JLG 30 e

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: (717) 485-5161
Fax: (717) 485-6417
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
SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS
A
feed lines to system components can then be disconnected

with minimal fluid loss.
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.
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.
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.
KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.
USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
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
3120743
JLG Lift
A-2
INTRODUCTION
REVISON LOG
March, 1989
October, 1994
August, 1997
January, 1999
Cvr, Intro., - and Pgs.
May 1, 2000
May 1, 2001
October 1, 2001
A-3
- Original Issue
- Revised
- Revised
- Revised
-Revised
-Revised
-Revised
JLG Lift
3120743
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH
PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A
B
C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SECTION 1 - SPECIFICATIONS
1.1
1.2
1.3
1.4
1.5
1.6
1.8
1.9
1.10
CAPACITIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
COMPONENT DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
PERFORMANCE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
PRESSURE SETTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
MAJOR COMPONENT WEIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
CRITICAL STABILITY WEIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
SERIAL NUMBER LOCATIONS. (See Figure 1-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
SECTION 2 - PROCEDURES
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19
2.20
2.21
2.22
2.23
2.24
2.25
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
SERVICING AND MAINTENANCE GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
LUBRICATION INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
CYLINDERS - THEORY OF OPERATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
VALVES - THEORY OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
MOTOR CONTROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
WEAR PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
BOOM MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
CYLINDER CHECKING PROCEDURES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
CYLINDER REPAIR.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
CYLINDER REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
TILT INDICATOR SWITCH LEVELING PROCEDURE. (If Equipped.) . . . . . . . . . . . . . . . . . . . . . . .2-32
BOOM LIMIT SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
POWER TRACK REMOVAL PROCEDURE (35/n35/40/n40/45 electric). . . . . . . . . . . . . . . . . . . . .2-32
PRESSURE SETTING PROCEDURES. (In Sequence) (See Figure 2-29) . . . . . . . . . . . . . . . . . . .2-32
SWING BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38
DRIVE TORQUE HUB. (See Figure 2-34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43
DRIVE BRAKE ASSEMBLY. (See Figure 2-35.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45
MID AND LOWER LIFT CYLINDER BLEEDING PROCEDURE. (40/n40/45 electric) . . . . . . . . . . .2-48
BOOM SYNCHRONIZING PROCEDURE. (40/n40/45 electric) . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
FREE WHEELING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49
FOOTSWITCH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49
P/q controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49
AXLE DRAIN PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50
PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . .2-50
SECTION 3 - TROUBLESHOOTING
3.1
3.2
3.3
3120743
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
TROUBLESHOOTING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
HYDRAULIC CIRCUIT CHECKS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
JLG Lift
iv
TABLE OF CONTENTS (Continued)
List of Figures
FIGURE NO.
1-1.
1-2.
1-3.
1-4.
1-5.
1-6.
1-7.
1-8.
1-9.
1-10.
2-1.
2-1.
2-1.
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-8.
2-9.
2-10.
2-11.
2-12.
2-13.
2-14.
2-15.
2-16.
2-17.
2-18.
2-19.
2-20.
2-21.
2-22.
2-23.
2-24.
2-25.
2-26.
2-27.
2-28.
2-29.
2-30.
2-31.
2-32.
2-33.
2-34.
2-35.
2-36.
2-37.
2-38.
2-39.
2-40.
TITLE
PAGE NO.
Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

Lubrication Chart - 30 electric. (Sheet 1 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Lubrication Chart - 30 electric. (Sheet 2 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Lubrication Chart - 35/n35 electric. (Sheet 3 of 6).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Lubrication Chart - 35/n35 electric. (Sheet 4 of 6).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Lubrication Chart - 40/n40/45 electric. (Sheet 5 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Lubrication Chart - 40/n40/45 electric. (Sheet 6 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Serial Number Locations - 30 electric. (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
Serial Number Locations - 35/n35 electric. (Sheet 2 of 3).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
Serial Number Locations - 40/n40/45 electric. (Sheet 3 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
Sevcon Controller Troubleshooting Flow Charts. (Sheet 1 of 4).. . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Location and Thickness of Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
Location of Components - Platform Support (Model 30). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Location of Components - Removal of Base Boom. (Model 30) . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Location of Components - Platform Support. (Models 35/n35/40/n40/45) . . . . . . . . . . . . . . . . . .2-13
Location of Components - Slave Leveling Cylinder.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
Location of Components - Removal of Base Boom. (Models 35/n35/40/n40/45) . . . . . . . . . . . . .2-14
Location of Components - Aft End of Fly Boom Wear Pad Adjustments. . . . . . . . . . . . . . . . . . . .2-15
Location of Components - Removal of Telescope Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
Location of Components - Front Base Boom Wear Pad Adjustments. . . . . . . . . . . . . . . . . . . . . .2-15
Boom Prop Configurations - 30 electric. (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19
Removal of Cylinder Retainer.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Removal of Set Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Removal of Seals and O-Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
Removal of Piston Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
Rod Seal Installation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
"O"-Ring Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
Steer Cylinder Piston Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
Installing Retainer Ring on Telescope Cylinder Barrel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
Lift Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Upper Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
Mid Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29
Lower Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
Upper Telescope Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
Tilt Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
Pressure Setting Procedure - 30 electric. (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35
Swing Bearing Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38
Swing Bearing Tolerance Boom Placement - 30/n30/n35 electric. (Sheet 1 of 2). . . . . . . . . . . . .2-39
Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40
Swing Bearing Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42
Worm Gear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42
Worm Gear Shim Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42
Drive Hub Assembly - 30/35/n35/40/n40/45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44
Drive Brake Assembly - 30/35/n35/40/n40/45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47
Port "P" Location.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
Synchronizing Valve.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
Upright Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
JLG Lift
3120743
TABLE OF CONTENTS
List of Figures
FIGURE NO.
2-41.
2-42.
3-1.
3-1.
3-1.
3-1.
3-2.
3-2.
3-2.
3-3.
3-4.
3-5.
3-6.
(Continued)
TITLE
PAGE NO
Drive Brake Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49

Drive Axle Drain Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50
Electrical Schematic 30 electric. (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Electrical Schematic 35/40/45 electric. (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Electrical Schematic. 35/40/45 electric. (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Hydraulic Diagram - 30 electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
Hydraulic Diagram - 35 electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Hydraulic Diagram - 40/45 electric.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
List of Tables
TABLE NO.
1-1
1-2
1-3
1-4
2-1
2-2
2-3
3-1
3-2
3-3
3-4
3-5
3-6
3120743
TITLE
PAGE NO.
Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Cylinder Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
Holding Valve Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . .2-51
Platform Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Boom Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Turntable Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Chassis Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Hydraulic System - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Electrical System - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
JLG Lift
vi
TABLE OF CONTENTS (Continued)
This page left intentionally blank.
vii
JLG Lift
3120743
SECTION 1. SPECIFICATIONS
1.1
Tires - G 78 - 15, Load Range E, 10 Ply Rating, 80 psi (5.5

kg/cm2).
CAPACITIES.
Hydraulic Oil Tank.

4.0 gallons (15.14 liters).
Tires - G 78 - 15, Load Range E, 10 Ply Rating, Foam

Filled. (Optional)
Hydraulic System.
Solid Tires - 22 x 6.5 x 16 Lug Tread Non marking Compound. (Optional)
Approximately 4.8 gallons (18.2 liters).
Tires 10 - 16.5 NHS, 8 Ply, 70 psi (4.9 kg/cm2).
Torque Hubs (2).
Tires 10 - 16.5 NHS, 8 Ply, 70 psi (4.9 kg/cm2), Foam Filled
17 ounces (0.5 liters).
Tires - 45 electric.
1.2
Tires - LT215 85R16, Load Range E, 10 Ply Rating, 90 psi

(6.2 kg/cm2).
COMPONENT DATA.
Tires - LT215 85R16, Load Range E, 10 Ply Rating, Foam

Filled. (Optional)
Battery Charger.
Input, 110 VAC,60 HZ.
Tires 10 - 16.5 NHS, 8 Ply, 70 psi (4.9 kg/cm2).
Output, 48 VDC (23 Amps.).

Batteries (8).
Tires 10 - 16.5 NHS, 8 Ply, 70 psi (4.9 kg/cm 2 ), Foam

Filled.
6 Volt, 370 AmpHour (20 hour rate).
Hydraulic Filter.
Drive System.
Return, 10 Micron.
Drive Motor - 36 VDC, 4.1 H.P. @ 1880 rpm. continuous,

rotation - reversible.
Hydraulic Pump/Electric Motor Assembly.

Motor - 48 VDC, 2.14 H.P. @ 2700 rpm.
Drive Brake- 24 VDC, spring-applied, electrically released.

Pump - 0.098 in.3/rev. (1.6 cm3/rev.).
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).
Pump Output - 1.09 gpm (4.13 lpm) @ 2000 psi (137.9

Bar).
1.3
PERFORMANCE DATA.
Solid Tires - 26 x 7 x 20 Lug Tread Non marking Compound. (Optional)
EE Rated, Certified By U/L.
Tires - n35/n40 electric.
Travel Speed.
Solid Tires - 22 x 6 x 16 Lug Tread Dual Service Compound.
30 electric - 4 mph (6.4 kph).
Solid Tires - 22 x 6 x 16 Lug Tread Non marking Compound. (Optional)

n35 electric - 2.5 mph (4.1 kph).
Tires - 35/40 electric. (Prior to March of 1996)
Tires - ST225 75R15, Load Range D, 8 Ply Rating, 80 psi

(5.5 kg/cm2).
n40 electric - 2.5 mph (4.1 kph).

45 electric - 2.6 mph (4.2 kph).
Tires - ST225 75R15, Load Range D, 8 Ply Rating, Foam

Filled. (Optional)
Tires - 35/40 electric. (March of 1996 to Present)
3120743
JLG Lift
1-1
Gradeability.
40/n40 electric - Lift Up - 50 - 60 seconds.
25%
40/n40 electric - Lift Down - 23 - 29 seconds.
Maximum Slope
45 electric - Lift Up - 58 - 68 seconds.
5%.
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.).
Swing Speed - 360 Degrees.

30 electric - 55 - 65 seconds.
35/n35 electric - 65 - 75 seconds.
40/n40 electric - 85 - 95 seconds.
n35 electric - 5 ft. 3 in. (1.60 m.).
45 electric - 85 - 95 seconds.
40 electric - 4 ft. 3 in. (1.31 m.).
Machine Weight.
n40 electric - 5 ft. 3 in. (1.60 m.).
30 electric - 4,770 lb. (2,164 kg).

35 electric - 9,500 lb. (4,309 kg).
45 electric - 4 ft. 3 in. (1.31 m.).
n35 electric - 10,200 lb. (4,627 kg).

40 electric - 10,700 lb. (4,853 kg).
Turning Radius (Outside).
n40 electric - 11,830 lb. (5,366 kg).
30 electric - 11 ft. 10 in. (3.63 m.).
45 electric - 11,800 lb. (5,352 kg).
35 electric - 11 ft. 10 in. (3.63 m.).
Max. Tire Load.
n35 electric - 11 ft. 10 in. (3.63 m.).
30 electric - 2560 lbs. (1,161 kg).
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.).
35 electric - 3580 lbs. (1,624 kg).

n35 electric - 4250 lbs. (1,928 kg).
40 electric - 4700 lbs. (2,132 kg).
Upper Boom Speed.
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.).
Lower Boom Speed.

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.).
1-2
JLG Lift
3120743
Up and Over Platform Height.
Working Height.
30 electric - 16 ft.,7.0 in. (5.05 m.).
30 electric - 30 ft., 0 in. (9.14 m.).
35/n35 electric - 17 ft.,11.0 in. (5.46 m.).
35/n35 electric - 35 ft., 0 in. (10.67 m.).
40/n40 electric - 20 ft.,0 in. (6.10 m.).
40/n40 electric - 40 ft., 0 in. (12.19 m.).
45 electric - 24 ft.,7 in. (7.49 m.).
45 electric - 45 ft., 0 in. (13.72 m.).
Horizontal Reach Up and Over.

30 electric - 13 ft.,5.0 in. (4.09 m.).
1.4
Table 1-1.Torque specifications
35/n35 electric - 20 ft.,6.0 in. (6.25 m.).

40/n40 electric - 20 ft.,6.0 in. (6.25 m.).
Description
45 electric - 22 ft. 8 in.,(6.91 m.).
A. Bearing To
Chassis
B. Bearing To
Turntable
C. Wheel Bolts
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.).
TORQUE SPECIFICATIONS.
Torque Value
(Dry)
See Note
Interval Hours
50/600*
See Note
50/600*
90 ft. lb.
(122 Nm)
150***
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.
Wheel Base.
30 electric - 6 ft., 4 in. (1.93 m.).
35/n35 electric - 6 ft., 7.25 in. (2.01 m.).
NOTE: When maintenance becomes necessary or a fastener has loosened, refer to the Torque Chart, Figure
1-1, to determine proper torque value.
40/n40 electric - 6 ft., 7.25 in. (2.01 m.).

45 electric - 6 ft., 7.25 in. (2.01 m.).
3120743
JLG Lift
1-3
1.5
LUBRICATION.
1.6
PRESSURE SETTINGS.
Model 30 electric.
Hydraulic Oil.
Hydro-Air Valve 4640725.

Table 1-2.Hydraulic Oil
HYDRAULIC SYSTEM
OPERATING
TEMPERATURE RANGE
Lift Down Relief - 900 psi (62 bar).
SAE VISCOSITY GRADE
Articulate and Lift Down Relief - 725 psi (49.99 bar).

