 2 for an explanation of the lubricant key designations appearing in the Lubrication Chart 3120752 SECTION 2 SERVICE PROCEDURES 2 5 BATTERY CHARGER ASSEMBLY AND DISASSEMBLY General Information DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGER IF MACHINE IS STILL UNDER WARRANTY OPENING THE BAT TERY CHARGER WHILE THE MACHINE IS UNDER WARRANTY WILL VOID THE CHARGER WARRANTY IF UNDER WARRANTY REQUEST A REPLACEMENT CHARGER FROM THE FACTORY ALSO BEFORE REPLACING ANY COMPONENT USE THE CHAR GER MANUFACTURER
128. y dry batteries and coat terminals with an anti corrosion compound Mast Chain Inspection Procedure Inspect mast chains for the following conditions Wear Always inspect that segment of chain that operates over a sheave As the chain flexes over the extend retract sheaves joints and plate edges very gradually wear Chain stretch can be measured using a manufacturers wear scale or steel tape When chains have elongated 3 they must be removed and replaced Refer to Table 2 3 for proper chain specifications and allowable stretch toler ances Peening and wear of chain plate edges are caused by sliding over a chain worn contact face of a sheave or unusually heavy loads All of the above require replace ment of the chain and correction of the cause Chain side wear noticeable when pin heads and outside plates show a definite wear pattern is caused by misalignment of the sheave chain anchors and must be corrected promptly Do not repair chains if a section of chain is damaged replace the entire chain set Rust and Corrosion Rust and corrosion will cause a major reduction in the load carrying capacity of the chain because these are primary reasons for side plate crack ing The initial lubrication at the factory is applied in a hot dip tank to assure full penetration into the joint Do not steam clean or degrease chains At time of chain installa tion factory lube must be supplemented by a mainte nance program to provide a film of o

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