JLG 30e Installation and user guide

CORPORATE OFFICE
JLG INDUSTRIES, INC.
1 JLG Drive
McConnellsburg, PA.
17233-9533
USA
Telephone: [phone]
Fax: [phone]
Models
30e
35e
n35e
40e
n40e
45e
3120743
October 1, 2001
SERVICE & MAINTENANCE
WWW.JLG.COM
Property of American Airlines

JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
Phone: [phone]
Fax: [phone]
JLG Industries (UK)
Unit 12, Southside
Bredbury Park Industrial Estate
Bredbury
Stockport
SK6 2sP
England
Phone: [phone]
Fax: [phone]
JLG Deutschland GmbH
Max Planck Strasse 21
D-27721 Ritterhude/lhlpohl
Bei Bremen
Germany
Phone: [phone]
Fax: [phone]
JLG Industries (Italia)
Via Po. 22
20010 Pregnana Milanese - MI
Italy
Phone: [phone]
Fax: [phone]
JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
Phone: [phone]
Fax: [phone]
JLG Europe B.V.
Jupiterstraat 234
2132 HJ Foofddorp
The Netherlands
Phone: [phone]
Fax: [phone]
JLG Industries (Norge AS)
Sofeimyrveien 12
N-1412 Sofienyr
Norway
Phone: [phone]
Fax: [phone]
JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
Phone: [phone]
Fax: [phone]
JLG Industries (Europe)
Kilmartin Place,
Ta n n o c h s i d e P a r k
Uddingston G71 5PH
Scotland
Phone: [phone]
Fax: [phone]
JLG Industries (Pty) Ltd.
Unit 1, 24 Industrial Complex
Herman Street
Meadowdale
Germiston
South Africa
Phone: [phone]
Fax: [phone]
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P. I . C a s t e l l b i s b a l S u r
08755Castellbisbal
Spain
Phone: [phone]
Fax: [phone]
JLG Industries (Sweden)
Enkopingsvagen 150
Box 704
SE - 175 27 Jarfalla
Sweden
Phone: [phone]
Fax: [phone]
Property of American Airlines

INTRODUCTION
3120743 – JLG Lift – A-2
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.
Property of American Airlines

INTRODUCTION
A-3 –JLG Lift –3120743
REVISON LOG
March, 1989 - Original Issue
October, 1994 - Revised
August, 1997 - Revised
January, 1999 - Revised
Cvr, Intro., - and Pgs.
May 1, 2000 -Revised
May 1, 2001 -Revised
October 1, 2001 -Revised
Property of American Airlines

3120743 –JLG Lift –iv
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.6 PRESSURE SETTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.8 MAJOR COMPONENT WEIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.9 CRITICAL STABILITY WEIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.4 CYLINDERS - THEORY OF OPERATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.5 VALVES - THEORY OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.6 MOTOR CONTROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.7 WEAR PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2.8 BOOM MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2.9 CYLINDER CHECKING PROCEDURES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
2.10 CYLINDER REPAIR.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
2.11 CYLINDER REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
2.12 TILT INDICATOR SWITCH LEVELING PROCEDURE. (If Equipped.). . . . . . . . . . . . . . . . . . . . . . .2-32
2.13 BOOM LIMIT SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
2.14 POWER TRACK REMOVAL PROCEDURE (35/n35/40/n40/45 electric). . . . . . . . . . . . . . . . . . . . .2-32
2.15 PRESSURE SETTING PROCEDURES. (In Sequence) (See Figure 2-29) . . . . . . . . . . . . . . . . . . .2-32
2.16 SWING BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38
2.17 DRIVE TORQUE HUB. (See Figure 2-34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43
2.18 DRIVE BRAKE ASSEMBLY. (See Figure 2-35.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45
2.19 MID AND LOWER LIFT CYLINDER BLEEDING PROCEDURE. (40/n40/45 electric) . . . . . . . . . . .2-48
2.20 BOOM SYNCHRONIZING PROCEDURE. (40/n40/45 electric) . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
2.21 FREE WHEELING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49
2.22 FOOTSWITCH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49
2.23 P/q controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49
2.24 AXLE DRAIN PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50
2.25 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . .2-50
SECTION 3 - TROUBLESHOOTING
3.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 TROUBLESHOOTING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.3 HYDRAULIC CIRCUIT CHECKS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Property of American Airlines