Swing Relief - 1000 psi (68.95 bar).
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)
Steer Relief - 1100 psi (75.84 bar).
20W-20
Main Relief at Pump - 2600 psi (179.27 bar).
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.
Model 35/n35 electric.

Upper Lift Down Relief - 600 psi (41.37 bar).
Lower Lift Down Relief - 600 psi (41.37 bar).
Telescope In Relief - 2150 psi (148.25 bar).
Platform Level Up Relief - 2500 psi (172.37 bar).
Lubrication Specifications
Platform Level Down Relief - 1200 psi (82.74 bar).
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.)
Extreme Pressure Gear Lube (oil) meeting API service
classification GL-5 or MIL-Spec MIL-L-2105.
Hydraulic Oil. API service classification GL-3, e.g.
Mobilfluid 424.
EPGL
HO
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)
Model 40/n40/45 electric.

Upper Lift Down Relief - 650 psi (44.82 bar).
Mid/Lower Lift Down Relief - 1700 psi (117.21 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.
1-4
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).

JLG Lift
3120743
1.7
Table 1-4. Cylinder Specifications.
CYLINDER SPECIFICATIONS.
NOTE: All dimensions are given in inches (in.), with the metric equivalent, millimeters (mm) given in parentheses.
Table 1-4. Cylinder Specifications.

e30
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
DESCRIPTION
BORE
STROKE
ROD DIA.
e45
Upper Lift Cylinder
3.00
(76.2)
14.62
(371.5)
1.50
(38.1)
DESCRIPTION
BORE
STROKE
ROD DIA.
Lower Lift Cylinder
3.00
(76.2)
14.62
(371.5)
1.50
(38.1)
Upper Lift Cylinder
3.00
(76.2)
28.3125
(719.1)
1.50
(38.1)
Steer Cylinder
(Double Rod)
2.00
(50.8)
3.00
(76.2)
each direction
1.25
(31.8)
each rod
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
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 direction
1.25
(31.8)
each rod
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)
1.8
e40/n40e
3120743
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.
JLG Lift
1-5
Model 30/35/n35 electric.
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.
1-6
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.
JLG Lift
3120743
Figure 1-1. Torque Chart

.
3120743
JLG Lift
1-7
Figure 1-2. Lubrication Chart - 30 electric. (Sheet 1 of 6)
1-8
JLG Lift
3120743
Figure 1-3. Lubrication Chart - 30 electric.
3120743
JLG Lift
1-9
Figure 1-4. Lubrication Chart - 35/n35 electric. (Sheet 3 of 6).
1-10
JLG Lift
3120743
Figure 1-5. Lubrication Chart - 35/n35 electric. (Sheet 4 of 6).

L
3120743
JLG Lift
1-11
Figure 1-6. Lubrication Chart - 40/n40/45 electric. (Sheet 5 of 6).
1-12
JLG Lift
3120743
Figure 1-7. Lubrication Chart - 40/n40/45 electric. (Sheet 6 of 6).
3120743
JLG Lift
1-13
Figure 1-8. Serial Number Locations - 30 electric. (Sheet 1 of 3)
).
1-14
JLG Lift
3120743
Figure 1-9. Serial Number Locations - 35/n35 electric. (Sheet 2 of 3).
3120743
JLG Lift
1-15
Figure 1-10. Serial Number Locations - 40/n40/45 electric. (Sheet 3 of 3).
1-16
JLG Lift
3120743
SECTION 2. PROCEDURES
2.1
and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to
prevent entry of foreign matter.
GENERAL.
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.
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.
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.
2.2
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.
SERVICING AND MAINTENANCE

GUIDELINES.
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.
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.
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.
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
3120743
JLG Lift
2-1
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.
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.
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.
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.
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.
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.
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).
2-2
JLG Lift
3120743
2.3
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.
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.
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. 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.
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. 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.
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.
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
3120743
JLG Lift
2-3
2.4
CYLINDERS - 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.
2.5
VALVES - 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.
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.
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
2-4
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3120743
2.6
Features.
MOTOR CONTROLLER.
1. Features in Traction Mode.
Modes of Operation.
a. Maximum Speed Control.

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.
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.
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. 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.
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.
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JLG Lift
2-5
2. General Features.
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.
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.
7 Flashes - Low Battery Voltage.

This includes battery voltage below 13 volts.
Flash codes are as follows:

LED On - Controller Operational.
8 Flashes - Thermal Cutback, Controller.
LED Off - Internal Fault or Power Not Turned On.
This includes MOSFET temperature above 80

degrees C (176 degrees F).
1 Flash - Internal Fault
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.
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.
11 Flashes - Tachometer out of calibration.
4 Flashes - Motor Permanently High.
Tachometer output is sensed when vehicle is in

neutral failure occurs when at the input to
MOS90:
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.
2-6
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.
JLG Lift
3120743
2. 1 FLASH - Internal Fault. (Replace MOS90)

1. At battery connection, the LED should not illuminate. At key ON, the LED should illuminate steadily. If
the LED
illuminates and remains steady, but no
drive can be selected, contact JLG Service Department.
3. 2 FLASHES - Procedure Fault. (Recycle Footswitch)

- Illegal start up sequence, 2 directions selected,
pump selected.
- Drive inhibited.
- Flashes until fault is cleared.
4. 3 FLASHES - Motor Permanently Low.

- Point A < 7V in neutral, or < 7V for 15mS in
drive, or contactor coil short circuit or brake coil.
- Drive & pump inhibited.

- Recycle to neutral to clear.
5. 4 FLASHES - Motor Permanently High.

- Direction contactor welded. (Point A within 6V
of B + ve in neutral).
Figure 2-1. Sevcon Controller Troubleshooting Flow
Charts. (Sheet 1 of 4).
3120743
JLG Lift
2-7
- Drive inhibited.
- Flashes in neutral until fault is cleared.
6. 5 FLASHES - Motor Neither Low Nor High. (Open

Circuit)
- Direction contactors (or line contactor) did not
close.
- Point A not within 6V of B + ve after 500mS.
- Drive inhibited.

2-8
- Flashes until fault is cleared, when contactor

closes.
NOTE: If recycling to neutral does not clear the fault, then
the fail-safe is due to an S/C contactor coil and the
key switch must be recycled (and coil replaced).
7. 6 FLASHES - Drive Hand Controller Fault.

- 3.5-0V Input: Voltage <2.5V on power up.
- Voltage >4.5V in drive.
JLG Lift
3120743
- Controller drives at minimum speed.

- Flashes in drive until fault cleared.
8. 7 FLASHES - Low Battery Voltage - Battery Voltage < 13V.
- Drive inhibited.
- Recycle to neutral to clear flashes.

9. 8 FLASHES - Thermal Cutback, Controller.
- Heat sink temperature > 80 degrees C (176
degrees F).
3120743
JLG Lift
2-9
- (Current limit will be zero at 90 degrees C [194

degrees F]).
- Allow unit to cool down, to clear flashing.
10. 10 FLASHES - Tachometer Fault.

- Controller > 33%, no tachometer
output for 1 second.
NOTE: If the machine is operated at a very slow speed or

stalled when climbing a grade of 20% or greater, a
10 flash fault will occur. Recycle footswitch to
recover.
11. 11 FLASHES - Tachometer out of calibrate.

- Pin voltage @ MOS90 above 9
volts or below 6 volts when in neutral.

2-10
JLG Lift
3120743
2.7
WEAR PADS.
Main Boom. (Models 35/n35/40/n40/45)

1. Shim up wear pads until snug to adjacent surface.
2. Replace wear pads when worn to thickness shown
in Figure 2-2.
3. Adjust wear pads as follows:
a. a. Loosen jam nut on adjustment bolt, turn bolt
CW until wear pad is snug to adjacent surface.
b. b.After adjustments have been made, tighten the
jam nuts on wear pad bolts.
Figure 2-2. Location and Thickness of Wear Pads.
3120743
JLG Lift
2-11
2.8
BOOM MAINTENANCE.
c. Remove hardware securing the upper link pin

#1. Using a suitable brass drift and hammer,
remove pin #1 from the upright and remove
upper link.
Removal. (Model 30)

1. Remove the platform/support as follows:
d. Using a suitable lifting equipment, adequately

support boom weight along entire length.
a. Disconnect electrical cable from control console.
e. Remove hardware securing the lift cylinder pin

remove pin #2 from the base boom.
b. Using an overhead crane or suitable lifting

device, strap support the platform/support.
c. Remove hardware from pin #1. Using a suitable
brass drift and hammer, remove pin #1 from the
platform support.
f. Remove hardware securing the base boom pin

remove pin #3 from the upright.
d. Supporting the platform/support, remove the

hardware from pin #2. Using a suitable brass
drift and hammer, remove pin #2 from the fly
boom and remove the platform.
Figure 2-4. Location of Components - Removal of Base

Boom. (Model 30)
Figure 2-3. Location of Components - Platform

Support (Model 30).
2. Remove the boom from upright as follows:
a. Remove hardware securing the hose clamp to
the base boom section and remove hose
clamps. Pull wiring harness through the aft end
of the base boom section.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF
CONTAMINANTS INTO SYSTEM.
b. Using a suitable lifting equipment, adequately
support boom link weight along entire length.
2-12
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3120743
11. Shut down machine systems and check for leakage.
Inspection.
Removal. (Models 35/n35/40/n40/45)
1. Inspect boom pivot pin for wear, scoring or other

damage, and for tapering or ovality. Replace pin as
necessary.
2. Inspect upper link pins for wear, scoring or other
damage, and for tapering or ovality. Ensure pin surfaces are protected prior to installation. Replace pins
as necessary.
3. Inspect inner diameter of boom pivot bushings for
scoring, distortion, wear or other damage. Replace
bushings as necessary.
4. Inspect inner diameter of link pivot bushings for
1. Remove the platform/support as follows:

a. Disconnect electrical cable from control console.
b. Using an overhead crane or suitable lifting
device, strap support the platform/support.
c. Remove hardware from pin #1. Using a suitable
brass drift and hammer, remove pin #1 from the
platform support.
d. Supporting the platform/support, remove the
hardware from pin #2. Using a suitable brass
drift and hammer, remove pin #2 from the fly
boom and remove the rotator.
5. Inspect all threaded components for damage such

as stretching, thread deformation, or twisting.
Replace as necessary.
6. Inspect structural units of boom assembly for bending, cracking, separation of welds, or other damage.
Replace boom sections as necessary.
Installation.
1. Using suitable lifting equipment, position boom
assembly on upright so that boom pivot holes in
both boom and upright are aligned.
2. Install boom pivot pin, ensuring that location of the
hole in pivot pin aligns with attach point on upright.
3. Using all applicable safety precautions, operate lifting equipment in order to position boom lift cylinder
so that holes in cylinder rod end and boom structure
are aligned. Insert cylinder pins.
4. If necessary, gently tap pin into position with a soft
headed mallet, ensuring that attach hole in pin are
aligned with attach hole in boom structure. Secure
with hardware.
5. Using suitable lifting equipment, position upper link
assembly on upright so that link pivot holes in both
link and upright are aligned.
6. Install link pivot pin, ensuring that location of the
Figure 2-5. Location of Components Platform Support. (Models 35/n35/40/n40/45)

e. Supporting the slave cylinder, remove the hardware from pin #3. Using a suitable brass drift
and hammer, remove pin #3 from the fly boom.
f. Tag and disconnect hydraulic lines to the slave
leveling cylinder. Use a suitable container to
retain any residual hydraulic fluid. Cap hydraulic
lines and ports. Remove the slave cylinder.
7. Route the wiring harness through the boom and

install clamp.
8. Install the platform to the boom and link assembly.
9. Connect all wiring to control console.
10. Using all safety precautions, operate machine systems and extend and retract boom for four or five
cycles.
3120743
JLG Lift
2-13
f. Remove hardware securing the base boom pin

remove pin #3 from the upright.
Figure 2-6. Location of Components - Slave Leveling

Cylinder.
2. Remove the boom from upright as follows:
a. Remove hardware securing the cover plate on
the side of the base boom section and remove
hose clamps. Disconnect wiring harness from
ground control harness connector.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF
CONTAMINANTS INTO SYSTEM.
Figure 2-7. Location of Components - Removal of Base

Boom. (Models 35/n35/40/n40/45)
g. Using all applicable safety precautions, carefully
lift boom assembly clear of upright and lower to
ground or suitable supported work surface.
b. Tag and disconnect hydraulic lines from boom

to control valve. Use a suitable container to
retain any residual hydraulic fluid. Cap hydraulic
lines and ports.
c. Using a suitable lifting equipment, adequately
support boom weight along entire length.
d. Remove hardware securing the lift cylinder pin
e. Remove hardware securing the master cylinder
pin #2. Using a suitable brass drift and hammer,
2-14
JLG Lift
3120743
Disassembly Boom Sections.

1. Loosen jam nuts on aft end of fly boom wear pad
adjustment and loosen adjustments.
2. Using a portable power source, attach hose to telescope cylinder port block. Using all applicable
safety precautions, activate hydraulic system and
extend cylinder rod pin #1. Shut down hydraulic
system.
Figure 2-9. Location of Components - Removal of Telescope Cylinder.

