JLG 25AM Service And Maintenance Manual
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JLG 25AM Service And Maintenance Manual

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Service and Maintenance Manual
Models
25AM
30AM
38AM
PVC 2002
31215808
February 25, 2020 - Rev A
AS/NZS

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  • Page 1 Service and Maintenance Manual Models 25AM 30AM 38AM PVC 2002 31215808 February 25, 2020 - Rev A AS/NZS...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 3: General

    FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY, OR DEATH, AND IS A SAFETY VIOLATION. MODIFICATION OF THE MACHINE WITHOUT APPROVAL BY JLG INDUS- TRIES, INC. IS A SAFETY VIOLATION. • Remove all rings, watches and jewelry when perform- ing any maintenance.
  • Page 4 INTRODUCTION REVISON LOG Original Issue A - February 25, 2020 31215808...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................... . A-1 Hydraulic System Safety .
  • Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Lubrication Information ................2-7 Hydraulic System .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 2.13 Sequence Cable replacement kit..............2-33 Remove Old Cable .
  • Page 8 25AM Mast Assembly Components (6 - Section) ........
  • Page 9 LIST OF TABLES TABLE NO. TITLE PAGE NO. Hydraulic Oil Operating Range ..............1-2 Lubricant Key .

  • Page 10: Table No

    LIST OF TABLES TABLE NO. TITLE PAGE NO. 31215808...
  • Page 11 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 12: General Specifications

    SECTION 1 - GENERAL SPECIFICATIONS SECTION 1. GENERAL SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS Machine Specifications 30AM 30AM SPECIFICATION 25AM 38AM (EXCEPT CE) (CE ONLY) Gross Machine Weight: (Platform Empty) 905 lb 1110 lb 1110 lb 1395 lb (411kg) (503kg) (503kg) (633kg)

  • Page 13: Performance Data

    +20°F (–7°C) JLG recommends using hydraulic premium fluid. Aside from JLG recommendations, 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. If use of hydraulic oil other than standard UTTO is desired, contact JLG Industries for proper recommendations.

  • Page 14: Lubrication Specifications

    SECTION 1 - GENERAL SPECIFICATIONS Lubrication Specifications Table 1-2. Lubricant Key SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350° F. Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.) Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 EPGL or MIL-Spec MIL-L-2105.

  • Page 15: Battery Maintenance

    SECTION 1 - GENERAL SPECIFICATIONS 1.9 BATTERY MAINTENANCE 1.10 HYDRAULIC PRESSURE ADJUSTMENT (See Figure 1-2.) NOTE: This information applies to wet cell batteries only. Do not attempt to open a maintenance-free sealed battery. Adjust system pressure so that platform will raise with rated capacity in platform.

  • Page 16: Cylinder Specifications

    All dimensions are given in inches (in.), with the metric equivalent, centimeters (cm), given in parentheses. BORE STROKE ROD DIA. DESCRIPTION in./(cm) in./(cm) in./(cm) Lift Cylinder - 1.63 56.50 1.38 25AM (4.14) (143.50) (3.50) Lift Cylinder - 1.63 56.50 1.38 30AM (4.14) (143.50) (3.50) Lift Cylinder - 1.63...

  • Page 17: Threadlocking Compound

    SECTION 1 - GENERAL SPECIFICATIONS 1.12 THREADLOCKING COMPOUND JLG PN Loctite® ND Industries Description 0100011 242™ Vibra-TITE™ 121 Medium Strength (Blue) 1001095650 243™ Vibra-TITE™ 122 Medium Strength (Blue) 0100019 271™ High Strength (Red) Vibra-TITE™ 140 0100071 262™ Vibra-TITE™ 131 Medium - High Strength (Red) NOTE: Loctite®...

