JLG 45e Service Manual

SERVICE & MAINTENANCE

Models

30e

35e

n35e

40e

n40e

45e

3120743

October 1, 2001

WWW.JLG.COM

CORPORATE OFFICE

JLG INDUSTRIES, INC. 1 JLG Drive McConnellsburg, PA. 17233-9533

USA

Telephone: [phone] Fax: [phone]

JLG Industries (Australia)	JLG Industries (UK)	JLG Deutschland GmbH
P.O. Box 5119	Unit 12, Southside	Max Planck Strasse 21
11 Bolwarra Road	Bredbury Park Industrial Estate	D-27721 Ritterhude/lhlpohl
Port Macquarie	Bredbury	Bei Bremen
N.S.W. 2444	Stockport	Germany
Australia	SK6 2sP	Phone: [phone]
Phone: [phone]	England	Fax: [phone]
Fax: [phone]	Phone: [phone]
	Fax: [phone]
JLG Latino Americana Ltda.	JLG Europe B.V.	JLG Industries (Norge AS)
Rua Eng. Carlos Stevenson,	Jupiterstraat 234	Sofeimyrveien 12
80-Suite 71	2132 HJ Foofddorp	N-1412 Sofienyr
13092-310 Campinas-SP	The Netherlands	Norway
Brazil	Phone: [phone]	Phone: [phone]
Phone: [phone]	Fax: [phone]	Fax: [phone]
Fax: [phone]
JLG Industries (Europe)	JLG Industries (Pty) Ltd.	Plataformas Elevadoras
Kilmartin Place,	Unit 1, 24 Industrial Complex	JLG Iberica, S.L.
Tannochside Park	Herman Street	Trapadella, 2
Uddingston G71 5PH	Meadowdale	P.I. Castellbisbal Sur
Scotland	Germiston	08755Castellbisbal
Phone: [phone]	South Africa	Spain
Fax: [phone]	Phone: [phone]	Phone: [phone]
	Fax: [phone]	Fax: [phone]

JLG Industries (Italia)

Via Po. 22

20010 Pregnana Milanese - MI

Italy

Phone: [phone]

Fax: [phone]

JLG Polska

UI. Krolewska

00-060 Warsawa

Poland

Phone: [phone]

Fax: [phone]

JLG Industries (Sweden)

Enkopingsvagen 150

Box 704

SE - 175 27 Jarfalla

Sweden

Phone: [phone]

Fax: [phone]

INTRODUCTION

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 VIOLATION.

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 CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.

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 DURING 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 CAUTIONS ON MACHINE AND IN SERVICEMANUAL.

•KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS.

•USE CAUTION WHEN CHECKING A HOT, PRESSURIZED 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 DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS.

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

•KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.

•USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

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A-2

INTRODUCTION

	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

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3120743

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

1.4TORQUE 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

2.2SERVICING AND MAINTENANCE GUIDELINES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.3 LUBRICATION INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2.4CYLINDERS - 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

2.9CYLINDER CHECKING PROCEDURES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2.10CYLINDER 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

3.3HYDRAULIC CIRCUIT CHECKS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

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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

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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

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SECTION 1. SPECIFICATIONS

1.1CAPACITIES.

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).

1.2COMPONENT 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 Brake24 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 Compound. (Optional)

Tires - n35/n40 electric.

Solid Tires - 22 x 6 x 16 Lug Tread Dual Service Compound.

Solid Tires - 22 x 6 x 16 Lug Tread Non marking Compound. (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 Compound. (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).

1.3PERFORMANCE DATA.

EERated, 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).

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Gradeability.

25%

Maximum Slope

5%.

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.

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.

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.).

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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.).

1.4TORQUE SPECIFICATIONS.

Table 1-1.Torque specifications

	Description	Torque Value	Interval Hours
		(Dry)
	A. Bearing To	See Note	50/600*
	Chassis
	B. Bearing To	See Note	50/600*
	Turntable
	C. Wheel Bolts	90 ft. lb.	150***
		(122 Nm)

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 fastener has loosened, refer to the Torque Chart, Figure 1-1, to determine proper torque value.

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1.5 LUBRICATION.

Hydraulic Oil.

Table 1-2.Hydraulic Oil

		HYDRAULIC SYSTEM
		OPERATING	SAE VISCOSITY GRADE
		TEMPERATURE RANGE
	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

NOTE: Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. 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 Industries for proper recommendations.

