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41AM
JLG 41AM Service And Maintenance Manual
84 pages
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Ser
vice and Maintenance Manual
Model(s)
AM Series
20AM
25AM
30AM
36AM
41AM
3120752
June 29, 2018 - Rev N
2
Table of Contents
Default Chapter
5
Introduction - Operation/Safety Precautions
5
Introduction - Maintenance Safety Precautions
6
General
6
Hydraulic System Safety
6
Maintenance Safety
6
Effectivity Changes
7
Table of Contents
9
Section 1 - Specifications
13
Capacities
13
Hydraulic Oil Reservoir
13
Component Data
13
Hydraulic Pump/Electric Motor Assembly
13
Batteries (1) - DC Models
13
Battery Charger - DC Models
13
Performance Data
13
Platform Capacity
13
Platform Cycle Performance
13
Machine Height (Platform Stowed)
14
Maximum Platform Height (Mast Extended)
14
Maximum Working Height (Average Person)
14
Machine Overall Width and Length (Base)
14
Outrigger Footprint
14
Outrigger Machine Leveling Capability
14
Torque Requirements
14
Lubrication
14
Hydraulic Oil (HO)
14
Hydraulic Pressure Adjustment
15
Cylinder Specifications
15
Serial Number Locations
15
Hydraulic Pressure Setting - Adjustment Screw Located at Base of Pump Motor
15
Torque Chart
17
Section 2 - Service Procedures
25
Machine Preparation, Inspection, and Maintenance
25
General
25
Preparation, Inspection, and Maintenance
25
Pre-Start Inspection
25
Pre-Delivery Inspection and Frequent Inspection
25
Annual Machine Inspection
25
Preventative Maintenance
25
Preventive Maintenance and Inspection Schedule
26
Servicing and Maintenance Guidelines
29
General
29
Safety and Workmanship
29
Cleanliness
29
Components Removal and Installation
29
Component Disassembly and Reassembly
29
Pressure-Fit Parts
29
Bearings
29
Gaskets
29
Bolt Usage and Torque Application
30
Hydraulic Lines and Electrical Wiring
30
Hydraulic System
30
Lubrication and Servicing
30
Batteries
30
Mast Chain Inspection Procedure
30
Mast Cable Inspection Procedure
31
Lubrication Information
32
Hydraulic System
32
Hydraulic Oil
32
Changing Hydraulic Oil
32
Lubrication Specifications
32
Battery Charger - Assembly and Disassembly
33
General Information
33
Battery Charger Removal
33
Cover Removal
33
Transformer Replacement
34
Printed Circuit Board Replacement
34
DC Circuit Breaker Replacement
34
AC Circuit Breaker and Voltage Selection Switch Replacement
35
Shunt Assembly, Varistor, and SCR Rectifier Replacement (See Illustration)
35
Hydraulic Lift Pump - Servicing
36
FENNER BRAND PUMP - Brush Replacement
36
Motor Cap/Motor Installation
36
Motor Brush Installation
36
Brush Housing Final Assembly Tips
37
MONARCH BRAND PUMP - Brush Replacement
38
Motor Assembly - Remove/Install - Reference Marks
38
Motor/Brush Cover - Remove/Install
38
Brush Carrier Assembly - Remove/Install
39
Brush Assembly - Remove/Install
39
TANK and PUMP REMOVAL - (All Pumps)
40
Tank Installation
40
Filter Screen Installation
40
Pump Installation
40
Pressure Adjust Valve Installation
41
Pressure Check Valve Installation
41
Hydraulic Lift Cylinder - Removal, Inspection and Rebuild
42
Cylinder Removal
42
Cylinder Disassembly
42
Lift Cylinder Component Inspection
42
Lift Cylinder Internal Component Assembly Cross-Section
43
Cylinder Assembly
44
Installation
44
Mast Assembly and Disassembly Procedures
45
Mast Disassembly Procedure
45
Mast Section - Assembly/Disassembly Reference
45
Platform Section Removal (All Masts)
46
Mast Section 6 Removal (7 Section Mast)
46
Mast Section 5 Removal (6 & 7 Section Mast)
46
Mast Section 4 Removal (All Masts)
46
Mast Section 3 Removal (All Masts)
47
Mast Section 2 Removal (All Masts)
47
Mast Section 1 Disassembly (All Masts)
47
Mast Assembly
48
Mast Section 1 - Assembly (All Masts)
48
Mast Section 2 - Assembly (All Masts)
48
20AM Mast Assembly Components. (5 - Section)
49
25AM & 36AM Mast Assembly Components. (6 - Section)
50
30AM & 41AM Mast Assembly Components. (7 - Section)
51
Mast Chain/Cable Routing Diagram
52
Mast Section 3 - Assembly (All Masts)
53
Mast Section 4 - Assembly (All Masts)
54
Mast Section 5 - Assembly (25/30/36/41 Ft. Masts)
55
Mast Section 6 - Assembly (30/41 Ft. Masts)
56
Platform Mounting Section - Assy. (All Masts)
56
Mast to Base Frame Installation
58
Mast Chains/Cables and Sequencing Cables Adjustment
59
Mast Chain/Cable Adjustment
59
Mast Chain/Cable/Sequence Cable Adjustment Components. (Typical)
59
Sequencing Cable Adjustment
60
Sequence Cable Replacement Kit
61
Remove Old Cable
61
Replacement Cable Installation
61
Clamp Installation (Drum/Socket Type)
61
Section 3 - Troubleshooting
63
General
63
Troubleshooting Information
63
Hydraulic Circuit Checks
63
Electrical System - Multimeter Basics
63
Grounding
63
Backprobing
63
Min/Max
63
Polarity
64
Scale
64
Continuity Measurement over Long Distances
64
Requirements
64
Procedure
64
Continuity Measurement
64
Resistance Measurement
65
Electrical Switch Testing
67
Basic Check
67
Limit Switches
67
Automatic Switches
67
Switch Wiring - Low Side, High Side
67
Outrigger Interlock Contacts
70
Outrigger Socket and Outrigger Beam - Interlock Contacts
70
Outrigger Socket - Contactor Screw Mounting Instructions
70
Outrigger Beam - Interlock Contactor Plate Mounting Instructions
70
Outrigger Socket Contactor Heads and Outrigger Beam - Contactor Plate Mounting Hardware (ORIGINAL and 5/2001 - DESIGN)
71
Detent Screws
72
Hydraulic Schematic. (am Series) (2792491_A)
73
Electrical Diagram. (am Series - 12V-DC)
74
Other manuals for JLG 41AM
Operation And Safety Manual
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JLG 41AM Specifications
General
Platform Height
41 ft
Platform Capacity
750 lb
Weight
6, 490 lb
Drive Speed
2.5 mph
Gradeability
25 %
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