Parts Manual

ManualsBrandsJLG ManualsSpecial machinery45ic ANSI

Illustrated Parts Manual

Models

40ic

45ic

P/N

3120735

September 30 2011

Summary of content (158 pages)

PAGE 1
Illustrated Parts Manual Models 40ic 45ic P/N 3120735 September 30 2011
PAGE 2
PAGE 3
REVISION LOG August 1, 1996 - Original Issue of Manual August 15, 1997 - Revised Manual December 1, 2000 - Revised Manual (Edited to B/M 0010531 Revision 21 & B/M 0010530 Revision 22) August 16, 2005 - Revised Manual January 31, 2008 - Revised Manual September 30, 2011 - Revised Manual 3120735 A
PAGE 4
REVISION LOG B 3120735
PAGE 5
TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 1 - FRAME.............................................................................................................1-1 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 FRAME AND STEERING INSTALLATIONS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 TIRE AND WHEEL DRIVE INSTALLATIONS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 DRIVE HUB ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . .
PAGE 6
TABLE OF CONTENTS (CONTINUED) FIGURE NO. TITLE PAGE NO. SECTION 7 - ELECTRICAL.................................................................................................. 7-1 7-1 7-2 7-3 ELECTRICAL DIAGRAMS AND DIAGRAM LIST.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 HARNESS INSTALLATIONS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 7
SECTION 1 FRAME TABLE OF CONTENTS FIGURE DESCRIPTION PAGE 1-1 FRAME AND STEERING INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 TIRE AND WHEEL DRIVE INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1-3 DRIVE HUB ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1-4 DRIVE MOTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . .
PAGE 8
S E C T I O N SECTION 1 FRAME FIGURE 1-1. FRAME AND STEERING INSTALLATIONS.
PAGE 9
SECTION 1 FRAME FIGURE 1-1. FRAME AND STEERING INSTALLATIONS. FIG & ITEM # PART NUMBER QTY. Ref. 2360402 2360403 0256855 0252856 STEERING AND SPINDLES INSTALLATION (ANSI Spec) (CSA Spec) Ref. Ref. Ref.
PAGE 10
S E C T I O N SECTION 1 FRAME FIGURE 1-1. FRAME AND STEERING INSTALLATIONS.
PAGE 11
SECTION 1 FRAME FIGURE 1-1. FRAME AND STEERING INSTALLATIONS. FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 12
S E C T I O N SECTION 1 FRAME FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS.
PAGE 13
SECTION 1 FRAME FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS.
PAGE 14
S E C T I O N SECTION 1 FRAME FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS. (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY.
PAGE 15
Ref. – S E C T I O N Ref. – 1 Ref. – SECTION 1 FRAME FIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONS.
PAGE 16
S E C T I O N SECTION 1 FRAME FIGURE 1-3. DRIVE HUB ASSEMBLY.
PAGE 17
SECTION 1 FRAME FIGURE 1-3. DRIVE HUB ASSEMBLY.
PAGE 18
S E C T I O N SECTION 1 FRAME FIGURE 1-4. DRIVE MOTOR ASSEMBLY.
PAGE 19
SECTION 1 FRAME FIGURE 1-4. DRIVE MOTOR ASSEMBLY.
PAGE 20
S E C T I O N SECTION 1 FRAME FIGURE 1-5. DRIVE BRAKE ASSEMBLY.
PAGE 21
SECTION 1 FRAME FIGURE 1-5. DRIVE BRAKE ASSEMBLY. FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 22
S E C T I O N SECTION 1 FRAME FIGURE 1-5. DRIVE BRAKE ASSEMBLY.
PAGE 23
SECTION 1 FRAME FIGURE 1-5. DRIVE BRAKE ASSEMBLY. (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 24
S E C T I O N SECTION 1 FRAME FIGURE 1-6. VALVES, BATTERY AND TILT INDICATOR INSTALLATIONS (FRAME MOUNTED).
PAGE 25
SECTION 1 FRAME FIGURE 1-6. VALVES, BATTERY AND TILT INDICATOR INSTALLATIONS (FRAME MOUNTED).
PAGE 26
S E C T I O N SECTION 1 FRAME FIGURE 1-6. VALVES, BATTERY AND TILT INDICATOR INSTALLATIONS (FRAME MOUNTED).