9. Loosen jam nuts on front wear pad adjustments and
loosen adjustments.
Figure 2-8. Location of Components - Aft End of Fly
Boom Wear Pad Adjustments.
10. Remove hardware securing the front wear pads on

base boom section, remove wear pads.
3. Carefully disconnect hydraulic hose from retract port

of cylinder. There will be initial weeping of hydraulic
fluid which can be caught in a suitable container.
After initial discharge, there should be no further
leakage from the retract port.
4. Remove hardware securing telescope cylinder #1 to
the fly boom section, then remove pin from fly.
5. Remove hardware securing telescope cylinder to
the base boom section.
WHEN REMOVING TELESCOPE CYLINDER FROM BOOM SECTIONS. CARE SHOULD BE TAKEN NOT TO LEAVE CYLINDER
REST ON POWERTRACK WHICH COULD CAUSE DAMAGE TO
POWERTRACK.
Figure 2-10. Location of Components - Front Base

Boom Wear Pad Adjustments.
6. Using a suitable lifting device, remove telescope cylinder from boom sections.
7. Using a piece of tape, mark the length of hoses and
wires from front of fly boom and bottom of base
boom for reassembly.
8. Remove hardware securing the front cover on base
boom section.
1. Remove wire clamp on the inside of the fly nose.

2. Manually push the fly boom section into base boom
section to gain access to the powertrack attachment
bolts on the right side of the base boom section.
3. Remove hardware securing the powertrack to the aft
end of the fly boom section.
4. Using a suitable lifting device, remove fly boom from
boom section.
5. Remove hydraulic lines and electrical cables from
powertrack.
6. Remove hardware securing powertrack to the base
boom section. Remove powertrack.
3120743
JLG Lift
2-15
Inspection.
1. Inspect boom pivot pin for wear, scoring or other
damage, and for tapering or ovality. Replace pin as
necessary.
WHEN INSERTING THE TELESCOPE CYLINDER INTO THE BOOM,

CARE MUST BE TAKEN NOT TO DAMAGE THE POWER TRACK
ASSEMBLY.
2. Inspect lift and master cylinder pins for wear, scoring

or other damage, and for tapering or ovality. Ensure
pin surfaces are protected prior to installation.
Replace pins as necessary.
11. Slowly slide the telescope cylinder into boom

assembly, align rod end with attach point in fly section. Insert pin and secure with retaining ring.
3.
12. Align bolt holes at aft end of base boom section with
telescope cylinder port block. Secure telescope cylinder with hardware.
Inspect telescope cylinder rod attach pin for wear,

scoring or other damage. Replace pin as necessary.
4. Inspect inner diameter of boom pivot bushings for

5. Inspect wear pads for wear as shown in paragraph
2-6, Wear Pads.
6. Inspect all threaded components for damage such
as stretching, thread deformation, or twisting.
7. Inspect structural units of boom assembly for bending, cracking, separation of welds, or other damage.
Replace boom sections as necessary.
13. Install wear pads at end of base boom section.

Adjust the adjustable wear pads to zero clearance.
Adjust pads alternately side to side, so that fly boom
section is centered in base boom section.
14. Retract boom section fully. Adjust wear pads at aft
end of boom section to zero clearance. Adjust pads
alternately side to side, so that fly boom section is
centered in base boom section.
15. Disconnect auxiliary power source from telescope
cylinder.
Installation.
Assembly.
1. Using suitable lifting equipment, position boom
assembly on upright so that boom pivot holes in
both boom and upright are aligned.
1. Install power track to the attach point on the inside

of the base boom section. Secure power track with
hardware.
2. Install boom pivot pin, ensuring that location of the

2. Install hydraulic lines and electrical cables into the

power track.
3. Using all applicable safety precautions, operate lifting equipment in order to position boom lift and
master cylinders so that holes in cylinder rod ends
and boom structure are aligned. Insert cylinder pins.
3. Install wear pads to the aft end of the fly section.

4. Using suitable lifting equipment, slide fly section into
the base section until power track attach point aligns
with holes in side of base section.
4. If necessary, gently tap pins into position with a soft

headed mallet, ensuring that attach holes in pins are
aligned with attach holes in boom structure. Secure
with hardware.
5. Attach the power track to the aft end of fly boom

section. Secure power track with hardware.
6. Using suitable lifting equipment, slide fly boom section out to gain access to telescope cylinder attach
pin hole.
5. Connect all hosing and wiring.

6. Install the slave leveling cylinder to the boom
assembly.
7. Measure the distance between the telescope cylinder port block attach point on base boom section
and the attach point on fly boom section.
7. Install the platform to the boom assembly.

8. Connect all hosing and wiring at platform control
station.
8. Connect a suitable auxiliary hydraulic power source

to the telescope cylinder port block.
9. Using all safety precautions, operate machine systems and extend and retract boom for four or five
cycles.
9. Extend the telescope cylinder the distance of the

two attach points.
10. Secure the sling and lifting device at the telescope
cylinders approximate center of gravity, and lift the
cylinder to the aft end of the boom assembly.
2-16
10. Shut down machine systems and check for leakage.
JLG Lift
3120743
2.9
CYLINDER CHECKING PROCEDURES.
NOTE: Cylinder checks must be performed any time a cylinder component is replaced or when improper system
operation is suspected.
Cylinder Without Counterbalance Valves.

30 electric - Steer.
35/n35/40/n40/45 electric - Steer, Master,
and Rotate.
WHEN WORKING ON THE UPPER BOOM LIFT CYLINDER RAISE

THE UPPER BOOM TO HORIZONTAL AND PLACE A BOOM PROP
APPROXIMATELY 1 INCH 2.54 CM BELOW THE MAIN BOOM.
REFER TO FIG. 2-11. IF WORKING ON LOWER BOOM LIFT CYLINDER, RAISE LOWER BOOM HALFWAY, FULLY ELEVATE UPPER
BOOM AND ATTACH OVERHEAD CRANE TO THE UPRIGHT FOR
SUPPORT, LEAVING APPROXIMATELY 1 INCH 2.54 CM OF SLACK
IN CHAIN OR SLING FOR TEST PURPOSES.
1. Using all applicable safety precautions, activate

hydraulic system and fully extend cylinder to be
checked. Shut down hydraulic system.
2. After completing the above, shut down hydraulic

system and allow machine to sit for 10-15 minutes.
This is done to relieve pressure in the hydraulic
lines. Carefully remove hydraulic hoses from appropriate cylinder port block.
2. Carefully disconnect hydraulic hose from retract port

of cylinder. There will be initial weeping of hydraulic
fluid which can be caught in a suitable container.
After initial discharge, there should be no further
leakage from the retract port.
3. There will be initial weeping of hydraulic fluid, which

can be caught in a suitable container. After the initial
discharge, there should not be any further leakage
from the ports. If leakage continues at a rate of 6-8
drops per minute or more, the following cylinder
repairs must be made. If the retract port is leaking,
the piston is leaking, the piston seals are defective
and must be replaced. If the extend port is leaking,
the counterbalance is defective and must be
replaced.
3. Activate hydraulic system, and activate cylinder

extend function.
4. If cylinder retract port leakage is less than 6-8 drops
per minute, carefully reconnect hose to retract port
and retract cylinder. If leakage continues at a rate of
6-8 drops per minute or more, cylinder repairs must
be made.
4. If no repairs are necessary or when repairs have

been made, carefully reconnect hydraulic hoses to
the appropriate ports.
5. With cylinder fully retracted, shut down motor and

carefully disconnect hydraulic hose from cylinder
extend port.
5. Remove boom prop/overhead crane, activate

hydraulic system and run cylinder through complete
cycle to check for leaks and operation.
6. Activate hydraulic system and activate cylinder

retract function. Check extend port for leakage.
7. If extend port leakage is less than 6-8 drops per
minute, carefully reconnect hose to extend port,
then activate cylinder through one complete cycle
and check for leaks. If leakage continues at a rate of
6-8 drops per minute or more, cylinder repairs must
be made.
Cylinders With Single Counterbalance Valve.
Cylinders With Dual Counterbalance Valve.

35/n35 electric - Telescope, an Slave
Cylinders.
40/n40/45 electric- Lower Lift, Mid Lift,
Telescope, and Slave
Cylinders.
30/35/n35 electric - Upper and Lower Lift Cylinders.

40/n40/45 electric - Upper Lift Cylinder.
OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION
ONLY.
OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION
ONLY.

hydraulic system.

hydraulic system.
3120743
JLG Lift
2-17
WHEN WORKING ON THE UPPER BOOM LIFT CYLINDER RAISE

THE UPPER BOOM TO HORIZONTAL AND PLACE A BOOM PROP
APPROXIMATELY 1 INCH 2.54 CM BELOW THE MAIN BOOM.
REFER TO FIG. 2-11. IF WORKING ON LOWER BOOM LIFT CYLINDER, RAISE LOWER BOOM HALFWAY, FULLY ELEVATE UPPER
BOOM AND ATTACH OVERHEAD CRANE TO THE UPRIGHT FOR
SUPPORT, LEAVING APPROXIMATELY 1 INCH 2.54 CM OF SLACK
IN CHAIN OR SLING FOR TEST PURPOSES.
2. When working on the platform slave cylinder, stroke
platform slave level cylinder forward until platform
sits at a 45 degree angle.
3. After completing the above, shut down hydraulic
system and allow machine to sit for 10-15 minutes.
This is done to relieve pressure in the hydraulic
lines. Carefully remove hydraulic hoses from appropriate cylinder port block.
4. There will be initial weeping of hydraulic fluid, which

can be caught in a suitable container. After the initial
discharge, there should not be any further leakage
from the ports. If leakage continues at a rate of 6-8
drops per minute or more, the following cylinder
repairs must be made. If the retract port is leaking,
the piston is leaking, the piston seals are defective
and must be replaced. If the extend port is leaking,
the counterbalance is defective and must be
replaced.
5. To check piston seals, carefully remove the counterbalance valve from the retract port. After initial discharge there should not be any further leakage from
the ports. If leakage occurs at a rate of 6-8 drops per
minute or more, the piston seals are defective and
must be replaced.
6. If no repairs are necessary or when repairs have
been made, carefully reconnect hydraulic hoses to
the appropriate ports.
7. Remove boom prop/overhead crane, activate
hydraulic system and run cylinder through complete
cycle to check for leaks and operation.
2-18
JLG Lift
3120743
Figure 2-11. Boom Prop Configurations - 30 electric. (Sheet 1 of 3)
3120743
JLG Lift
2-19
Figure 2-11. Boom Prop Configurations - 35/n35 electric. (Sheet 2 of 3)
2-20
JLG Lift
3120743
Figure 2-11. Boom Prop Configurations - 40/n40/45 electric. (Sheet 3 of 3)
3120743
JLG Lift
2-21
6. Attach a suitable pulling device to the cylinder rod

port block end or cylinder rod end, as applicable.
2.10 CYLINDER REPAIR.

NOTE: The following are general procedures that apply to
all of the cylinders on this machine. Procedures that
apply to a specific cylinder will be so noted.
Disassembly.
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD AND PISTON. AVOID PULLING THE ROD OFF
CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES.
7. With the barrel clamped securely, apply pressure to
the rod pulling device and carefully withdraw the
complete rod assembly from the cylinder barrel.
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON

A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
1. Connect a suitable auxiliary hydraulic power source
to the cylinder port block fitting.
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.

RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.
ONCE THE HEAD GLAND HAS CLEARED THE CYLINDER CASE

MOUTH, THE ROD MUST BE SUPPORTED CLOSE TO THE CYLINDER CASE PRIOR TO THE PISTON BEING PULLED PAST THE
CYLINDER CASE THREADS, AND/OR THE PISTON AND PISTON
SEALS.
NOTE: Step (8) applies to the steer cylinder.
2. Operate the hydraulic power source and extend the

cylinder. Shut down and disconnect the power
source. Adequately support the cylinder rod, if applicable.
3. If applicable, remove the cartridge type holding
valve, manual descent valve, and fittings from the
port block. Discard o-rings.
4. Place the cylinder barrel into a suitable holding fixture. Tap around outside of cylinder head retainer
with a suitable hammer to shatter loctite.
8. Remove the remaining head gland from the barrel if

you have not already done so.
9. Using suitable protection, clamp the cylinder rod in
a vise or similar holding fixture as close to the piston
as possible.
10. Remove the set screw(s) if applicable, and nut which
attach the piston and spacer(s), if applicable, to the
rod, and remove piston and spacers. Discard self
locking set screws.
NOTE: Step (11) applies to the slave leveling and master
cylinders. (Cylinders built from 12/94 to present)
11. Remove the set screw, and nut which attach the piston and spacer to the rod. Using a suitable nylon
strap wrench loosen piston and remove piston and
spacers. Discard self locking set screws
Figure 2-12. Removal of Cylinder Retainer.

5. Using a suitable chain wrench, loosen the cylinder
head retainer, if applicable, and/or cylinder head
gland, and remove from cylinder barrel.
NOTE: Steer cylinder has cylinder head retainer at both
ends. Remove both retainers.
2-22
JLG Lift
Figure 2-13. Removal of Set Screws.
3120743
12. Remove and discard the o-rings, seal rings and

backup rings.
21. Inspect cylinder head(s) inside diameter for scoring

or other damage and ovality and tapering. Replace
as necessary.
22. Inspect seal and o-ring grooves in head(s) for burrs
and sharp edges. Dress applicable surfaces as necessary.
23. If applicable, inspect cylinder head retainer(s) or end
cap(s) for surface or thread damage. Repair or
replace as necessary.
24. Inspect cylinder head(s) outside diameter for scoring or other damage and ovality and tapering.
25. If applicable, inspect rod and barrel bushing for
signs of correct lubrication and excessive wear.
Figure 2-14. Removal of Seals and O-Rings.

