CORPORATE OFFICE
JLG INDUSTRIES, INC.
1 JLG Drive
McConnellsburg, PA.
17233-9533
USA
Telephone: (717) 485-5161
Fax: (717) 485-6417
Models
30e
35e
n35e
40e
n40e
45e
3120861
October 1, 2001
SERVICE & MAINTENANCE
WWW.JLG.COM
JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
Phone: (61) 2 65 811111
Fax: (61) 2 65 810122
JLG Industries (UK)
Unit 12, Southside
Bredbury Park Industrial Estate
Bredbury
Stockport
SK6 2sP
England
Phone: (44) 870 200 7700
Fax: (44) 870 200 7711
JLG Deutschland GmbH
Max Planck Strasse 21
D-27721 Ritterhude/lhlpohl
Bei Bremen
Germany
Phone: (49) 421 693 500
Fax: (49) 421 693 5035
JLG Industries (Italia)
Via Po. 22
20010 Pregnana Milanese - MI
Italy
Phone: (39) 02 9359 5210
Fax: (39) 02 9359 5845
JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
Phone: (55) 19 3295 0407
Fax: (55) 19 3295 1025
JLG Europe B.V.
Jupiterstraat 234
2132 HJ Foofddorp
The Netherlands
Phone: (31) 23 565 5665
Fax: (31) 23 557 2493
JLG Industries (Norge AS)
Sofeimyrveien 12
N-1412 Sofienyr
Norway
Phone: (47) 6682 2000
Fax: (47) 6682 2001
JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
Phone: (48) 91 4320 245
Fax: (48) 91 4358 200
JLG Industries (Europe)
Kilmartin Place,
Tannochside Park
Uddingston G71 5PH
Scotland
Phone: (44) 1 698 811005
Fax: (44) 1 698 811055
JLG Industries (Pty) Ltd.
Unit 1, 24 Industrial Complex
Herman Street
Meadowdale
Germiston
South Africa
Phone: (27) 11 453 1334
Fax: (27) 11 453 1342
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755Castellbisbal
Spain
Phone: (34) 93 77 24700
Fax: (34) 93 77 11762
JLG Industries (Sweden)
Enkopingsvagen 150
Box 704
SE - 175 27 Jarfalla
Sweden
Phone: (46) 8 506 59500
Fax: (46) 8 506 59534
INTRODUCTION
3120861 – JLG Lift – A-1
SECTION A. INTRODUCTION - MAINTENANCE SAFETY
PRECAUTIONS
A GENERAL
This section contains the general safety precautions which
must be observed during maintenance of the aerial plat-
form. It is of utmost importance that maintenance person-
nel pay strict attention to these warnings and precautions
to avoid possible injury to themselves or others, or dam-
age to the equipment. A maintenance program must be
followed to ensure that the machine is safe to operate.
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 mainte-
nance 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 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 CON-
TROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPER-
ATOR.
B HYDRAULIC SYSTEM SAFETY
It should be noted that the machines hydraulic systems
operate at extremely high potentially dangerous pressures.
Every effort should be made to relieve any system pres-
sure prior to disconnecting or removing any portion of the
system.
Relieve system pressure by cycling the applicable control
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.
C MAINTENANCE
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL
INJURY OR DEATH AND IS A SAFETY VIOLATION.
• NO SMOKING IS MANDATORY. NEVER REFUEL DUR-
ING ELECTRICAL STORMS. ENSURE THAT FUEL
CAP IS CLOSED AND SECURE AT ALL OTHER
TIMES.
• 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 WARNINGS AND CAU-
TIONS ON MACHINE AND IN SERVICEMANUAL.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM
STANDING SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSUR-
IZED COOLANT SYSTEM.