v–JLG Lift –3120743
TABLE OF CONTENTS (Continued)
List of Figures
FIGURE NO. TITLE PAGE NO.
1-1. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1-2. Lubrication Chart - 30 electric. (Sheet 1 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1-3. Lubrication Chart - 30 electric. (Sheet 2 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1-4. Lubrication Chart - 35/n35 electric. (Sheet 3 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1-5. Lubrication Chart - 35/n35 electric. (Sheet 4 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
1-6. Lubrication Chart - 40/n40/45 electric. (Sheet 5 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1-7. Lubrication Chart - 40/n40/45 electric. (Sheet 6 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1-8. Serial Number Locations - 30 electric. (Sheet 1 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
1-9. Serial Number Locations - 35/n35 electric. (Sheet 2 of 3).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
1-10. Serial Number Locations - 40/n40/45 electric. (Sheet 3 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
2-1. Sevcon Controller Troubleshooting Flow Charts. (Sheet 1 of 4).. . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2-1. Sevcon Controller Troubleshooting Flow Charts. (Sheet 2 of 4).. . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-1. Sevcon Controller Troubleshooting Flow Charts. (Sheet 3 of 4).. . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2-1. Sevcon Controller Troubleshooting Flow Charts. (Sheet 4 of 4).. . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2-2. Location and Thickness of Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2-3. Location of Components - Platform Support (Model 30). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2-4. Location of Components - Removal of Base Boom. (Model 30) . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2-5. Location of Components - Platform Support. (Models 35/n35/40/n40/45) . . . . . . . . . . . . . . . . . .2-13
2-6. Location of Components - Slave Leveling Cylinder.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-7. Location of Components - Removal of Base Boom. (Models 35/n35/40/n40/45) . . . . . . . . . . . . .2-14
2-8. Location of Components - Aft End of Fly Boom Wear Pad Adjustments. . . . . . . . . . . . . . . . . . . .2-15
2-9. Location of Components - Removal of Telescope Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2-10. Location of Components - Front Base Boom Wear Pad Adjustments. . . . . . . . . . . . . . . . . . . . . . 2-15
2-11. Boom Prop Configurations - 30 electric. (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19
2-12. Removal of Cylinder Retainer.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-13. Removal of Set Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-14. Removal of Seals and O-Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2-15. Removal of Piston Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
2-16. Rod Seal Installation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
2-17. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2-18. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
2-19. "O"-Ring Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
2-20. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
2-21. Steer Cylinder Piston Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
2-22. Installing Retainer Ring on Telescope Cylinder Barrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
2-23. Lift Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2-24. Upper Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
2-25. Mid Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29
2-26. Lower Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
2-27. Upper Telescope Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
2-28. Tilt Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
2-29. Pressure Setting Procedure - 30 electric. (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
2-30. Swing Bearing Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38
2-31. Swing Bearing Tolerance Boom Placement - 30/n30/n35 electric. (Sheet 1 of 2). . . . . . . . . . . . . 2-39
2-32. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40
2-33. Swing Bearing Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42
2-34. Worm Gear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42
2-35. Worm Gear Shim Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2-36. Drive Hub Assembly - 30/35/n35/40/n40/45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44
2-37. Drive Brake Assembly - 30/35/n35/40/n40/45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47
2-38. Port "P" Location.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
2-39. Synchronizing Valve.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
2-40. Upright Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
Property of American Airlines