13. Remove the rod from the holding fixture. Remove
the cylinder head gland if applicable. Discard the orings, back-up rings, rod seals, and wiper seals.
26. Inspect travel limiting collar or spacer(s) for burrs

and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or equivalent.
27. If applicable, inspect port block fittings and holding
valve. Replace as necessary.
28. Inspect the oil ports for blockage or other presence
of dirt or other foreign material. Repair as necessary.
Assembly.
NOTE: Prior to cylinder assembly, ensure that the proper
cylinder seal kit is used. See your JLG Parts Manual.
Apply a light film of hydraulic oil to all components
prior to assembly.
Figure 2-15. Removal of Piston Seals.
Cleaning and Inspection.
1. Place a new wiper seal and rod seal into the applicable cylinder head gland(s) grooves.
14. Clean all parts thoroughly in approved solvent.

15. Inspect the cylinder rod for scoring, tapering, ovality,
or other damage. If necessary, dress rod with
Scotch-Brite or equivalent. Replace rod if necessary.
16. Inspect threaded portion of rod if applicable for
excessive damage. Dress threads as necessary.
17. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for
tapering or ovality. Replace if necessary.
18. Inspect threaded portion of barrel for damage. Dress
threads as necessary.
19. Inspect piston surface for damage and scoring and
for distortion. Dress or replace piston as necessary.
20. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as necessary.
3120743
JLG Lift
Figure 2-16. Rod Seal Installation.

2. Using a soft mallet, tap a new wiper seal into the
applicable cylinder head gland grooves. Install a
new wear ring into applicable cylinder head gland
groove.
2-23
7. If applicable, correctly place new o-ring in the inner

piston diameter groove.
8. If applicable, correctly place new seals and guide
lock rings in the outer piston diameter groove.
Figure 2-17. Wiper Seal Installation.
Figure 2-20. Piston Seal Kit Installation.

NOTE: Step (9) applies to Upper, Mid, Lower Lift, Master,
and Slave Cylinders.
9. Push the piston onto the rod until it abuts the spacer
end and install the attaching nut, and spot drill cylinder rod for set screw then install setscrew. (See
Table 2-1.)
NOTE: Step (10) applies to Steer Cylinder.
Figure 2-18. Poly-Pak Piston Seal Installation.
3. Place a new o-ring in the applicable outside diameter groove of the cylinder head.
10. Push the piston onto the rod until it straddles the oring in the center groove and abuts the retaining
ring. Install the other retaining ring and spacer.
Figure 2-21. Steer Cylinder Piston Installation.

Figure 2-19. "O"-Ring Installation.
4. Install retainer or retaining ring onto the cylinder rod.
5. Carefully install the cylinder head on the cylinder
rod, ensuring that the o-ring and back-up rings are
not damaged or dislodged. Push the head along the
rod to the rod end as applicable.
6. Using suitable protection, clamp the cylinder rod in
a vise or similar holding fixture as close to the piston
as possible.
2-24
NOTE: Step (11) applies to the Slave Leveling and Master

Cylinders. (Cylinders built from 12/94 to present)
11. Install piston onto rod by hand tighten the piston
hand tight and install the attaching nut, and spot drill
cylinder rod for set screw then install setscrew. (See
Table 2-1.).
NOTE: Step (12) applies to 35/n35/40/n40/45 electric Telescope Cylinder.
JLG Lift
3120743
12. Push the piston onto the rod until it abuts the spacer
end and install the attaching locknut. (See Table 21.)
18. If applicable, apply loctite #222 and secure the cylinder head retainer using a suitable chain wrench.
NOTE: Step (19) applies to the Steer Cylinder.
19. Secure the cylinder head with retainer ring.
WHEN REBUILDING THE LIFT CYLINDERS, APPLY LOCTITE 242

TO PISTON NUT AND SETSCREWS.
13. Remove cylinder rod from the holding valve.
14. Place new o-rings and seals in the applicable outside diameter grooves of both the piston and the cylinder head.
15. Position the cylinder barrel in a suitable holding fixture.
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE

CYLINDER ROD, HEAD AND PISTON. AVOID PULLING THE ROD
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
AND CYLINDER BARREL SURFACES.
16. With barrel clamped securely, and while adequately
supporting the rod, insert the piston end into the cylinder barrel. Ensure that the piston loading o-ring
and seal ring are not damaged or dislodged.
NOTE: These cylinders use setscrews which should be discarded and replaced whenever they are removed.
17. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder or if applicable until the cylinder head threads
engage the barrel threads.
Figure 2-22. Installing Retainer Ring on

Telescope Cylinder Barrel.
NOTE: Step (20) applies to the Steer Cylinder.
20. Insert the other cylinder head gland into the barrel
cylinder. Secure the cylinder head retainer using a
suitable chain wrench.
21. After the cylinder has been reassembled, the rod
should be pushed all the way in (fully retracted) prior
to the reinstallation of any holding valves.
22. If applicable, install the cartridge type holding valve
and fittings in the rod port block using new o-rings
as applicable. (See table 2-2 holding valve torque
specifications)
IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON

THE MACHINE, EXTREME CARE SHOULD BE USED TO INSURE
THAT THE OUTER END OF THE ROD IS SUPPORTED. USE
EITHER A TRAVELING OVERHEAD HOIST, FORKLIFT, OR OTHER
MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE
EXTENDING ROD.
3120743
JLG Lift
2-25
Figure 2-23. Lift Cylinder Assembly.
2-26
JLG Lift
3120743
Table 2-1. Cylinder Piston Nut Torque Specifications

Table 2-1. Cylinder Piston Nut Torque Specifications
Description
Nut Torque Valve

(Wet)
Setscrew Torque
Value (Dry)
Model 30 electric
Upper Lift Cylinder
200 ft. lbs.

(271 Nm)
100 in. lbs.

(12 Nm)
Lower Lift Cylinder
200 ft. lbs.

(271 Nm)
100 in. lbs.

(12 Nm)
N/A
N/A
Steer Cylinder
Master Cylinder
(From 1/95 to present)
80 ft. lbs.
(109 Nm)
100 in. lbs.

(12 Nm)
Rotator Cylinder
N/A
N/A
Steer Cylinder
N/A
N/A
Telescope Cylinder Piston Nut Torque

Specifications.
Description
Locknut Torque Value (Dry)
Tele Cylinder
150 ft. lbs. (203 Nm)
Description
Nut Torque Value

(Wet)
Model 35/n35 electric

Upper Lift Cylinder
200 ft. lbs.

(271 Nm)
100 in. lbs.

(12 Nm)
Lower Lift Cylinder
400 ft. lbs.

(542 Nm)
100 in. lbs.

(12 Nm)
Slave Cylinder (To 12/94)
50 ft. lbs.
(68 Nm)
100 in. lbs.

(12 Nm)
Slave Cylinder
80 ft. lbs.
(109 Nm)
100 in. lbs.

(12 Nm)
Master Cylinder (To 1/95)
50 ft. lbs.
(68 Nm)
100 in. lbs.

(12 Nm)
Master Cylinder
80 ft. lbs.
(109 Nm)
100 in. lbs.

(12 Nm)
Rotator Cylinder
N/A
N/A
Steer Cylinder
N/A
N/A

Specifications.
Description
Tele Cylinder
150 ft. lbs. (203 Nm)
Model 45 electric
Upper Lift Cylinder
200 ft. lbs.

(271 Nm)
100 in. lbs.

(12 Nm)
Mid Lift Cylinder
400 ft. lbs.

(542 Nm)
100 in. lbs.

(12 Nm)
Lower Lift Cylinder
400 ft. lbs.

(542 Nm)
100 in. lbs.

(12 Nm)
Slave Cylinder
(To 12/94)
50 ft. lbs.
(68 Nm)
100 in. lbs.

(12 Nm)
80 ft. lbs.
(109 Nm)
100 in. lbs.

(12 Nm)
50 ft. lbs.
(68 Nm)
100 in. lbs.

(12 Nm)
80 ft. lbs.
(109 Nm)
100 in. lbs.

(12 Nm)
N/A
N/A
N/A
N/A
Slave Cylinder
(From 12/94
to present)
Master Cylinder
(To 1/95)
Master Cylinder
(From 1/95
to present)
Rotator Cylinder
Steer Cylinder
Model 40/n40 electric

Upper Lift Cylinder
200 ft. lbs.

(271 Nm)
100 in. lbs.

(12 Nm)
Mid Lift Cylinder
200 ft. lbs.

(271 Nm)
100 in. lbs.

(12 Nm)
Lower Lift Cylinder
400 ft. lbs.

(542 Nm)
100 in. lbs.

(12 Nm)
Slave Cylinder (To 12/94)
50 ft. lbs.
(68 Nm)
100 in. lbs.

(12 Nm)
80 ft. lbs.
(109 Nm)
100 in. lbs.

(12 Nm)
50 ft. lbs.
(68 Nm)
100 in. lbs.

(12 Nm)
Slave Cylinder
(From 12/23/94
to present)
Master Cylinder (To 1/95)
3120743
Setscrew Torque
Value (Dry)

Specifications.
Description
Tele Cylinder
150 ft. lbs. (203 Nm)
JLG Lift
2-27
Table 2-2.Holding Valve Torque Specifications.

Description
SUN - 7/8 HEX M20 X 1.5 THDS.
SUN - 1 1/8 HEX 1 -14 UNS THDS.
SUN - 1 1/4 HEX M36 X 2 THDS.
5. Remove the cylinder from the boom and place in a

suitable work area.
Torque Value
30-35 ft. lbs.
(41-48 Nm)
45-50 ft. lbs.
(61-68 Nm)
150-160 ft. lbs.
(204-217 Nm)
RACINE - 1 1/8 HEX 1 1/16 - 12 THDS.
50-55 ft. lbs.

(68-75 Nm)
RACINE - 1 3/8 HEX 1 3/16 - 12 THDS.
75-80 ft. lbs.

(102-109 Nm)
RACINE - 1 7/8 HEX 1 5/8 - 12 THDS.
100-110 ft. lbs.

(136-149 Nm)
2.11 CYLINDER REMOVAL AND

INSTALLATION.
Upper (Main) Boom Lift Cylinder Removal.
(See Figure 2-24)
Figure 2-24. Upper Boom Lift Cylinder Removal.
1. 30/35/n35 electric - Place the machine on a flat and

level surface. Place the Upper Boom in a horizontal
position. Shut down machine and prop boom.
40/n40/45 electric - Place the machine on a flat and
level surface. Place the Upper Boom in a horizontal
position. Place Lower and Mid Booms 5 degree
above horizontal. Shut down machine and prop
boom.
Upper (Main) Boom Lift Cylinder Installation.

NOTE: Coat I.D. of bushings with specified lubricant prior to
installing pins.
2. Tag, disconnect and cap the upper boom lift cylinder

hydraulic lines and ports.
3. Remove the hardware securing the cylinder rod
attach pin #1 to the boom. Using a suitable brass
drift, drive out the cylinder rod attach pin #1.
4. Secure the cylinder with suitable slings or supports
as required. Remove the hardware securing the barrel end attach pin #2. Using a suitable brass drift,
drive out the barrel end attach pin #2.
1. 30/35/n35/40/n40/45 electric - Install Lift Cylinder in

place using suitable slings or supports, aligning
attach pin mounting holes on upright.
2. Using a suitable drift, drive the barrel end attach pin
#2 through the mounting holes in the lift cylinder
and upright. Secure in place with pin retaining hardware.
3. Remove cylinder port plugs and hydraulic line caps
and correctly attach lines to cylinder ports.
4. With function speed switch at its slowest setting,
extend the cylinder rod until attach pin hole aligns
with those in boom. Using a suitable drift, drive the
cylinder rod attach pin #1 through the aligned
holes. Secure the pin in place with pin retaining
hardware.
5. Cycle cylinder completely to check for proper functioning. Place boom in stowed position. Check
hydraulic fluid level and adjust accordingly.
2-28
JLG Lift
3120743
Mid Boom Lift Cylinder Removal.

(See Figure 2-25.)
Mid Boom Lift Cylinder Installation.
1. 40/n40/45 electric - Place machine on flat and level

surface. Place the Upper Boom in a horizontal position. Place the Mid Boom in a 10 degree elevated
position. See Figure 2-11. Support Upper Boom with
a prop. Support upright with an overhead crane.

installing pins.
2. Using slings, restrain the lower lift cylinder.

attach pin #3 to the boom. Using an appropriate
brass drift, drive out the cylinder rod attach pin #3.
4. Tag, disconnect and cap the lift cylinder hydraulic
lines and ports.
5. Remove the hardware securing the barrel end attach
pin #4 to the boom. Using an appropriate brass
drift, drive out the cylinder barrel pin #4.
6. Carefully remove cylinder from boom. Place in a
suitable work area.
1. 40/n40/45 electric - With the booms positioned and

supported as in Figure 2-11, place cylinder in position and secure in place using slings.
2. Install the cylinder barrel pin #4, being sure to align
the hole in the cylinder barrel pin with the retaining
pin screw hole. When holes align, install hardware.
3. Correctly install hydraulic lines to cylinder as previously tagged. Extend cylinder rod slowly until attach
pin hole aligns with those in boom.
4. Using a suitable brass drift, drive the cylinder rod
attach pin #3 through the aligned holes. Secure the
pin in place using retaining hardware.
5. Remove boom prop and overhead crane. Take the
lift cylinder through one complete cycle to assure
correct functioning. Place boom in stowed position.
Check hydraulic fluid and adjust accordingly.
Figure 2-25. Mid Boom Lift Cylinder Removal.
3120743
JLG Lift
2-29
Lower Boom Lift Cylinder Removal.

