JLG 25AM Installation and user guide

Service and Maintenance Manual
Models
25AM
30AM
38AM
PVC 2002
31215808
February 25, 2020 - Rev A
AS/NZS
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INTRODUCTION
31215808 A-1
SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
AGENERAL
This section contains the general safety precautions
which must be observed during maintenance of the
mobile elevating work platform. It is of utmost impor-
tance that maintenance personnel pay strict attention
to these warnings and precautions to avoid possible
injury to themselves or others, or damage to the equip-
ment. A maintenance program must be followed to
ensure that the machine is safe to operate.
MODIFICATION OF THE MACHINE WITHOUT APPROVAL BY JLG INDUS-
TRIES, INC. IS A SAFETY VIOLATION.
The specific precautions to be observed during mainte-
nance are inserted at the appropriate point in the man-
ual. 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 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
adequate support is provided.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER
THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA IS THE
RESPONSIBILITY OF THE OWNER/OPERATOR.
B HYDRAULIC SYSTEM SAFETY
It should be noted that the machine’s hydraulic systems
operate at extremely high potentially dangerous pres-
sures. Every effort should be made to relieve any system
pressure prior to disconnecting or removing any por-
tion of the system.
Relieve system pressure by cycling the applicable con-
trol several times with the engine stopped and ignition
on, to direct any line pressure back into the reservoir.
Pressure feed lines to system components can then be
disconnected with minimal fluid loss.
CMAINTENANCE
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION
MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY, OR DEATH, AND
IS A SAFETY VIOLATION.
• Remove all rings, watches and jewelry when perform-
ing 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 warnings and cautions 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 it has
been safely restrained from any movement by block-
ing or overhead sling, or the safety prop has been
engaged.
• Before making adjustments, lubricating or performing
any other maintenance, shut off all power controls.
• Battery should always be disconnected during
replacement of electrical components.
• Keep all support equipment and attachments stowed
in their proper place.
• Use only approved, nonflammable cleaning solvents.
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INTRODUCTION
A-2 31215808
REVISON LOG
Original Issue A - February 25, 2020
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31215808 i
TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
C Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
SECTION 1 - GENERAL SPECIFICATIONS
1.1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Platform Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Machine Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Serial Number Plate Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.7 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.8 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hydraulic Oil (HO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.9 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.10 Hydraulic Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.11 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.12 threadlocking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.13 Torque Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Metric Fastener Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
SECTION 2 - SERVICE PROCEDURES
2.1 Machine Preparation, Inspection, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Maintenance and Inspection Schedule Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Footnotes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Servicing and Maintenance Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Components Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Hydraulic Lines and Electrical Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Mast Chain Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
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ii 31215808
TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.
2.4 Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5 Battery Charger - Assembly and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Battery Charger Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Printed Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
DC Circuit Breaker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
AC Circuit Breaker and Voltage Selection Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Shunt Assembly, Varistor, and SCR Rectifier Replacement (See Illustration) . . . . . . . . . . . . . . . . . . . . . 2-10
2.6 Fuse Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.7 Bucher Brand Pump - Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Motor Assembly - Remove/Install - Reference Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Motor/Brush Cover - Remove/Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Brush Carrier Assembly - Remove/Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Brush Assembly - Remove/Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Tank And Pump Removal - (All Pumps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Tank Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Filter Screen Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Pressure Adjust Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Pressure Check Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.8 Hydraulic Lift Cylinder - Removal, Inspection and rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Lift Cylinder Component Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2.9 Mast Disassembly Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Mast Disassembly Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Platform Section Removal (All Masts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Mast Section 6 Removal (7 Section Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Mast Section 5 Removal (6 & 7 Section Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Mast Section 4 Removal (All Masts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Mast Section 3 Removal (All Masts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Mast Section 2 Removal (All Masts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Mast Section 1 Disassembly (All Masts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2.10 Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Mast Section 1 - Assembly (All Masts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Mast Section 2 - Assembly (All Masts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Mast Section 3 - Assembly (All Masts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Mast Section 4 - Assembly (All Masts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Mast Section 5 - Assembly (All Masts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Mast Section 6 - Assembly (25 ft. Masts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Platform Mounting Section - Assy. (All Masts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.11 Mast To Base Frame Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2.12 Mast Chains/cables And Sequencing Cables Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Mast Chain/Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Sequencing Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
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31215808 iii
TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.