  • Page 18: Torque Charts

    SECTION 1 - GENERAL SPECIFICATIONS 1.13 TORQUE CHARTS SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Tensile Clamp Torque Torque Size Bolt Dia (Loctite® 242™ or 271™ or (Loctite®...
  • Page 19 SECTION 1 - GENERAL SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load...
  • Page 20 SECTION 1 - GENERAL SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry) Area...
  • Page 21 SECTION 1 - GENERAL SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load...
  • Page 22 SECTION 1 - GENERAL SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...
  • Page 23 SECTION 1 - GENERAL SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...

  • Page 24: Metric Fastener Torque Chart

    SECTION 1 - GENERAL SPECIFICATIONS Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Tensile Stress Clamp Load Torque (Loctite® 262™ or 271™ or Size Pitch Torque (Lube) (Loctite®...
  • Page 25 SECTION 1 - GENERAL SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAPSCREWS M3 - M5* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp Load (Loctite®...
  • Page 26 SECTION 1 - GENERAL SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Torque (Loctite® 262™ or Tensile Clamp Load (Lube or Loctite® 242™ or 271™ Size Pitch (Dry or Loctite®...
  • Page 27 SECTION 1 - GENERAL SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAPSCREWS M6 AND ABOVE* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp (Loctite®...
  • Page 28 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 29: Service Procedures

    JLG Service Training School for the those personnel that are responsible to place the machine in subject JLG product model. Refer to the machine Service and operation readiness and maintain its safe operating condition. Maintenance Manual and appropriate JLG inspection form for For maximum service life and safe operation, ensure that all performance of this inspection.

  • Page 30: Preventive Maintenance And Inspection Schedule

    Maintenance nance Manual. NOTICE JLG Industries, Inc. recognizes a Factory-Trained Service Technician as a person who has successfully completed the JLG Service Training School for the specific JLG product model. 2.2 PREVENTIVE MAINTENANCE AND INSPECTION Maintenance and Inspection Schedule Codes SCHEDULE 1.

  • Page 31: Am Model - Preventive Maintenance & Inspection Schedule

    SECTION 2 - SERVICE PROCEDURES Table 2-2. AM Model - Preventive Maintenance & Inspection Schedule INTERVAL PRE-DELIVERY ANNUAL AREA ON MACHINE (YEARLY) OR FREQUENT INSPECTION INSPECTION MAST AND PLATFORM ASSEMBLY Mast Sections Chains, Cables, and Sequencing Cables Chains Lubricating 1,2,7,9 Platform, Platform Gate, and Latches Guard Rails and Parts Covers and Shields...
  • Page 32 Instruments, Gauges Switches, Lights, Horn GENERAL No Unauthorized Modifications or Additions General Structural Condition and Welds Paint and Appearance Notify JLG of Machine Ownership Annual Machine Inspection Due All Relevant Safety Publications Incorporated All Decals/Placards Installed, Secure, Legible All Fasteners, Pins, Shields, and Covers...

  • Page 33: Servicing And Maintenance Guidelines

    SECTION 2 - SERVICE PROCEDURES 2.3 SERVICING AND MAINTENANCE GUIDELINES Component Disassembly and Reassembly When disassembling or reassembling a component, complete General the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck The following information is provided to assist you in the use your work to assure that nothing has been overlooked.

  • Page 34: Lubrication And Servicing

    If any cracks are discovered, replace all chains, as seem- ingly 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 lifting capacity of these chains.

  • Page 35: Lubrication Information

    SECTION 2 - SERVICE PROCEDURES 2.4 LUBRICATION INFORMATION Hydraulic Oil For best performance, JLG recommends the use of ISO-Vg Hydraulic System grade 32, 46 oil with a viscosity range between 15-250 SUS at 100 degrees F (32-54 cST at 40 degrees C).

  • Page 36: Battery Charger - Assembly And Disassembly

    The AM Series dual AC input battery charger allows for replacement of the following internal components. Consult your Illustrated Parts Manual for part numbers of these com- ponents which are available from the JLG Parts Department: • Transformer • Printed Circuit Board •...

