JLG 40H 40H+6 Parts Manual (3120241) – PDF Download En

Description

JLG 40H 40H+6 Parts Manual (3120241) – PDF Download

TABLE OF CONTENTS:

JLG 40H 40H+6 Parts Manual (3120241) – PDF Download

SECTION 1 - FRAME.........................................................................................................................................................  9
	FIGURE 1-1. FRAME AND STEERING INSTALLATION - 2WD BUILT PRIOR TO MID 1984 (WITH DOUBLE ROD STEER CYLINDER)............................................................ 10
	FIGURE 1-2. FRAME AND STEERING INSTALLATION - 2WD BUILT MID 1984 TO PRESENT (WITH SINGLE ROD STEER CYLINDER).......................................................... 14
	FIGURE 1-3. FRAME AND STEERING INSTALLATION - 4WD..................................................................................................................... 18
	FIGURE 1-4. TIRES AND WHEEL DRIVE INSTALLATIONS....................................................................................................................... 22
	FIGURE 1-5. DRIVE HUB ASSEMBLY........................................................................................................................................ 26
	FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY (4WD FRONT)...................................................................................................................... 30
	FIGURE 1-7. BRAKE ASSEMBLY - AUSCO AND MICO........................................................................................................................... 34
	FIGURE 1-8. BRAKE ASSEMBLY - AUSCO.................................................................................................................................... 38
	FIGURE 1-9. BRAKE ASSEMBLY - MICO..................................................................................................................................... 40
	FIGURE 1-10. BRAKE ASSEMBLY - AUSCO 29479 (4WD FRONT)................................................................................................................. 44
	FIGURE 1-11. BRAKE ASSEMBLY - AUSCO 37845 (4WD FRONT)................................................................................................................. 46
	FIGURE 1-12. DRIVE MOTOR ASSEMBLY..................................................................................................................................... 48
	FIGURE 1-13. VALVES INSTALLATION (FRAME MOUNTED)...................................................................................................................... 54
	FIGURE 1-14. LOCKOUT VALVE ASSEMBLY................................................................................................................................... 58
	FIGURE 1-15. TOW PACKAGE INSTALLATION................................................................................................................................. 60
SECTION 2 - TURNTABLE..................................................................................................................................................... 63
	FIGURE 2-1. TURNTABLE AND BOOMS INSTALLATIONS......................................................................................................................... 64
	FIGURE 2-2. CONTROL VALVES INSTALLATION - RACINE...................................................................................................................... 68
	FIGURE 2-3. RACINE PROPORTIONAL CONTROL VALVE ASSEMBLY - OUTLET SECTION............................................................................................... 72
	FIGURE 2-4. RACINE PROPORTIONAL CONTROL VALVE ASSEMBLY - WORKING SECTION.............................................................................................. 74
	FIGURE 2-5. RACINE PROPORTIONAL CONTROL VALVE ASSEMBLY - INLET SECTION................................................................................................ 76
	FIGURE 2-6. RACINE PROPORTIONAL CONTROL VALVE ASSEMBLY - SERVO SECTION................................................................................................ 80
	FIGURE 2-7. CONTROL VALVES INSTALLATION - BERTEA...................................................................................................................... 84
	FIGURE 2-8. CONTROL VALVES ASSEMBLY VICKERS VALVES.................................................................................................................... 88
	FIGURE 2-9. VICKERS VALVE ASSEMBLIES (PRIOR TO OCTOBER 1994).......................................................................................................... 94
	FIGURE 2-10. VICKERS VALVE ASSEMBLY - STANDARD CONTROLS (OCTOBER 1994 TO PRESENT)..................................................................................... 98
	FIGURE 2-11. VICKERS VALVE ASSEMBLY - HYDRAULIC CONTROLS (OCTOBER 1994 TO PRESENT)....................................................................................102
