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E450AJ
JLG E450AJ Service Manual
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Se
r
vice and Main
tenanc
e Manual
Models
E450A
E450A
J
M450A
M450A
J
SN 0300208529
to Present
PN - 3121714
November 30, 2018 - Rev D
AS/NZS
2
Table of Contents
Default Chapter
3
General
3
Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Specifications
19
Operating Specifications
19
Tires
19
Capacities
19
Dimensional Data
20
Torque Specifications
20
Lubrication Specifications
20
Hydraulic Oil
20
Critical Stability Weights
21
Maintenance & Lubrication Diagram
22
Maintenance and Lubrication
23
Torque Chart (SAE Fasteners - Sheet 1 of 5)
26
Torque Chart (SAE Fasteners - Sheet 2 of 5)
27
Torque Chart (SAE Fasteners - Sheet 3 of 5)
28
Torque Chart (METRIC Fasteners - Sheet 4 of 5)
29
Torque Chart (METRIC Fasteners - Sheet 5 of 5)
30
General
31
Machine Preparation, Inspection, and Maintenance
31
Preparation, Inspection, and Maintenance
31
Pre-Start Inspection
31
Pre-Delivery Inspection and Frequent Inspection
31
Annual Machine Inspection
31
Preventative Maintenance
31
Service and Guidelines
32
General
32
Safety and Workmanship
32
Cleanliness
32
Components Removal and Installation
32
Component Disassembly and Reassembly
33
Pressure-Fit Parts
33
Bearings
33
Gaskets
33
Bolt Usage and Torque Application
33
Hydraulic Lines and Electrical Wiring
33
Hydraulic System
33
Lubrication
34
Battery
34
Lubrication and Servicing
34
Lubrication and Information
34
Hydraulic System
34
Hydraulic Oil
34
Changing Hydraulic Oil
34
Lubrication Specifications
34
Cylinder Drift
35
Theory
35
Cylinder Leakage Test
35
Cylinder Thermal Drift
35
Pins and Composite Bearing Repair Guidelines
36
Welding on JLG Equipment
36
Do the Following When Welding on JLG Equipment
36
Do NOT Do the Following When Welding on JLG Equipment
36
Inspection and Preventive Maintenance Schedule
37
Engine Operating Temperature Specifications - Kubota
40
Chassis & Turntable
41
Tires & Wheels
41
Tire Inflation
41
Tire Damage
41
Tire Replacement
41
Wheel Replacement
41
Wheel Installation
41
Spindle
42
Setting Wheel Bearing End Play
42
Specifications
42
Checking
42
Greasing Requirements
42
Spindle Assembly
43
Chassis Component Location
44
Tilt Module
45
Speed Sensor
46
Relay
47
System Fuses
48
Ignition Relay Fuse
49
Drive Fuses
50
Drive Limit Switch
51
Steering Installation and Spindle
52
Drive Hub
53
Roll and Leak Testing
53
Tightening and Torquing Bolts
53
Main Disassembly
54
Main Assembly - Sheet 2 of 2
55
Output Carrier Disassembly
56
Planet Gear
57
Input Carrier Disassembly
58
Hub-Spindle Disassembly
59
Cover Disassembly
60
Input Carrier Assembly
61
Output Planet Gear Assembly
61
Output Carrier Assembly
62
Hub-Spindle Assembly
62
Cover Assembly
63
Main Assembly
63
Drive Hub - Sheet 1 of 2
64
Drive Hub - Sheet 2 of 2
65
Drive Motor
66
Disassembly
66
Inspection
66
Removal
66
Assembly
67
Installation
67
Drive Motor
68
Swing Bearing
69
Turntable Bearing Mounting Bolt Condition Check
69
Wear Tolerance
70
Replacement of Swing Bearing
71
Swing Bearing Torquing Sequence
72
Swing Bearing Torque Value
75
Checking Worm Gear End Play
75
Adjusting End Play
75
Swing Components
76
Swing Motor
77
Swing Motor Troubleshooting
78
Swing Motor - Exploded View
79
Preparation before Disassembly
80
Disassembly and Inspection
80
Assembly
87
One Piece Stator Construction
93
Two Piece Stator Construction