  • Page 37: Transformer Replacement

    SECTION 2 - SERVICE PROCEDURES Transformer Replacement Printed Circuit Board Replacement 1. Disconnect the wiring connecting the transformer to 1. Disconnect the wide wiring connector from the end of other components within the charger assembly. the circuit board. 2. Remove the four nuts from the cap screws securing the 2.

  • Page 38: Ac Circuit Breaker And Voltage Selection Switch Replacement

    SECTION 2 - SERVICE PROCEDURES AC Circuit Breaker and Voltage Selection Switch Replacement 1. Remove the wiring from the AC breaker or Voltage Selec- tion Switch terminals. 2. 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.

  • Page 39: Fuse Replacement

    SECTION 2 - SERVICE PROCEDURES 2.6 FUSE REPLACEMENT 1. Remove the tie strap which is holding boot to positive end of battery over battery cable. 2. Remove nut from cap screw attaching battery cable to fuse. 3. Replace the fuse. 4.

  • Page 40: Bucher Brand Pump - Brush Replacement

    SECTION 2 - SERVICE PROCEDURES 2.7 BUCHER 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.

  • Page 41: Brush Carrier Assembly - Remove/Install

    SECTION 2 - SERVICE PROCEDURES Brush Carrier Assembly - Remove/Install 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 reference only).

  • Page 42: Tank And Pump Removal - (All Pumps)

    SECTION 2 - SERVICE PROCEDURES Tank And Pump Removal - (All Pumps) Pump Installation Tank Installation Pump Installation 1. Pump Assembly 3. Pump Shaft Seal 2. Pump Assembly Screws 4. Pump End Head Tank Installation 1. Tank Assembly 3. O-Ring Seal 2.

  • Page 43: Pressure Adjust Valve Installation

    SECTION 2 - SERVICE PROCEDURES Pressure Adjust Valve Installation Pressure Check Valve Installation Pressure Adjust Valve Installation Pressure Check Valve Installation 1. Adjust Valve Cap 4. Valve Ball 1. Check Valve Assembly 5. Check Valve Port 2. Adjustment Screw 5. Adjust Valve Port 2.

  • Page 44: Hydraulic Lift Cylinder - Removal, Inspection And Rebuild

    SECTION 2 - SERVICE PROCEDURES 2.8 HYDRAULIC LIFT CYLINDER - REMOVAL, Cylinder Disassembly INSPECTION AND REBUILD 1. Before disassembling the cylinder, clean away all dirt and foreign substances from openings, particularly the head area. NOTE: Always protect the chrome surface of the cylinder rod dur- HYDRAULIC CYLINDERS ARE DESIGNED TO HOLD HYDRAULIC FLUID UNDER ing assembly and disassembly.
  • Page 45 SECTION 2 - SERVICE PROCEDURES RETAINING RING GROOVE WEAR RING CYLINDER HEAD PISTON RETAINING O-RING SEAL RING BACKUP RING O-RING SEAL WIPER LOCKNUT CYLINDER TORQUE TUBE PISTON ASSEMBLY 175-200 ft.lbs. (237-271 Nm) WHEN ASSEMBLING CYLINDER APPLY ANTI-SEIZE CYLINDER COMPOUND CYLINDER HEAD AROUND THE HEAD IN THIS AREA ONLY...
  • Page 46 SECTION 2 - SERVICE PROCEDURES 1001099734-C 1001255984-A MAF30640 1. Barrel 6. Seal, Rod 11. Seal, Piston 16. Plug 2. Nut 7. Rod Wiper 12. Knob - Red 17. Ring, Wear 3. Piston 8. O-Ring 13. Poppet, Solenoid Valve 4. Rod 9.

  • Page 47: Cylinder Assembly

    SECTION 2 - SERVICE PROCEDURES Cylinder Assembly Installation (See Figure 2-1.) 1. Remove the plastic plugs from the cylinder. 1. Rinse the inside of the tube with hydraulic fluid and allow 2. Pull rod out of cylinder approximately 3 ft. to drain.

