Jlg E45A_AJ ANSI Parts Manual User Manual

Illustrated Parts ManualModelsE45A/AJE40AJPE40AJPnarrowM45A/AJM40AJPM40AJPnarrowP/N3120766August 31, 2011

1-4 3120766SECTION 1 FRAMESECTION1FRAME105 7020036 Cup, Bearing - Inner (1 per Assembly) 2106 7020038 Cup, Bearing - Outer (1 per Assembly) 2107 70200

4-4 3120766SECTION 4 PLATFORMSECTION4PLATFORMPEDESTAL PANEL & FOOTSWITCH INSTALLATION Ref.0861176 E45 & M45 Ref. 7/F0861314 E40 & M40 Ref.

3120766 4-5SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. RE

4-6 3120766SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-2.PLATFORM PADDING INSTALLATION

3120766 4-7SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-2. PLATFORM PADDING INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0270338 PLATF

4-8 3120766SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-3.PLATFORM CONSOLE ASSEMBLY 121313131514820301(M45 & M40)8 (E45 & E40)19109742742616

3120766 4-9SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-3. PLATFORM CONSOLE ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.CONSOLE BOX ASSEM

4-10 3120766SECTION 4 PLATFORMSECTION4PLATFORM38 3311005 Locknut #10-24NC 639 3311605 Locknut 3/8”-16NC 440 Not Used41 4360330 Switch, Toggle - SPST 1

3120766 4-11SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-3. PLATFORM CONSOLE ASSEMBLY (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

4-12 3120766SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-4.CONTROLLER ASSEMBLY (SWING AND LIFT) 1091111071011021031101061121084856391122221207936181

3120766 4-13SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-4. CONTROLLER ASSEMBLY (SWING AND LIFT)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.CONTR

3120766 1-5SECTION1FRAMESECTION 1 FRAMEFIGURE 1-1. STEER INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

4-14 3120766SECTION 4 PLATFORMSECTION4PLATFORM112 4460265 Connector - 9 Position 14460226 Socket, Female 8FIGURE 4-4. CONTROLLER ASSEMBLY (SWING AND

3120766 4-15SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-4. CONTROLLER ASSEMBLY (SWING AND LIFT) (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QT

4-16 3120766SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-5.CONTROLLER ASSEMBLY (DRIVE AND STEER) CONNECTTO PLUG1457610231524252616181720191718864

3120766 4-17SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-5. CONTROLLER ASSEMBLY (DRIVE AND STEER)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.CONT

4-18 3120766SECTION 4 PLATFORMSECTION4PLATFORMHANDLE ASSEMBLIES Ref.7022812 Controller Assembly p/n 160027370002736 Controller Assembly p/n 1001118418

3120766 5-1SECTION5CYLINDERSECTION 5 CYLINDERTABLE OF CONTENTSFIGURE DESCRIPTION PAGE5-1 JIB CYLINDER ASSEMBLY (AJ & AJP) . . . . . . . . . . .

5-2 3120766SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-1.JIB CYLINDER ASSEMBLY (AJ & AJP) 12112661819519251814101620221792324212713138877

3120766 5-3SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-1. JIB CYLINDER ASSEMBLY (AJ & AJP)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.168377

5-4 3120766SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-2.PLATFORM LEVEL CYLINDER ASSEMBLY (E45A & M45A)

3120766 5-5SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-2. PLATFORM LEVEL CYLINDER ASSEMBLY (E45A & M45A)FIG & ITEM # PART NUMBER DESCRIPTION Q

1-6 3120766SECTION 1 FRAMESECTION1FRAMEFIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION 76101201202203104103102511428831109115A

5-6 3120766SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-3.PLATFORM LEVEL CYLINDER ASSEMBLY (AJ & AJP) 111323122220201215141437891019161764222155

3120766 5-7SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-3. PLATFORM LEVEL CYLINDER ASSEMBLY (AJ & AJP)FIG & ITEM # PART NUMBER DESCRIPTION QTY.

