JLG 45HA Parts Manual (3120626) – PDF Download En

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JLG 45HA Parts Manual (3120626) – PDF Download

TABLE OF CONTENTS:

JLG 45HA Parts Manual (3120626) – PDF Download

SECTION 1 - FRAME...........................................................................................................................................................................................................  9
	FIGURE 1-1. FRAME AND STEERING INSTALLATION - 5FT-9IN/1.75M 2WD FRAME (WITH SINGLE ROD CYLINDER)........................................................................................................................ 10
	FIGURE 1-2. FRAME AND STEERING INSTALLATION - 6FT-6IN/2M 2WD FRAME (WITH DOUBLE ROD CYLINDER)........................................................................................................................... 14
	FIGURE 1-3. FRAME AND STEERING INSTALLATION 6FT-6IN/2M 4WD FRAME........................................................................................................................................................ 18
	FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS.......................................................................................................................................................................... 22
	FIGURE 1-5. DRIVE HUB ASSEMBLIES........................................................................................................................................................................................ 28
	FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLIES.................................................................................................................................................................................. 34
	FIGURE 1-7. DRIVE BRAKE ASSEMBLY - AUSCO................................................................................................................................................................................ 40
	FIGURE 1-8. DRIVE BRAKE ASSEMBLY - MICO................................................................................................................................................................................. 42
	FIGURE 1-9. DRIVE MOTOR ASSEMBLY - 2WD.................................................................................................................................................................................. 46
	FIGURE 1-10. DRIVE MOTOR ASSEMBLY - 4WD................................................................................................................................................................................. 50
	FIGURE 1-11. VALVES INSTALLATION (FRAME MOUNTED)........................................................................................................................................................................ 54
	FIGURE 1-12. LOCKOUT VALVE ASSEMBLY..................................................................................................................................................................................... 58
	FIGURE 1-13. TOW PACKAGE INSTALLATION................................................................................................................................................................................... 60
SECTION 2 - TURNTABLE....................................................................................................................................................................................................... 63
	FIGURE 2-1. CONTROL VALVES INSTALLATIONS - STEPPER VALVES............................................................................................................................................................... 64
	FIGURE 2-2. CONTROL VALVES INSTALLATIONS - VICKERS (KOHLER GAS AND ELECTRIC MACHINES)................................................................................................................................... 68
	FIGURE 2-3. CONTROL VALVES INSTALLATIONS - VICKERS (FORD GAS, DEUTZ DIESEL AND KUBOTA DIESEL)........................................................................................................................... 72
	FIGURE 2-4. STEP CONTROL VALVE ASSEMBLY................................................................................................................................................................................. 76
	FIGURE 2-5. VALVE ASSEMBLY - FPS (STEER)................................................................................................................................................................................ 78
	FIGURE 2-6. VALVE ASSEMBLY - 4 STACK BANG-BANG.......................................................................................................................................................................... 80
	FIGURE 2-7. VALVE ASSEMBLY - FPS........................................................................................................................................................................................ 84
	FIGURE 2-8. CONTROL VALVE ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994).................................................................................................................................................... 86
	FIGURE 2-9. CONTROL VALVE ASSEMBLY - (VICKERS) (OCTOBER 1994 TO PRESENT)................................................................................................................................................ 90
	FIGURE 2-10. VALVE ASSEMBLY - SINGLE STACK BANG-BANG.................................................................................................................................................................... 94
	FIGURE 2-11. ACCESSORY VALVE ASSEMBLY (MILLER).......................................................................................................................................................................... 96
	FIGURE 2-12. ACCESSORY VALVE ASSEMBLY (HYDRAFORCE)...................................................................................................................................................................... 98
	FIGURE 2-13. TURNTABLE, BEARING AND SWING DRIVE INSTALLATION............................................................................................................................................................100
	FIGURE 2-14. SWING BRAKE ASSEMBLY.......................................................................................................................................................................................104
	FIGURE 2-15. SWING MOTOR ASSEMBLY.......................................................................................................................................................................................106
	FIGURE 2-16. FORD ENGINE INSTALLATION - WITH ELECTRONIC IGNITION (PRIOR TO MARCH 1990)..................................................................................................................................108