3120743 –JLG Lift –vi
TABLE OF CONTENTS
List of Figures (Continued)
FIGURE NO. TITLE PAGE NO
2-41. Drive Brake Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49
2-42. Drive Axle Drain Plate.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50
3-1. Electrical Schematic 30 electric. (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
3-1. Electrical Schematic 30 electric. (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
3-1. Electrical Schematic 30 electric. (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
3-1. Electrical Schematic 30 electric. (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
3-2. Electrical Schematic 35/40/45 electric. (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
3-2. Electrical Schematic. 35/40/45 electric. (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
3-2. Electrical Schematic. 35/40/45 electric. (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
3-3. Electrical Schematic. 35/40/45 electric. (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
3-4. Hydraulic Diagram - 30 electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
3-5. Hydraulic Diagram - 35 electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
3-6. Hydraulic Diagram - 40/45 electric.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
List of Tables
TABLE NO. TITLE PAGE NO.
1-1 Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-2 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-3 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-4 Cylinder Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
2-1 Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
2-2 Holding Valve Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
2-3 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . .2-51
3-1 Platform Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2 Boom Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-3 Turntable Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3-4 Chassis Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
3-5 Hydraulic System - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
3-6 Electrical System - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Property of American Airlines

vii –JLG Lift –3120743
TABLE OF CONTENTS (Continued)
This page left intentionally blank.
Property of American Airlines

SECTION 1 - SPECIFICATIONS
3120743 –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/cm2).
Foam Filled - 205 75R15, 6 Ply Rating, 70 psi (4.9 kg/cm2).
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/cm2).
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/cm2).
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/cm2).
Tires 10 - 16.5 NHS, 8 Ply, 70 psi (4.9 kg/cm2), Foam Filled
Tires - 45 electric.
Tires - LT215 85R16, Load Range E, 10 Ply Rating, 90 psi
(6.2 kg/cm2).
Tires - LT215 85R16, Load Range E, 10 Ply Rating, Foam
Filled. (Optional)
Tires 10 - 16.5 NHS, 8 Ply, 70 psi (4.9 kg/cm2).
Tires 10 - 16.5 NHS, 8 Ply, 70 psi (4.9 kg/cm2), Foam
Filled.
Hydraulic Filter.
Return, 10 Micron.
Hydraulic Pump/Electric Motor Assembly.
Motor - 48 VDC, 2.14 H.P. @ 2700 rpm.
Pump - 0.098 in.3/rev. (1.6 cm3/rev.).
Pump Output - 1.09 gpm (4.13 lpm) @ 2000 psi (137.9
Bar).
1.3 PERFORMANCE DATA.
EE Rated, Certified By U/L.
Travel Speed.
30 electric - 4 mph (6.4 kph).
35 electric - 3 mph (4.8 kph).
n35 electric - 2.5 mph (4.1 kph).
40 electric - 3 mph (4.8 kph).
n40 electric - 2.5 mph (4.1 kph).
45 electric - 2.6 mph (4.2 kph).
Property of American Airlines

SECTION 1 - SPECIFICATIONS
1-2 –JLG Lift –3120743
Gradeability.
25%
Maximum Slope
5%.
Turning Radius (Inside).
30 electric - 4 ft. 4.50 in. (1.33 m.).
35 electric - 4 ft. 3 in. (1.31 m.).
n35 electric - 5 ft. 3 in. (1.60 m.).
40 electric - 4 ft. 3 in. (1.31 m.).
n40 electric - 5 ft. 3 in. (1.60 m.).
45 electric - 4 ft. 3 in. (1.31 m.).
Turning Radius (Outside).
30 electric - 11 ft. 10 in. (3.63 m.).
35 electric - 11 ft. 10 in. (3.63 m.).
n35 electric - 11 ft. 10 in. (3.63 m.).
40 electric - 11 ft. 10 in. (3.63 m.).
n40 electric - 11 ft. 10 in. (3.63 m.).
45 electric - 11 ft. 10 in. (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 - 4,770 lb. (2,164 kg).
35 electric - 9,500 lb. (4,309 kg).
n35 electric - 10,200 lb. (4,627 kg).
40 electric - 10,700 lb. (4,853 kg).
n40 electric - 11,830 lb. (5,366 kg).
45 electric - 11,800 lb. (5,352 kg).
Max. Tire Load.
30 electric - 2560 lbs. (1,161 kg).
35 electric - 3580 lbs. (1,624 kg).
n35 electric - 4250 lbs. (1,928 kg).
40 electric - 4700 lbs. (2,132 kg).
n40 electric - 5600 lbs. (2,540 kg).
45 electric - 5850 lbs. (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 - 15 ft.,7.0 in. (4.75 m.).
35/n35 electric - 17 ft.,0 in. (5.18 m.).
40 electric - 17 ft.,7.0 in. (5.36 m.).
n40 electric - 17 ft.,4 in. (5.28 m.).
45 electric - 18 ft.,8.0 in. (5.69 m.).
Property of American Airlines