Lubrication Specifications

		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		Synthetic Lithium Lubricant, Gredag 741 Grease. (JLG
			Part No. 3020022)

1.6PRESSURE 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).

*MPG may be substituted for these lubricants, if necessary, but service intervals will be reduced.

NOTE: Refer to Lubrication Chart, Figure1-2, for specific lubrication procedures.

Hydro-Air Valve 4640726.

Steer Relief - 1500 psi (103.42 bar).

Main Relief at Pump - 3200 psi (220.64 bar).

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1.7CYLINDER SPECIFICATIONS.

NOTE: All dimensions are given in inches (in.), with the metric equivalent, millimeters (mm) given in parentheses.

Table 1-4. Cylinder Specifications.

e30

DESCRIPTION	BORE	STROKE	ROD DIA.
Upper Lift Cylinder	3.00	14.62	1.50
	(76.2)	(371.5)	(38.1)
Lower Lift Cylinder	3.00	14.62	1.50
	(76.2)	(371.5)	(38.1)
Steer Cylinder	2.00	3.00	1.25
(Double Rod)	(50.8)	(76.2)	(31.8)
		each direc-	each rod
		tion
e35/n35e

DESCRIPTION	BORE	STROKE	ROD DIA.
Upper Lift Cylinder	3.00	24.4375	1.50
	(76.2)	(620.7)	(38.1)
Lower Lift Cylinder	3.50	25.375	2.00
	(88.9)	(644.5)	(50.8)
Telescope Cylinder	2.00	79	1.25
	(50.8)	(2006.6)	(31.8)
Master Cylinder	2.00	9.375	1.00
	(50.8)	(238.1)	(25.4)
Slave Cylinder	2.00	9.375	1.00
	(50.8)	(238.1)	(25.4)
Rotator Cylinder	1.875	15.250	1.00
	(47.6)	(387.3)	(25.4)
Steer Cylinder	2.00	3.00	1.25
(Double Rod)	(50.8)	(76.2)	(31.8)
		each direc-	each rod
		tion
e40/n40e

DESCRIPTION	BORE	STROKE	ROD DIA.
Upper Lift Cylinder	3.00	28.3125	1.50
	(76.2)	(719.1)	(38.1)
Mid Lift Cylinder	3.00	21.25	1.50
	(76.2)	(539.7)	(38.1)
Lower Lift Cylinder	3.50	23.1875	2.00
	(88.9)	(589.0)	(50.8)
Telescope Cylinder	2.00	79	1.25
	(50.8)	(2006.6)	(31.8)

Table 1-4. Cylinder Specifications.

	Master Cylinder	2.00	9.375	1.00
		(50.8)	(238.1)	(25.4)
	Slave Cylinder	2.00	9.375	1.00
		(50.8)	(238.1)	(25.4)
	Rotator Cylinder	1.875	15.250	1.00
		(47.6)	(387.3)	(25.4)
	Steer Cylinder	2.00	3.00 (76.2)	1.25 (31.8)
	(Double Rod)	(50.8)	eachdirection	each rod
	e45
	DESCRIPTION	BORE	STROKE	ROD DIA.
	Upper Lift Cylinder	3.00	28.3125	1.50
		(76.2)	(719.1)	(38.1)
	Mid Lift Cylinder	3.00	21.25	1.50
		(76.2)	(539.7)	(38.1)
	Lower Lift Cylinder	3.50	23.1875	2.00
		(88.9)	(589.0)	(50.8)
	Telescope Cylinder	2.00	79	1.25
		(50.8)	(2006.6)	(31.8)
	Master Cylinder	2.00	9.375	1.00
		(50.8)	(238.1)	(25.4)
	Slave Cylinder	2.00	9.375	1.00
		(50.8)	(238.1)	(25.4)
	Rotator Cylinder	1.875	15.250	1.00
		(47.6)	(387.3)	(25.4)
	Steer Cylinder	2.00	3.00 (76.2)	1.25 (31.8)
	(Double Rod)	(50.8)	eachdirection	each rod

1.8MAJOR COMPONENT WEIGHTS.

SELECT LIFTING EQUIPMENT WITH CAPACITY CAPABLE OF SAFELY SUPPORTING WEIGHT.