	FIGURE 2-17. FORD ENGINE INSTALLATION - WITH DISTRIBUTORLESS IGNITION SYSTEM (MARCH 1990 TO PRESENT)....................................................................................................................114
	FIGURE 2-18. DUAL FUEL INSTALLATION (FORD ELECTRONIC IGNITION - PRIOR TO MARCH 1990)....................................................................................................................................122
	FIGURE 2-19. DUAL FUEL INSTALLATION (FORD DISTRIBUTORLESS IGNITION - MARCH 1990 TO PRESENT).............................................................................................................................124
	FIGURE 2-20. GENERATOR INSTALLATION - 110V (FORD) (OPTIONAL)............................................................................................................................................................126
	FIGURE 2-21. DEUTZ ENGINE INSTALLATION..................................................................................................................................................................................130
	FIGURE 2-22. GENERATOR INSTALLATION 110 VOLT (DEUTZ) (OPTIONAL).........................................................................................................................................................136
	FIGURE 2-23. PUMP ASSEMBLY - BARNES (FORD AND DEUTZ POWERED MACHINES)...................................................................................................................................................140
	FIGURE 2-24. KUBOTA ENGINE INSTALLATION.................................................................................................................................................................................142
	FIGURE 2-25. THROTTLE AND FUEL SHUT-OFF INSTALLATION (KUBOTA)...........................................................................................................................................................148
	FIGURE 2-26. KOHLER ENGINE INSTALLATIONS................................................................................................................................................................................150
	FIGURE 2-27. DUAL FUEL INSTALLATION - KOHLER............................................................................................................................................................................154
	FIGURE 2-28. GENERATOR INSTALLATION (KOHLER) (OPTIONAL).................................................................................................................................................................156
	FIGURE 2-29. ELECTRIC POWERED MACHINES COMPONENTS INSTALLATION..........................................................................................................................................................158
	FIGURE 2-30. PUMP ASSEMBLY - BARNES (KOHLER, KUBOTA AND ELECTRIC POWERED MACHINES)......................................................................................................................................162
	FIGURE 2-31. BATTERY CHARGER ASSEMBLY (ELECTRIC POWERED MACHINE)........................................................................................................................................................164
	FIGURE 2-32. DOUBLE BATTERY PACKAGE AND INVERTER INSTALLATIONS (ELECTRIC MACHINE OPTIONS)...............................................................................................................................166
	FIGURE 2-33. TANKS INSTALLATION.........................................................................................................................................................................................168
	FIGURE 2-34. ROTARY OIL COUPLING INSTALLATION...........................................................................................................................................................................174
	FIGURE 2-35. OPTIONAL MANUAL DESCENT INSTALLATION.......................................................................................................................................................................176
	FIGURE 2-36. GROUND CONTROL BOX INSTALLATION (MACHINES WITH ELECTRIC BOOM LIMIT SWITCHES BUILT PRIOR TO MAY 1988).......................................................................................................178
	FIGURE 2-37. GROUND CONTROL BOX INSTALLATON (GAS/DIESEL MACHINES WITH HYDRAULIC BOOM LIMIT SWITCHES BUILT MAY 1988 TO MARCH 1990 AND ELECTRIC MACHINES WITH HYDRAULIC BOOM LIMIT SWITCHES BUILT MAY 1988 TO PRESENT)....182
	FIGURE 2-38. GROUND CONTROL BOX INSTALLATION (GAS/DIESEL MACHINES WITH HYDRAULIC BOOM LIMIT SWITCHES BUILT MARCH 1990 TO PRESENT).......................................................................................186
	FIGURE 2-39. TILT INDICATOR, LIGHTS AND ALARMS INSTALLATIONS (TURNTABLE MOUNTED)........................................................................................................................................190
	FIGURE 2-40. HOODS INSTALLATION (GAS/DIESEL MACHINES BUILT PRIOR TO MARCH 1990 AND ALL ELECTRIC MACHINES)...............................................................................................................194
	FIGURE 2-41. HOODS INSTALLATION (GAS/DIESEL MACHINES BUILT MARCH 1990 THROUGH 1992).....................................................................................................................................198
	FIGURE 2-42. HOODS INSTALLATION (GAS/DIESEL MACHINES BUILT 1993 TO PRESENT).............................................................................................................................................200
SECTION 3 - BOOM............................................................................................................................................................................................................203
	FIGURE 3-1. BOOMS AND LIMIT SWITCHES INSTALLATIONS......................................................................................................................................................................204
	FIGURE 3-2. MAIN BOOM ASSEMBLY..........................................................................................................................................................................................208
	FIGURE 3-3. TOWER BOOM ASSEMBLIES.......................................................................................................................................................................................212
	FIGURE 3-4. BOOM WIPERS INSTALLATION....................................................................................................................................................................................216
SECTION 4 - PLATFORM........................................................................................................................................................................................................219