SECTION 1 - SPECIFICATIONS
3120743 –JLG Lift –1-3
Up and Over Platform Height.
30 electric - 16 ft.,7.0 in. (5.05 m.).
35/n35 electric - 17 ft.,11.0 in. (5.46 m.).
40/n40 electric - 20 ft.,0 in. (6.10 m.).
45 electric - 24 ft.,7 in. (7.49 m.).
Horizontal Reach Up and Over.
30 electric - 13 ft.,5.0 in. (4.09 m.).
35/n35 electric - 20 ft.,6.0 in. (6.25 m.).
40/n40 electric - 20 ft.,6.0 in. (6.25 m.).
45 electric - 22 ft. 8 in.,(6.91 m.).
Machine Width.
30 electric - 5 ft.,9 in. (1.75 m.).
35 electric - 5 ft.,9 in. (1.75 m.).
n35 electric - 4 ft.,11 in. (1.50 m.).
40 electric - 5 ft.,9 in. (1.75 m.).
n40 electric - 4 ft.,11 in. (1.50 m.).
45 electric - 5 ft.,9 in. (1.75 m.).
Wheel Base.
30 electric - 6 ft., 4 in. (1.93 m.).
35/n35 electric - 6 ft., 7.25 in. (2.01 m.).
40/n40 electric - 6 ft., 7.25 in. (2.01 m.).
45 electric - 6 ft., 7.25 in. (2.01 m.).
Working Height.
30 electric - 30 ft., 0 in. (9.14 m.).
35/n35 electric - 35 ft., 0 in. (10.67 m.).
40/n40 electric - 40 ft., 0 in. (12.19 m.).
45 electric - 45 ft., 0 in. (13.72 m.).
1.4 TORQUE SPECIFICATIONS.
NOTE: *Check swing bearing bolts for security after first 50
hours of operation and every 600 hours thereafter.
(See paragraph 2-16, - Swing Bearing.)
NOTE: ***Torque in cross pattern. Foam filled or solid tires
may require more frequent torque intervals.
NOTE: When maintenance becomes necessary or a fas-
tener has loosened, refer to the Torque Chart, Figure
1-1, to determine proper torque value.
Table 1-1.Torque specifications
Description Torque Value
(Dry) Interval Hours
A. Bearing To
Chassis
See Note 50/600*
B. Bearing To
Tu rnta ble
See Note 50/600*
C. Wheel Bolts 90 ft. lb.
(122 Nm)
150***
Property of American Airlines

