JLG 40H/40H+6 Boom Lifts Parts Catalog
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3120241 40H/40H+6 3
TABLE OF CONTENTS
3120241 40H/40H+6 5
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
SECTION 1 - FRAME
3120241 40H/40H+6 9
SECTION 1 - FRAME
SECTION 1 - FRAME
10 40H/40H+6 3120241
FIGURE 1-1. FRAME AND STEERING INSTALLATION - 2WD BUILT PRIOR TO MID 1984 (WITH
DOUBLE ROD STEER CYLINDER)
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The JLG 40H/40H+6 Boom Lifts Parts Catalog is an essential workshop manual designed for the precise identification and maintenance of your boom lift equipment. This comprehensive guide provides professional-grade, step-by-step instructions with detailed diagrams and clear illustrations, covering critical components such as the frame, turntable, boom, platforms, cylinders, hydraulic systems, electrical systems, decals, recommended service parts, and special options.
Crafted for user-friendliness, this trusted manual ensures accurate part identification and maintenance procedures, making it an invaluable resource for both professionals and enthusiasts. As an OEM-standard guide, it is a crucial addition to your workshop resources, supporting effective equipment upkeep and repair.
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