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

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

TABLE OF CONTENTS:

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

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
TABLE OF CONTENTS
6 40H/40H+6 3120241
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
TABLE OF CONTENTS
3120241 40H/40H+6 7
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

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• This is the SAME exact manual used by your dealers to fix your vehicle.
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