2.13 Sequence Cable replacement kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Remove Old Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Replacement Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Clamp Installation (Drum/Socket Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
2.14 Load Sensing System (LSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Setting Spring Pre-Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Setting Positive Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Adjusting Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
SECTION 3 - TROUBLESHOOTING
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Troubleshooting Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.4 Electrical System - Multimeter Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Scale. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Continuity Measurement Over Long Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Requirements: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.5 Electrical Switch Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Basic Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Automatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Switch Wiring - Low Side, High Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.6 Outrigger Interlock Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Outrigger Socket and Outrigger Beam - Interlock Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Outrigger Socket - Contactor Screw Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Outrigger Beam - Interlock Contactor Plate Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Detent Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.7 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.8 Electric Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
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iv 31215808
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. Battery Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-2. Hydraulic Pressure Setting - Adjustment Screw Located at Base of Pump Motor
(Remove Hex Head Cap as Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2-1. Lift Cylinder Internal Component Assembly Cross-Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2-2. Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2-3. Mast Section - Assembly/Disassembly Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2-4. 25AM Mast Assembly Components (6 - Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2-5. 30AM & 38AM Mast Assembly Components (7 - Section). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2-6. Mast Chain/Cable Routing Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2-7. Mast Chain/Cable/Sequence Cable Adjustment Components. (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2-8. Load Sensing System (LSS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
3-1. Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-4. Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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_A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-7. Electrical Schematic - Sheet 1 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-8. Electrical Schematic - Sheet 2 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-9. Electrical Schematic - Sheet 3 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-10. Electrical Schematic - Sheet 4 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-11. Electrical Schematic - Sheet 5 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3-12. Electrical Schematic - Sheet 6 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-13. Electrical Schematic - Sheet 7 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-14. Electrical Schematic - Sheet 8 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-15. Electrical Schematic - Sheet 9 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-16. Electrical Schematic - Sheet 10 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
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31215808 v
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Hydraulic Oil Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 Lubricant Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-3 Model AM - Lubrication Intervals for Various Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2-1 Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 AM Model - Preventive Maintenance & Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-3 Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-4 AM Series Mast Component Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
3-1 AC Unit - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-2 DC Unit - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
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vi 31215808
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
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SECTION 1 - GENERAL SPECIFICATIONS
31215808 1-1
SECTION 1. GENERAL SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS
Machine Specifications
1.2 ELECTRICAL SPECIFICATIONS
1.3 BATTERY SPECIFICATIONS
SPECIFICATION 25AM 30AM
(EXCEPT CE)
30AM
(CE ONLY) 38AM
GrossMachineWeight:(Platform Empty)
DC:
AC:
905lb
(411kg)
1110lb
(503kg)
1110lb
(503kg)
1395lb
(633kg)
825lb
(374kg)
1030lb
(467kg)
1030lb
(467kg)
1265lb
(574kg)
MachineHeight:(Platform Stowed)
*MachineHeightinTilt-BackMode
77.3in.
(2m)
77.3in.
(2m)
77.3in.
(2m)
*77in.(2m)
104.3in.(2.64m)
MaximumOutriggerPadLoad:
(peroutrigger)
510lb
(231kg)
510lb
(231kg)
510lb
(231kg)
510lb
(231kg)
OutriggerFootprint:(Lengthx Width) 68x62in.
(1.72x1.57 m)
79x79in.
(2.0x 2.0m)
75x72in.
(1.90x1.83 m)
86x84in.
(2.18x2.13m)
MachineBase- Overall:(LengthxWidth) 49x29in.
(1.24mx74cm)
52x29in.
(1.32mx74cm)
52x29in.
(1.32mx74cm)
57.5 x29 in.