5-8 3120766SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-4.LIFT CYLINDER ASSEMBLY - LOWER

3120766 5-9SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-4. LIFT CYLINDER ASSEMBLY - LOWERFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.LOWER LIFT C

5-10 3120766SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-5.LIFT CYLINDER ASSEMBLY - MID

3120766 5-11SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-5. LIFT CYLINDER ASSEMBLY - MIDFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.MID LIFT CYLI

5-12 3120766SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-6.LIFT CYLINDER ASSEMBLY - UPPER

3120766 5-13SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-6. LIFT CYLINDER ASSEMBLY - UPPERFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.UPPER LIFT

5-14 3120766SECTION 5 CYLINDERSECTION5CYLINDER— — — — — — — — — — 2901804 Seal Kit - Upper Lift Cylinder (Includes Items 13-19) 1FIGURE 5-6. LIFT CYL

3120766 5-15SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-6. LIFT CYLINDER ASSEMBLY - UPPER (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV

3120766 1-7SECTION1FRAMESECTION 1 FRAMEFIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.WHEEL DRIVE INS

5-16 3120766SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-7.MASTER CYLINDER ASSEMBLY (A MODELS)

3120766 5-17SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-7. MASTER CYLINDER ASSEMBLY (A MODELS)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.168332

5-18 3120766SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-8.MASTER CYLINDER ASSEMBLY (AJ & AJP MODELS)

3120766 5-19SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-8. MASTER CYLINDER ASSEMBLY (AJ & AJP MODELS)FIG & ITEM # PART NUMBER DESCRIPTION QTY.

5-20 3120766SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-9.ROTATOR CYLINDER ASSEMBLY (E45 & M45 ONLY) (PRIOR TO S/N 49945 ONLY)

3120766 5-21SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-9. ROTATOR CYLINDER ASSEMBLY (E45 & M45 ONLY) (PRIOR TO S/N 49945 ONLY)FIG & ITEM # PA

5-22 3120766SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-10.STEER CYLINDER ASSEMBLY

3120766 5-23SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-10. STEER CYLINDER ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.1683591 STEER CYL

5-24 3120766SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-11.TELESCOPE CYLINDER ASSEMBLY (E45 & M45)

3120766 5-25SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-11. TELESCOPE CYLINDER ASSEMBLY (E45 & M45)FIG & ITEM # PART NUMBER DESCRIPTION QTY. R

1-8 3120766SECTION 1 FRAMESECTION1FRAME4520232 Monarch 26” x 7” x 20” Solid (Non-Marking) (Sold as Assembly Only)4AE40AJPnarrow & M40AJPnarrow:452

5-26 3120766SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-12.TELESCOPE CYLINDER ASSEMBLY (E40 & M40)

3120766 5-27SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-12. TELESCOPE CYLINDER ASSEMBLY (E40 & M40)FIG & ITEM # PART NUMBER DESCRIPTION QTY. R

5-28 3120766SECTION 5 CYLINDERSECTION5CYLINDERFIGURE 5-12. TELESCOPE CYLINDER ASSEMBLY (E40 & M40) (CONTINUED)FIG & ITEM # PART NUMBER DESCRI

3120766 6-1SECTION6HYDRAULICSECTION 6 HYDRAULICTABLE OF CONTENTSFIGURE DESCRIPTION PAGE6-1 STANDARD HYDRAULIC DIAGRAM (E45A & M45A) . . . . . .

6-2 3120766SECTION 6 HYDRAULICSECTION6HYDRAULICFIGURE 6-1.STANDARD HYDRAULIC DIAGRAM (E45A & M45A)

3120766 6-3SECTION 6 HYDRAULICSECTION6HYDRAULICFIGURE 6-1. STANDARD HYDRAULIC DIAGRAM (E45A & M45A)FIG & ITEM # PART NUMBER DESCRIPTION QTY.

6-4 3120766SECTION 6 HYDRAULICSECTION6HYDRAULIC47 2220502 Fitting, 45° 248 to 49 Not Used50 2752581 Hose 151 4566188 Tube 152 4566623 Tube 153 4100026

3120766 6-5SECTION 6 HYDRAULICSECTION6HYDRAULICFIGURE 6-1. STANDARD HYDRAULIC DIAGRAM (E45A & M45A) (CONTINUED)FIG & ITEM # PART NUMBER DESCR

6-6 3120766SECTION 6 HYDRAULICSECTION6HYDRAULICFIGURE 6-2.STANDARD HYDRAULIC DIAGRAM (E45AJ & M45AJ)

3120766 6-7SECTION 6 HYDRAULICSECTION6HYDRAULICFIGURE 6-2. STANDARD HYDRAULIC DIAGRAM (E45AJ & M45AJ)FIG & ITEM # PART NUMBER DESCRIPTION QTY