	FIGURE 2-12. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION.....................................................................................................106
	FIGURE 2-13. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION.....................................................................................................110
	FIGURE 2-14. CONTROL VALVE ASSEMBLY - BANG-BANG WITH INLET SECTION....................................................................................................114
	FIGURE 2-15. CONTROL VALVE ASSEMBLY - 1 SECTION BANG-BANG.............................................................................................................116
	FIGURE 2-16. ACCESSORY VALVE ASSEMBLY (MILLER) HYDRAULIC CONTROLS BUILT THROUGH 1989).................................................................................118
	FIGURE 2-17. ACCESSORY VALVE ASSEMBLY (HYDRAFORCE) (HYDRAULIC CONTROLS MACHINES BUILT 1990 TO SEPTEMBER 1991).........................................................120
	FIGURE 2-18. STEERING VALVE ASSEMBLY..................................................................................................................................122
	FIGURE 2-19. SWING DRIVE, BEARING AND LOCK INSTALLATIONS..............................................................................................................124
	FIGURE 2-20. SWING MOTOR ASSEMBLY.....................................................................................................................................128
	FIGURE 2-21. SWING BRAKE ASSEMBLIES - PRIOR TO APRIL 1992.............................................................................................................130
	FIGURE 2-22. SWING BRAKE ASSEMBLY - APRIL 1992 TO PRESENT.............................................................................................................134
	FIGURE 2-23. SWING HUB ASSEMBLY.......................................................................................................................................138
	FIGURE 2-24. ROTARY COUPLING ASSEMBLY AND INSTALLATION................................................................................................................140
	FIGURE 2-25. DEUTZ F2L511 ENGINE INSTALLATION.........................................................................................................................142
	FIGURE 2-26. GENERATOR INSTALLATION - DEUTZ F2L511....................................................................................................................148
	FIGURE 2-27. DEUTZ F3L912 ENGINE INSTALLATION.........................................................................................................................152
	FIGURE 2-28. ADECO THROTTLE COMPONENTS INSTALLATION - DEUTZ F3L912 ENGINE MACHINES ONLY...............................................................................158
	FIGURE 2-29. GENERATOR INSTALLATION - DEUTZ F3L912....................................................................................................................162
	FIGURE 2-30. DEUTZ F3L1011 ENGINE INSTALLATION........................................................................................................................166
	FIGURE 2-31. GENERATOR INSTALLATION - DEUTZ F3L1011...................................................................................................................172
	FIGURE 2-32. FORD LSG 423 ENGINE INSTALLATION (WITH DISTRIBUTOR) (PRIOR TO MARCH 1995)................................................................................176
	FIGURE 2-33. ADECO THROTTLE INSTALLATIONS - FORD ENGINE MACHINES......................................................................................................184
	FIGURE 2-34. PRECISION GOVERNOR INSTALLATION - FORD ENGINE MACHINES...................................................................................................186
	FIGURE 2-35. GENERATOR INSTALLATION - FORD ENGINE MACHINES BUILT PRIOR TO MARCH 1995..................................................................................188
	FIGURE 2-36. FORD LRG 423 DIS ENGINE ASSEMBLY (DISTRIBUTORLESS IGNITION SYSTEM) (MARCH 1995 TO S/N 36897).............................................................192
	FIGURE 2-37. FORD LRG 425 DIS ENGINE ASSEMBLY (DISTRIBUTORLESS IGNITION SYSTEM) (SN 36897 to Present).................................................................198
	FIGURE 2-38. GENERATOR INSTALLATION - FORD MACHINES BUILT MARCH 1995 TO PRESENT.......................................................................................204
	FIGURE 2-39. DUEL FUEL INSTALLATION (FORD MACHINES)...................................................................................................................208
	FIGURE 2-40. WISCONSIN VG4D ENGINE INSTALLATION.......................................................................................................................210
	FIGURE 2-41. PUMP COUPLING INSTALLATIONS..............................................................................................................................216