(1.46mx74cm)
MaximumWindSpeed 0mph(0kph)-Machineratedforindooruseonly
MaximumHorizontalManualSideForce:
(PlatformfullyextendedwithMaximumload)
45Pound Force(200Newtons)
MaximumHydraulicSystemPressure PressureReliefSet to2800PSI(193bar)atFactory
MODEL 25AM 30AM 38AM
SystemVoltage:
DC Models:
ACModels:
12VoltsDC
100/120/240VoltsAC
BatteryCharger( D C M o d e l s )
Input:
Output:
120/240VoltsAC-50/60Hz-VoltageSelectable
12 Volt - 10 Amps DC - w/Auto Charge Sensing Circuit
Battery Type WET/DRY COMBO AGM (VRLA)
Voltage 12VoltsDC
AmpHour (AH)Rating 105AmpHr.@ 20Hr. 100AmpHr.@ 20Hr.
ReserveCapacity 165Min. N/A
ColdCrankingAmps 625Amps@0°F N/A
Weight 54lb(24kg) 78lb (35kg)
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SECTION 1 - GENERAL SPECIFICATIONS
1-2 31215808
1.4 PERFORMANCE DATA
Platform Data
1.5 MACHINE COMPONENT WEIGHTS
1.6 SERIAL NUMBER PLATE LOCATIONS
For machine identification, a serial number plate is affixed to
the machine. The plate is located on the back of the mast, just
above the mast support bracket.
1.7 TORQUE REQUIREMENTS
When maintenance becomes necessary or a fastener has loos-
ened, refer to the applicable Torque Specification chart in this
section of the manual to determine proper torque values for
various size fasteners.
1.8 LUBRICATION
Hydraulic Oil (HO)
Hydraulic oils must have anti-wear qualities at least to API Ser-
vice Classification GL-3, and sufficient chemical stability for
mobile hydraulic system service. JLG Industries, recommends
standard UTTO 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°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.
SPECIFICATION 25AM 30AM 38AM
Occupants:(PersonsallowedinPlatform)
PlatformCapacity:
ANSI:
(U.S.A,Brazil,Japan,China,LatinAmerica)
CE:
(Europe,Australia)
350lb
(160kg)
300lb
(136kg)
300lb
(136kg)
350lb
(160kg)
300lb
(136kg)
300lb
(136kg)
PlatformHeight-MastFullyExtended- (GroundtoPlat-
formFloor):
25ft.
(7.62m)
30ft.
(9.14m)
38ft.
(11.58 m)
PlatformWorkingHeight-(Average Size Person): 31ft.
(9.4 m)
36ft.
(11m)
44ft.
(13.4m)
PlatformCyclePerformance-(inseconds)(w/max.rated
load)
Pump - Lift Up:
LiftDown:
62 72 120
32-42 32-42 45-55
MODEL 25AM 30AM 38AM
PlatformWeight:(StandardPlatform) 55lb(25kg)
DCVoltageBatteryPack: (WetCell) 70lb(32kg)
Table 1-1. Hydraulic Oil Operating Range
HYDRAULIC SYSTEM OPERATING
TEMPERATURE RANGE SAE VISCOSITYGRADE
+0°F to+180°F(-18°Cto-83°C) 10W
+0°F to+210°F(-18°Cto+99°C) 10W-20,10W-30
+50°Fto+210°F (+10°Cto+99°C) 20W-20
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SECTION 1 - GENERAL SPECIFICATIONS
31215808 1-3
Lubrication Specifications
1
4
2
3
Table 1-2. Lubricant Key
NOTE: Refer to Lubrication Chart, Table 1-3 on page 1-3for specific
lubrication locations on machine.
KEY SPECIFICATIONS
MPG
MultipurposeGreasehavingaminimumdrippingpointof350°F.Excellent
waterresistance andadhesivequalities,andbeingof extremepressure
type.(TimkenOK40poundsminimum.)
EPGL ExtremePressureGearLube(oil)meetingAPI serviceclassificationGL-5
orMIL-SpecMIL-L-2105.
HO HydraulicOil.ISO-Vggrade32,46.