SECTION 1 - SPECIFICATIONS
1-4 –JLG Lift –3120743
1.5 LUBRICATION.
Hydraulic Oil.
NOTE: Hydraulic oils must have anti-wear qualities at least
to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system ser-
vice. JLG Industries recommends Mobilfluid 424
hydraulic oil, which has an SAE viscosity index of
152.
NOTE: 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 Mobilfluid 424 is desired, contact JLG Indus-
tries for proper recommendations.
Lubrication Specifications
*MPG may be substituted for these lubricants, if neces-
sary, but service intervals will be reduced.
NOTE: Refer to Lubrication Chart, Figure1-2, for specific
lubrication procedures.
1.6 PRESSURE SETTINGS.
•Model 30 electric.
Hydro-Air Valve 4640725.
Lift Down Relief - 900 psi (62 bar).
Articulate and Lift Down Relief - 725 psi (49.99 bar).
Swing Relief - 1000 psi (68.95 bar).
Hydro-Air Valve 4640726.
Steer Relief - 1100 psi (75.84 bar).
Main Relief at Pump - 2600 psi (179.27 bar).
•Model 35/n35 electric.
Hydro-Air Valve 4640843.
Upper Lift Down Relief - 600 psi (41.37 bar).
Lower Lift Down Relief - 600 psi (41.37 bar).
Swing Relief - 1000 psi (68.95 bar).
Telescope In Relief - 2150 psi (148.25 bar).
Platform Level Up Relief - 2500 psi (172.37 bar).
Platform Level Down Relief - 1200 psi (82.74 bar).
Hydro-Air Valve 4640726.
Steer Relief - 1500 psi (103.42 bar).
Main Relief at Pump - 2600 psi (179.27 bar).
•Model 40/n40/45 electric.
Hydro-Air Valve 4640797.
Upper Lift Down Relief - 650 psi (44.82 bar).
Mid/Lower Lift Down Relief - 1700 psi (117.21 bar).
Swing Relief - 1000 psi (68.95 bar).
Telescope In Relief - 2150 psi (148.25 bar).
Platform Level Up Relief - 2500 psi (172.37 bar).
Platform Level Down Relief - 1200 psi (82.74 bar).
Hydro-Air Valve 4640726.
Steer Relief - 1500 psi (103.42 bar).
Main Relief at Pump - 3200 psi (220.64 bar).
Table 1-2.Hydraulic Oil
HYDRAULIC SYSTEM
OPERATING
TEMPERATURE RANGE
SAE VISCOSITY GRADE
0 F to 23 F (-18 C to -5 C) 10W
0 F to 210 F (-18 C to +99 C) 10W-20,10W-30
50 F to 210 F (+10 C to +99 C) 20W-20
Table 1-3.Lubrication Specifications
KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point
of 350 F (178 C). Excellent water resistance and
adhesive qualities, and being of extreme pressure
type. (Timken OK 40 pounds minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service
classification GL-5 or MIL-Spec MIL-L-2105.
HO Hydraulic Oil. API service classification GL-3, e.g.
Mobilfluid 424.
OG* Open Gear Lube - Mobiltac 375NC, Aerosol spray.
(JLG Part No. 3020036)
BG* Bearing Grease (JLG Part No. 3020029) Mobilith SHA
460.
LL SyntheticLithiumLubricant, Gredag741 Grease. (JLG
Part No. 3020022)
Property of American Airlines

