Accessing Hydraulic Hose Fittings on the JLG 45HA Tower Cylinder

[MikePhua]

JLG and the 45HA Boom Lift Design
JLG Industries, founded in 1969, has long been a leader in aerial work platforms and telehandlers. The 45HA articulating boom lift is part of JLG’s hybrid series, combining electric and hydraulic systems for versatile performance in both indoor and outdoor environments. With a working height of 51 feet and a horizontal outreach of over 24 feet, the 45HA is designed for maneuverability and precision in tight spaces.
Its tower lift cylinder, located within the articulating boom structure, plays a critical role in raising and lowering the upper boom sections. Hydraulic hoses connected to this cylinder must withstand high pressure and frequent articulation, making their placement and serviceability crucial.
Challenges in Hose Access and Tool Clearance
One of the most common service frustrations with the 45HA is the limited clearance around the hydraulic hose fittings on the tower lift cylinder. These fittings are often recessed within the boom structure, surrounded by metal brackets and pivot blocks that restrict tool access. Standard wrenches are too bulky to reach the fittings, and even compact adjustable wrenches may not provide the necessary torque or angle.
This issue is not unique to JLG. Many manufacturers prioritize compact design and structural integrity, sometimes at the expense of service accessibility. Mechanics often resort to specialized tools or partial disassembly to reach critical hydraulic connections.
Recommended Tools and Techniques
To address tight clearance around hydraulic fittings, technicians have developed several strategies:

• Crowfoot wrenches: These open-end wrench heads attach to ratchet extensions, allowing access in confined spaces.
  
• Angle wrenches: Brands like Snap-on offer angle wrenches with unique offsets that can reach around obstructions.
  
• Service wrenches: Thin-profile wrenches designed for hydraulic service can be alternated with angle wrenches for incremental turns.
  
• Pin removal and pivot block rotation: In some cases, knocking out a pivot pin allows the block to swing away, exposing the fittings. This method requires caution and proper support to avoid damaging the boom or cylinder.
  

A technician working on a 45HA in Alabama discovered that removing a large pin through the pivot block allowed the block to swing outward, granting full access to the hose fittings. This approach avoided cutting or bending tools and preserved the integrity of the surrounding structure.
Design Critique and Maintenance Philosophy
The difficulty in accessing hydraulic fittings raises broader questions about equipment design. While compactness and strength are essential, serviceability should not be compromised. A more user-friendly design could include:

• Removable access panels near critical hydraulic junctions
  
• Repositioned fittings with swivel adapters for easier reach
  
• Modular hose routing with quick-disconnect couplings
  

Manufacturers like Genie and Skyjack have begun incorporating such features in newer models, responding to technician feedback and reducing service times.
Preventive Maintenance Recommendations
To minimize future service challenges:

• Inspect hose routing and fitting torque during scheduled maintenance
  
• Apply anti-seize compound on threads to ease future removal
  
• Replace hoses with high-flex rated lines to reduce fatigue
  
• Document hose part numbers and fitting types for quick reordering
  
• Keep a set of specialty wrenches and crowfoot adapters in the service kit
  

Conclusion
Servicing hydraulic hose connections on the JLG 45HA tower lift cylinder requires creativity, patience, and the right tools. While the design presents challenges, experienced technicians can overcome them with strategic disassembly and specialized equipment. As aerial platforms evolve, balancing compact engineering with service accessibility will remain a key factor in equipment reliability and technician satisfaction.