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL
BOOM HAS BEEN SAFELY RESTRAINED FROM ANY
MOVEMENT BY BLOCKING OR OVERHEAD SLING,
OR BOOM 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 COMPO-
NENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACH-
MENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
INTRODUCTION
A-2 – JLG Lift – 3120861
REVISON LOG
March, 1989 - Original Issue
October, 1994 - Revised
August, 1997 - Revised
January, 1999 - Revised
June, 1999 -Revised
October 1, 2001 -Revised
3120743 – JLG Lift – i
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
IINTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
EFFECTIVITY CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
SECTION 1 - SPECIFICATIONS
1.1 CAPACITIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 COMPONENT DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 PERFORMANCE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5 LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 PRESSURE SETTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7 CYLINDER SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.8 MAJOR COMPONENT WEIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.9 CRITICAL STABILITY WEIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.10 SERIAL NUMBER LOCATIONS. (See Figure 1-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
SECTION 2 - PROCEDURES
2.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 SERVICING AND MAINTENANCE GUIDELINES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 LUBRICATION INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 CYLINDERS - THEORY OF OPERATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5 VALVES - THEORY OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.6 MOTOR CONTROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.7 WEAR PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.8 BOOM MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.9 CYLINDER CHECKING PROCEDURES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.10 CYLINDER REPAIR.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.11 CYLINDER REMOVAL AND INSTALLATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.12 TILT INDICATOR SWITCH LEVELING PROCEDURE. (If Equipped.) . . . . . . . . . . . . . . . . . . . . . . 2-29
2.13 BOOM LIMIT SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.14 POWER TRACK REMOVAL PROCEDURE (35/n35/40/n40/45 electric). . . . . . . . . . . . . . . . . . . . . 2-29
2.15 PRESSURE SETTING PROCEDURES. (In Sequence) (See Figure 2-29) . . . . . . . . . . . . . . . . . . 2-29
2.16 SWING BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
2.17 DRIVE TORQUE HUB. (See Figure 2-34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2.18 DRIVE BRAKE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
2.19 MID AND LOWER LIFT CYLINDER BLEEDING PROCEDURE. (40/n40/45 electric) . . . . . . . . . . 2-46
2.20 BOOM SYNCHRONIZING PROCEDURE. (40/n40/45 electric) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
2.21 FREE WHEELING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
2.22 FOOTSWITCH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
2.23 AXLE DRAIN PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
2.24 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
SECTION 3 - TROUBLESHOOTING
3.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 TROUBLESHOOTING INFORMATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 HYDRAULIC CIRCUIT CHECKS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
ii – JLG Lift – 3120743
TABLE OF CONTENTS (Continued)
FIGURE NO. TITLE PAGE NO.
1-1. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-2. Lubrication Chart - 30 electric. (Sheet 1 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-2. Lubrication Chart - 30 electric. (Sheet 2 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1-2. Lubrication Chart - 35/n35 electric. (Sheet 3 of 6).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-2. Lubrication Chart - 35/n35 electric. (Sheet 4 of 6).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1-2. Lubrication Chart - 40/n40/45 electric. (Sheet 5 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1-2. Lubrication Chart - 40/n40/45 electric. (Sheet 6 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1-3. Serial Number Locations - 30 electric. (Sheet 1 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1-3. Serial Number Locations - 35/n35 electric. (Sheet 2 of 3).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1-3. Serial Number Locations - 40/n40/45 electric. (Sheet 3 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
2-1. Sevcon Controller Troubleshooting Flow Charts. (Sheet 1 of 4).. . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-1. Sevcon Controller Troubleshooting Flow Charts. (Sheet 2 of 4).. . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-1. Sevcon Controller Troubleshooting Flow Charts. (Sheet 3 of 4).. . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-1. Sevcon Controller Troubleshooting Flow Charts. (Sheet 4 of 4).. . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-2. Location and Thickness of Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-3. Locations of Components - Platform Support (Model 30). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-4. Location of Components - Removal of Base Boom. (Model 30) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-5. Location of Components - Platform Support. (Models 35/n35/40/n40/45) . . . . . . . . . . . . . . . . . . 2-12
2-6. Location of Components - Slave Leveling Cylinder.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-7. Location of Components - Removal of Base Boom. (Models 35/n35/40/n40/45) . . . . . . . . . . . . . 2-12
2-8. Location of Components - Aft End of Fly Boom Wear Pad Adjustments. . . . . . . . . . . . . . . . . . . . 2-13
2-9. Location of Components - Removal of Telescope Cyllinder.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2-10. Location of Components - Front Base Boom Wear Pad Adjustments. . . . . . . . . . . . . . . . . . . . . . 2-13
2-11. Boom Prop Configurations - 30 electric. (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2-11. Boom Prop Configurations - 35/n35 electric. (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2-11. Boom Prop Configurations - 35/n35 electric. (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2-12. Removal of Cylinder Retainer.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2-13. Removal of Set Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2-14. Removal of Seals and O-Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2-15. Removal of Piston Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2-16. Rod Seal Installation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-17. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-18. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-19. "O"-Ring Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-20. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-21. Steer Cylinder Piston Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2-22. Installing Retainer Ring on Telescope Cylinder Barrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2-23. Lift Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2-24. Upper Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2-25. Mid Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2-26. Lower Boom Lift Cyllinder Removal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2-27. Upper Telescope Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2-28. Tilt Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2-29. Pressure Setting Procedures - 30 electric. (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2-29. Pressure Setting Procedures - 35/n35 electric. (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
2-29. Pressure Setting Procedures - 40/n40/45 electric. (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
2-30. Swing Bearing Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
2-31. Swing Bearing Tolerance Boom Placement - 30/35/n35 electric. . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2-31. Swing Bearing Tolerance Boom Placement - 40/n40/45 electric. . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
2-32. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
2-33. Swing Bearing Torquing Sequence.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
2-34. Drive Hub Assembly - 30/35/n35/40/n40/45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
2-35. Drive Brake Assembly - 30/35/n35/40/n40/45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
2-36. Port "P" Location.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
2-37. Synchronizing Valve.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
2-38. Upright Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
3120743 – JLG Lift – iii
TABLE OF CONTENTS
2-39. Drive Brake Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
2-40. Drive Axle Drain Plate.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
3-1. Electrical Schematic 30 electric. (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-1. Electrical Schematic 30 electric. (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-1. Electrical Schematic 30 electric. (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-1. Electrical Schematic 30 electric. (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-2. Electrical Schematic 35/40/45 electric. (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-2. Electrical Schematic. 35/40/45 electric. (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3-2. Electrical Schematic. 35/40/45 electric. (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-2. Electrical Schematic. 35/40/45 electric. (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-3. Hydraulic Diagram - 30 electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-4. Hydraulic Diagram - 35 electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-5. Hydraulic Diagram - 40/45 electric.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
TABLE NO. TITLE PAGE NO.