SECTION 1 - SPECIFICATIONS
3120743 –JLG Lift –1-5
1.7 CYLINDER SPECIFICATIONS.
NOTE: All dimensions are given in inches (in.), with the met-
ric equivalent, millimeters (mm) given in parenthe-
ses.
1.8 MAJOR COMPONENT WEIGHTS.
SELECT LIFTING EQUIPMENT WITH CAPACITY CAPABLE OF
SAFELY SUPPORTING WEIGHT.
1.9 CRITICAL STABILITY WEIGHTS.
DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS
OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE:
BATTERIES, FILLED TIRES, PLATFORM) DO NOT MODIFY UNIT IN
ANY WAY TO AFFECT STABILITY.
Table 1-4. Cylinder Specifications.
e30
DESCRIPTION BORE STROKE ROD DIA.
Upper Lift Cylinder 3.00
(76.2)
14.62
(371.5)
1.50
(38.1)
Lower Lift Cylinder 3.00
(76.2)
14.62
(371.5)
1.50
(38.1)
Steer Cylinder
(Double Rod)
2.00
(50.8)
3.00
(76.2)
each direc-
tion
1.25
(31.8)
each rod
e35/n35e
DESCRIPTION BORE STROKE ROD DIA.
Upper Lift Cylinder 3.00
(76.2)
24.4375
(620.7)
1.50
(38.1)
Lower Lift Cylinder 3.50
(88.9)
25.375
(644.5)
2.00
(50.8)
Telescope Cylinder 2.00
(50.8)
79
(2006.6)
1.25
(31.8)
Master Cylinder 2.00
(50.8)
9.375
(238.1)
1.00
(25.4)
Slave Cylinder 2.00
(50.8)
9.375
(238.1)
1.00
(25.4)
Rotator Cylinder 1.875
(47.6)
15.250
(387.3)
1.00
(25.4)
Steer Cylinder
(Double Rod)
2.00
(50.8)
3.00
(76.2)
each direc-
tion
1.25
(31.8)
each rod
e40/n40e
DESCRIPTION BORE STROKE ROD DIA.
Upper Lift Cylinder 3.00
(76.2)
28.3125
(719.1)
1.50
(38.1)
Mid Lift Cylinder 3.00
(76.2)
21.25
(539.7)
1.50
(38.1)
Lower Lift Cylinder 3.50
(88.9)
23.1875
(589.0)
2.00
(50.8)
Telescope Cylinder 2.00
(50.8)
79
(2006.6)
1.25
(31.8)
Master Cylinder 2.00
(50.8)
9.375
(238.1)
1.00
(25.4)
Slave Cylinder 2.00
(50.8)
9.375
(238.1)
1.00
(25.4)
Rotator Cylinder 1.875
(47.6)
15.250
(387.3)
1.00
(25.4)
Steer Cylinder
(Double Rod)
2.00
(50.8)
3.00 (76.2)
eachdirection
1.25 (31.8)
each rod
e45
DESCRIPTION BORE STROKE ROD DIA.
Upper Lift Cylinder 3.00
(76.2)
28.3125
(719.1)
1.50
(38.1)
Mid Lift Cylinder 3.00
(76.2)
21.25
(539.7)
1.50
(38.1)
Lower Lift Cylinder 3.50
(88.9)
23.1875
(589.0)
2.00
(50.8)
Telescope Cylinder 2.00
(50.8)
79
(2006.6)
1.25
(31.8)
Master Cylinder 2.00
(50.8)
9.375
(238.1)
1.00
(25.4)
Slave Cylinder 2.00
(50.8)
9.375
(238.1)
1.00
(25.4)
Rotator Cylinder 1.875
(47.6)
15.250
(387.3)
1.00
(25.4)
Steer Cylinder
(Double Rod)
2.00
(50.8)
3.00 (76.2)
eachdirection
1.25 (31.8)
each rod
Table 1-4. Cylinder Specifications.
Property of American Airlines

SECTION 1 - SPECIFICATIONS
1-6 –JLG Lift –3120743
1.10 SERIAL NUMBER LOCATIONS.
(SEE FIGURE 1-3)
Model 30/35/n35 electric.
For machine identification, a serial number plate is affixed
to the turntable, facing the platform basket. If the serial
number plate is damaged or missing, the machine serial
number is stamped on the top left side of the frame and
the top left side of the turntable. In addition, the serial
number is stamped on top of the end of the upper boom
at the platform, and lower boom at the upright.
Model 30/35/n35 electric.
For machine identification, a serial number plate is affixed
to the left rear of frame, in front of left rear wheel. If the
serial number plate is damaged or missing, the machine
serial number is stamped on the top left side of the frame
and the top left side of the turntable. In addition, the serial
number is stamped on top of the end of the upper boom,
mid boom, and lower boom at the left rear of the booms.
Property of American Airlines

SECTION 1 - SPECIFICATIONS
3120743 –JLG Lift –1-7
.
Figure 1-1. Torque Chart
Property of American Airlines

SECTION 1 - SPECIFICATIONS
1-8 –JLG Lift –3120743
.
Figure 1-2. Lubrication Chart - 30 electric. (Sheet 1 of 6)
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SECTION 1 - SPECIFICATIONS
3120743 –JLG Lift –1-9
Figure 1-3. Lubrication Chart - 30 electric.
Property of American Airlines

SECTION 1 - SPECIFICATIONS
1-10 –JLG Lift –3120743
Figure 1-4. Lubrication Chart - 35/n35 electric. (Sheet 3 of 6).
Property of American Airlines

SECTION 1 - SPECIFICATIONS
3120743 –JLG Lift –1-11
L
Figure 1-5. Lubrication Chart - 35/n35 electric. (Sheet 4 of 6).
Property of American Airlines

SECTION 1 - SPECIFICATIONS
1-12 –JLG Lift –3120743
Figure 1-6. Lubrication Chart - 40/n40/45 electric. (Sheet 5 of 6).
Property of American Airlines