JLG Boom Lift 20AM 25AM 30AM 36AM 41AM Service & Maintenance Manual 3120752 2025

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JLG Boom Lift 20AM 25AM 30AM 36AM 41AM Service & Maintenance Manual 3120752 2025
Size: 3.68 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Service & Maintenance Manual, Electrical and Hydraulic Diagrams
SN 0900000001-0900038985
Model: JLG 20AM 25AM 30AM 36AM 41AM Boom Lift
Part Number: 3120752
Publication Date: 2025
Number of Pages: 84 Pages

Contents:
INTRODUCTION - operation/safety precautions
INTRODUCTION - Maintenance safety precautions

General​

Hydraulic System Safety​

Maintenance Safety​

Effectivity Changes
TABLE OF CONTENTS
Section 1. specifications

1.1 Capacities​

Hydraulic Oil Reservoir​

1.2 Component Data​

Hydraulic Pump/Electric Motor Assembly​

Batteries (1) – DC Models​

Battery Charger – DC Models​

1.3 Performance Data​

Platform Capacity​

Platform Cycle Performance​

Machine Weight (with Standard Platform)​

Machine Height (Platform Stowed)​

Maximum Platform Height (Mast Extended)​

Maximum Working Height (Average Person)​

Machine Overall Width and Length (Base)​

Outrigger Footprint​

Outrigger Machine Leveling Capability​

1.4 Torque Requirements​

1.5 Lubrication​

Hydraulic Oil (HO)​

1.6 Hydraulic Pressure Adjustment​

1.7 Cylinder Specifications​

1.8 Serial Number Locations​

Section 2. SERVICE PROCEDURES

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE​

General​

Preparation, Inspection, and Maintenance​

Pre-Start Inspection​

Pre-Delivery Inspection and Frequent Inspection​

Annual Machine Inspection​

Preventative Maintenance​

2.2 Preventive Maintenance and Inspection Schedule​

2.3 Servicing and Maintenance Guidelines​

General​

Safety and Workmanship​

Cleanliness​

Components Removal and Installation​

Component Disassembly and Reassembly​

Pressure-Fit Parts​

Bearings​

Gaskets​

Bolt Usage and Torque Application​

Hydraulic Lines and Electrical Wiring​

Hydraulic System​

Lubrication and Servicing​

Batteries​

Mast Chain Inspection Procedure​

Mast Cable Inspection Procedure​

2.4 Lubrication Information​

Hydraulic System​

Hydraulic Oil​

Changing Hydraulic Oil​

Lubrication Specifications​

2.5 Battery Charger - Assembly and Disassembly​

General Information​

Battery Charger Removal​

Cover Removal​

Transformer Replacement​

Printed Circuit Board Replacement​

DC Circuit Breaker Replacement​

AC Circuit Breaker and Voltage Selection Switch Replacement​

Shunt Assembly, Varistor, and SCR Rectifier Replacement (See Illustration)​

2.6 hydraulic LIFT pump - servicing​

FENNER BRAND PUMP - Brush Replacement​

Motor Cap/Motor Installation​

Motor Brush Installation​

Brush Housing Final Assembly Tips​

MONARCH BRAND PUMP - Brush Replacement​

Motor Assembly - Remove/Install - Reference Marks​

Motor/Brush Cover - Remove/Install​

Brush Carrier Assembly - Remove/Install​

Brush Assembly - Remove/Install​

TANK AND PUMP REMOVAL - (All Pumps)​

Tank Installation​

Filter Screen Installation​

Pump Installation​

Pressure Adjust Valve Installation​

Pressure Check Valve Installation​

2.7 Hydraulic Lift Cylinder - Removal, Inspection and rebuild​

Cylinder Removal​

Cylinder Disassembly​

Lift Cylinder Component Inspection​

Cylinder Assembly​

Installation​

2.8 Mast Assembly And Disassembly Procedures​

Mast Disassembly Procedure​

Platform Section Removal (All Masts)​

Mast Section 6 Removal (7 Section Mast)​

Mast Section 5 Removal (6 & 7 Section Mast)​

Mast Section 4 Removal (All Masts)​

Mast Section 3 Removal (All Masts)​

Mast Section 2 Removal (All Masts)​

Mast Section 1 Disassembly (All Masts)​

2.9 Mast Assembly​

Mast Section 1 - Assembly (All Masts)​

Mast Section 2 - Assembly (All Masts)​

Mast Section 3 - Assembly (All Masts)​

Mast Section 4 - Assembly (All Masts)​

Mast Section 5 - Assembly (25/30/36/41 ft. Masts)​

Mast Section 6 - Assembly (30/41 ft. Masts)​

Platform Mounting Section - Assy. (All Masts)​

2.10 Mast To Base Frame Installation​

2.11 MAST CHAINS/CABLES AND SEQUENCING CABLES ADJUSTMENT​

Mast Chain/Cable Adjustment​

Sequencing Cable Adjustment​

2.12 Sequence Cable replacement kit​

Remove Old Cable​

Replacement Cable Installation​

Clamp Installation (Drum/Socket Type)​

Section 3. troubleshooting

3.1 General​

3.2 Troubleshooting Information​

3.3 Hydraulic Circuit Checks​

3.4 ELECTRICAL SYSTEM - MULTIMETER BASICS​

Grounding​

Backprobing​

Min/Max​

Polarity​

Scale​

Continuity Measurement Over Long Distances​

Requirements:​

Procedure​

3.5 ELECTRICAL SWITCH TESTING​

Basic Check​

Limit Switches​

Automatic Switches​

Switch Wiring - Low Side, High Side​

3.6 Outrigger Interlock Contacts​

Outrigger Socket and Outrigger Beam - Interlock Contacts​

Outrigger Socket - Contactor Screw Mounting Instructions​

Outrigger Beam - Interlock Contactor Plate Mounting Instructions​

Detent Screws​