94
Final Checks
94
Battery Maintenance and Charging
95
Battery Charging (on Board Charger)
95
Battery Maintenance, Quarterly
95
Optional on Board Generator
95
Battery Charger
97
Operating Instructions
97
Battery Charger Fault Codes
98
Maintenance Instructions
98
Battery Charger (E450A/AJ)
99
Battery Charger (M450AJ)
100
Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell
102
Checking/Changing the Battery Charger Algorithm
102
Generator
103
Alternator
103
Control Fuse
103
Dynamo and Dynamo Voltage Regulator
103
Dynamo Output Fuse
103
Engine
103
Generator
104
Engine Starter
105
Start Battery
105
Start Control Relay
105
Fuel Control Relay
106
Glow Plug
106
Glow Plug Control Relay
106
Engine Low Oil Pressure Switch
107
Engine Oil Temperature Sensor
107
Fuel Pump
107
Fuel Solenoid
107
Alternator Output Current Sensor
108
Engine Speed Sensor
108
RBS Engine/Generator Controller
108
System Controls
109
System Settings
109
System Status and Performance Monitoring
109
Warnings and Safety Precautions
109
RBS Shutdown
110
RBS Start
110
Maintenance Schedule
111
RBS Alarms and Flash Codes
111
Resetting the RBS Controller
111
Troubleshooting
112
APU Engine Start Battery Boosting
113
Supplementary Fuse for Apu
114
Procedure
114
Tools and Material
114
Boom & Platform
117
Platform
117
Support Removal
117
Support Installation
118
Platform Support Torque Values
119
Rotator and Slave Cylinder Removal
120
Removal
120
Installation
120
Main Boom Powertrack (E/M450AJ)
121
Removal
121
Installation
121
Boom Maintenance
122
Removal
122
Disassembly
123
Inspection
123
Assembly
123
Installation
124
Wear Pads
125
Boom Limit Switches
125
Boom Cleanliness Guidelines
125
Boom Limit Switches
126
Platform Components and Attaching Hardware (M450A & E450A)
127
Articulating Jib Boom
128
Removal
128
Disassembly
128
Inspection
128
Assembly
128
Boom Synchronizing Procedure
129
Foot Switch Adjustment
129
Rotary Actuator
130
Theory of Operation
130
Tools Required for Assembly/Disassembly
130
Rotary Actuator (Exploded View)
131
Rotator- Assembly Drawing
132
Disassembly
133
Inspection
136
Assembly
137
Installing Counterbalance Valve
141
Greasing Thrust Washers
142
Testing the Actuator
142
Installation and Bleeding
143
Troubleshooting
144
Powertrack Maintenance
145
Removing a Link
145
Installing a New Link
148
Replacing Fixed End Brackets
153
Replacing Moving End Brackets
155
Skyguard
157
Function Test
157
Operation
157
Diagnostics & Troubleshooting
158
Basic Hydraulic Information & Schematics
159
Lubricating O-Rings in the Hydraulic System
159
Cup and Brush
159
Dip Method
160
Spray Method
160
Brush-On Method
160
Hydraulic Connection Assembly and Torque Specification
161
Tapered Thread Types
161
Straight Thread Types, Tube and Hose Connections
161
Straight Thread Types, Port Connections
162
Flange Connection Types
162
Tightening Methods
162
Assembly and Torque Specifications
163
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections
164
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections
165
Assembly Instructions for 37° (JIC) Flare Fittings
166
Flare (JIC) Thread - Steel
167
Flare (JIC) Thread - Aluminum/Brass
168
Assembly Instructions for 45° SAE Flare Fittings
170
Flare (SAE) - Steel
171
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
172
O-Ring Face Seal (ORFS) - Aluminum/Brass
173
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
174
DIN 24° Cone (MBTL & MBTS)