PAGE 27
SECTION 1 FRAME FIGURE 1-6. VALVES, BATTERY AND TILT INDICATOR INSTALLATIONS (FRAME MOUNTED). FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 28
S E C T I O N SECTION 1 FRAME FIGURE 1-7. ACCESSORY VALVE ASSEMBLY.
PAGE 29
SECTION 1 FRAME FIGURE 1-7. ACCESSORY VALVE ASSEMBLY. FIG & ITEM # PART NUMBER 4640969 1 2 2A 3 4 5 6 7 8 9 9A 10 10A 10B 11 11A 11B 11C 12 3120735 Not Serviced 7017410 7012967 7012944 7012969 7012540 7017419 7012953 7012968 7012518 7010542 7010543 7018902 7017429 7012967 7012941 7012907 7012944 7012795 7012773 7012772 7018912 7018913 7012773 7012772 7018912 7018916 7018905 DESCRIPTION QTY. REV. ACCESSORY VALVE ASSEMBLY Ref.
PAGE 30
S E C T I O N SECTION 1 FRAME FIGURE 1-8. VANGUARD GAS ENGINE INSTALLATIONS.
PAGE 31
SECTION 1 FRAME FIGURE 1-8. VANGUARD GAS ENGINE INSTALLATIONS.
PAGE 32
S E C T I O N SECTION 1 FRAME FIGURE 1-8. VANGUARD GAS ENGINE INSTALLATIONS.
PAGE 33
SECTION 1 FRAME FIGURE 1-8. VANGUARD GAS ENGINE INSTALLATIONS. (CONTINUED) FIG & ITEM # PART NUMBER 83 84 85 86 87 88 4921852 3539816 4400395 2221010 Not Used 3539929 89 4160150 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 201 201A 201B 201C 202 3120735 DESCRIPTION QTY.
PAGE 34
S E C T I O N SECTION 1 FRAME FIGURE 1-8. VANGUARD GAS ENGINE INSTALLATIONS.
PAGE 35
SECTION 1 FRAME FIGURE 1-8. VANGUARD GAS ENGINE INSTALLATIONS. (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 36
S E C T I O N SECTION 1 FRAME FIGURE 1-9. DUAL FUEL INSTALLATION (OPTION FOR VANGUARD GAS MACHINES).
PAGE 37
SECTION 1 FRAME FIGURE 1-9. DUAL FUEL INSTALLATION (OPTION FOR VANGUARD GAS MACHINES).
PAGE 38
S E C T I O N SECTION 1 FRAME FIGURE 1-9. DUAL FUEL INSTALLATION (OPTION FOR VANGUARD GAS MACHINES). FIG & ITEM # PART NUMBER 113 114 115 116 2220082 0641405 4711400 0100011 DESCRIPTION Fitting, Adapter Bolt 1/4"-20NC x 5/8" Flatwasher 1/4" Narrow Loctite #272 (Not Shown) QTY. REV.
PAGE 39
SECTION 1 FRAME FIGURE 1-9. DUAL FUEL INSTALLATION (OPTION FOR VANGUARD GAS MACHINES). FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 40
S E C T I O N SECTION 1 FRAME FIGURE 1-10. YANMAR DIESEL ENGINE INSTALLATION.
PAGE 41
SECTION 1 FRAME FIGURE 1-10. YANMAR DIESEL ENGINE INSTALLATION.
PAGE 42
S E C T I O N SECTION 1 FRAME FIGURE 1-10. YANMAR DIESEL ENGINE INSTALLATION.
PAGE 43
SECTION 1 FRAME FIGURE 1-10. YANMAR DIESEL ENGINE INSTALLATION. (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY.
PAGE 44
S E C T I O N SECTION 1 FRAME FIGURE 1-10. YANMAR DIESEL ENGINE INSTALLATION. (CONTINUED) FIG & ITEM # PART NUMBER 0256919/0256910 301 302 303 304 305 1 3620039 1320202 3311605 4711600 3570105 DESCRIPTION OIL COOLER INSTALLATION Cooler, Oil Clamp Locknut 3/8"-16NC Flatwasher 3/8" Plate, Cover QTY. REV. Ref.
PAGE 45
SECTION 1 FRAME FIGURE 1-10. YANMAR DIESEL ENGINE INSTALLATION. (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 46
S E C T I O N SECTION 1 FRAME FIGURE 1-11. PISTON PUMP ASSEMBLY.