3120766 1-9SECTION1FRAMESECTION 1 FRAMEFIGURE 1-2. TIRE AND WHEEL DRIVE INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

6-8 3120766SECTION 6 HYDRAULICSECTION6HYDRAULIC47 2220677 Fitting, 45° 248 2753305 Hose 149 2752463 Hose 150 2220600 Fitting, Straight 251 4567946 Tub

3120766 6-9SECTION 6 HYDRAULICSECTION6HYDRAULICFIGURE 6-2. STANDARD HYDRAULIC DIAGRAM (E45AJ & M45AJ) (CONTINUED)FIG & ITEM # PART NUMBER DES

6-10 3120766SECTION 6 HYDRAULICSECTION6HYDRAULICFIGURE 6-3.STANDARD HYDRAULIC DIAGRAM (E40AJP & M40AJP)

3120766 6-11SECTION 6 HYDRAULICSECTION6HYDRAULICFIGURE 6-3. STANDARD HYDRAULIC DIAGRAM (E40AJP & M40AJP)FIG & ITEM # PART NUMBER DESCRIPTION

6-12 3120766SECTION 6 HYDRAULICSECTION6HYDRAULIC47 2220677 Fitting, 45° 248 2753336 Hose 149 2752463 Hose 150 2220600 Fitting, Straight 251 4567946 Tu

3120766 6-13SECTION 6 HYDRAULICSECTION6HYDRAULICFIGURE 6-3. STANDARD HYDRAULIC DIAGRAM (E40AJP & M40AJP) (CONTINUED)FIG & ITEM # PART NUMBER

6-14 3120766SECTION 6 HYDRAULICSECTION6HYDRAULICFIGURE 6-4.HYDRAULIC DIAGRAM LISTNote: Diagrams with asterisk (*) are shown in the preceding pages. In

3120766 7-1SECTION7ELECTRICALSECTION 7 ELECTRICALTABLE OF CONTENTSFIGURE DESCRIPTION PAGE7-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . .

7-2 3120766SECTION 7 ELECTRICALSECTION7ELECTRICAL FIGURE 7-1.ELECTRICAL DIAGRAM LISTFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.Note: Diagram

3120766 7-3SECTION 7 ELECTRICALSECTION7ELECTRICALFIGURE 7-2.ELECTRICAL SCHEMATIC (E45 & M45 Models)

1-10 3120766SECTION 1 FRAMESECTION1FRAMEFIGURE 1-3. DRIVE HUB ASSEMBLY

7-4 3120766SECTION 7 ELECTRICALSECTION7ELECTRICALFIGURE 7-2. ELECTRICAL SCHEMATIC (E45 & M45 Models)

3120766 7-5SECTION 7 ELECTRICALSECTION7ELECTRICAL

7-6 3120766SECTION 7 ELECTRICALSECTION7ELECTRICALFIGURE 7-2. ELECTRICAL SCHEMATIC (E45 & M45 Models)

3120766 7-7SECTION 7 ELECTRICALSECTION7ELECTRICAL

7-8 3120766SECTION 7 ELECTRICALSECTION7ELECTRICALFIGURE 7-3. ELECTRICAL SCHEMATIC (E40 & M40 Models)

3120766 7-9SECTION 7 ELECTRICALSECTION7ELECTRICAL

7-10 3120766SECTION 7 ELECTRICALSECTION7ELECTRICAL Figure 7-3. ELECTRICAL SCHEMATIC (E40 & M40 Models)

3120766 7-11SECTION 7 ELECTRICALSECTION7ELECTRICAL\

7-12 3120766SECTION 7 ELECTRICALSECTION7ELECTRICALFigure 7-3. ELECTRICAL SCHEMATIC (E40 & M40 Models)

3120766 7-13SECTION 7 ELECTRICALSECTION7ELECTRICAL“THIS PAGE INTENSIONALLY LEFT BLANK”

3120766 1-11SECTION1FRAMESECTION 1 FRAMEFIGURE 1-3. DRIVE HUB ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.2780236 DRIVE HUB ASSEMBLY Re

7-14 3120766SECTION 7 ELECTRICALSECTION7ELECTRICALFIGURE 7-4. HARNESS COMPONENTS INSTALLATION

3120766 7-15SECTION 7 ELECTRICALSECTION7ELECTRICALBOOM LIMITSWITCHESJ1J1J2P2J2J3J3J4J4J5J5J7J8J9HORNTOGENERATORMODULEGROUNDCONTROLBOXBEACONLIGHTPOSI-T