175
Assembly Instructions for Bulkhead (BH) Fittings
176
Bulkhead Fittings (BH) - INCH
177
Bulkhead Fittings (BH) - METRIC
178
Assembly Instructions for O-Ring Boss (ORB) Fittings
180
O-Ring Boss (ORB) - Table 1 of 6
181
O-Ring Boss (ORB) - Table 2 of 6
182
O-Ring Boss (ORB) - Table 3 of 6
183
O-Ring Boss (ORB) - Table 4 of 6
184
O-Ring Boss (ORB) - Table 5 of 6
185
O-Ring Boss (ORB) - Table 6 of 6
186
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings
188
Metric Flat Face Port (MFF) - L Series - Table 1 of 3
189
Metric Flat Face Port (MFF) - L Series - Table 2 of 3
190
Metric Flat Face Port (MFF) - L Series - Table 3 of 3
191
Metric Flat Face Port (MFF) - S Series - Table 1 of 3
192
Metric Flat Face Port (MFF) - S Series - Table 2 of 3
193
Metric Flat Face Port (MFF) - S Series - Table 3 of 3
194
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends
196
Metric Pipe Parallel O-Ring Boss (MPP)
197
Assembly Instructions for Adjustable Port End (BSPP) Fittings
198
British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
199
British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3
200
British Standard Parallel Pipe Port (BSPP) - L Series - Table 3 of 3
201
British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3
202
British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3
203
British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3
204
Assembly Instructions for Flange Connections: (FL61 and FL62)
206
Flange Code (FL61 & FL62) -Inch Fasteners
207
Flange Code (FL61 & FL62) - Metric Fasteners
208
Double Wrench Method
209
FFWR and TFFT Methods
210
Adjustable Stud End Assembly
210
O-Ring Installation (Replacement)
211
Hydraulic Cylinders
212
Platform Level (Slave) Cylinder (E450Aonly)
212
Platform Level (Slave) Cylinder (E450A Only)
213
Composite Bearing Installation
215
Wiper Seal Installation
216
Platform Level (Slave) Cylinder E/M450AJ
217
Platform Level (Slave) Cylinder - E/M450AJ (SN B300002487 to Present)
219
Composite Bearing Installation
221
Wiper Seal Installation
222
Jib Lift Cylinder (E/M 450AJ Only)
223
Jib Lift Cylinder (SN 0300208529 to Present, SN B300001429 through B300002486)
224
Jib Lift Cylinder (SN B300002487 to Present)
225
Composite Bearing Installation
227
Wiper Seal Installation
228
Lower Lift Cylinder
229
Cylinder Head Removal
230
Lower Lift Cylinder - E450A (SN 0300235601 through 0300239755 E450AJ/M450AJ (SN 0300208529 through 0300239252, SN B300001429 through B300002461)
231
Lower Lift Cylinder - E450A (SN 0300239756 to Present)
232
Lower Lift Cylinder - E450AJ/M450AJ (SN B300002487 to Present)
234
Composite Bearing Installation
236
Wiper Seal Installation
237
MID Lift Cylinder
238
Cylinder Head Removal
239
MID Lift Cylinder - E450AJ/M450AJ (SN B300002487 to Present)
242
Composite Bearing Installation
244
Wiper Seal Installation
245
Upper Lift Cylinder
246
Cylinder Head Removal
247
Upper Lift Cylinder - E450A (SN 0300239756 to Present)
249
Upper Lift Cylinder - E450AJ/M450AJ (SN 0300239756 to Present)
250
Upper Lift Cylinder - E450AJ/M450AJ (SN B300002487 to Present)
251
Composite Bearing Installation
253
Wiper Seal Installation
254
Master Cylinder (E450A Only)
255
Master Cylinder (E450A Only)
256
Composite Bearing Installation
258
Wiper Seal Installation
259
Master Cylinder E/M450AJ
260
Master Cylinder E/M450AJ (SN 0300208529 to Present, SN B300001429 through B300002486)
261