1.9CRITICAL 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.

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1.10SERIAL 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.

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Figure 1-1. Torque Chart

.

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Figure 1-2. Lubrication Chart - 30 electric. (Sheet 1 of 6)

.

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Figure 1-3. Lubrication Chart - 30 electric.

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Figure 1-4. Lubrication Chart - 35/n35 electric. (Sheet 3 of 6).

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Figure 1-5. Lubrication Chart - 35/n35 electric. (Sheet 4 of 6).

L

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Figure 1-6. Lubrication Chart - 40/n40/45 electric. (Sheet 5 of 6).

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Figure 1-7. Lubrication Chart - 40/n40/45 electric. (Sheet 6 of 6).

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Figure 1-8. Serial Number Locations - 30 electric. (Sheet 1 of 3)

).

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Figure 1-9. Serial Number Locations - 35/n35 electric. (Sheet 2 of 3).

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Figure 1-10. Serial Number Locations - 40/n40/45 electric. (Sheet 3 of 3).

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SECTION 2. PROCEDURES

2.1GENERAL.

This section provides information necessary to perform maintenance on the aerial platform. Descriptions, techniques and specific procedures are designed to provide the safest and most efficient maintenance for use by personnel responsible for ensuring the correct installation and operation of machine components and systems.

WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK IS RESUMED.

The maintenance procedures included consist of servicing and component removal and installation, disassembly, and assembly, inspection, lubrication and cleaning. Information on any special tools or test equipment is also provided where applicable.

2.2SERVICING AND MAINTENANCE GUIDELINES.

General.

The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter.

Safety and Workmanship.

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.

Cleanliness.

1.The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals and filters are provided to keep oil supplies clean; however, these items must be maintained on a scheduled basis in order to function properly.

2.At any time when hydraulic oil lines are disconnected, clear adjacent areas as well as the openings

and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter.

3.Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their containers until they are ready to be used.

Component Removal and Installation.

1.Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be parallel to each other and as near perpendicular as possible to top of part being lifted.

2.Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90 degrees.

3.If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc. have been removed and that no adjacent parts are interfering.

Component Disassembly and Reassembly.

When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.

Pressure Fit Parts.

When assembling pressure fit parts, use an “anti-seize” or molybdenum disulfide base compound to lubricate the mating surface.

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Bearings.

Hydraulic Lines and Electrical Wiring.

1.When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing.

2.Discard bearings if the races and balls (or rollers) are pitted, scored or burned.

3.If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearings until they are ready to be installed.

4.Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race.

Gaskets.

Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand fabricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the right location as blank gaskets can cause serious system damage.

Bolt Usage and Torque Application.

1.Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent.

2.Unless specific torque requirements are given within the text, standard torque values should be used on heat treated bolts, studs and steel nuts, in accordance with recommended shop practices (See Figure 1-1).

Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit. This will assure that they are correctly reinstalled.

Hydraulic System.

1.Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system.

2.Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate components, as required, to aid assembly.

Lubrication.

Service applicable components with the amount, type, and grade of lubricant recommended in this manual, at the specified interval. When recommended lubricants are not available, consult your local supplier for an equivalent that meets or exceeds the specifications listed.

Batteries.

Clean batteries using a non-metallic brush and a solution of baking soda and water. Rinse with clean water. After cleaning, thoroughly dry batteries and coat terminals with an anti-corrosion compound.

Lubrication and Servicing.

Components and assemblies requiring lubrication and servicing are shown in Lubrication Chart.

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2.3 LUBRICATION INFORMATION.

Hydraulic System.

1.The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g.; inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc. to enter when performing maintenance, or by permitting the pump to cavitate due to insufficient system warm-up.

2.The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage. Hydraulic system filters should be checked, cleaned, and/or replaced at the specified intervals required in Figure 1-2. Always examine filters for evidence of metal particles.

3.Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil.

4.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. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is operating, are recommended for use.

NOTE: Metal particles may appear in the oil or filters of new machines due to the wear-in of meshing components.

Hydraulic Oil.

1.Refer to Table 1-1 for recommendations for viscosity ranges.

2.JLG recommends Mobilfluid 424 Hydraulic Oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152.

NOTE: Start-up of hydraulic system with oil temperatures below -15 degrees F. is not recommended. If it is necessary to start the system in a sub-zero environment, it will be necessary to heat the oil with a low density 100VAC heater to a minimum temperature of -15 degrees F.