PAGE 47
SECTION 1 FRAME FIGURE 1-11. PISTON PUMP ASSEMBLY. FIG & ITEM # PART NUMBER 3600256 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 7018925 7018926 7018927 Not Used 7018929 7018930 7018931 7018932 7018933 7018934 7018935 7018936 7018937 7018938 7018939 7018953 7024016 7018940 3120735 DESCRIPTION PISTON PUMP ASSEMBLY QTY. REV. Ref.
PAGE 48
S E C T I O N SECTION 1 FRAME FIGURE 1-12.
PAGE 49
SECTION 1 FRAME FIGURE 1-12. GEAR PUMP ASSEMBLY FIG & ITEM # PART NUMBER 3600199 1 2 3 4 5 6 7 8 9 10 11 12 13 14 7010955 Kit 7010956 Kit Kit 7010957 Kit 7010958 7010959 Not Used 7010954 7010978 7010960 7010961 7010953 3120735 DESCRIPTION GEAR PUMP ASSEMBLY QTY. REV. Ref.
PAGE 50
S E C T I O N SECTION 1 FRAME FIGURE 1-13.
PAGE 51
SECTION 1 FRAME FIGURE 1-13.
PAGE 52
S E C T I O N SECTION 1 FRAME FIGURE 1-14. FRAME COVERS INSTALLATIONS.
PAGE 53
SECTION 1 FRAME FIGURE 1-14. FRAME COVERS INSTALLATIONS.
PAGE 54
S E C T I O N SECTION 1 FRAME FIGURE 1-14. FRAME COVERS INSTALLATIONS. FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 55
SECTION 2 TURNTABLE TABLE OF CONTENTS FIGURE DESCRIPTION PAGE 2-1 TURNTABLE MOUNTED COMPONENTS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-2 CONTROL VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2-3 SWING DRIVE AND TURNTABLE BEARING INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . 2-8 2-4 SWING MOTOR ASSEMBLY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 56
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-1. TURNTABLE MOUNTED COMPONENTS INSTALLATION.
PAGE 57
SECTION 2 TURNTABLE FIGURE 2-1. TURNTABLE MOUNTED COMPONENTS INSTALLATION.
PAGE 58
SECTION 2 TURNTABLE S E C T I O N 2 T U R N T A B L E FIGURE 2-1. TURNTABLE MOUNTED COMPONENTS INSTALLATION. (CONTINUED) FIG & ITEM # PART NUMBER 0256577 301 302 303 304 305 306 307 308 309 to 316 317 318 2-4 0256524 3380426 1702963 0641404 3311405 1320043 2920028 2920029 3990001 Not Used 4460265 4460268 DESCRIPTION LIGHT PANEL INSTALLATION QTY. REV. Ref.
PAGE 59
SECTION 2 TURNTABLE FIGURE 2-1. TURNTABLE MOUNTED COMPONENTS INSTALLATION. (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 60
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-2. CONTROL VALVE ASSEMBLY.
PAGE 61
SECTION 2 TURNTABLE FIGURE 2-2. CONTROL VALVE ASSEMBLY.
PAGE 62
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-3. SWING DRIVE AND TURNTABLE BEARING INSTALLATIONS.
PAGE 63
SECTION 2 TURNTABLE FIGURE 2-3. SWING DRIVE AND TURNTABLE BEARING INSTALLATIONS.
PAGE 64
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-4. SWING MOTOR ASSEMBLY.
PAGE 65
SECTION 2 TURNTABLE FIGURE 2-4. SWING MOTOR ASSEMBLY.
PAGE 66
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-5. SWING BEARING ASSEMBLY.
PAGE 67
SECTION 2 TURNTABLE FIGURE 2-5. SWING BEARING ASSEMBLY.
PAGE 68
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-5. SWING BEARING ASSEMBLY. FIG & ITEM # PART NUMBER 116 117 2160003 Not Available Not Available DESCRIPTION Fitting, Grease - 45° Capscrew, Socket Head 5/16”-18NC Washer 5/16” (Not Shown) QTY. REV.
PAGE 69
SECTION 2 TURNTABLE FIGURE 2-5. SWING BEARING ASSEMBLY. FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 70
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-6. GROUND CONTROL BOX ASSEMBLY.
PAGE 71
SECTION 2 TURNTABLE FIGURE 2-6. GROUND CONTROL BOX ASSEMBLY.