7-16 3120766SECTION 7 ELECTRICALSECTION7ELECTRICALFIGURE 7-4. HARNESS COMPONENTS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.HARNES

3120766 7-17SECTION 7 ELECTRICALSECTION7ELECTRICALPLATFORM BOX ASSEMBLY COMPONENTS Ref.101 to 116 Not Used117 4460428 Connector, Strain Relief 1118 t

7-18 3120766SECTION 7 ELECTRICALSECTION7ELECTRICAL301C 4460265 Connector - 9 Position (E40 & M40 Only) 14460227 Pin, Male 3302 Harness Assembly -

3120766 7-19SECTION 7 ELECTRICALSECTION7ELECTRICAL305 4922117 Harness Assembly - Ground Control Can 1 3/B305A 4460321 Connector - 4 Position 14460227

7-20 3120766SECTION 7 ELECTRICALSECTION7ELECTRICAL506B 4460749 Cap, Shell 14460750 Bar, Buss - 6 Position 14460744 Connector, 6 Position 14460745 Lock

3120766 7-21SECTION 7 ELECTRICALSECTION7ELECTRICAL511 Not Available Speed Sensor Harness 2511A 4460225 Connector - 6 Position 14460226 Socket, Female

7-22 3120766SECTION 7 ELECTRICALSECTION7ELECTRICAL601D Connector, Strain Relief Options: 14460071 110V GFI (ANSI)4460071 220V GFI (ANSI)Supply Locally

3120766 8-1SECTION8DECALSSECTION 8 DECALSTABLE OF CONTENTSFIGURE DESCRIPTION PAGE8-1 DECALS INSTALLATION - STANDARD . . . . . . . . . . . . . . . .

1-12 3120766SECTION 1 FRAMESECTION1FRAME62 7021340 Coupler 163 to 65 Not Used 66 Kit 4 Ring, Retaining 167 to 80 Not Used81 Kit 2 Bearing, Ball 182 K

8-2 3120766SECTION 8 DECALSSECTION8DECALSFIGURE 8-1.DECALS INSTALLATION - STANDARD

3120766 8-3SECTION 8 DECALSSECTION8DECALS (Continued)FIGURE 8-1. DECALS INSTALLATION - STANDARDFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.STAN

8-4 3120766SECTION 8 DECALSSECTION8DECALS28 1704431 Decal - Battery Charger Led Indicator (S/N 49542 to Present Only)129 to 30 Not Used31 0860520 Box,

3120766 8-5SECTION 8 DECALSSECTION8DECALS73 Decal - Fuel Warning Options: A/RNot Required E45 & E40 01702962 M45 & M40 174 to 76 Not Used77 17

8-6 3120766SECTION 8 DECALSSECTION8DECALSFIGURE 8-2.DECALS INSTALLATION - COUNTRY SPEC

3120766 8-7SECTION 8 DECALSSECTION8DECALS (Continued)FIGURE 8-2. DECALS INSTALLATION - COUNTRY SPECFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

8-8 3120766SECTION 8 DECALSSECTION8DECALS9 1701504 Decal - Hydraulic Oil 110 1701642 Decal - Arrow 211 Decal - Caution/Danger Options: 11703924 Canad

3120766 8-9SECTION 8 DECALSSECTION8DECALS26 Decal - Key Platform Options: A/R1704253 Canadian French/English Dual Language 1Not Required Chinese/Engli

8-10 3120766SECTION 8 DECALSSECTION8DECALS50 1702300 Decal - Tie Down 451 Not Used52 Not Available Decal - Bar Code 153 Decal - 500 LBS. Max Capacity

3120766 8-11SECTION 8 DECALSSECTION8DECALS73 Decal - Fuel Warning Options: A/RNot Required E45 & E40 01702962 M45 & M40 174 to 76 Not Used77 1

3120766 1-13SECTION1FRAMESECTION 1 FRAMEFIGURE 1-3. DRIVE HUB ASSEMBLY (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

8-12 3120766SECTION 8 DECALSSECTION8DECALSFIGURE 8-2. DECALS INSTALLATION - COUNTRY SPEC (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV

3120766 9-1SECTION9RECOMMENDEDSERVICEPARTSSTOCKSECTION 9 RECOMMENDED SERVICE PARTS STOCKMODELS E45/M45/E40 & M40The following list will service