Lower Boom Lift Cylinder Installation.
1. 30/35/n35 electric - Place machine on flat and level
surface. Place the Upper Boom in a horizontal position. Place the Lower Boom in a horizontal position.
See Figure 2-11. Support Upper Boom with a prop.
Support upright with an overhead crane.

installing pins.
2. 40/n40/45 electric - Place machine on flat and level

surface. Place the Upper Boom in a horizontal position. Place the Mid and Lower Booms in a 10 degree
elevated position. See Figure 2-11. Support Upper
Boom with a prop. Support upright with an overhead
crane.
2. Using slings, restrain the lower lift cylinder.
attach pin #5 to the boom. Using an appropriate
brass drift, drive out the cylinder rod attach pin #5.
4. Tag, disconnect and cap the lift cylinder hydraulic
lines and ports.
5. Remove the hardware securing the barrel end attach
pin #6 to the boom. Using an appropriate brass
drift, drive out the cylinder barrel pin #6.
1. 30/35/n35/40/n40/45 electric - With the booms positioned and supported as in Figure 2-11, place cylinder in position and secure in place using slings.
2. Install the cylinder barrel pin #6, being sure to align
the hole in the cylinder barrel pin with the retaining
pin screw hole. When holes align, install hardware.
3. Correctly install hydraulic lines to cylinder as previously tagged. Extend cylinder rod slowly until attach
pin hole aligns with those in boom.
4. Using a suitable brass drift, drive the cylinder rod
attach pin #5 through the aligned holes. Secure the
pin in place using retaining hardware.
5. Remove boom prop and overhead crane. Take the
lift cylinder through one complete cycle to assure
correct functioning. Place boom in stowed position.
Check hydraulic fluid and adjust accordingly.
6. Carefully remove cylinder from boom. Place in a

suitable work area.
Figure 2-26. Lower Boom Lift Cylinder Removal.
2-30
JLG Lift
3120743
Upper Boom Telescope Cylinder Removal.

(See Figure 2-27.)
1. 35/n35/40/n40/45 electric - Place machine on flat
and level surface, with Upper Boom in the horizontal
position. Extend Upper Boom until fly attach pin #1
is accessible on fly.
2. Support Upper Boom basket end with a prop. Support Upper Upright end with an overhead crane (See
Figure 2-11.)
3. Tag, disconnect hydraulic lines to telescope cylinder.
Use suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports.
4. Remove the retaining rings that retain the telescope
cylinder rod to the fly boom.
5. Using a suitable brass drift, carefully drive the telescope cylinder rod pin #1 from the fly boom.
Figure 2-27. Upper Telescope Cylinder Removal.
Upper Boom Telescope Cylinder Installation.
6. Remove the four (4) bolts securing the telescope

cylinder barrel end to the base boom.
1. 35/n35/40/n40/45 electric - Attach a hydraulic power

supply to the telescope cylinder ports. Using suitable supports or lifting devices at each end of the
cylinder, extend the rod so that the cylinder pin
attach holes are the same distance apart as the
boom pin attach holes.
NOTE: Care should be taken when removing the telescope

cylinder, do not leave cylinder rest on powertrack
which could cause damage to powertrack.
7. Using a suitable brass drift, carefully drive the telescope cylinder pin from the base boom.
2. Using suitable lifting equipment, carefully lower the

cylinder to the boom assembly.
8. Attach a suitable sling to the telescope cylinder.

Using a suitable lifting device attached to the sling
carefully pull the telescope cylinder from the boom
assembly.
3. Using another lifting device, support the rod end of

the cylinder and install the cylinder into the boom
assembly.
4. Remove lifting devices from the telescope cylinder.
9. Using another lifting device, support the rod end of

the cylinder and remove the cylinder from the boom
assembly.
5. Carefully install the telescope cylinder rod pin #1

through the fly boom and secure it with the retaining
rings.
10. Carefully lift the cylinder clear of the boom assembly

and lower to the ground or suitably supported work
area.
6. Carefully install the telescope cylinder barrel end to

base, securing cylinder to the base boom with four
(4) bolts and hardware.
7. Remove applicable hydraulic line and port caps and
correctly connect the hydraulic lines to the telescope cylinder. Ensure all hoses are correctly
routed.
8. Remove boom prop and overhead crane. Actitive
hydraulic system.
9. Using all applicable safety precautions, operate the
boom functions. Check for correct operation and
hydraulic leaks. Secure as necessary.
10. Check fluid level of hydraulic tank and add as necessary.
3120743
JLG Lift
2-31
2.12 TILT INDICATOR SWITCH LEVELING

PROCEDURE. (IF EQUIPPED.)
2.14 POWER TRACK REMOVAL PROCEDURE

(35/N35/40/N40/45 ELECTRIC).
1. Position the Upper Boom to horizontal.
2. Align the (2) holes at left side rear of the Upper
Boom.
PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINIMUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION
AND ADJUSTMENT OF SWITCH.
3. Remove the cover on left side of Upper Boom.

(exposing hydraulic and electric lines)
Manual Adjustment.
4. Disconnect and remove 3 pronged plug and 35 pin

plug from electric lines.
11. Park the machine on a flat level surface. Be sure it is

as level as possible, with tires filled to rated pressure.
5. Disconnect hydraulic lines. (2)

6. Remove Power Track bolts (2) at right side center of
Upper Boom. (shown in Figure 2-9)
NOTE: Ensure switch mounting is level and securely

attached.
7. Remove holding block at rear of telescoping cylinder (4) bolts.
12. Tighten the three flange nuts with a socket wrench.

Each nut should be tightened approximately onequarter of its springs travel.
8. Pull the Power Track towards the rear from the right
side of the track.
13. Using bubble level on top of indicator, Tighten or

loosen the three flange nuts until indicator is level.
9. Disconnect the Power Track from left rear of Upper

Boom.(2) bolts.
14. Individually push down on one corner at a time.

There should be enough travel to cause the indicator to trip. If the indicator does not trip in all three
tests, the flange nuts have been tightened too far.
10. Remove the hydraulic and electrical lines from the

Power Track.
11. Install in reverse order of removal.
2.15 PRESSURE SETTING PROCEDURES. (IN

SEQUENCE) (SEE FIGURE 2-29)
NOTE: Model 30 electric.
Main Relief at Pump.

1. Install pressure gauge at port G on 4640725 valve.
2. Activate and bottom out either Upper or Lower Lift
Up. Adjust Main Relief to 2600 psi (179.27 bar).
Lift Down Relief.
Figure 2-28. Tilt Switch.
1. With pressure gauge at G port on 4640725 valve,

activate and bottom out Upper Lift Down.
2.13 BOOM LIMIT SWITCHES.
2. Adjust Upper Lift Relief to 900 psi (62 bar).
There are no adjustments to be made to the two Boom

Limit Switches which bolt in place on the upright.
3. Activate and bottom out Lower Lift Down.

4. Adjust Lower Lift Relief to 725 psi (49.99 bar).
Swing Relief.
activate and bottom out Swing function in either
direction.
2. Adjust Swing Relief to 1000 psi (68.95 bar).
2-32
JLG Lift
3120743
Steer Relief.
Platform Level Down Relief.

activate and bottom out Steer Left or Right.

activate and bottom out Platform Level Down.
2. Adjust Steer Relief to 1100 (75.84 bar).
2. Adjust Platform Level Down Relief to 1200 psi (82.74

bar).
3. Shut down hydraulic system and remove pressure

gauge.
Steer Relief.
Model 35/n35 electric.

2. Adjust Steer Relief to 1500 psi (103.42 bar).

gauge.

Model 40/n40/45 electric.
Lift Down Relief.


2. Adjust Upper Lift Relief to 600 psi (41.37 bar).
Upper Lift Down Relief.
Lower Lift Down Relief.


activate and bottom out Mid/Lower Lift Down.
2. Adjust Upper Lift Relief to 650 psi (44.82 bar).
2. Adjust Lower Lift Relief to 600 psi (41.37 bar).
Mid/Lower Lift Down Relief.
Swing Relief.

activate and bottom out Mid/Lower Lift Down.

direction.
2. Adjust Mid/Lower Lift Relief to 1700 psi (117.21 bar).
Swing Relief.
Telescope In Relief.

direction.

activate and bottom out Telescope In.
2. Adjust Telescope In Relief to 2150 psi (148.25 bar).
Telescope In Relief.
Platform Level Up Relief.

activate and bottom out Platform Level Up.
2. Adjust Platform Level Up Relief to 2500 (172.37 bar).
3120743
JLG Lift

activate and bottom out Telescope In.
2. Adjust Telescope In Relief to 2150 psi (148.25 bar).
2-33
Platform Level Up Relief.
Steer Relief.

activate and bottom out Platform Level Up.

2. Adjust Platform Level Up Relief to 2500 psi (172.37

bar).
2. Adjust Steer Relief to 1500 psi (103.42 bar), for Models 35/n35/40/n40/45. Adjust pressure to 1100 psi
(75.84 bar), for Models 30/n30.
Platform Level Down Relief.

activate and bottom out Platform Level Down.

gauge.
2. Adjust Platform Level Down Relief to 1200 psi (82.74

bar).
2-34
JLG Lift
3120743
Figure 2-29. Pressure Setting Procedure - 30 electric. (Sheet 1 of 3)
3120743
JLG Lift
2-35
Figure 2-29. Pressure Setting Procedure - 35/n35 electric. (Sheet 2 of 3)
2-36
JLG Lift
3120743
Figure 2-29. Pressure Setting Procedure - 40/n40/45 electric. (Sheet 3 of 3)
3120743
JLG Lift
2-37
2.16 SWING BEARING.

Turntable Bearing Mounting Bolt Condition
Check.
NOTE: This check is designed to replace the existing bearing bolt torque checks on JLG Lifts in service. This
check must be performed after the first 50 hours of
machine operation and every 600 hours of machine
operation thereafter. If during this check any bolts
are found to be missing or loose, replace missing or
loose bolts with new bolts and torque to the value
specified in the torque chart, after lubricating the bolt
threads with loctite #271. After replacing and torquing bolt or bolts recheck all existing bolts for looseness.
Figure 2-30. Swing Bearing Feeler Gauge Check.
1. Check the frame to bearing. Attach bolts as follows:
a. Elevate the fully retracted boom to 70 degrees
(full elevation).
Wear Tolerance.
b. At the positions indicated on Figure 2-30. try and

insert the.0015" feeler gauge between the bolt
head and hardened washer at the arrow indicated position.
c. Assure that the.0015" feeler gauge will not penetrate under the bolt head to the bolt shank.
d. Swing the turntable 90 degrees, and check
some selected bolts at the new position.
e. Continue rotating the turntable at 90 degrees
intervals until a sampling of bolts have been
checked in all quadrants.
2. Check the turntable to bearing. Attach bolts as follows:
a. Elevate the fully retracted boom to 70 degrees
(full elevation).
b. At the positions indicated on Figure 2-30. try and
c.
Lower the boom to horizontal and fully extend

the boom.
d. At the position indicated on Figure 2-30. try and

2-38
JLG Lift
1. 30 electric - With the boom positioned over the side

of the machine, the Upper Boom fully elevated and
Lower Boom stowed, (See Figure 2-31 a.), using a
magnetic base dial indicator, measure and record
the distance between the swing bearing and turntable. (See Figure 2-32.)
35/n35 electric - With the boom positioned over the
side of the machine, the Upper Boom horizontal with
telescope fully extended and Lower Boom fully elevated, (See Figure 2-31 a.), using a magnetic base
dial indicator, measure and record the distance
between the swing bearing and turntable. (See Figure 2-32.)
40/n40/45 electric - With the boom positioned over
the side of the machine, the Upper Boom horizontal
with telescope fully extended and Mid/Lower Boom
stowed, (See Figure 2-31 a.), using a magnetic base
dial indicator, measure and record the distance
between the swing bearing and turntable. (See Figure 2-32.)
2. 30 electric - At the same point, with the boom positioned over the side of the machine, the Upper
Boom horizontal and the Lower Boom fully elevated,
(See Figure 2-31 b.) using a magnetic base dial indicator, measure and record the distance between the
swing bearing and turntable (See Figure 2-32).
3120743
Figure 2-31. Swing Bearing Tolerance Boom Placement - 30/n30/n35 electric. (Sheet 1 of 2)
3120743
JLG Lift
2-39
Figure 2 31. Swing Bearing Tolerance Boom Placement - 40/n40/45 electric. (Sheet 2 of 2)
40/n40/45 electric - At the same point, with the boom positioned over the side of the machine, the Upper Boom fully
elevated and the Mid/Lower Boom fully elevated, (See Figure 2-31 b.) using a magnetic base dial indicator, measure
and record the distance between the swing bearing and
turntable (See Figure 2-32).
3. If a difference greater than 0.057 in. (1.40 mm) is
determined, the swing bearing should be replaced.
4. If a difference less than 0.057 in. (1.40 mm) is determined, and any of the following conditions exist, the
bearing should be removed.
a. Metal particles in the grease.
b. Increased drive power.
c. Noise.
Figure 2-32. Swing Bearing Tolerance Measuring Point.
35/n35 electric - At the same point, with the boom positioned over the side of the machine, the Upper Boom fully
elevated and the Lower Boom horizontal, (See Figure 2-31
b.) using a magnetic base dial indicator, measure and
record the distance between the swing bearing and turntable (See Figure 2-32).
2-40
JLG Lift
d. Rough rotation.
5. If bearing inspection shows no defects, reassemble
bearing and return to service.
3120743
Replacement of Swing Bearing.
Multi-Purpose Grease (MPG) can be substituted,

however the service interval will be shorter.
1. Removal.
a. Attach an adequate support sling to the boom
and draw all slack from sling. Prop or block the
boom if feasible.
b. Tag and disconnect hydraulic lines running
through center of turntable and frame. Use a
suitable container to retain any residual hydraulic fluid. Cap lines and ports.
a. Using suitable lifting equipment, install bearing/

rotation box assembly to frame with soft spot
(red) 90 degree relative to load axis. If reusing
old bearing, ensure that scribed line of outer
race of the bearing aligns with the scribed mark
on the frame.
c. Attach suitable overhead lifting equipment to the

base of turntable weldment.
d. Use a suitable tool to scribe a line on the inner
race of the swing bearing and on the underside
of the turntable. This will aid in aligning the bearing upon installation. Remove bolts, nuts and
washers which attach the turntable to the bearing inner race. Discard nuts and bolts.
e. Use the lifting equipment to carefully lift the complete turntable assembly from the bearing.
Ensure that no damage occurs to the turntable,
bearing or frame mounted components.
JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED GRADE 8