PAGE 72
SECTION 2 TURNTABLE S E C T I O N 2 T U R N T A B L E FIGURE 2-6. GROUND CONTROL BOX ASSEMBLY.
PAGE 73
SECTION 2 TURNTABLE FIGURE 2-6. GROUND CONTROL BOX ASSEMBLY. (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 74
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-7. TURNTABLE AND HOODS INSTALLATION.
PAGE 75
SECTION 2 TURNTABLE FIGURE 2-7. TURNTABLE AND HOODS INSTALLATION. FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 101 102 103 104 105 106 107 108 109 110 111 3120735 PART NUMBER DESCRIPTION 4620088 TURNTABLE 0253709 HOODS INSTALLATION Note: Replacement decals must be ordered separately - See Section 8.
PAGE 76
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-7. TURNTABLE AND HOODS INSTALLATION.
PAGE 77
SECTION 3 BOOM TABLE OF CONTENTS FIGURE DESCRIPTION PAGE 3-1 BOOM AND LIMIT SWITCHES INSTALLATIONS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-2 MAIN BOOM COMPONENTS ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 78
SECTION 3 BOOM FIGURE 3-1. BOOM AND LIMIT SWITCHES INSTALLATIONS.
PAGE 79
SECTION 3 BOOM FIGURE 3-1. BOOM AND LIMIT SWITCHES INSTALLATIONS.
PAGE 80
SECTION 3 BOOM FIGURE 3-1. BOOM AND LIMIT SWITCHES INSTALLATIONS.
PAGE 81
SECTION 3 BOOM FIGURE 3-1. BOOM AND LIMIT SWITCHES INSTALLATIONS. (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 82
SECTION 3 BOOM FIGURE 3-2. MAIN BOOM COMPONENTS ASSEMBLY.
PAGE 83
SECTION 3 BOOM FIGURE 3-2. MAIN BOOM COMPONENTS ASSEMBLY.
PAGE 84
SECTION 3 BOOM FIGURE 3-2. MAIN BOOM COMPONENTS ASSEMBLY.
PAGE 85
SECTION 4 PLATFORMS TABLE OF CONTENTS FIGURE DESCRIPTION PAGE 4-1 PLATFORM COMPONENTS INSTALLATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4-2 ROTATOR MOTOR/PUMP/TANK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4-3 PLATFORM CONSOLE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4-4 CONTROLLER ASSEMBLY - DRIVE/STEER.. . . . . . . . . . . . . . . . . . . . . . .
PAGE 86
SECTION 4 PLATFORMS FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION.
PAGE 87
SECTION 4 PLATFORMS FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION.
PAGE 88
SECTION 4 PLATFORMS FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION.
PAGE 89
SECTION 4 PLATFORMS FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION.
PAGE 90
SECTION 4 PLATFORMS FIGURE 4-2. ROTATOR MOTOR/PUMP/TANK ASSEMBLY.
PAGE 91
SECTION 4 PLATFORMS FIGURE 4-2. ROTATOR MOTOR/PUMP/TANK ASSEMBLY.
PAGE 92
SECTION 4 PLATFORMS FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY.
PAGE 93
SECTION 4 PLATFORMS FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY.
PAGE 94
SECTION 4 PLATFORMS FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY.
PAGE 95
SECTION 4 PLATFORMS FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY. (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 96
SECTION 4 PLATFORMS FIGURE 4-4. CONTROLLER ASSEMBLY - DRIVE/STEER.
PAGE 97
SECTION 4 PLATFORMS FIGURE 4-4. CONTROLLER ASSEMBLY - DRIVE/STEER.
PAGE 98
SECTION 4 PLATFORMS FIGURE 4-4. CONTROLLER ASSEMBLY - DRIVE/STEER.
PAGE 99
SECTION 5 CYLINDER TABLE OF CONTENTS FIGURE DESCRIPTION PAGE 5-1 UPPER LIFT CYLINDER ASSEMBLIES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5-2 MID LIFT CYLINDER ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5-3 LOWER LIFT CYLINDER ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5-4 MASTER CYLINDER ASSEMBLY.. . . . . . . . . . . . . . . . . . . . . .
PAGE 100
SECTION 5 CYLINDER FIGURE 5-1. UPPER LIFT CYLINDER ASSEMBLIES.