9-2 3120766SECTION 9 RECOMMENDED SERVICE PARTS SECTION9RECOMMENDEDSERVICEPARTSSTOCKVARIABLE PARTS7020642 Breaker, Circuit (ANSI Spec 105/132V-60Hz &am

3120766 10-1SECTION10SPECIALOPTIONSSECTION 10 SPECIAL OPTIONSNote: This list is to accomodate machines ordered with special equipment. Options may not

10-2 3120766SECTION 10 SPECIAL OPTIONSSECTION10SPECIALOPTIONS7016623 Bulb - Brake (1 Per Taillight) 27016624 Bulb - Tail (1 Per Taillight)0270408 Plat

3120766 1INDEXPART NUMBER INDEXStarting Serial No. XXXXXXXXXXOriginal Issue - XX/XXXXRevised - XX/XX/XXXXMODEL M45A/E45A M40A/E40AP/N P

2 3120766INDEXPART NUMBER INDEXStarting Serial No. XXXXXXXXXXOriginal Issue - XX/XXXXRevised - XX/XX/XXXXMODEL M45A/E45A M40A/E40A063046

3120766 3INDEXPART NUMBER INDEXStarting Serial No. XXXXXXXXXXOriginal Issue - XX/XXXXRevised - XX/XX/XXXXMODEL M45A/E45A M40A/E40A13200

4 3120766INDEXPART NUMBER INDEXStarting Serial No. XXXXXXXXXXOriginal Issue - XX/XXXXRevised - XX/XX/XXXXMODEL M45A/E45A M40A/E40A170425

3120766 5INDEXPART NUMBER INDEXStarting Serial No. XXXXXXXXXXOriginal Issue - XX/XXXXRevised - XX/XX/XXXXMODEL M45A/E45A M40A/E40A27525

1-14 3120766SECTION 1 FRAMESECTION1FRAMEFIGURE 1-4. HYDRAULIC COMPONENTS INSTALLATION 11A1B1C8732A25411910121101091081146

6 3120766INDEXPART NUMBER INDEXStarting Serial No. XXXXXXXXXXOriginal Issue - XX/XXXXRevised - XX/XX/XXXXMODEL M45A/E45A M40A/E40A342269

3120766 7INDEXPART NUMBER INDEXStarting Serial No. XXXXXXXXXXOriginal Issue - XX/XXXXRevised - XX/XX/XXXXMODEL M45A/E45A M40A/E40A44602

8 3120766INDEXPART NUMBER INDEXStarting Serial No. XXXXXXXXXXOriginal Issue - XX/XXXXRevised - XX/XX/XXXXMODEL M45A/E45A M40A/E40A474000

3120766 9INDEXPART NUMBER INDEXStarting Serial No. XXXXXXXXXXOriginal Issue - XX/XXXXRevised - XX/XX/XXXXMODEL M45A/E45A M40A/E40A70116

10 3120766INDEXPART NUMBER INDEXStarting Serial No. XXXXXXXXXXOriginal Issue - XX/XXXXRevised - XX/XX/XXXXMODEL M45A/E45A M40A/E40A70206

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (Au

3120766 1-15SECTION1FRAMESECTION 1 FRAMEFIGURE 1-4. HYDRAULIC COMPONENTS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0257816 HYDRAU

1-16 3120766SECTION 1 FRAMESECTION1FRAMEFIGURE 1-5. BRAKE/STEER VALVE ASSEMBLY

3120766 1-17SECTION1FRAMESECTION 1 FRAMEFIGURE 1-5. BRAKE/STEER VALVE ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.4641149 BRAKE/STEER V

1-18 3120766SECTION 1 FRAMESECTION1FRAMEFIGURE 1-6. BATTERIES AND CHARGER INSTALLATIONS

3120766 1-19SECTION1FRAMESECTION 1 FRAMEFIGURE 1-6. BATTERIES AND CHARGER INSTALLATIONSFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.BATTERIES IN

1-20 3120766SECTION 1 FRAMESECTION1FRAMEBATTERY CHARGER INSTALLATIONS 0257815 ANSI Spec (105V/132V - 60Hz) (Prior to S/N49542) Ref. 20259825 ANSI Spec

3120766 1-21SECTION1FRAMESECTION 1 FRAMEFIGURE 1-6. BATTERIES AND CHARGER INSTALLATIONS (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1-22 3120766SECTION 1 FRAMESECTION1FRAMEFIGURE 1-7. BATTERY CHARGER ASSEMBLY (Prior to S/N 49542)