BEARING NUTS AND BOLTS BE DISCARDED AND REPLACED
WITH NEW NUTS AND BOLTS. SINCE THE SWING BEARING IS
THE ONLY STRUCTURAL LINK BETWEEN THE FRAME AND
TURNTABLE, IT IS IMPERATIVE THAT SUCH REPLACEMENT
HARDWARE MEETS JLG SPECIFICATIONS. USE OF GENUINE
JLG HARDWARE IS HIGHLY RECOMMENDED.
f. Carefully place the turntable on a suitably supported trestle.

g. Use a suitable tool to scribe a line on the outer
race of the swing bearing and the frame. This
line will aid in aligning the bearing upon installation. Remove the bolts and washers which
attach the outer race of the bearing to the frame.
Discard the bolts. Use suitable lifting equipment
to remove the bearing and rotation box assembly from the frame; move to a clean, suitably
supported work area.
b. Apply a light coating of Loctite 271 to the new

bearing bolts and loosely install the bolts and
washers through the frame and outer race of
bearing.
IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT

WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL
SHOULD BE CHECKED PRIOR TO USE.
h. Remove the two cap screws securing the bearing to the rotation box to separate the two for
inspection.
2. Installation.
a. Install bearing to rotation box with two cap
screws, so that fill plug of bearing is as close to
gear as bolt pattern will allow. Do not tighten cap
screws.
b. Line up high spot (blue) of bearing with center
tooth of worm gear. Set backlash to 0.008 0.010 inch (0.20 - 0.25 mm). Tighten capscrews
as shown in Figure 2-33.
c. Following the torque sequence diagram shown

in Figure 2-33, tighten the bolts to an initial
torque of 175 ft. lbs. (237 Nm). Then following
the same sequence, tighten to a final torque of
240 ft. lbs. (326 Nm).
d. Remove lifting equipment from bearing.
e. Use suitable lifting equipment to carefully position the turntable assembly above the machine
frame.
c. Apply Tribol Molub-Alloy 936 Open Gear Compound to bearing and worm gear teeth.
f. Carefully lower the turntable onto the swing

bearing. Ensure that the scribed line of the inner
race of the bearing aligns with the scribed mark
on the turntable. If a new swing bearing is used,
ensure that the filler plug fitting is at 90 degrees
from the fore and aft centerline of the turntable.
d. Grease bearing with Mobilith SHC Bearing

Grease. Grease fitting is on inside wall of inner
race of bearing.
g. Apply a light coating of Loctite 271 to the new

bearing bolts and install through the turntable
and inner race of bearing.
NOTE: If Tribol Molub-Alloy 936 Open Gear Compound or

Mobilith SHC Bearing Grease are not available,
h. Following the torque sequence shown in Figure

2-33, tighten the bolts to an initial torque of 175
ft. lbs. (237 Nm). Then following the same
3120743
JLG Lift
2-41
sequence, tighten the bolts to 240 ft. lbs (326

Nm).
i. Remove the lifting equipment.
j. Route hydraulic lines through center of turntable
and frame and connect as tagged prior to
removal.
k. Using all applicable safety precautions, activate
the hydraulic system and functionally check
swing system for proper and safe operation.
Figure 2-34. Worm Gear Tolerance
Adjusting End Play.

1.
Remove end plate.
2. Measure and record total thickness of existing shim

pack.
3. Determine thickness of shim pack required to obtain
+.001",-.005" end play.
4. Adjust shim pack thickness as required to obtain
proper end play. Reduce end play by removing
thicker shims and replacing with thinner shims,
included in kit.
Figure 2-33. Swing Bearing Torquing Sequence
Swing Bearing Torque Values.

1. Dry - 220 ft. lbs. (298 Nm).
5. Replace end plate and torque bolts to 90 ft. lbs. (122

Nm).
2. Loctite - 240 ft. lbs. (326 Nm).
6. Recheck end play.
Checking Worm Gear End Play.

NOTE: JLG Industries requires that a annual inspection be
performed on the worm gear end play.
1. Using a dial indicator, measure end play of worm
gear, by applying side to side movement by hand to
platform.
2. If tolerance exceeds.010", reduce end play to less
than.005". Refer to Adjusting End Play.
Figure 2-35. Worm Gear Shim Kit
2-42
JLG Lift
3120743
10. The bearing cups (3 and 5) will remain in housing (7)

as will bearing cone (6). Bearing cone (4) will remain
on the spindle (1). The seal (2) will be automatically
removed during this procedure.
2.17 DRIVE TORQUE HUB.

(SEE FIGURE 2-34)
Disassembly.
1. Loosen all cover bolts (28 and 29) and drain oil from
unit.
2. Remove the cover bolts (28 and 29) and lift off cover
(23). Remove and discard o-ring (22) from counterbore of cover (23).
3. Remove input gear (24) and thrust washer (26)
4. Lift out the carrier assembly (14) and top thrust
washer (27).
5. Remove input thrust spacer (25).
6. Lift out internal gear (13) and thrust washer (27).
NOTE: Eye protection should be worn during retaining ring
(9) removal.
7. Remove the retaining ring (9) from the spindle (1)
and discard.
NOTE: If bearing replacement is necessary, the bearing

cups can be removed with a slide hammer puller or
driven out with a punch.
11. To remove the cluster gears (19) from the carrier
(14), drive the roll pin (20) into the planet shaft (18).
The planet shaft may now be tapped out of the carrier. After planet shaft has been removed, the roll pin
(20) can be driven out.
12. The cluster gear (19) can now be removed from the
carrier (14). The tanged thrust washer (15) will be
removed from the cluster gear.
13. The needle bearings (16) and thrust spacer (17) are
now removed from cluster gear (19).
NOTE: When rebuilding or repairing the unit, the retaining
ring (9), o-rings (22), and lip seal (2) should always
be replaced.
8. Remove thrust washer (8) from the spindle (1).

9. The spindle (1) may now be pressed out of the
housing (7).
3120743
JLG Lift
2-43
Figure 2-36. Drive Hub Assembly - 30/35/n35/40/n40/45.
2-44
JLG Lift
3120743
shoulder bolts (29). A tap with a hammer may be

necessary to align shoulder bolt with hub counterbore.
Assembly.
1. With the hub shaft sub-assembly resting on the spindle (1) install internal gear (13). The spline of the
internal gear (13). The spline of the internal gear (13)
bore will mesh with the spline of the output shaft (1).
13. Install bolts (28) into remaining holes.
2. Thrust washer (27) is installed on the face of the

spindle (1). Sufficient grease or petroleum jelly
should be used to hold thrust washer (27) in place.
15. Torque bolts (28 and 29) to 23 - 27 ft. lbs. (31- 36

Nm).
3. Place o-ring (22) into hub counterbore. Use petroleum jelly to hold in place. Locate and mark the four
counter beamed holes in the face of the housing (7).
This is for identification later in the assembly.
4. Thrust spacer (25) is installed into the bore of the
spindle (1). This should be a slip fit and the thrust
spacer should rotate in this location.
14. Pipe plugs (30) are to be installed into input cover

(23) using a lubricant seal.
16. Fill unit one-half full with EP90 lubricant.
2.18 DRIVE BRAKE ASSEMBLY.

(SEE FIGURE 2-35.)
Disassembly.
1. After removing brake from its installation, place
brake on a clean dry work bench with mounting
plate uppermost.
5. Place carrier assembly (14) on a flat surface with the

cluster gears (19) up. Find the punch marked tooth
on each large gear and locate at 12 oclock (straight
up) from each planet pin.
2. Unscrew capscrews (9) in equal increments to

ensure the spring pressure within the brake is
reduced gradually and evenly.
6. With shoulder side of ring gear (21) facing down,

place ring gear over (into mesh with) large gears. Be
sure that punch marks remain in correct location
during installation. The side of the ring gear with an
X stamped on it should be up.
3. Remove and lay aside the shaft (3) mounting plate

(4) sub-assembly. Should it be necessary to replace
ball bearings (11), remove circlips (12 and 13) and
press bearing off.
7. While holding ring gear (21) and cluster gears (19) in

mesh, place small side of cluster gears into mesh
with the internal gear (13) and input gear (24). On
the ring gear, locate the hole marked X over one of
the marked counterbored holes in assembly (7).
NOTE: If gears do not mesh easily or carrier assembly does
not rotate freely, then remove the carrier and ring
gear and check the cluster gear timing.
4. Remove friction plates (5, 6, 7) and spacers (8) and

set aside. Spacers are factory set for each brake to
obtain required air-gap and are not interchangeable
between brakes.
5. Armature (2) and coil springs (10) can be removed
and set aside.
Inspection.
8. Input gear (24) is installed, meshing with the teeth of

the large diameter cluster gear (19). The counterbore on the input gear (24) locates on the shoulder
of the input spacer (25). This is to be a slip fit and
should operate freely.
1.
9. Thrust washer (26) is installed onto the input gear

(24) and should locate on the gear teeth shoulder.
3. Examine the friction plates and the shaft (3) for wear
and/or damage to the spline.
10. Thrust washer (27) is installed into the counterbore

of the carrier.
4. Examine the pole faces of the magnet (1) and the

armature (2) for bruises, swellings or damage. Any
bruises, swellings or damage should be stoned flat.
2. Examine the coil springs (10).
11. Place o-ring (22) into input cover (23) counterbore.

Use petroleum jelly to hold o-ring in place.
12. The input cover (23) is now installed on this assembly. Taking care to correctly align pipe plug hole (30)
with those in the housing (7), usually 90 degrees to
one another, locate the four counterbore holes in
housing (7), marked in step (3) and install four
3120743
Inspection the friction plates (5, 6) and the mating

surfaces on the armature (2) and mounting plate (4)
for wear and/or damage.
5. Examine input and output splines of shaft for wear

and/or damage.
6. Check ball bearing (11) for axial float and/or wear.
NOTE: It is essential when replacing plates (5, 6, 7) that
spacers (8) are also replaced.
JLG Lift
2-45
Assembly.
7.
9.
Clean all parts thoroughly.
8. Reverse disassembly procedure above, taking particular care with the assembly sequence of plates (5,
6, 7).
NOTE: Assemble plate (6) with two center-punches facing
towards mounting plate (4).
2-46
If new plates have been fitted, then new spacers will

have to be adjusted for air gap of 0.014 - 0.024
inches (0.35 - 0.60 mm) as shown in Figure 2-35.
10. After checking air gap, connect power supply.

11. Switch on power supply and ensure brake fully
releases.
12. The brake can be adjusted for friction plate wear by
removing spacers (8) and machining them to maintain the correct air gap. Length of all three spacers
should be within 0.001 in. (0.025 mm).
JLG Lift
3120743
Figure 2-37. Drive Brake Assembly - 30/35/n35/40/n40/45.
3120743
JLG Lift
2-47
2.19 MID AND LOWER LIFT CYLINDER

BLEEDING PROCEDURE.
(40/N40/45 ELECTRIC)
2.20 BOOM SYNCHRONIZING PROCEDURE.