  • Page 48: Mast Disassembly Procedure

    25 ft. machines use six (6) mast sections, the 30 and 38 ft. Model Extend Device Sections models use seven (7) mast sections. 25AM Chain & Cable 1. After the platform and other hardware have been 30AM Chain & Cable...

  • Page 49: Platform Section Removal (All Masts)

    SECTION 2 - SERVICE PROCEDURES Platform Section Removal NOTE: Step 15 applies to removal of the cable assemblies used on (All Masts) mast section-5. 3. Remove cable adjust nuts from threaded ends of cable attached to the cable anchor plate on BOTTOM end of 15.

  • Page 50: Mast Section 2 Removal (All Masts)

    SECTION 2 - SERVICE PROCEDURES NOTE: When sliding mast sections apart, be careful not to scratch 2.10 MAST ASSEMBLY or score the anodized finish in the slide pad channels. (See Figure 2-4. or Figure 2-5.) 28. Carefully slide mast section-3 out BOTTOM of section-2. Mast Section 1 - Assembly (All Masts) Remove slide pads, shims and chain anchor plate, if nec-...
  • Page 51 SECTION 2 - SERVICE PROCEDURES MAST SECTION-5 MAST SECTION-1 MAST SECTION-2 MAST SECTION-3 MAST SECTION-4 MAST SECTION-6 LIFT CYLINDER BRACKET 0801297-H MAF30610H Figure 2-4. 25AM Mast Assembly Components (6 - Section) 31215808 2-23...
  • Page 52 SECTION 2 - SERVICE PROCEDURES MAST MAST SECTION-1 SECTION-6 MAST SECTION-2 MAST SECTION-3 MAST SECTION-4 MAST SECTION-5 MAST SECTION-7 LIFT CYLINDER BRACKET 0801298-I MAF30620I Figure 2-5. 30AM & 38AM Mast Assembly Components (7 - Section) 2-24 31215808...
  • Page 53 SECTION 2 - SERVICE PROCEDURES SECTION 7 SECTION 6 SECTION 5 SECTION 4 SECTION 3 SECTION 2 SECTION 1 HYDRAULIC CHAIN ASSEMBLY CYLINDER LIFTS HERE BRACKETS MAF30630 Figure 2-6. Mast Chain/Cable Routing Diagram 31215808 2-25...

  • Page 54: Mast Section 3 - Assembly (All Masts)

    SECTION 2 - SERVICE PROCEDURES d. When mast slide pads are shimmed properly, there d. Slide the whole anchor block assembly with sheave should be no side to side movement of slide pad in pin, wheels and pin attach bars into top of mast sec- rail channel.

  • Page 55: Mast Section 4 - Assembly (All Masts)

    SECTION 2 - SERVICE PROCEDURES 25. Carefully slide mast section-3 into section-2 until ends 37. While mast section-4 is still extended from section-3, are even. Check to make sure chain assembly (wide assemble cable sheaves to top of mast section-4 as fol- chains) are seating properly in chain anchor block chain lows;...

  • Page 56: Mast Section 5 - Assembly (All Masts)

    SECTION 2 - SERVICE PROCEDURES Mast Section 5 - Assembly 52. Carefully slide mast section-5 back into section-4 until (All Masts) ends are even. Check to make sure cable set from top of section-3 is seating properly in cable sheave wheels NOTE: When sliding mast sections together, be careful not to attached to top of mast section-4.
  • Page 57 SECTION 2 - SERVICE PROCEDURES d. Attach to top of mast section-6 using two (2) 3/8 in. Platform Mounting Section - Assy. (All Masts) x 1/2 in. long socket head-countersunk-flathead cap screws, each side. Apply Medium Strength Thread- NOTE: Reference to mast sections -6/-7 made following is depen- locking Compound and tighten.
  • Page 58 SECTION 2 - SERVICE PROCEDURES 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.