3120766 1-23SECTION1FRAMESECTION 1 FRAMEFIGURE 1-7. BATTERY CHARGER ASSEMBLY (PRIOR TO S/N 49542)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.No

REVISION LOG3120766 AMay 1, 1999 - Original Issue Of ManualJune 30, 1999 - Revised Manual September 30, 1999 - Revised Manual (Revised to B/M 0010554

1-24 3120766SECTION 1 FRAMESECTION1FRAME17 7020651 Shunt Assembly 118 7011528 Relief, Strain 119 7020659 Relief, Strain 220 7020670 Transformer, Mai

3120766 1-25SECTION1FRAMESECTION 1 FRAMEFIGURE 1-7. BATTERY CHARGER ASSEMBLY (PRIOR TO S/N 49542) (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION

1-26 3120766SECTION 1 FRAMESECTION1FRAMEFIGURE 1-8. BATTERY CHARGER ASSEMBLY (S/N 49542 to Present)

3120766 1-27SECTION1FRAMESECTION 1 FRAMEFIGURE 1-8. BATTERY CHARGER ASSEMBLY (S/N 49542 TO PRESENT)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1-28 3120766SECTION 1 FRAMESECTION1FRAME18 Varistor Options: A/R7011596 Charger p/n 0400196 17020663 Charger p/n 0400197 17020663 Charger p/n 0400195

3120766 1-29SECTION1FRAMESECTION 1 FRAMEFIGURE 1-8. BATTERY CHARGER ASSEMBLY (S/N 49542 TO PRESENT) (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTI

1-30 3120766SECTION 1 FRAMESECTION1FRAMEFIGURE 1-9. ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED)

3120766 1-31SECTION1FRAMESECTION 1 FRAMEFIGURE 1-9. ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. R

1-32 3120766SECTION 1 FRAMESECTION1FRAME45 4922103 Cable, Electrical (Contactor/Module to Charger) 14460444 Connector, DC 146 2540020 Grommet 347 Clam

3120766 1-33SECTION1FRAMESECTION 1 FRAMEFIGURE 1-9. ELECTRICAL COMPONENTS INSTALLATION (FRAME MOUNTED) (CONTINUED)FIG & ITEM # PART NUMBER DESCRI

REVISION LOGB 3120766

1-34 3120766SECTION 1 FRAMESECTION1FRAMEFIGURE 1-10. MOTOR/GENERATOR INSTALLATION (M45 & M40 ONLY) BATTERY LOCATED ON FRAME SIDE(SHOWN HEREFOR CLA

3120766 1-35SECTION1FRAMESECTION 1 FRAMEFIGURE 1-10. MOTOR/GENERATOR INSTALLATION (M45 & M40 ONLY)FIG & ITEM # PART NUMBER DESCRIPTION QTY. R

1-36 3120766SECTION 1 FRAMESECTION1FRAME50 1060731 Cable, Battery (Includes Terminal Boot) (– Battery to Ground)151 1060730 Cable, Battery (Includes T

3120766 1-37SECTION1FRAMESECTION 1 FRAME130 Not Used131 7020160 Flange, Air Intake 1132 7020159 Flange, Air Intake 1133 7020165 Heater, Air 1134 70181

1-38 3120766SECTION 1 FRAMESECTION1FRAMEFIGURE 1-11. FRAME COVERS INSTALLATION

3120766 1-39SECTION1FRAMESECTION 1 FRAMEFIGURE 1-11. FRAME COVERS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.FRAME COVERS INSTALLA

1-40 3120766SECTION 1 FRAMESECTION1FRAME27 Flex-Trim Options: A/RNot Required E45A, E45AJ, E40AJP & E40AJPnarrow 02820105 M45A, M45AJ, M40AJP &

3120766 2-1SECTION2TURNTABLESECTION 2 TURNTABLETABLE OF CONTENTSFIGURE DESCRIPTION PAGE2-1 VALVES AND HORN INSTALLATIONS . . . . . . . . . . . . . .