	FIGURE 2-42. MAIN PUMP ASSEMBLY (FORD AND DEUTZ F3L912 MACHINES WITH VICKERS VALVES BUILT PRIOR TO MAY/JUNE 1987 - HAS ONE OUTLET IN END COVER).......................220
	FIGURE 2-43. MAIN PUMP ASSEMBLY (FORD AND DEUTZ F3L912 AND DEUTZ F3L1011 MACHINES WITH VICKERS VALVES BUILT MAY/JUNE 1987 TO PRESENT - HAS 2 OUTLETS IN END COVER)....222
	FIGURE 2-44. MAIN PUMP ASSEMBLY (DEUTZ F2L511 MACHINES)...............................................................................................................224
	FIGURE 2-45. PISTON PUMP ASSEMBLY - FRONT (OPTION ON FORD MACHINES)...................................................................................................226
	FIGURE 2-46. PISTON PUMP ASSEMBLY - REAR (OPTION ON FORD MACHINES)....................................................................................................230
	FIGURE 2-47. TANKS AND HEATERS INSTALLATION...........................................................................................................................232
	FIGURE 2-48. GROUND CONTROLS COMPONENTS INSTALLATION (RACINE VALVE MACHINES)..........................................................................................236
	FIGURE 2-49. GROUND CONTROL COMPONENTS INSTALLATION (VICKERS VALVE MACHINES WITH STANDARD CONTROLS)...................................................................240
	FIGURE 2-50. GROUND CONTROL COMPONENTS INSTALLATION (MACHINES WITH HYDRAULIC CONTROLS)................................................................................246
	FIGURE 2-51. ELECTRICAL COMPONENTS INSTALLATION (TURNTABLE MOUNTED)...................................................................................................252
	FIGURE 2-52. HOODS INSTALLATION.......................................................................................................................................254
SECTION 3 - BOOM..........................................................................................................................................................257
	FIGURE 3-1. 2 SECTION BOOM ASSEMBLIES.................................................................................................................................258
	FIGURE 3-2. 3 SECTION BOOM ASSEMBLIES.................................................................................................................................264
	FIGURE 3-3. BOOM WIPERS INSTALLATION (2 SECTION)......................................................................................................................270
	FIGURE 3-4. BOOM WIPERS INSTALLATION (3 SECTION)......................................................................................................................272
	FIGURE 3-5. EXTEND-A-REACH INSTALLATIONS (40H+6 MACHINES).............................................................................................................276
SECTION 4 - PLATFORMS.....................................................................................................................................................279
	FIGURE 4-1. STANDARD PLATFORM AND FOOTSWITCH INSTALLATION.............................................................................................................280
	FIGURE 4-2. LOW MOUNT PLATFORM AND FOOTSWITCH INSTALLATION............................................................................................................286
	FIGURE 4-3. ROTATOR MOTOR ASSEMBLY....................................................................................................................................292
	FIGURE 4-4. CONSOLE BOX ASSEMBLIES - PQ CONTROLLERS WITHOUT PROP TELE (MACHINES BUILT PRIOR TO SEPTEMBER 1991)........................................................294
	FIGURE 4-5. CONSOLE BOX ASSEMBLIES - PQ CONTROLLERS WITH PROP TELE (MACHINES BUILT PRIOR TO SEPTEMBER 1991)...........................................................298
	FIGURE 4-6. CONSOLE BOX ASSEMBLIES - PQ CONTROLLERS AND VICKERS VALVE (MACHINES BUILT SEPTEMBER 1991 TO PRESENT)......................................................302
	FIGURE 4-7. CONSOLE BOX ASSEMBLY - OEM CONTROLLERS....................................................................................................................306
	FIGURE 4-8. CONSOLE BOX ASSEMBLY - HYDRAULIC CONTROLS.................................................................................................................310
	FIGURE 4-9. CAPACITY INDICATOR INSTALLATION (OPTIONAL)................................................................................................................314
	FIGURE 4-10. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS..............................................................................................................320
SECTION 5 - CYLINDER......................................................................................................................................................323
	FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY - 4WD/2WS (PRIOR TO SEPTEMBER 1992) (USE WITH OPTIONAL OSCILLATING AXLE)...................................................324
	FIGURE 5-2. AXLE LOCKOUT CYLINDER ASSEMBLY............................................................................................................................328
	FIGURE 5-3. LIFT CYLINDER ASSEMBLY - BOOM (PRIOR TO APRIL 1993).......................................................................................................330
	FIGURE 5-4. LIFT CYLINDER ASSEMBLY - BOOM (APRIL 1993 TO PRESENT).....................................................................................................332
	FIGURE 5-5. LIFT CYLINDER ASSEMBLY - EXTEND-A-REACH (40H+6 ONLY)......................................................................................................334
	FIGURE 5-6. MASTER CYLINDER ASSEMBLIES................................................................................................................................336
	FIGURE 5-7. PLATFORM LEVEL CYLINDER ASSEMBLIES (BUILT PRIOR TO JANUARY 1987)..........................................................................................338
	FIGURE 5-8. PLATFORM LEVEL CYLINDER ASSEMBLIES (BUILT JANUARY 1987 TO APRIL 1992).....................................................................................340
	FIGURE 5-9. PLATFORM LEVEL CYLINDER ASSEMBLIES (BUILT APRIL 1992 TO PRESENT)..........................................................................................342
	FIGURE 5-10. PLATFORM LEVEL CYLINDER ASSEMBLIES (MODEL 40H+6 EXTEND-A-REACH) (Prior to SN 47925)......................................................................344
	FIGURE 5-11. PLATFORM LEVEL CYLINDER ASSEMBLIES (MODEL 40H+6 EXTEND-A-REACH) (SN 47925 to Present)....................................................................346
	FIGURE 5-12. STEER CYLINDER ASSEMBLY - 2WD (PRIOR TO MID 1984)........................................................................................................348
	FIGURE 5-13. STEER CYLINDER ASSEMBLY - 2WD (MID 1984 TO PRESENT)......................................................................................................350
	FIGURE 5-14. STEER CYLINDER ASEMBLY - 4WD.............................................................................................................................352
	FIGURE 5-15. TELESCOPE CYLINDER ASSEMBLY (2-SECTION) (PRIOR TO JULY 1985).............................................................................................354
	FIGURE 5-16. TELESCOPE CYLINDER ASSEMBLY (2-SECTION) (JULY 1985 TO PRESENT)...........................................................................................356
	FIGURE 5-17. TELESCOPE CYLINDER ASSEMBLY (3-SECTION)..................................................................................................................358
	FIGURE 5-18. CYLINDER BELLOWS INSTALLATION............................................................................................................................360
SECTION 6 - HYDRAULICS....................................................................................................................................................363
	FIGURE 6-1. HYDRAULIC DIAGRAM LIST....................................................................................................................................364
	FIGURE 6-2. AXLE LOCKOUT HYDRAULIC DIAGRAM............................................................................................................................368
	FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM (2WD).............................................................................................................................370
	FIGURE 6-4. DRIVE HYDRAULIC DIAGRAM (4WD).............................................................................................................................372
	FIGURE 6-5. LEVEL HYDRAULIC DIAGRAM (2-SECTION).......................................................................................................................374
	FIGURE 6-6. LEVEL HYDRAULIC DIAGRAM (3-SECTION).......................................................................................................................376
	FIGURE 6-7. LEVEL HYDRAULIC DIAGRAM WITH EXTEND-A-REACH AND ROTATE SUPPORT............................................................................................378
	FIGURE 6-8. LIFT HYDRAULIC DIAGRAM (VICKERS)..........................................................................................................................380
	FIGURE 6-9. MANUAL DESCENT HYDRAULIC DIAGRAM..........................................................................................................................382
	FIGURE 6-10. PUMP HYDRAULIC DIAGRAM WITH 3-CYLINDER DEUTZ.............................................................................................................384