(40/N40/45 ELECTRIC)
NOTE: If the Lower Boom assembly does not fully lower:
NOTE: Bleeding procedure should only be necessary if

rebuilding or replacing lift cylinder.
1. Remove all personnel from the platform.
1. Check oil level in the hydraulic oil tank (all booms

must be retracted). See Figure 2-36 for location of
bleeder fitting in pilot port P at rod end of mid cylinder.
2. Pull the red knob located under the main control

valve.
2. Lay an oil drip pan under the rod end port block
(Mid Cylinder) and crack bleeder open from the fitting in the port block.
3. From the platform, turn the speed control knob to
the slow position.
4. Lift up very slowly. This will force any air out of the
circuit. If the lower boom is not extending, turn the
speed control up very slowly until the lower boom
starts to move.
3.
From Ground Control, activate the lift control switch,

raise Lower Boom 6 feet (1.83m).
4.
After raising Lower Boom, release the red knob.
5.
Activate Lower Boom Down, fully lower boom.
6.
Repeat step 1 thru 5 if necessary
5. Raise the lower boom approx. 1 foot (30.48mm),

then close bleeder while the boom is still moving.
6. Lift down all the way.
7. Repeat this procedure until all air has been purged
from the circuit. Re-check the hydraulic oil level.
8. To test, cycle the lower lift function 3-4 times to see if
both cylinders stop at the same time when fully
extended.
Figure 2-38. Port "P" Location.
2-48
Figure 2-39. Synchronizing Valve.
Figure 2-40. Upright Leveling.
JLG Lift
3120743
2.21 FREE WHEELING PROCEDURE.
2.22 FOOTSWITCH ADJUSTMENT.
Use the following procedures ONLY for emergency movement to a suitable maintenance area. (See Figure 2-38.)
Adjust switch so that functions will operate when pedal is

at center of travel. If switch operates within last 1/4 inch
(6.35 mm) of travel, top or bottom, it should be adjusted.
1. Chock all wheels securely.

2. Engage the mechanical release on both brakes by
loosening, completely reversing (towards drive
motor) and tightening the three nuts on each brake.
3. Connect suitable equipment, remove chocks, and
move machine.
4. After moving machine, position on a firm, level surface.
5. Chock wheels securely.
6. Disengage the mechanical release on both drive
brakes by loosening, completely reversing (towards
torque hub) and tightening the three nuts on each
brake.
7. Remove chocks from wheels as desired.
2.23 P/Q CONTROLLER.

The PQ Controller converts manual input into proportional
electrical output signals for commanding proportional flow
control valves. The PQ Controller is a sealed unit and can
withstand hostile and rugged outdoor weather conditions.
The control handle enters the housing through a sealed
bearing, reducing the possibility of water entering the
housing.
The PQ Controller incorporates a mechanical safety lock
whereby the operator must make an additional motion to
unlock the control handle prior to operation. This feature
eliminates the possibility of the control being accidently
energized while in the neutral position. The controller also
incorporates a neutral-position-off switch. When the control handle is in its neutral position, a switch contact
opens, thus removing power from the electrical circuitry of
the controller. The control handle is spring loaded, and will
automatically return to the neutral-off position should the
operator accidently lose grip of the handle. this feature
gives the operator positive control of the machine at all
times, requiring the operator to hold the control handle
during the duration of the desired function.
Switch adjustment
Refer to manual 3120351.
Figure 2-41. Drive Brake Release.
Pulse Width Modulation (PWM) Fine tune

adjustment
Refer to manual 3120351.
3120743
JLG Lift
2-49
2.24 AXLE DRAIN PLATES

The electric boom lifts are equipped with two maze-type
water drains, located on the underside of the axle box.
This S type drain arrangement is required to meet EE rating, although dust and debris can accumulate and clog
these drains, trapping water inside the axle box. Periodically check and open drains with compressed air, or
remove and clean them if necessary.
JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL

INSPECTION BE PERFORMED IN ACCORDANCE WITH THE
ANNUAL MACHINE INSPECTION REPORT FORM.
NOTE: This machine requires periodic safety and maintenance inspections by a JLG Dealer. A decal located
on the turntable affords a place to record (stamp)
inspection dates. Notify dealer if inspection is overdue.
The inspection and maintenance code numbers are as follows:
1. Check for proper and secure installation.
2. Check for visible damage and legibility.
3. Check for proper fluid level.
4. Check for any structural damage; cracked or broken
welds; bent or warped surfaces.
5. Check for leakage.
Figure 2-42. Drive Axle Drain Plate.
6. Check for presence of excessive dirt or foreign

material.
7. Check for proper operation and freedom of movement.
2.25 PREVENTIVE MAINTENANCE AND

INSPECTION SCHEDULE.
8. Check for excessive wear or damage.
The preventive maintenance and inspection checks are

listed and defined in the following table. This table is
divided into two basic parts, the AREA to be inspected,
and the INTERVAL at which the inspection is to take
place. Under the AREA of the table, the various systems
along with components that make up that system are
listed. The INTERVAL portion of the table is divided into
five columns representing the various inspection time
periods. The numbers listed within the interval column
represent the applicable inspection code for which that
component is to be checked.
The checks and services listed in this schedule are not
intended to replace any local or regional regulations that
may pertain to this type of equipment nor should the lists
be considered as all inclusive. Variances in interval times
may occur due to climate and/or conditions and depending on the location and use of the machine.
9. Check for proper tightness and adjustment.

10. Drain, clean and refill.
11. Check for proper operation while engine is running.
12. Check for proper lubrication.
13. Check for evidence of scratches, nicks or rust and
for straightness of rod.
14. Check for condition of element; replace as necessary.
15. Check for proper inflation.
16. Clean or replace suction screen.
NOTE: *Inspection and Maintenance Code 10, 12 and 16 to
be performed every two years.
JLG Industries requires that a complete annual inspection

be performed in accordance with the Annual Machine
Inspection Report form. Forms are supplied with each
new machine and are also available from JLG Customer
Service. Forms must be completed and returned to JLG
Industries.
2-50
JLG Lift
3120743
Table 2-3.PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

AREA
PLATFORM AND BOOMS
INTERVAL
DAILY
WEEKLY
MONTHLY
1.
Platform Gate
1, 4
2.
Platform
1, 4
3.
Platform Rotator
12
4.
Footswitch
1, 11
5.
Controller
1, 11
6.
Switches
1, 11
7.
Placards and Decals
1, 2
8.
Control Tags
1, 2
9.
Hoses and Cables
10.
Pins
11.
Bushings
12.
Wear Pads
13.
Cylinders
3 MONTH
6 MONTH
YEARLY
12
5, 11
4, 5, 8
1, 5, 6, 13
TURNTABLE
1.
Gauges/Ground Controls
2.
Valves
3.
1, 2, 11
1, 11
Hydraulic Hoses
4.
Shields
5.
Limits Switches
1, 7
6.
Placards and Decals
1, 2
7.
Swing Bearing
8.
Swing Motor
1
1, 5, 6
9, 12
8
CHASSIS
1.
Batteries
2.
Wheel and Tire Assemblies
8, 9, 15
3.
Drive Motors
1, 5, 6
4.
Drive Torque Hubs *
1, 5, 6
5.
Drive Brakes
1, 5, 6
6.
Hydraulic Pump/Motor
7.
Steer Components
4, 6
8.
Front Axle Pin
3120743
8
8
JLG Lift
2-51
Table 2-3.PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

9.
Hydraulic Oil Tank *
10.
Breather - Hydraulic Tank
11.
Hydraulic Hoses and Tubing
12.
Placards and Decals
13.
Tilt Alarm Switch
14.
Shields
15.
Wheel Bearings *
16.
Swing Bearing/Worn Gear
2-52
6, 14
1
1, 2
1
1
8
1
JLG Lift
9, 12
3120743
SECTION 3. TROUBLESHOOTING
3.1
GENERAL.
This section contains troubleshooting information to be

used for locating and correcting most of the operating
problems which may develop in the aerial platform. If a
problem should develop which is not presented in this
section or which is not corrected by listed corrective
actions, technically qualified guidance should be obtained
before proceeding with any maintenance.
3.2
TROUBLESHOOTING INFORMATION.
The troubleshooting procedures applicable to the aerial

platform are listed and defined in Tables 3-1 through 3-6.
As an aid to table use, the aerial platform is divided into six
major groups, each covered separately within this section.
These groups are as follows: platform assembly, boom
assembly, turntable assembly, chassis assembly, hydraulic system and electrical system.
Each malfunction within and individual group or system is
followed by a listing of probable causes which will enable
determination of the applicable remedial action. The probable causes and the remedial action should, where possible, be checked in order listed in the tables.
It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems.
3120743
It should be recognized that the majority of the problems

arising in the machine will be centered in the hydraulic
and electrical systems. For this reason, every effort has
been made to ensure that all likely problems in these
areas are given the fullest possible treatment. In the
remaining machine groups only those problems which are
symptomatic of greater problems of which have more
than one probable cause and remedy are included. This
means that problems for which the probable cause and
remedy may be immediately obvious are not listed in this
section.
The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine
if the circuit is lacking hydraulic oil or electrical control
power. This can be ascertained by overriding the bypass
valve (mechanically or electrically) so that oil is available
to the function valve, then overriding the function valve
mechanically. If the function performs satisfactorily, the
problem exists with the control circuit.
3.3
HYDRAULIC CIRCUIT CHECKS.
The first reference for improper function of a hydraulic system, where the cause is not immediately apparent, should
be the Troubleshooting Chart. The best place to begin the
problem analysis is at the power source (pump). Once it is
determined that the pump is serviceable, then a systematic check of the circuit components, beginning with the
control would follow. For aid in troubleshooting, refer to
the Illustrated Parts Manual for hydraulic diagrams of the
various circuits.
JLG Lift
3-1
Table 3-1.Platform Assembly - Troubleshooting

TROUBLESHOOTING CHART
TROUBLE
PROBABLE CAUSE
REMEDY
PLATFORM LEVELING SYSTEM.

Automatic leveling inoperative.
(35/n35/n40/45 electric)
Hydraulic system oil low.
Replenish oil as necessary.
Dual check valves dirty/inoperative.
Clean or replace as necessary.
Restricted or broken hydraulic line or fitting on

slave cylinder or main lift cylinder.
Clean, repair, or replace line or fitting.
Worn seal(s) in slave level or main lift cylinder.
Replace seal(s).
Counterbalance valve in slave cylinder defective.
Replace counterbalance valve.
Slave level or main lift cylinder not functioning

properly.
Repair or replace cylinder.
Counterbalance valve on slave leveling cylinder

improperly adjusted or not functioning properly.
Replace valve.
Worn seal(s) in slave level or main lift cylinder.
Replace seal(s).
Damaged slave level or main lift cylinder.
Level control switch inoperative.
Repair or replace control switch lever.

Run systems test
System orifice plugged/dirty.
Clean orifice.
Restricted or broken hydraulic line or fitting.
Control valve not functioning properly.
Repair or replace valve.
No electric to control valve.
See proper wiring diagram. Run systems test
Slave cylinder not functioning properly.
Repair or replace pump.
Main proportional valve in-operative
Run systems test
Incorrect personality settings
check settings
Platform will not maintain level attitude.
No response to platform leveling controls.
3-2
JLG Lift
3120743
Table 3-1.Platform Assembly - Troubleshooting
Platform will not adjust up to level.

Hydraulic pump not functioning properly.
Slave cylinder not functioning properly.
Electrical failure.
See proper wiring diagram. Run systems test
Orifice plugged.
Clean orifice.
Platform will not adjust down to level.

See: Platform will not adjust up to level.
3120743
JLG Lift
3-3
Table 3-2.Boom Assembly - Troubleshooting

TROUBLE
PROBABLE CAUSE
REMEDY
CONTROL VALVES.
Valve spool sticking.
Dirt in oil causing excessive temperature buildup.
Flush system and change oil using recommended viscosity
Moisture in oil.
Flush system and change oil using recommended viscosity
Incorrect valve mounting causing warping of the

unit.
Loosen valve and check mounting.

Repair as necessary.
Valve spool scored.
Remove valve and repair or replace as necessary.
Tie-bolts in valve over torqued.
Correctly torque bolts.
Return spring weak or broken.
Relief valve malfunctioning causing excessive

pressure within valve.
Check pressure delivery to and from valve and

repair or replace as necessary.
Valve leaking.
3-4
Dirt or other foreign material under seal.
Remove and repair valve as necessary.
Valve spool scored.
Remove valve and repair or replace as

necessary.
Excessive back pressure caused by restricted

return line to reservoir.
Remove line and clear obstruction or replace

line as necessary.
Damaged valve seals.
Remove valve and repair or replace as

necessary.
JLG Lift
3120743

BOOM ELEVATION SYSTEM.
No response to lift control switch.
Lift control switch inoperative.
Repair or replace control switch.Run systems test
Lift cylinder holding valve inoperative.
Repair or replace holding valve.
Electrical malfunction.
See wiring diagram. Run systems test.
Restricted or broken supply line on valve bank or

hydraulic pump.
Clean or replace line.
Lift cylinder not functioning properly.
Dump valve (bypass) not operating.
Determine cause and repair or replace valve.
Load capacity exceeded (personnel or equipment on platform).
Reduce load.(Refer to capacity placard.)
Electrical failure to valves.
See proper wiring diagram. Run systems test.
Pressure relief valve not functioning properly.
Re-adjust or replace valve.
Lift cylinder not functioning properly.
Motor/Pump does not respond when LIFT control

switch is moved to UP position.
Refer to Electrical Diagram and/or Electrical System Troubleshooting Chart. Run systems test.
Binding lift cylinder or boom pivot pin.
Repair or replace cylinder or pin.
Bypass valve (dump) not functioning.
Boom will not raise.
Boom will not lower.

See: Boom will not raise.
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Pressure relief valve not functioning properly.
Holding valve not functioning properly.
JLG Lift
3-5

Boom raises and lowers erratically.
Replenish oil as required.
Lack of lubricant on cylinder shafts and/or boom

pivot.
Lubricate as required.
(Refer to Lubrication Chart.)
Counterbalance valve on lift cylinder improperly

adjusted or not functioning properly.
Replace valve.
Worn seals in lift cylinder.
Replace seals.
Cylinder not functioning properly.
Worn seals in lift cylinder.
Replace seals.
Boom drifts down.
Lower Lift Function.