  • Page 59: Mast To Base Frame Installation

    SECTION 2 - SERVICE PROCEDURES 2.11 MAST TO BASE FRAME INSTALLATION 8. Before setting machine upright on base, install a short 90° elbow fitting, flow control valve and another short 90° elbow fitting on the end of the flow control valve in 1.

  • Page 60: Mast Chains/Cables And Sequencing Cables Adjustment

    SECTION 2 - SERVICE PROCEDURES 2.12 MAST CHAINS/CABLES AND SEQUENCING Adjust using the following procedure; 1. With mast retracted, step into the platform and bounce CABLES ADJUSTMENT your weight up and down a few times to be certain plat- form is at the bottom of travel. Be certain all chain/cable Mast Chain/Cable Adjustment sets are seated in their sheaves properly at the top of each mast section.

  • Page 61: Sequencing Cable Adjustment

    25% after adjusting. THE MANUFACTURER OF THE DRUM/SOCKET CLAMP RECOMMENDS THE USE OF THEIR CABLE CLAMP ASSEMBLY KIT (JLG PN - 7023275) TO ASSEMBLE THE CLAMP TO THE WIRE ROPE. THE KIT CONSISTS OF VISE JAWS TO HOLD THE...
  • Page 62 SECTION 2 - SERVICE PROCEDURES NOTE: The tools in the clamp assembly kit may be fabricated if done properly the outer strands will form a symmetrical basket. Do not straighten out the spiral lay of the strands, necessary. The vise clamp consists of vise jaws with a hole unlay any wires that make up the strand, or allow the drilled 1/32 in.
  • Page 63 SECTION 2 - SERVICE PROCEDURES 7. Coat the threads of the socket and sleeve with lubricant 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 visible, proof load the cable and retighten the socket fitting.

  • Page 64: Load Sensing System (Lss)

    SECTION 2 - SERVICE PROCEDURES 2.14 Load Sensing System (LSS) SEE DETAIL A DETAIL A SECTION A - A 1001255532-A MAF30820A 1. Coil Spring 3. Lock Nut 5. Nut 7. Lock Nut 2. Capscrew 4. Bolt 6. Capscrew 8. Support Figure 2-8.

  • Page 65: Setting Spring Pre-Load

    SECTION 2 - SERVICE PROCEDURES Setting Spring Pre-Load Adjusting Switch 1. Adjust the height of the coil springs (1) to 2.250 in. by 6. Load platform with 105% of the total rated capacity. tightening the capscrew (6) and lock nut (7) (using center 7.
  • Page 66 SECTION 2 - SERVICE PROCEDURES 2-38 31215808...
  • Page 67 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 68: Troubleshooting

    SECTION 3 - TROUBLESHOOTING SECTION 3. TROUBLESHOOTING 3.1 GENERAL 3.3 HYDRAULIC CIRCUIT CHECKS This section contains troubleshooting information to be used The first reference for improper function of a hydraulic system, for locating and correcting most operating problems. If a where the cause is not immediately apparent, should be the problem should develop which is not presented in this section Hydraulic Diagram Circuit.

  • Page 69: Polarity

    SECTION 3 - TROUBLESHOOTING Polarity Procedure Finding a negative voltage or current reading when expecting Test multimeter leads resistance. Subtract this value from the a positive reading frequently means the leads are reversed. measured resistance of the wires to get a more accurate mea- Check what reading is expected, the location of the signal and surement.
  • Page 70 SECTION 3 - TROUBLESHOOTING Voltage Measurement Resistance Measurement Figure 3-1. Voltage Measurement (DC) Figure 3-2. Resistance Measurement • If 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- tance)
  • Page 71 SECTION 3 - TROUBLESHOOTING Continuity Measurement Current Measurement Figure 3-3. Continuity Measurement Figure 3-4. Current Measurement (DC) • Some meters require a separate button press to enable • Set up the meter for the expected current range audible continuity testing •...