	FIGURE 4-1. STANDARD PLATFORM AND FOOTSWITCH INSTALLATION...............................................................................................................................................................220
	FIGURE 4-2. LOW MOUNT PLATFORM AND FOOTSWITCH INSTALLATIONS.............................................................................................................................................................226
	FIGURE 4-3. FIBERGLASS PLATFORM INSTALLATION............................................................................................................................................................................230
	FIGURE 4-4. ROTATOR MOTOR ASSEMBLY......................................................................................................................................................................................232
	FIGURE 4-5. CONSOLE BOX ASSEMBLY - PQ CONTROLLERS AND STEPPER VALVES....................................................................................................................................................234
	FIGURE 4-6. CONSOLE BOX ASSEMBLY - PQ CONTROLLERS AND VICKERS VALVES....................................................................................................................................................238
	FIGURE 4-7. CONSOLE BOX ASSEMBLY - PQ CONTROLLERS AND VICKERS VALVE.....................................................................................................................................................242
	FIGURE 4-8. CONSOLE BOX ASSEMBLY - OEM CONTROLS AND VICKERS VALVE (MACHINES BUILT PRIOR TO OCTOBER 1990)................................................................................................................246
	FIGURE 4-9. CONSOLE BOX ASSEMBLY - OEM CONTROLLERS AND VICKERS VALVE (MACHINES BUILT OCTOBER 1990 TO PRESENT)...........................................................................................................250
	FIGURE 4-10. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS................................................................................................................................................................254
SECTION 5 - CYLINDER........................................................................................................................................................................................................259
	FIGURE 5-1. ACCUMULATOR ASSEMBLY (MACHINES WITH STEPPER VALVES).........................................................................................................................................................260
	FIGURE 5-2. AXLE LOCKOUT CYLINDER ASSEMBLY..............................................................................................................................................................................262
	FIGURE 5-3. LEVEL CYLINDER ASSEMBLY (TOWER BOOM)........................................................................................................................................................................264
	FIGURE 5-4. LIFT CYLINDER ASSEMBLY (MAIN BOOM)..........................................................................................................................................................................266
	FIGURE 5-5. LIFT CYLINDER ASSEMBLY (TOWER BOOM).........................................................................................................................................................................268
	FIGURE 5-6. PLATFORM LEVEL CYLINDER ASSEMBLY (MAIN BOOM) (PRIOR TO OCTOBER 1992)........................................................................................................................................270
	FIGURE 5-7. PLATFORM LEVEL CYLINDER ASSEMBLY (MAIN BOOM) (OCTOBER 1992 TO PRESENT)......................................................................................................................................272
	FIGURE 5-8. STEER CYLINDER ASSEMBLY (2WD - DOUBLE ACTING ROD)...........................................................................................................................................................274
	FIGURE 5-9. STEER CYLINDER ASSEMBLY (2WD SINGLE ACTING ROD).............................................................................................................................................................276
	FIGURE 5-10. STEER CYLINDER ASSEMBLY (4WD)..............................................................................................................................................................................278
	FIGURE 5-11. TELESCOPE CYLINDER ASSEMBLY (MAIN BOOM) (PRIOR TO JUNE 1991)...............................................................................................................................................280
	FIGURE 5-12. TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM (JUNE 1991 TO PRESENT).............................................................................................................................................282
	FIGURE 5-13. TELESCOPE CYLINDER ASSEMBLY (TOWER BOOM) (JULY 1988 TO PRESENT)............................................................................................................................................284
	FIGURE 5-14. CYLINDER BELLOWS INSTALLATION (OPTIONAL)...................................................................................................................................................................286
SECTION 6 - HYDRAULIC.......................................................................................................................................................................................................289
	FIGURE 6-1. HYDRAULIC DIAGRAM - AXLE LOCKOUT............................................................................................................................................................................290
	FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM (2WD WITH SWIVEL AND WITH VICKERS VALVES)...........................................................................................................................................292
	FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM (4WD WITH SWIVEL AND WITH VICKERS VALVES)...........................................................................................................................................296
	FIGURE 6-4. LIFT AND LEVEL (TOWER BOOM) HYDRAULIC DIAGRAM (VICKERS VALVES AND HYDRAULIC BOOM LIMIT SWITCHES)............................................................................................................300
	FIGURE 6-5. LIFT AND SLAVE (MAIN BOOM) HYDRAULIC DIAGRAM................................................................................................................................................................302
	FIGURE 6-6. PUMP HYDRAULIC DIAGRAM (VICKERS VALVES - FORD GAS AND DEUTZ DIESEL MACHINES)................................................................................................................................304