PAGE 101
SECTION 5 CYLINDER FIGURE 5-1. UPPER LIFT CYLINDER ASSEMBLIES.
PAGE 102
SECTION 5 CYLINDER FIGURE 5-2. MID LIFT CYLINDER ASSEMBLIES.
PAGE 103
SECTION 5 CYLINDER FIGURE 5-2. MID LIFT CYLINDER ASSEMBLIES.
PAGE 104
SECTION 5 CYLINDER FIGURE 5-2. MID LIFT CYLINDER ASSEMBLIES.
PAGE 105
SECTION 5 CYLINDER FIGURE 5-2. MID LIFT CYLINDER ASSEMBLIES. (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 106
SECTION 5 CYLINDER FIGURE 5-3. LOWER LIFT CYLINDER ASSEMBLIES.
PAGE 107
SECTION 5 CYLINDER FIGURE 5-3. LOWER LIFT CYLINDER ASSEMBLIES.
PAGE 108
SECTION 5 CYLINDER FIGURE 5-3. LOWER LIFT CYLINDER ASSEMBLIES.
PAGE 109
SECTION 5 CYLINDER FIGURE 5-3. LOWER LIFT CYLINDER ASSEMBLIES. (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 110
SECTION 5 CYLINDER FIGURE 5-4. MASTER CYLINDER ASSEMBLY.
PAGE 111
SECTION 5 CYLINDER FIGURE 5-4. MASTER CYLINDER ASSEMBLY. FIG & ITEM # 1 1A 2 2A 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 PART NUMBER DESCRIPTION QTY. REV. 1683325 MASTER CYLINDER ASSEMBLY Ref.
PAGE 112
SECTION 5 CYLINDER FIGURE 5-5. PLATFORM ROTATOR CYLINDER ASSEMBLY.
PAGE 113
SECTION 5 CYLINDER FIGURE 5-5. PLATFORM ROTATOR CYLINDER ASSEMBLY. FIG & ITEM # PART NUMBER 1682930 1 2 3 4 5 6 7 8 9 10 11 12 7001609 7001610 Kit Kit 7001611 7001612 7001613 Kit Kit Kit Kit 7001614 7001608 DESCRIPTION PLATFORM ROTATOR CYLINDER ASSEMBLY Nut, Hex Piston Seal O-Ring Barrel Weldment Rod Head O-Ring Ring, Back-up Seal Wiper Ring, Retainer –––––––––– Seal Kit - 1682930 Cylinder (Includes Items 3,4, and 811) QTY. REV. Ref.
PAGE 114
SECTION 5 CYLINDER FIGURE 5-6. SLAVE (PLATFORM LEVEL) CYLINDER ASSEMBLY.
PAGE 115
SECTION 5 CYLINDER FIGURE 5-6. SLAVE (PLATFORM LEVEL) CYLINDER ASSEMBLY.
PAGE 116
SECTION 5 CYLINDER FIGURE 5-7. STEER CYLINDER ASSEMBLY.
PAGE 117
SECTION 5 CYLINDER FIGURE 5-7. STEER CYLINDER ASSEMBLY.
PAGE 118
SECTION 5 CYLINDER FIGURE 5-8. TELESCOPE CYLINDER ASSEMBLIES.
PAGE 119
SECTION 5 CYLINDER FIGURE 5-8. TELESCOPE CYLINDER ASSEMBLIES.
PAGE 120
SECTION 5 CYLINDER FIGURE 5-9. OPTIONAL CYLINDER BELLOWS INSTALLATION.
PAGE 121
SECTION 5 CYLINDER FIGURE 5-9. OPTIONAL CYLINDER BELLOWS INSTALLATION. FIG & ITEM # PART NUMBER 0254851 0254028 1 2 3 0460110 0460111 0460113 0460112 4 5 6 7 8 0460114 0460113 0460102 0460103 1320033 1320037 QTY. REV. OPTIONAL CYLINDER BELLOWS INSTALLATION MODEL 45IC OPTIONAL CYLINDER BELLOWS INSTALLATION MODEL 40IC DESCRIPTION Ref. – Ref.