  • Page 72: Electrical Switch Testing

    A low side switch will allow voltage to be present on the load. Another type of limit switch used by JLG is the inductive prox- No power is applied because the switch is stopping current imity switch, also referred to as a "prox switch".

  • Page 73: Ac Unit - Troubleshooting

    SECTION 3 - TROUBLESHOOTING Table 3-1. AC Unit - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Outrigger LED light does not turn on. Outriggers are not properly inserted in outrigger sock- Check all outriggers for proper installation in outrigger ets. sockets. Power source is OFF. Check power source.

  • Page 74: Dc Unit - Troubleshooting

    SECTION 3 - TROUBLESHOOTING Table 3-2. DC Unit - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Outrigger LED light does not turn on. Outriggers are not properly inserted in outrigger sock- Check all outriggers for proper installation in outrigger ets. sockets. Power source is OFF. Check power source.

  • Page 75: Outrigger Interlock Contacts

    SECTION 3 - TROUBLESHOOTING 3.6 OUTRIGGER INTERLOCK CONTACTS Outrigger Beam - Interlock Contactor Plate Mounting Instructions Outrigger Socket and Outrigger Beam - Interlock (See Figure 3-5.) Contacts Assemble an insulating bushing into each of the screw It is very important that the outrigger interlock contacts holes in the floor of the outrigger beam.
  • Page 76 SECTION 3 - TROUBLESHOOTING OUTRIGGER BEAM APPLY LOW STRENGTH ACORN NUT BRASS THREADLOCKING NYLON FLAT HEAD SCREW COMPOUND TO THREADS WASHERS JACK END OF OUTRIGGER BEAM CONTACTOR INSULATOR PLATE BUSHING O-RINGS ROUND HEAD SCREW INSULATOR BUSHING NYLON WASHERS OUTRIGGER SOCKET (FLOOR) APPLY MEDIUM OPEN END OF...

  • Page 77: Detent Screws

    SECTION 3 - TROUBLESHOOTING On the inside of the outrigger beam, install two nylon Detent Screws washers on the screw with the two (2) o-rings installed (See Figure 3-5.) (one towards jack end) and three (3) nylon washers on the other screw (towards open end of beam). OUTRIGGER BEAMS are manufactured with a series of holes drilled around the CONTACTOR PLATE assembly.
  • Page 78 SECTION 3 - TROUBLESHOOTING 31215808 3-11...

  • Page 79: Hydraulic Schematic

    SECTION 3 - TROUBLESHOOTING 3.7 HYDRAULIC SCHEMATIC 2792491_A Figure 3-6. Hydraulic Schematic (AM Series) (2792491_A) 3-12 31215808...