3.The only exception to the above is to drain and fill the system with Mobil DTE11 oil or its equivalent. This will allow start up at temperatures down to -20

degrees F. However, use of this oil will give poor performance at temperatures above 120 degrees F. Systems using DTE11 oil should not be operated at temperatures above 200 degrees F. under any condition.

Changing Hydraulic Oil.

1.Use of any of the recommended hydraulic oils eliminates the need for changing the oil on a regular basis. However, filter elements must be changed after the first 50 hours of operation and every 300 hours thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils. JLG Industries recommends changing the hydraulic oil every two years.

2.Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to clean all possible contaminants from the service container. Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed.

3.While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service.

Lubrication Specifications

Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose requirements. Should any question arise regarding the use of greases in maintenance stock, consult your local supplier for evaluation. Refer to Table 1-2 for an explanation of the lubricant key designations appearing in the Lubrication Chart.

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2.4CYLINDERS - THEORY OF OPERATION.

Systems Incorporating Double Acting

Cylinders.

30 electric - Upper Boom Lift, Lower Boom Lift, and Steer.

35/n35 electric - Upper Boom Lift, Lower Boom Lift, Telescope, Slave, Master, Rotator, and Steer.

40/n40/45 electric - Upper Boom Lift, Mid Boom Lift, Lower Boom Lift, Telescope, Slave, Master, Rotator, and Steer.

A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions. Directing oil (by actuating the corresponding control valve to the piston side of the cylinder) forces the piston to travel toward the rod end of the barrel, extending the cylinder rod (piston attached to rod). When the oil flow is stopped, movement of the rod will stop. By directing oil to the rod side of the cylinder, the piston will be forced in the opposite direction and the cylinder rod will retract.

Holding valves are used in the Lift circuits to prevent retraction of the cylinder rod should a hydraulic line rupture or leak develop between the cylinder and its related control valve.

2.5VALVES - THEORY OF OPERATION.

Control Valves.

30 electric - Control Valve 4640725 this valve controls Swing, Lower Lift, and Upper Lift.

35/n35 electric - Control Valve 4640843 this valve controls Platform, Telescope, Swing, Lower Lift, and Upper Lift.

40/n40/45 electric - Control Valve 4640797 this valve controls Platform, Telescope, Swing, Lower Lift, and Upper Lift.

It consists of cartridge type valves in an anodized aluminum manifold. The cartridge valves provide for control of flow, volume of flow and pressure in the hydraulic system.

The directional control valves are solenoid operated, three position, 4-way sliding spool type valves. One valve is provided for each of the three functions. Energizing one of the electrical coils on a valve will divert the supply of hydraulic oil to provide motion of that function in one direction. Energizing the other coil will divert the oil for motion in the other direction. When neither coil is energized, the supply of hydraulic oil is blocked.

Flow control valves in the lift circuits provide for control of the rate of flow when the oil is flowing out of the cap ends of the cylinders (the load is being lowered). An adjusting

screw on each cartridge flow control valve allows the rate of flow (speed) to be adjusted. When oil is flowing into the cap end of the lift cylinders, an internal check valve feature allows unrestricted flow.

Pressure relief valves limit the pressure in the swing circuit and the rod end of each lift cylinder. When the pressure in one of those circuits reaches the set point of the valve, the valve opens, allowing enough flow to return to the reservoir so that the set pressure is not exceeded. An adjusting screw on each cartridge relief valve allows the set pressure to be adjusted.

The aluminum manifold provides the passages through which the hydraulic oil is diverted to provide the desired movement of the actuators. No moving parts of the valves slide against the manifold and so it is not subject to wear.

Steer Valve 4640726. (30/35/n35/40/n40/45 electric)

This valve controls the STEER function. It consists of screw-in cartridge type valves in an anodized aluminum manifold. The cartridge valves provide for control of direction of flow and pressure in the STEER hydraulic circuit.

The directional control valve is a solenoid operated, three position, 4-way sliding spool type valve. Energizing one of the electrical coils on the valve will divert the supply of hydraulic oil to provide steering in one direction. Energizing the other coil will divert the oil for steering in the other direction. When neither coil is energized, the supply of hydraulic oil is blocked.