PAGE 122
SECTION 5 CYLINDER FIGURE 5-9. OPTIONAL CYLINDER BELLOWS INSTALLATION. (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 123
SECTION 6 HYDRAULICS TABLE OF CONTENTS FIGURE DESCRIPTION PAGE 6-1 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6-2 HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 124
SECTION 6 HYDRAULICS FIGURE 6-1. HYDRAULICS DIAGRAM LIST 2792244* 2792277* 2792243 Note: Diagrams with asterisk (*) are shown in the preceding pages. Information on diagrams not shown are available from JLG Service/Parts Departments. Hydraulic Diagram - 4Oic Hydraulic Diagram - 45ic Hydraulic Schematic Ref. Ref. Ref.
PAGE 125
SECTION 6 HYDRAULICS FIGURE 6-1) HYDRAULICS DIAGRAM LIST (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 126
SECTION 6 HYDRAULICS FIGURE 6-2.
PAGE 127
SECTION 6 HYDRAULICS FIGURE 6-2. HYDRAULIC DIAGRAM SHEET (SHEET 2 OF 2).
PAGE 128
SECTION 6 HYDRAULICS FIGURE 6-2) HYDRAULIC DIAGRAM FIG & ITEM # PART NUMBER 2792244 2792277 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 S E C T I O N 6 H Y D R A U L I C S 27 28 29 30 31 32 33 2220606 2752522 2752486 2750834 Not Used 2220603 2220371 2220577 2220473 2220738 2220622 2752488 2220657 2750993 2220416 2220466 2752433 2220415 2220502 2752459 2220497 2220609 2220873 2220428 2220429 2752619 2752482 2753050 2220899 2752620 2752580 2220472 2752614 2220635 2753115 2753113
PAGE 129
SECTION 6 HYDRAULICS FIGURE 6-2) HYDRAULIC DIAGRAM (CONTINUED) FIG & ITEM # PART NUMBER 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 3120735 2752579 2752585 2220504 2753005 2220727 2220684 2752435 2752573 2220677 2752574 2220435 2220811 2220602 2752575 2752581 4566188 4566187 4566623 4100026 2752438 1702124 2221020 2220584 2220934 4640861 2752441 2752440 2220605 2220619 2220578 2220451 2220600 2750763 2752472 2752984
PAGE 130
SECTION 6 HYDRAULICS FIGURE 6-2) HYDRAULIC DIAGRAM (CONTINUED) FIG & ITEM # PART NUMBER 80 81 82 83 84 85 86 87 88 89 2220618 2752931 2752935 2752591 2752445 2752982 2752983 2752981 2220582 2220240 2220221 2220408 2220372 2752404 2220414 2220374 4640994 2752937 2752938 2752504 2220385 2220383 2220386 0100038 0100011 Not Used S E C T I O N 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 6 H Y D R A U L I C S 6-8 DESCRIPTION Fitting, Reducer Hose Hose Hose Hose Hose Hose Hose Fitting, Straight Fitti
PAGE 131
SECTION 7 ELECTRICAL FIGURE DESCRIPTION PAGE 7-1 ELECTRICAL DIAGAMS AND DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7-2 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7-3 HARNESS INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 132
SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAMS AND DIAGRAM LIST. FIG & ITEM # PART NUMBER DESCRIPTION QTY. ELECTRICAL COMPONENTS AND DIAGRAMS LIST Note: Items with * indicate electrical drawings shown in this manual. All other electrical drawings are available from JLG Service Department upon request. Ref. ALARM ELECTRICAL COMPONENTS (MOTION) (OPTIONAL - DOMESTIC & LATIN AMERICA/ STANDARD - JAPANESE) Alarm Ref. Ref.
PAGE 133
SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAMS AND DIAGRAM LIST. (Continued) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 134
SECTION 7 ELECTRICAL FIGURE 7-2. ELECTRICAL DIAGRAM - STANDARD (SHEET 1 OF 2).
PAGE 135
SECTION 7 ELECTRICAL FIGURE 7-2.
PAGE 136
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS INSTALLATIONS.
PAGE 137
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS INSTALLATIONS.
PAGE 138
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS INSTALLATIONS.
PAGE 139
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS INSTALLATIONS.
PAGE 140
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS INSTALLATIONS. (CONTINUED) FIG & ITEM # S E C T I O N 7 E L E C T R I C A L DESCRIPTION QTY. REV. 4921846 4921847 HARNESS ASSEMBLY - 12/4 (MAIN BOOM) (40ic) HARNESS ASSEMBLY - 12/4 (MAIN BOOM) (45ic) Ref. Ref.