	FIGURE 6-11. PUMP HYDRAULIC DIAGRAM WITH FORD ENGINES (MARCH 1995 TO PRESENT).........................................................................................388
	FIGURE 6-12. ROTATE HYDRAULIC DIAGRAMS 2-SECTION AND 3-SECTION BOOMS..................................................................................................392
	FIGURE 6-13. SEQUENCE HYDRAULIC DIAGRAM...............................................................................................................................394
	FIGURE 6-14. STEER HYDRAULIC DIAGRAM 2WD AND 4WD......................................................................................................................396
	FIGURE 6-15. SWING HYDRAULIC DIAGRAM..................................................................................................................................398
	FIGURE 6-16. TELESCOPE HYDRAULIC DIAGRAM..............................................................................................................................400
SECTION 7 - ELECTRICAL....................................................................................................................................................403
	FIGURE 7-1. ELECTRICAL DIAGRAM LIST...................................................................................................................................404
	FIGURE 7-2. WIRING DIAGRAM - DUAL FUEL (FORD AND WISCONSIN ENGINES)...................................................................................................414
	FIGURE 7-3. WIRING DIAGRAM - 110V GENERATOR (DEUTZ ENGINE)............................................................................................................416
	FIGURE 7-4. WIRING DIAGRAM - 110V GENERATOR (FORD ENGINE).............................................................................................................418
	FIGURE 7-5. WIRING DIAGRAM - PLATFORM CONSOLE STANDARD CONTROLS.......................................................................................................420
	FIGURE 7-6. WIRING DIAGRAM - PLATFORM CONSOLE HYDRAULIC CONTROLS......................................................................................................422
	FIGURE 7-7. WIRING DIAGRAM - STANDARD (DEUTZ F2L511/F3L912 AND WISCONSIN ENGINES WITH STANDARD CONTROLS)..............................................................424
	FIGURE 7-8. WIRING DIAGRAM - STANDARD (DEUTZ F2L511/F3L912 AND WISCONSIN ENGINES WITH HYDRAULIC CONTROLS).............................................................426
	FIGURE 7-9. WIRING DIAGRAM - STANDARD (DEUTZ F3L1011 ENGINES WITH STANDARD CONTROLS)..................................................................................428
	FIGURE 7-10. WIRING DIAGRAM - STANDARD (DEUTZ F3L1011 ENGINES WITH HYDRAULIC CONTROLS)................................................................................430
	FIGURE 7-11. WIRING DIAGRAM - STANDARD (FORD LRG423 DIS ENGINE WITH STANDARD CONTROLS)................................................................................432
	FIGURE 7-12. WIRING DIAGRAM - STANDARD (FORD LSG423/LRG425 DIS ENGINE WITH HYDRAULIC CONTROLS)........................................................................434
SECTION 8 - DECALS........................................................................................................................................................437
	FIGURE 8-1. DECALS INSTALLATION - DOMESTIC............................................................................................................................438
	FIGURE 8-2. DECALS INSTALLATION - LATIN AMERICA.......................................................................................................................444
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK...............................................................................................................................447
	FIGURE 9-1. MODELS 40H/40H+6 (STANDARD CONTROLS) STANDARD PARTS.......................................................................................................448
	FIGURE 9-2. MODELS 40H/40H+6 (STANDARD CONTROLS) VARIABLE PARTS.......................................................................................................450
SECTION 10 - SPECIAL OPTIONS..............................................................................................................................................451
	FIGURE 10-1. MISCELLANEOUS SPECIAL OPTIONS............................................................................................................................452
	FIGURE 10-2. EURO SPEC COMPONENTS.....................................................................................................................................456
PART NUMBER INDEX.........................................................................................................................................................459

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

S.M