	FIGURE 6-7. PUMP HYDRAULIC DIAGRAM (VICKERS VALVES - ELECTRIC MACHINES).................................................................................................................................................308
	FIGURE 6-8. ROTATION HYDRAULIC DIAGRAM..................................................................................................................................................................................312
	FIGURE 6-9. STEER WITH SWIVEL HYDRAULIC DIAGRAM.........................................................................................................................................................................314
	FIGURE 6-10. SWING HYDRAULIC DIAGRAM (WITH VICKERS VALVES)..............................................................................................................................................................316
	FIGURE 6-11. TELESCOPE (MAIN BOOM) HYDRAULIC DIAGRAM....................................................................................................................................................................318
	FIGURE 6-12. TELESCOPE (TOWER BOOM) HYDRAULIC DIAGRAM (FORD GAS AND DEUTZ DIESEL).......................................................................................................................................320
	FIGURE 6-13. TELESCOPE (TOWER BOOM) HYDRAULIC DIAGRAM (ELECTRIC MACHINES)...............................................................................................................................................322
	FIGURE 6-14. HYDRAULIC DIAGRAM LIST.....................................................................................................................................................................................324
SECTION 7 - ELECTRICAL......................................................................................................................................................................................................327
	FIGURE 7-1. ELECTRICAL DIAGRAM LIST.....................................................................................................................................................................................328
	FIGURE 7-2. ACCESSORY VALVE WIRING DIAGRAM..............................................................................................................................................................................334
	FIGURE 7-3. CONTACTOR BOX WIRING DIAGRAM (ELECTRIC MACHINES)............................................................................................................................................................336
	FIGURE 7-4. DUEL FUEL WIRING DIAGRAM (FORD MACHINES OPTION).............................................................................................................................................................338
	FIGURE 7-5. GENERATOR WIRING DIAGRAM (DEUTZ MACHINES OPTION)............................................................................................................................................................340
	FIGURE 7-6. GENERATOR WIRING DIAGRAM (FORD MACHINES OPTION).............................................................................................................................................................342
	FIGURE 7-7. PLATFORM WIRING DIAGRAM (GAS AND DIESEL MACHINES)...........................................................................................................................................................344
	FIGURE 7-8. PLATFORM WIRING DIAGRAM (ELECTRIC MACHINES).................................................................................................................................................................346
	FIGURE 7-9. STANDARD WIRING DIAGRAM (DEUTZ DIESEL MACHINES).............................................................................................................................................................348
	FIGURE 7-10. STANDARD WIRING DIAGRAM (FORD GAS MACHINES)................................................................................................................................................................350
	FIGURE 7-11. STANDARD WIRING DIAGRAM (ELECTRIC MACHINES)................................................................................................................................................................352
SECTION 8 - DECALS..........................................................................................................................................................................................................353
	FIGURE 8-1. DECALS INSTALLATIONS (45HA PRIOR TO AUGUST 1991)............................................................................................................................................................354
	FIGURE 8-2. DECALS INSTALLATIONS (45HA AUGUST 1991 TO PRESENT)..........................................................................................................................................................358
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK.................................................................................................................................................................................363
	FIGURE 9-1. MODELS 45HA GAS AND DIESEL MACHINES WITH VICKERS VALVES STANDARD PARTS......................................................................................................................................364
	FIGURE 9-2. MODELS 45HA GAS AND DIESEL MACHINES WITH VICKERS VALVES VARIABLE PARTS......................................................................................................................................366
SECTION 10 - SPECIAL OPTIONS................................................................................................................................................................................................367
	FIGURE 10-1. SPECIAL OPTIONS LIST.......................................................................................................................................................................................368
	FIGURE 10-2. U/L MACHINES SPECIAL OPTIONS...............................................................................................................................................................................372
	FIGURE 10-3. 440V ELECTRIC PEDESTAL MACHINE SPECIAL OPTIONS.............................................................................................................................................................374
	FIGURE 10-4. JAPANESE MACHINE OPTIONS...................................................................................................................................................................................376
PART NUMBER INDEX...........................................................................................................................................................................................................377

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