PAGE 141
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS INSTALLATIONS. (CONTINUED) FIG & ITEM # PART NUMBER 800 4921852 801 to 831 832 833 to 836 837 838 839 to 840 841 842 843 to 845 846 847 848 849 850 851 852 853 854 855 856 to 869 870 871 872 Not Used Not Required Not Used 4460265 4460267 Not Used 4460656* 4460657* Not Used 4460654* 4460445 4460374 4460375 Not Used Not Used 4460658* 4460659* Not Used 4460655 Not Used 3730113 Not Used 3990010 DESCRIPTION HARNESS ASSEMBLY - VANGUARD REV. Ref.
PAGE 142
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS INSTALLATIONS.
PAGE 143
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS INSTALLATIONS. (CONTINUED) FIG & ITEM # PART NUMBER 1001 1001A 1002 1002A 1003 1003A 1004 4921569 4921593 4460205 4921568 1921592 4460134 Not Available 4460265 4460268 Not Available DESCRIPTION QTY. OPTIONAL HARNESS ASSEMBLIES Harness Options - 110V Receptacle (Main Boom): 40ic 45ic Plug, Twistlock Harness Options - 110V Receptacle (Tower Boom): 40ic 45ic Receptacle, Twistlock Harness, Light Panel Plug, Connector Socket, Female Harness, Worklights Ref.
PAGE 144
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS INSTALLATIONS. (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 145
SECTION 8 DECALS TABLE OF CONTENTS FIGURE DESCRIPTION PAGE 8-1 DECALS INSTALLATION - ANSI SPECS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8-2 DECALS INSTALLATION - JAPANESE AND LATIN AMERICA SPECS . . . . . . . . . . . . . . . .
PAGE 146
SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION - ANSI SPEC.
PAGE 147
SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION - ANSI SPEC.
PAGE 148
SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION - ANSI SPEC. (CONTINUED) FIG & ITEM # PART NUMBER 101 102 103 1701505 1701542 1701543 1702251 DESCRIPTION QTY. DECAL INSTALLATION (OPTIONAL PARTS) Ref. Decal - Fuel Diesel Gas Decal - LP Gas Decal - LP Gas Liquid Withdrawal System 1 REV.
PAGE 149
SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION - ANSI SPEC. (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 150
SECTION 8 DECALS FIGURE 8-2. DECALS INSTALLATION - JAPANESE AND LATIN AMERICA.
PAGE 151
SECTION 8 DECALS FIGURE 8-2. DECALS INSTALLATION - JAPANESE AND LATIN AMERICA.
PAGE 152
SECTION 8 DECALS FIGURE 8-2. DECALS INSTALLATION - JAPANESE AND LATIN AMERICA. (CONTINUED) FIG & ITEM # 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 S E C T I O N 8 D E C A L S PART NUMBER DESCRIPTION QTY. REV. 0256145 0256146 DECALS INSTALLATION - LATIN AMERICA (40ic) DECALS INSTALLATION - LATIN AMERICA (45ic) Ref. Ref.
PAGE 153
SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODELS 40ic/45ic Lifts The following lists will service fleets of machines (built to current production per date on the front cover) with emergency repair parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep service parts stock supplied. For further information, contact your JLG dealer or the JLG Industries Parts Department.
PAGE 154
S E C T I O N SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODELS 40ic/45ic Lifts The following lists will service fleets of machines (built to current production per date on the front cover) with emergency repair parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep service parts stock supplied. For further information, contact your JLG dealer or the JLG Industries Parts Department.
PAGE 155
SECTION 10 SPECIAL OPTIONS Note: This list is to accommodate machines ordered with special equipment. Options may not be applicable to all models. For more specific parts information contact the JLG Parts Department. FIG & ITEM # PART NUMBER 10–1 SPECIAL OPTIONS LIST QTY. REV. Ref. Airline Installation - 1/2" (40ic) Airline Installation - 1/2" (45ic) Ref. Ref. 0270723 Amber Beacon Installation (Platform) Ref. 0256789 Camera Mounting Installation Ref. – 1702788 Decal - Biodegradeable Ref.
PAGE 156
S E C T I O N SECTION 10 SPECIAL OPTIONS FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 157
PAGE 158
3120735 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +61 2 65 811111 +61 2 65 810122 +55 19 3295 1025 JLG Deutschland GmbH Max-Planck-Str.