A pressure relief valve limits the pressure in the steer circuit. When the pressure reaches the set point of the valve, the valve opens, allowing enough flow to return to the reservoir so that pressure is not exceeded. An adjusting screw on the cartridge relief valve allows the set pressure to be adjusted.

The aluminum manifold provides the passages through which hydraulic oil is diverted to provide the desired movement of the steer cylinder. No moving parts of the valves slide against the manifold and so it is not subject to any wear.

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2.6 MOTOR CONTROLLER.

Modes of Operation.

1.Traction Motor Drive.

a.Drive in either forward or reverse will start only if the following conditions are satisfied:

1.Function switches off.

2.No procedure or diagnostic faults present.

3.FWD or REV selected as appropriate.

b.Once in “drive” mode, activating a function switch shall not cause drive mode to be exited, the pump/traction contactor drive shall not be energized (shall be left at the traction position). If a function switch is selected during traction, a procedure fault will occur when neutral is selected, remaining until a function switch and both directions are no longer selected.

c.When neutral is selected, the controller will control smooth stopping of the machine, using plug braking, before the electric brake is allowed to operate.

d.If a function switch is activated in neutral, when the vehicle has stopped and the brake is applied, then pump mode will become operational.

1.Pump Motor Drive.

a.Pump motor drive will start only if the following conditions are satisfied:

1.FWD and REV switch off.

2.Traction mode off (brake applied).

a.Pump drive shall only be enabled when the direction selector inputs are in neutral and the machine is stationary. Once pump drive mode has been entered, then the status of the direction selector inputs shall no longer interlock pump operation. If a direction switch is selected during pump drive, a procedure fault will occur when the function switch is no longer selected, remaining until both directions and the function switch are no longer selected.

Features.

1. Features in Traction Mode.

a. Maximum Speed Control.

The controller incorporates a function to limit the maximum speed of the machine to a percentage of maximum possible speed. The function operates in such a manner as to control vehicle speed by limiting the percentage on of the switching device to keep the machine speed below the maximum permitted value or, if required, to apply variable plug braking to restrict machine speed when traveling down a grade. The speed is controlled based on the percentage of accelerator input.

1.Features in Pump Mode.

a.Proportional Control of Pump Motor Speed.

The pump motor speed shall be controlled by varying the percentage on of the switching element in relation to a separate pump accelerator input.

b.Soft Start.

The pump motor speed control incorporates a “soft start” facility by applying acceleration delay to changes in the applied percentage on of the switching element.

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2.General Features.

a.Diagnostics.

To obtain flash code, depress footswitch and repeat operation which caused fault. After fault occurs, maintain footswitch and function position and read flash code. NOTE: Flash code repeats after pause.

Flash codes are as follows:

LED On - Controller Operational.

LED Off - Internal Fault or Power Not Turned On.

1 Flash - Internal Fault

2 Flashes - Procedure Fault. (Recycle Footswitch)

This includes direction or function selected at power on, or direction and function selected together.

3 Flashes - Motor Permanently Low. This includes MOSFET short circuit.

4 Flashes - Motor Permanently High.

This includes direction or pump/traction contactor welded.

5 Flashes - Motor Neither Low Nor High. (Open Circuit)

This includes direction or pump/traction contactor open circuit, MOSFET open circuit and hardware fail-safe trip.

6 Flashes - Faulty Drive Hand Controller.

This includes drive hand controller greater than 30% at power on, and wire off. Note that the pump accelerator is not fault detected.

7 Flashes - Low Battery Voltage.

This includes battery voltage below 13 volts.

8 Flashes - Thermal Cutback, Controller.

This includes MOSFET temperature above 80 degrees C (176 degrees F).

10 Flashes - Tachometer Fault.

When in traction drive with the controller pulsing at greater than 33% ON for more than 1 second, the tachometer input shall be monitored. Failure of the tachometer will result in a 10 flash diagnostic fault being raised and the brake applied, i.e., machine is disabled if tachometer fails. The fault is only recyclable using the footswitch.

11 Flashes - Tachometer out of calibration.

Tachometer output is sensed when vehicle is in neutral failure occurs when at the input to MOS90:

1 tachometer PCB output was above 9.0 volts or below 6 volts.

Prevents TRACTION and PUMP modes.

NOTE: Refer to Figure 2-1, Troubleshooting Flow Charts, for specific troubleshooting information.

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