CL ChainLube.Use agoodqualitychainlubricant
Table 1-3. Model AM - Lubrication Intervals for Various Components
ITEM COMPONENT NO/TYPE
LUBE POINTS LUBE/METHOD
INTERVAL HOURS
COMMENTS
3
MONTHS
150 Hrs.
6
MONTHS
300 Hrs.
1
YEAR
600 Hrs.
2
YEARS
1200 Hrs.
1HydraulicOil FillToLine
onReservoir
5Qt.(4.3L)
Reservoir
HO- Check
Hyd. Oil Level
HO- Change
Hyd. Oil

Checkoilleveleveryday.
Changehydraulicoilevery2 years.
2SwivelRaceways 2-FrontCasters MPG-PressureGun 
3LevelingJackScrews 4-JackThreads MPG-Brush 
4MastChains* 2-PerSection CL- BrushorSpray Inspect,lubricateifdryingor rusting.
*AppliesOnlytoMastSectionswithChains.
Key toLubricants: MPG-MultipurposeGrease
HO-HydraulicOil-ISO-Vggrade32,46
CL- ChainLube.Use agoodqualitychainlubricant
Notes: 1. Be certain to lubricate like items on each side of the machine.
2. Recommendedlubricatingintervalsarebased onnormaluse.Ifmachineissubjectedtosevereoperatingconditions,
suchasahighnumberofcycles,location, corrosive/dirtyenvironment,etc.,usermustadjustlubricatingrequirementsaccordingly.
3. Lubricatingintervalsarecalculatedon50hoursof machineoperationa week.
4. Priortocheckinghydraulicoillevel,operatemachine throughonecompletecycleoflift function (full up and down). Failure to do so will
resultin incorrectoillevelreadingonthehydraulicreservoir.
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SECTION 1 - GENERAL SPECIFICATIONS
1-4 31215808
1.9 BATTERY MAINTENANCE
NOTE: This information applies to wet cell batteries only. Do not
attempt to open a maintenance-free sealed battery.
Battery fluid level should be approximately 1/8 in. (3mm)
below vent tubes. (See Illustration).
Keep cable connections clean and free of corrosion.
BATTERY ACID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND CLOTH-
ING AT ALL TIMES.
BATTERY ACID RELEASES AN EXPLOSIVE GAS WHILE CHARGING, ALLOW NO
OPEN FLAMES, SPARKS OR LIGHTED TOBACCO PRODUCTS IN THE AREA WHILE
CHARGING BATTERIES. CHARGE BATTERIES ONLY IN A WELL VENTILATED
AREA.
ADD ONLY DISTILLED WATER TO BATTERIES. WHEN ADDING DISTILLED WATER
TO THE BATTERIES, A NON-METALLIC CONTAINER AND/OR FUNNEL MUST BE
USED.
1.10 HYDRAULIC PRESSURE ADJUSTMENT
(See Figure 1-2.)
Adjust system pressure so that platform will raise with rated
capacity in platform.
Turning adjustment screw clockwise, increases system pres-
sure, turning screw counterclockwise, decreases system pres-
sure.
Do not adjust system pressure higher than required to raise
the load. Make pressure adjustment with oil at normal operat-
ing temperature. If pressure is set when oil is cold, platform
may not raise rated load after oil has warmed.
MAF30650
4
1/8 in.
(3mm)
2
1
3
1. BatteryFillerCap
2. VentTube
3. FluidLevel
4. CellPlates
Figure 1-1. Battery Fluid Level
Figure 1-2. Hydraulic Pressure Setting - Adjust-
ment Screw Located at Base of Pump Motor
(Remove Hex Head Cap as Shown)
PRESSURE
ADJUSTMENT
SCREW
HYDRAULIC
OIL
TANK
GROUND
CONTROL
STATION
COVER
ADJUSTMENT
SCREWCAP
(SHOWNREMOVED)
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SECTION 1 - GENERAL SPECIFICATIONS
31215808 1-5
1.11 CYLINDER SPECIFICATIONS
All dimensions are given in inches (in.), with the metric equivalent,
centimeters (cm), given in parentheses.
