JLG Boom Lifts 30e,35e,n35e,40e,n40e,45e ANSI* Factory Service / Repair/ Workshop Manual ! (P/N: 3120743)

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 platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage 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 maintenance 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 pressure 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) This page left intentionally blank.

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 ANSI* Factory Service / Repair/ Workshop Manual ! (P/N: 3120743)

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