  • Page 80: Electric Schematic

    SECTION 3 - TROUBLESHOOTING 3.8 ELECTRIC SCHEMATIC SHEET 5: MAST CABLES, 25AM/30AM/38AM SHEET 2: 12V BATTERY PACK CABLE, RETRACTILE 16/5 CABLE, 16/5 303 in. CABLE, 16/5 DC CONTROL HARNESS, JUMPER (CONTROL BOX) HARNESS, DC CONTROL CABLE, ASSY BATTERY PACK HARNESS, DC CONTROL...
  • Page 81 SECTION 3 - TROUBLESHOOTING LSS ACCESSORY MODULE PLATFORM CONTROL BOX AH59+ BLU 2 CO52-A RED 2 RED 1 AH59- PLATFORM EMS GRN 3 RED-BLK 4 RED-BLK 5 CO52-B RED 1 BLK-WHT GRN 1 LB57- GRN 2 SW027 GRN 3 BLU 1 RED 1 LIFT UP S356...
  • Page 82 SECTION 3 - TROUBLESHOOTING PLAT/GROUND SELECT GENERIC GENERIC GENERIC LIFT/LOWER GENERIC GENERIC 5A FUSE RED 1 S356 BLK-WHT BLK 1 BLK 1 WHT 3 GRN D S279 WHT 1 BT70 GRN 3 S355 GRN 4 S283 HV925-2 GRN C ORG 1 HV925-1 HV927-1 GRN 4...
  • Page 83 SECTION 3 - TROUBLESHOOTING GENERIC GENERIC 115VAC OUTLET PLATFORM CONTROL HARNESS PLATFORM AC HARNESS (SHEET 4, CB) (SHEET 4, CB) 115/230V-12VDC TRANSFORMER T210-5 T215-1 BLK 7 BLK 5 BLK 9 BLK 8 Secondary Primary T212-6 T216-2 BLK 9 BLK 8 T208-7 T205-3 WHT 5...
  • Page 84 SECTION 3 - TROUBLESHOOTING PLAT/GROUND SELECTOR 115VAC OUTLET PLATFORM AC HARNESS (SHEET 4, CB) GENERIC GENERIC LIFT/LOWER CIRCUIT BREAKER RED 1 WHT 6 WHT 4 WHT 4 T1218-4A WHT 4 IP872 T204-4 RL931-2 YEL 2 RL931-4 YEL 3 12 AWG BLK 6 5 115/230VAC LINE T1218-1A 6 115/230VAC NEUT...
  • Page 85 SECTION 3 - TROUBLESHOOTING 100/110VAC-VDC TRANSFORMER RECTIFIER GRN 5 Primary Secondary T291-AC T289-(DC-) T299-9 T290-0 WHT 6 0VAC WHT 5 WHT 5 GRN 4 IP293 BLK 7 T297-AC T296-2 T294-(DC+) BLK 7 T301-10 BLK 5 100VAC 110VAC GRN 4 GRN 6 GRN 6 T288-7 GRN 7...
  • Page 86 SECTION 3 - TROUBLESHOOTING GENERIC O/R RELAY GENERIC GENERIC GROUND STUD POWER RELAY STARTER RELAY RL284-1 RL285-1 RL284-0 RL285-0 GRN 8 WHT 2 IP293 GRN 4 GRN 6 GRN 6 T288-7 GRN 7 T287-8 T295-1 RED 3 T292-2 GROUND STUD GENERIC O/R RELAY GENERIC...
  • Page 87 SECTION 3 - TROUBLESHOOTING 25AM S310 T307 PLATFORM CONTROLS GROUND CONTROLS S311 T308 S312 T309 S313 T310 BLK-WHT BLK-WHT S314 S319 T319 GROUND AC PLUG PLATFORM AC OUTLET S320 T320 GRN-YEL GRN-YEL S321 T321 30AM 38AM T322 PLATFORM CONTROLS GROUND CONTROLS...
  • Page 88 SECTION 3 - TROUBLESHOOTING 31215808 3-21...
  • Page 89 SECTION 3 - TROUBLESHOOTING HOUR METER T340 (TO LIFT UP VALVE, HV925) T337 T339 T338 DECENT ALARM T343 AH342- T344 (TO LIFT DOWN VALVE) BLU-ORN BLU-ORN AH342+ AH342+ B AH342- B SHEET 6 Figure 3-15. Electrical Schematic - Sheet 9 of 10 3-22 31215808...
  • Page 90 SECTION 3 - TROUBLESHOOTING STROBE LIGHT LB339- RL06-1B (TO POTTED RELAY, SHEET 2, A3) S340 RL06-7B S341 LB339+ SECURITY LOCK (OPTION) T348 SECURITY T349 LOCK (TO GROUND CONTROL BOX) CO346 S350 SHEET 6 1001248314-B MAF30790B Figure 3-16. Electrical Schematic - Sheet 10 of 10 31215808 3-23...
  • Page 91 SECTION 3 - TROUBLESHOOTING 3-24 31215808...
  • Page 92 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

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