DESCRIPTION BORE
in./(cm)
STROKE
in./(cm)
ROD DIA.
in./(cm)
LiftCylinder-
25AM
1.63
(4.14)
56.50
(143.50)
1.38
(3.50)
LiftCylinder-
30AM
1.63
(4.14)
56.50
(143.50)
1.38
(3.50)
LiftCylinder-
38AM
1.63
(4.14)
72.25
(183.52)
1.38
(3.50)
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SECTION 1 - GENERAL SPECIFICATIONS
1-6 31215808
1.12 THREADLOCKING COMPOUND
NOTE: Loctite® 243™ can be substituted in place of Loctite® 242™. Vibra-TITE™ 122 can be substituted in place of Vibra-TITE™ 121.
JLG PN Loctite® ND Industries Description
0100011 242™ Vibra-TITE™121 MediumStrength(Blue)
1001095650 243™ Vibra-TITE™122 MediumStrength(Blue)
0100019 271™ Vibra-TITE™140 HighStrength(Red)
0100071 262™ Vibra-TITE™ 131 Medium-HighStrength(Red)
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SECTION 1 - GENERAL SPECIFICATIONS
31215808 1-7
1.13 TORQUE CHARTS
SAE Fastener Torque Chart
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Size TPI Bolt Dia Tensile
Stress Area
Clamp
Load
Torque
(Dry)
Torque
Lubricated
Torque
(Loctite® 242™ or 271™ or
Vibra-TITE™ 111 or 140)
Torque
(Loctite® 262™ or
Vibra-TITE™ 111)
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
11/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
11/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
13/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
11/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
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SECTION 1 - GENERAL SPECIFICATIONS
1-8 31215808
SAE Fastener Torque Chart (Continued)
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Size TPI Bolt Dia Tensile Stress
Area Clamp Load
Torque
(Dry orLoctite®263)
K=0.20
Torque
(Loctite® 242™ or 271™ or
Vibra-TITE™ 111 or 140)
K=0.18
Torque
(Loctite® 262™ or
Vibra-TITE™ 131)
K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
11/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
11/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
13/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
11/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
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SECTION 1 - GENERAL SPECIFICATIONS
31215808 1-9
SAE Fastener Torque Chart (Continued)
Values for Magni Coating Fasteners (Ref 4150701)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Size TPI Bolt Dia Tensile Stress
Area Clamp Load
Torque
(Dry)
K=0.17
Torque
(Loctite® 242™ or 271™ or
Vibra-TITE™ 111 or 140)
K=0.16
Torque
(Loctite® 262™ or
Vibra-TITE™ 131)
K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 7 0.8
48 0.1120 0.00661 420 8 0.9
6 32 0.1380 0.00909 580 14 1.5
40 0.1380 0.01015 610 14 1.6
8 32 0.1640 0.01400 900 25 2.8
36 0.1640 0.01474 940 26 2.9
10 24 0.1900 0.01750 1120 36 4.1
32 0.1900 0.02000 1285 42 4.7
1/4 20 0.2500 0.0318 2020 86 9.7 80 9
28 0.2500 0.0364 2320 99 11.1 95 11
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20
24 0.3125 0.0580 3700 15 20 15 21 15 20
3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34
24 0.3750 0.0878 5600 30 40 28 38 25 34
7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48
20 0.4375 0.1187 7550 45 60 44 60 40 54
1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75
20 0.5000 0.1599 10700 75 100 71 97 65 88
9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109
18 0.5625 0.2030 12950 105 145 97 132 90 122
5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156
18 0.6250 0.2560 16300 145 195 136 185 125 170
3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272
16 0.7500 0.3730 23800 255 345 238 324 225 306
7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435
14 0.8750 0.5090 32400 400 545 378 514 355 483
1 8 1.0000 0.6060 38600 545 740 515 700 480 653
12 1.0000 0.6630 42200 600 815 563 765 530 721
11/8 7 1.1250 0.7630 42300 675 920 635 863 595 809
12 1.1250 0.8560 47500 755 1025 713 969 670 911
11/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142
12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265
13/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496
12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707
11/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992
12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
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