2-2 3120766SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-1. VALVES AND HORN INSTALLATIONS

3120766 2-3SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-1. VALVES AND HORN INSTALLATIONSFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.VALVE AND H

3120766 iFIGURE NO. TITLE PAGE NO.TABLE OF CONTENTSSECTION 1 - FRAME1-1 STEER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4 3120766SECTION 2 TURNTABLESECTION2TURNTABLEALARM INSTALLATIONS0259064 Motion Alarm Ref. 1101 0140031 Alarm, Motion (Remove ground strap before ins

3120766 2-5SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-1. VALVES AND HORN INSTALLATIONS (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV

2-6 3120766SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY

3120766 2-7SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-2. MAIN CONTROL VALVE ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.4641070 MAIN

2-8 3120766SECTION 2 TURNTABLESECTION2TURNTABLE19 7012947 Cartridge, (Emergency Descent) 17012518 Seal Kit - 7012947 Cartridge 17012949 Knob 120 70126

3120766 2-9SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2-10 3120766SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATION 672859410710113

3120766 2-11SECTION 2 TURNTABLESECTION2TURNTABLE.FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2-12 3120766SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-4. SWING MOTOR ASSEMBLY

3120766 2-13SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-4. SWING MOTOR ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.3160233 SWING MOTOR

ii 3120766FIGURE NO. TITLE PAGE NO.TABLE OF CONTENTS5-8 MASTER CYLINDER ASSEMBLY (AJ & AJP MODELS) . . . . . . . . . . . . . . . . . . . . . . .

2-14 3120766SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-5. SWING BEARING ASSEMBLY 1311827101011133171615468651291410710710810810911411011111211210

3120766 2-15SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-5. SWING BEARING ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.Note: Visually id

2-16 3120766SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-6. TANK AND MOTOR/GENERATOR COMPONENTS INSTALLATION (M45 & M40 ONLY)

3120766 2-17SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-6. TANK AND MOTOR/GENERATOR COMPONENTS INSTALLATION (M45 & M40 ONLY)FIG & ITEM # PAR

2-18 3120766SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-7. GROUND CONTROL BOX ASSEMBLY

3120766 2-19SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-7. GROUND CONTROL BOX ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.GROUND CONTR

2-20 3120766SECTION 2 TURNTABLESECTION2TURNTABLE38 3910804 Screw #8-32NC x 1/4” 6MOTOR CONTROLS INSTALLATION (M45 & M40 ONLY)Ref.0257824 M45 Model

3120766 2-21SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-7. GROUND CONTROL BOX ASSEMBLY (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2-22 3120766SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-8. HOODS AND BEACON LIGHT INSTALLATIONS

3120766 2-23SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-8. HOODS AND BEACON LIGHT INSTALLATIONSFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.HOO

3120766 1-1SECTION1FRAMESECTION 1 FRAMETABLE OF CONTENTSFIGURE DESCRIPTION PAGE1-1 STEER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .

2-24 3120766SECTION 2 TURNTABLESECTION2TURNTABLE109 4220162 Spacer 1110 0100011 Loctite #242 A/R111 4240032 Tie-Strap 1112 4460234 Clamp 1113 2820036

3120766 3-1SECTION3BOOMSECTION 3 BOOMTABLE OF CONTENTSFIGURE DESCRIPTION PAGE3-1 BOOMS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .

3-2 3120766SECTION 3 BOOMSECTION3BOOMFIGURE 3-1. BOOMS INSTALLATION

3120766 3-3SECTION 3 BOOMSECTION3BOOMFIGURE 3-1. BOOMS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.BOOMS INSTALLATIONS0258691 E45A

3-4 3120766SECTION 3 BOOMSECTION3BOOM11 Pin Options: 33422175 E45 & M453422481 E40 & M4012 Pin Options: 23422176 E45 & M453422845 E40 &

3120766 3-5SECTION 3 BOOMSECTION3BOOMFIGURE 3-1. BOOMS INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3-6 3120766SECTION 3 BOOMSECTION3BOOMFIGURE 3-2. MAIN BOOM ASSEMBLY (E45A & M45A)

3120766 3-7SECTION 3 BOOMSECTION3BOOMFIGURE 3-2. MAIN BOOM ASSEMBLY (E45A & M45A)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0801169 MAIN B

3-8 3120766SECTION 3 BOOMSECTION3BOOMFIGURE 3-3. MAIN BOOM ASSEMBLY (E45AJ & M45AJ)

3120766 3-9SECTION 3 BOOMSECTION3BOOMFIGURE 3-3. MAIN BOOM ASSEMBLY (E45AJ & M45AJ)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0801197 MAIN