1-1 Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-2 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-3 Cylinder Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-4 Cylinder Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-5 Cylinder Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-6 Cylinder Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2-1 Cylinder Piston Nut Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2-2 Holding Valve Torque Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2-3 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
3-1 PLATFORM ASSEMBLY - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 BOOM ASSEMBLY - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-2 BOOM ASSEMBLY - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-2 BOOM ASSEMBLY - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-2 BOOM ASSEMBLY - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-3 TURNTABLE ASSEMBLY - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-4 CHASSIS ASSEMBLY - TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-4 CHASSIS ASSEMBLY - TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-5 HYDRAULIC SYSTEM - TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-6 ELECTRICAL SYSTEM - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
iv – JLG Lift – 3120743
TABLE OF CONTENTS (Continued)
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SECTION 1 - SPECIFICATIONS
3120861 – JLG Lift – 1-1
SECTION 1. SPECIFICATIONS
1.1 CAPACITIES.
Hydraulic Oil Tank.
4.0 gallons (15.14 liters).
Hydraulic System.
Approximately 4.8 gallons (18.2 liters).
Torque Hubs (2).
17 ounces (0.5 liters).
1.2 COMPONENT DATA.
Battery Charger.
Input, 110 VAC,60 HZ.
Output, 48 VDC (23 Amps.).
Batteries (8).
6 Volt, 370 AmpHour (20 hour rate).
Drive System.
Drive Motor - 36 VDC, 4.1 H.P. @ 1880 rpm. continuous,
rotation - reversible.
Drive Brake- 24 VDC, spring-applied, electrically released.
Tires - 30 electric.
Tires - ST205 75R15, Load Range C, 6 Ply Rating, 70 psi
(4.9 kg/cm
2
).
Foam Filled - 205 75R15, 6 Ply Rating, 70 psi (4.9 kg/cm
2
).
Solid Tires - 26 x 7 x 20 Lug Tread Non marking Com-
pound. (Optional)
Tires - n35/n40 electric.
Solid Tires - 22 x 6 x 16 Lug Tread Dual Service Com-
pound.
Solid Tires - 22 x 6 x 16 Lug Tread Non marking Com-
pound. (Optional)
Tires - 35/40 electric. (Prior to March of 1996)
Tires - ST225 75R15, Load Range D, 8 Ply Rating, 80 psi
(5.5 kg/cm
2
).
Tires - ST225 75R15, Load Range D, 8 Ply Rating, Foam
Filled. (Optional)
Tires - 35/40 electric. (March of 1996 to Present)
Tires - G 78 - 15, Load Range E, 10 Ply Rating, 80 psi (5.5
kg/cm
2
).
Tires - G 78 - 15, Load Range E, 10 Ply Rating, Foam
Filled. (Optional)
Solid Tires - 22 x 6.5 x 16 Lug Tread Non marking Com-
pound. (Optional)
Tires 10 - 16.5 NHS, 8 Ply, 70 psi (4.9 kg/cm
2
).
Tires 10 - 16.5 NHS, 8 Ply, 70 psi (4.9 kg/cm
2
), Foam Filled
Tires - 45 electric.
Tires - LT215 85R16, Load Range E, 10 Ply Rating, 90 psi
(6.2 kg/cm
2
).
Tires - LT215 85R16, Load Range E, 10 Ply Rating, Foam
Filled. (Optional)
Tires 10 - 16.5 NHS, 8 Ply, 70 psi (4.9 kg/cm
2
).
Tires 10 - 16.5 NHS, 8 Ply, 70 psi (4.9 kg/cm
2
), Foam
Filled.
Hydraulic Filter.
Return, 10 Micron.
Hydraulic Pump/Electric Motor Assembly.
Motor - 48 VDC, 2.14 H.P. @ 2700 rpm.
Pump -1.6 cm
3
/rev.