If the lower boom assembly does not fully
lower.
The mid and lower booms are out of synchronization.
Refer to snchronization precedure.
Main Telescope system.

No response to telescope control.
Telescope control switch in operative.
Repair or replace control switch.
Damaged wiring on control switch or solenoid

valve.

hydraulic pump.
Telescope cylinder not functioning properly.
Control valve not funtioning properly.
Repair or replace control valve.
Pressure setting incorrect.
Check pressure/ re-adjust as nessary.
Telescope cylinder not functioning properly.
Boom will not extend.
3-6
JLG Lift
3120743
Boom extends and retracts erratically.

Wear pads worn.
Replace pads as required.
Control valve not funtioning properly.
Repair or replace control valve.
Worn seals in telescope cylinder.
Replace seals.
Cylinder not functioning properly.
Distorted boom section(s).
Replace distorted section (s).
Counterbalance valve not functioning properly.
Replace counterbalance valve.
BOOM SWING SYSTEM.

No response to swing control.
Swing control switch not functioning.
Repair or replace swing control switch.

hydraulic pump.
Swing motor not functioning properly.
Repair or replace motor.
Foreign objects (s) wedged between swing motor

pinion and swing gear.
Remove objects, check for damage, and repair or

replace component(s) as required.
No electric power to valve.
See proper wiring diagram. Run systems test.
Pressure relief valve in swing control circuit malfunctioning.
Repair or replace reducing valve.
Restrictor valve 9s) plugged.
Clean or replace restrictor valve.
Foreign object(s) wedged between swing motor

pinion and swing gear.
Remove object(s), check for damage and repair

or replace component(s) as required.
Swing joystick not functioning properly.
Boom will swing in only one direction.
3120743
JLG Lift
3-7
Boom swings erratically in either direction.
3-8
Lack of lubricant on swing gear or speed reducer

pinion.
Lubricate as required. (See Lubrication Chart.)
Swing motor not functioning properly.
Worn or broken teeth on swing gear or swing

motor pinion.
Replace gear(s) as required.
Restrictor valve plugged.
Clean or replace restrictor valve.
JLG Lift
3120743
Table 3-3.Turntable Assembly - Troubleshooting

TROUBLE
PROBABLE CAUSE
REMEDY
CONTROL VALVE.
Valve spool sticking.
Dirt in oil causing excessive temperature built-up.
Change oil using recommended viscosity and flush

system.
Incorrect valve mounting causing warping of the

unit.
Loosen valve and check mounting

Repair as necessary.
Valve spool scored.
Return spring weak or broken.
Relief valve malfunctioning causing excessive

pressure within valve.
Check pressure delivery to and from valve and

repair or replace as necessary.
Dirt or other foreign material under seal.
Remove and replace valve as necessary.
Valve spool scored.
Excessive back pressure caused by restricted

return line to reservoir.
Remove line and clear obstruction or replace line as

necessary.
Damaged valve seals.
Repair or replace valve as necessary.
Valve leaking.
Is the main relief valve, of the brake / steer valve set Check settings.
too low?
Is the pressure filter, of the brake / steer valve
clogged?
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JLG Lift
Check filter.
3-9
Table 3-4.Chassis Assembly - Troubleshooting

TROUBLE
PROBABLE CAUSE
REMEDY
DRIVE SYSTEM.
No response to drive control.
Sevcon overheated.
Check flash code on sevcon.
Restricted or broken pump supply line.
Clean, repair or replace line.
Restricted or broken line on valve bank.
Drive motor(s) not functioning properly.
Repair or replace motor(s).
Damaged wiring on control switch.
Repair or replace wiring.
Control switch not functioning properly.
Replace switch. Run systems check.
Brake(s) not releasing.
Determine cause and repair or replace.
Low batteries.
Check flash code on sevcon.
Clean, repair or replace line or fitting.
Drive motor(s) not functioning properly.
Repair or replace motor(s).
Circuit breaker open.
Determine and correct cause; reset circuit

breaker.
Brake(s) not releasing.
Determine cause and repair or replace.
Motor/Pump will not respond when DRIVE control

moved FORWARD.
Refer to Electric System Troubleshooting
Motor controller FORWARD contactor defective.
Repair or replace contactor. Run systems check.
Motor controller REVERSE contactor defective.

See: Machine will not travel forward.
Repair or replace contactor. Run system test.
Sevcon controller defective.
Check flash code
Machine will not travel in forward.
Machine will not travel in reverse.
Drive system very jerky.
3-10
JLG Lift
3120743

Machine will speed up in forward or reverse.
Wires loose or broken from Tach Drive System to
Sevcon controller.
Check flash code on sevcon. Repair or replace

wire as necessary.
Tach drive shaft broken off.
replace tach drive shaft.
Tach drive defective.
Check flash code.
Hydraulic s ystem oil low.
Hydraulic system pressure to low.
Adjust pressure.
Damaged wiring on control switch or solenoid.
See proper wiring diagram.
Control switch not operating properly.
Replace switch.
Restricted or broken hydraulicline on valve bank

or hydraulic pump.
Steer control valve not functioning properly.
Steer cylinder not functioning properly.
Hydraulic s ystem oil low.
Restricted hydraulic line or fitting.
Clean, repair or replace line or fitting.
Restricted crossover relief valve.
Clean or replace valve.
Steer system pressure low.
Adjust pressure.
Bent linkage (tie rods).
Repair or replace linkage as required.
Damaged wiring on control switch or solenoid

valve
Solenoid valve not function properly.
Control switch not functioning properly.
Replace switch.
Relief valve improperly set or not functioning

properly.
Reset, repair or repolace valves as required.
No response to steercontrol.
Machine hard to steer or steering is erratic.
Steering inoperative.
3120743
JLG Lift
3-11

Machine will not steer left or right.
3-12
Wiring on control switch is damaged.
Wiring on solenoid valve damaged.
Repair or replace wiring.
Coil in solenoid valve damaged.
Replace coil.
No oil flow or pressure to steer circuit.
Take pressure reading at steer valve and adjust

as necessary.
Bent cylinder rod.
C rossover relief valve sticking.
Repair crossover relief valve.
Damaged tie rod.
Replace tie rod.
Cylinder packing defective.
JLG Lift
3120743
Table 3-5.Hydraulic System - Troubleshooting

TROUBLE
PROBABLE CAUSE
REMEDY
HYDRAULIC SYSTEMS - GENERAL.

Hydraulic pump noisy.
Air entering system through broken line or fitting.
(Suction Side.)
Repair or replace line or fitting.
Air bubbles in oil. (Reservoir oil too low.)
Replenish oil as required.
Oil filter dirty.
Replace hydraulic filter.
Wrong type of hydraulic oil.
Replace hydraulic oil.
Pump cavitating. (Vacuum in pump due to oil starvation.)

Restricted suction line.
Clean, repair, or replace line.
Restricted reservoir air vent.
Clean or replace vent.
Oil viscosity too high.
Drain system and replace with recommended oil.

(Refer to Hydraulic Oils.)
Air leak in suction side of tank.
Repair leak.
Oil viscosity too high.

Bypass valve not operating properly.
Main relief valve set too low.
Reset valve as required.
Port relief set too high.
Restricted or blocked return line.
Repair or replace line.
Restricted suction line.
Clean, repair, or replace line.
Air entering system through broken line or fitting.
Repair or replace line or fitting.
Defective motor/pump.
Repair or replace motor.
System overheating.
Pump not delivering oil.
3120743
JLG Lift
3-13
Table 3-5.Hydraulic System - Troubleshooting

System pressure to low.
Leak in component, line or fitting.
Repair or replace component, line or fitting.
Main relief valve set too low.
Oil viscosity too low.

Sticking or binding valve spools, pistons.
Clean, repair, or replace components as required.
Hydraulic oil not at operating temperature.
Allow oil sufficient time to warm up.
System(s) operate erratically.
3-14
JLG Lift
3120743
Table 3-6.Electrical System - Troubleshooting

TROUBLE
PROBABLE CAUSE
REMEDY
ELECTRICAL SYSTEM.
Controller.
No electric power to controller.
Check electrical input to controller.
Steer valve will not function when thumb switch is moved in either direction.
No electric power to valve.
Check electrical output and electrical signal at the

valve.
Improper grounding.
Check for proper ground.
EMERGENCY STOP switch not position properly.
Place EMERGENCY STOP switch to the ON

position.
PLATFOR/GROUND SELECT switch not positioned properly.
Place PLATFOR/GROUND SELECT switch to

correct position.
Batteries defective or require charging.
Test batteries for serviceability. Replace or

charge batteries as necessary.
No voltage supplied to drive motors.
Check motor controller and contactors for proper

operation. Repair or replace as necessary.
Defective function switch.
Replace switch.
Defective circuit breaker.
Replace circuit breaker.
No voltage present at applicable control valve.
Check applicable wire for proper connection.

Using suitable test meter, perform continuity test
on wire. Repair or replace wire as necessary.
Defective motor/pump assembly.
Replace motor/pump assembly.
No response to a function control switch.
Drive motors will not operate when controller is activated.

Motor controller 200 Amp fuse blown.
Check flashcode on sevcon and determine cause

and repair. Replace fuse.
Batteries require charging or will not charge.
Charge or replace batteries as necessary.
Motor controller contactors not functioning properly.
Repair or replace contactor.
Motor/pump not functioning properly.
Repair or replace motor/pump.
See REMEDY column.
Refer to Section 8 for malfunction codes.
Hydraulic motor/pump will not run.
Motor controller malfunctioning.
3120743
JLG Lift
3-15
Figure 3-1. Electrical Schematic 30 electric. (Sheet 1 of 4)
3-16
JLG Lift
3120743
3120743
JLG Lift
3-17
3-18
JLG Lift
3120743
3120743
JLG Lift
3-19
Figure 3-2. Electrical Schematic 35/40/45 electric. (Sheet 1 of 4)
3-20
JLG Lift
3120743
Figure 3-2. Electrical Schematic. 35/40/45 electric. (Sheet 2 of 4)
3120743
JLG Lift
3-21
3-22
JLG Lift
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JLG Lift
3-23
Figure 3-4. Hydraulic Diagram - 30 electric.
3-24
JLG Lift
3120743
Figure 3-5. Hydraulic Diagram - 35 electric

.
3120743
JLG Lift
3-25
Figure 3-6. Hydraulic Diagram - 40/45 electric.
3-26
JLG Lift
3120743
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Customer Support Toll Free: (877) 554-5438
Fax: (717) 485-6417
JLG Worldwide Locations

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

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SERVICE & MAINTENANCE

JLG Industries (Australia)

JLG Industries (UK)

JLG Deutschland GmbH

JLG Industries (Italia)

JLG Latino Americana Ltda.

JLG Europe B.V.

JLG Industries (Norge AS)

JLG Industries (Europe)

JLG Industries (Pty) Ltd.

JLG Industries (Sweden)

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

feed lines to system components can then be disconnected

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY

HYDRAULIC SYSTEM SAFETY

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN

Relieve system pressure by cycling the applicable control

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

TABLE OF CONTENTS (Continued)

Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

Drive Brake Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49

Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

TABLE OF CONTENTS (Continued)

This page left intentionally blank.

Tires - G 78 - 15, Load Range E, 10 Ply Rating, 80 psi (5.5

Hydraulic Oil Tank.

Tires - G 78 - 15, Load Range E, 10 Ply Rating, Foam

Solid Tires - 22 x 6.5 x 16 Lug Tread Non marking Compound. (Optional)

Approximately 4.8 gallons (18.2 liters).

Tires 10 - 16.5 NHS, 8 Ply, 70 psi (4.9 kg/cm2).

Torque Hubs (2).

Tires 10 - 16.5 NHS, 8 Ply, 70 psi (4.9 kg/cm2), Foam Filled

17 ounces (0.5 liters).

Tires - LT215 85R16, Load Range E, 10 Ply Rating, 90 psi

Tires - LT215 85R16, Load Range E, 10 Ply Rating, Foam

Tires 10 - 16.5 NHS, 8 Ply, 70 psi (4.9 kg/cm2).

Output, 48 VDC (23 Amps.).

Tires 10 - 16.5 NHS, 8 Ply, 70 psi (4.9 kg/cm 2 ), Foam

6 Volt, 370 AmpHour (20 hour rate).

Drive Motor - 36 VDC, 4.1 H.P. @ 1880 rpm. continuous,

Hydraulic Pump/Electric Motor Assembly.

Drive Brake- 24 VDC, spring-applied, electrically released.

Pump Output - 1.09 gpm (4.13 lpm) @ 2000 psi (137.9

Solid Tires - 26 x 7 x 20 Lug Tread Non marking Compound. (Optional)

EE Rated, Certified By U/L.

Tires - n35/n40 electric.

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

30 electric - 4 mph (6.4 kph).

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

35 electric - 3 mph (4.8 kph).

Tires - 35/40 electric. (Prior to March of 1996)

40 electric - 3 mph (4.8 kph).

Tires - ST225 75R15, Load Range D, 8 Ply Rating, 80 psi

n40 electric - 2.5 mph (4.1 kph).

Tires - ST225 75R15, Load Range D, 8 Ply Rating, Foam

40/n40 electric - Lift Up - 50 - 60 seconds.

40/n40 electric - Lift Down - 23 - 29 seconds.

45 electric - Lift Up - 58 - 68 seconds.