1-2 3120766SECTION 1 FRAMESECTION1FRAMEFIGURE 1-1. STEER INSTALLATION

3-10 3120766SECTION 3 BOOMSECTION3BOOMFIGURE 3-4. MAIN BOOM ASSEMBLY (E40AJP & M40AJP)

3120766 3-11SECTION 3 BOOMSECTION3BOOMFIGURE 3-4. MAIN BOOM ASSEMBLY (E40AJP & M40AJP)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0801225 M

3-12 3120766SECTION 3 BOOMSECTION3BOOMFIGURE 3-5. SUPPORT AND ROTATOR ASSEMBLY (E45A & M45A) (PRIOR TO S/N49945) 12161618252326272120224303017361

3120766 3-13SECTION 3 BOOMSECTION3BOOMFIGURE 3-5. SUPPORT AND ROTATOR ASSEMBLY (E45A & M45A) (PRIOR TO S/N49945)FIG & ITEM # PART NUMBER DESC

3-14 3120766SECTION 3 BOOMSECTION3BOOMFIGURE 3-6. SUPPORT AND ROTATOR ASSEMBLY (E45A & M45A) (S/N49945TO PRESENT)

3120766 3-15SECTION 3 BOOMSECTION3BOOMFIGURE 3-6. SUPPORT AND ROTATOR ASSEMBLY (E45A & M45A) (S/N49945 TO PRESENT)FIG & ITEM # PART NUMBER DE

3-16 3120766SECTION 3 BOOMSECTION3BOOMFIGURE 3-7. SUPPORT/ROTATOR & JIB ASSEMBLIES (AJ & AJP)

3120766 3-17SECTION 3 BOOMSECTION3BOOMFIGURE 3-7. SUPPORT/ROTATOR & JIB ASSEMBLIES (AJ & AJP)FIG & ITEM # PART NUMBER DESCRIPTION QTY. RE

3-18 3120766SECTION 3 BOOMSECTION3BOOM123 3020022 Grease A/R124 to 126 Not Used127 0641610 Bolt 3/8”-16NC x 1 1/4” 1128 Not Used129 Platform Level Cyl

3120766 3-19SECTION 3 BOOMSECTION3BOOMFIGURE 3-7. SUPPORT/ROTATOR & JIB ASSEMBLIES (AJ & AJP) (CONTINUED)FIG & ITEM # PART NUMBER DESCRIP

3120766 1-3SECTION1FRAMESECTION 1 FRAMEFIGURE 1-1. STEER INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.STEER INSTALLATION OPTIONS: Re

3-20 3120766SECTION 3 BOOMSECTION3BOOMFIGURE 3-8. ROTATOR ASSEMBLY 12532323434252724442423202241526GENUINE PARTS515221B1A775353535341A

3120766 3-21SECTION 3 BOOMSECTION3BOOMFIGURE 3-8. ROTATOR ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.ROTATOR ASSEMBLIES Ref.0060044 E4

3-22 3120766SECTION 3 BOOMSECTION3BOOM41 Counterbalance Valve Assembly Options: 1Use 7017172 Helac p/n 24327 Stamped beside Mounting Screws (was p/n

3120766 3-23SECTION 3 BOOMSECTION3BOOMFIGURE 3-8. ROTATOR ASSEMBLY (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3-24 3120766SECTION 3 BOOMSECTION3BOOMFIGURE 3-9. CABLES/CLAMPS AND LIMIT SWITCHES INSTALLATIONS

3120766 3-25SECTION 3 BOOMSECTION3BOOMFIGURE 3-9. CABLES/CLAMPS AND LIMIT SWITCHES INSTALLATIONSFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.CAB

3-26 3120766SECTION 3 BOOMSECTION3BOOM29 0641410 Bolt 1/4"-20NC x 1 1/4" 130 3311405 Locknut 1/4"-20NC 131 Hose Clamp Block Options: 10

3120766 4-1SECTION4PLATFORMSECTION 4 PLATFORMTABLE OF CONTENTSFIGURE DESCRIPTION PAGE4-1 PLATFORM COMPONENTS INSTALLATION . . . . . . . . . . . .

4-2 3120766SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-1.PLATFORM COMPONENTS INSTALLATION 12133018302304305303944 3 18 19 20129130132146176111516103152

3120766 4-3SECTION 4 PLATFORMSECTION4PLATFORMFIGURE 4-1. PLATFORM COMPONENTS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.PLATFORM I