Pump Output - 4.13 lpm @ 137.9 Bar.
1.3 PERFORMANCE DATA.
EE Rated, Certified By U/L.
Travel Speed.
30 electric - 6.4 kph.
35 electric - 4.8 kph.
n35 electric - 4.1 kph.
40 electric - 4.8 kph.
n40 electric - 4.1 kph.
45 electric - 4.2 kph.
Gradeability.
25%.
Maximum Slope
3%
SECTION 1 - SPECIFICATIONS
1-2 – JLG Lift – 3120861
Turning Radius (Inside).
30 electric - 1.33 m.
35 electric - 1.31 m.
n35 electric - 1.60 m.
40 electric - 1.31 m.
n40 electric - 1.60 m.
45 electric - 1.31 m.
Turning Radius (Outside).
30 electric - 3.63 m.
35 electric - 3.63 m.
n35 electric - 3.63 m.
40 electric - 3.63 m.
n40 electric - 3.63 m.
45 electric - 3.63 m.
Upper Boom Speed.
30 electric - Lift Up - 15 - 25 seconds.
30 electric - Lift Down - 17 - 27 seconds.
35/n35 electric - Lift Up - 40 - 50 seconds.
35/n35 electric - Lift Down - 32 - 42 seconds.
40/n40 electric - Lift Up - 40 - 50 seconds.
40/n40 electric - Lift Down - 59 - 69 seconds.
45 electric - Lift Up - 40 - 50 seconds.
45 electric - Lift Down - 39 - 49 seconds.
Lower Boom Speed.
30 electric - Lift Up - 16 - 26 seconds.
30 electric - Lift Down - 19 - 29 seconds.
35/n35 electric - Lift Up - 49 - 59 seconds.
35/n35 electric - Lift Down - 30 - 40 seconds.
40/n40 electric - Lift Up - 50 - 60 seconds.
40/n40 electric - Lift Down - 23 - 29 seconds.
45 electric - Lift Up - 58 - 68 seconds.
45 electric - Lift Down - 28 - 38 seconds.
Swing Speed - 360 Degrees.
30 electric - 55 - 65 seconds.
35/n35 electric - 65 - 75 seconds.
40/n40 electric - 85 - 95 seconds.
45 electric - 85 - 95 seconds.
Machine Weight.
30 electric - 2,164 kg.
35 electric - 4,309 kg.
n35 electric - 10,200 lb. (4,627 kg).
40 electric - 4,853 kg.
n40 electric - 5,366 kg.
45 electric - 5,352 kg.
Max. Tire Load.
30 electric - 1,161 kg.
35 electric - 1,624 kg.
n35 electric - 1,928 kg.
40 electric - 2,132 kg.
n40 electric - 2,343 kg.
45 electric - 2,656 kg.
Machine Height (stowed).
30 electric - 6 ft. 7.0 in. (2.0 m.).
35/n35 electric - 6 ft. 7.0 in. (2.0 m.).
40/n40 electric - 6 ft. 7.0 in. (2.0 m.).
45 electric - 6 ft. 7.0 in. (2.0 m.).
Machine Length (stowed).
30 electric - 4.75 m.
35/n35 electric - 5.18 m.
40 electric - 5.36 m.
n40 electric - 5.28 m.
45 electric - 5.69 m.
Up and Over Platform Height.
30 electric - 5.05 m.
35/n35 electric - 5.46 m.
40/n40 electric - 6.10 m.
45 electric - 7.49 m.
Horizontal Reach Up and Over.
30 electric - 4.09 m.
35/n35 electric - 6.25 m.
40/n40 electric - 6.25 m.
45 electric - 6.91 m.
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JLG Boom Lifts 30e, 35e, n35e, 40e, n40e, 45e Service Repair Workshop Manual (P/N:3120743)
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Description
This is a comprehensive service repair workshop manual for the JLG Boom Lifts 30e, 35e, n35e, 40e, n40e, 45e. The manual features easy-to-read text sections with high-quality diagrams and instructions, making it suitable for both DIY enthusiasts and experienced mechanics. It provides step-by-step instructions and detailed exploded pictures and diagrams to effectively and efficiently complete the required job.
The applicable models covered in this manual include:
- JLG Boom Lifts 30e ANSI
- JLG Boom Lifts 35e ANSI
- JLG Boom Lifts n35e ANSI
- JLG Boom Lifts 40e ANSI
- JLG Boom Lifts n40e ANSI
- JLG Boom Lifts 45e ANSI
The service repair manual covers various sections including specifications, procedures, troubleshooting, and more. It is available in a file format compatible with all versions of Windows and Mac. The language of the manual is English, and it requires Adobe Reader and Win for access. All pages are printable, allowing for immediate use without any waiting time. This manual is a cost-effective solution, saving money on postage and packaging.