Master Cylinder E/M450AJ (SN B3000024867 to Present)
262
Composite Bearing Installation
264
Wiper Seal Installation
265
Steer Cylinder
266
Steer Cylinder
267
Rod Seal Installation
269
Piston Seal Kit Installation
270
Telescope Cylinder (E450A Only)
271
Telescope Cylinder (E450A Only)
272
Composite Bearing Installation
274
Wiper Seal Installation
275
Telescope Cylinder E/M450AJ
276
Cylinder Rod Support
277
Telescope Cylinder - E/M450AJ (SN 0300208529 to Present, SN B300001429 through B300002486)
278
Telescope Cylinder - E450AJ/M450AJ (SN B300002487 to Present)
279
Composite Bearing Installation
281
Wiper Seal Installation
282
Components Boom
283
Cylinder Removal and Installation
284
Main Boom Lift Cylinder Installation
284
Main Boom Lift Cylinder Removal
284
MID Boom Lift Cylinder Installation
285
MID Boom Lift Cylinder Removal
285
Lower Boom Lift Cylinder Installation
286
Lower Boom Lift Cylinder Removal
286
Main Boom Telescope Cylinder Installation
287
Main Boom Telescope Cylinder Removal
287
Pressure Setting Procedures
288
Lower Lift down Relief
288
Main Lift down Relief
288
Main Relief
288
Telescope Relief
288
MID and Lower Lift Cylinder Bleeding Procedure
288
Platform Level down Relief
289
Platform Level up Relief
289
Jib Lift (up and Down) Relief
290
Releveling Valve Relief
290
Steer Relief
290
Hydraulic Component Location
291
Steer Valve Pressure Adjustment
292
Steer Valve Component
293
Steer Valve Torque Specification
294
Main Valve Pressure Adjustment
295
Main Valve Components
296
Main Control Valve Torque Specification
297
Releveling Valve Torque Specification
298
Cartridge Torque Values
299
Jib Valve Torque Specification (SN 0300233452 to Present, SN B300002533 to Present)
300
SN B300001429 through B300002532) - Sheet 1 of 7
302
SN B300001429 through B300002532) - Sheet 2 of 7
303
SN B300001429 through B300002532) - Sheet 3 of 7
304
SN B300001429 through B300002532) - Sheet 4 of 7
305
SN B300001429 through B300002532) - Sheet 5 of 7
306
SN B300001429 through B300002532) - Sheet 6 of 7
307
SN B300001429 through B300002532) - Sheet 7 of 7
308
Hydraulic Schematic (SN 0300233452 to Present, SN B300002533 to Present) - Sheet 1 of 7
310
Hydraulic Schematic (SN 0300233452 to Present, SN B300002533 to Present) - Sheet 2 of 7
311
Hydraulic Schematic (SN 0300233452 to Present, SN B300002533 to Present) - Sheet 3 of 7
312
Hydraulic Schematic (SN 0300233452 to Present, SN B300002533 to Present) - Sheet 4 of 7
313
Hydraulic Schematic (SN 0300233452 to Present, SN B300002533 to Present) - Sheet 5 of 7
314
Hydraulic Schematic (SN 0300233452 to Present, SN B300002533 to Present) - Sheet 6 of 7
315
Hydraulic Schematic (SN 0300233452 to Present, SN B300002533 to Present) - Sheet 7 of 7
316
Jlg Control System
317
Introduction
317
To Connect the JLG Control System Analyzer
318
Using the Analyzer
318
Changing the Access Level of the Hand Held Analyzer
319
Adjusting Parameters Using the Hand Held Analyzer
320
Machine Setup
321
Level Vehicle Description
321
Analyzer Abbreviations
322
Machine Configuration Programming Information
324
Machine Configuration Programming Settings
328
Machine Personality Settings
329
Analyzer Software P1.4 - Sheet 1 of 5
333
Analyzer Software P1.4 - Sheet 2 of 5
334
Analyzer Software P1.4 - Sheet 3 of 5
335
Analyzer Software P1.4 - Sheet 4 of 5
336
Analyzer Software P1.4 - Sheet 5 of 5
337
Machine Orientation When Performing Test
338
Test Notes
339
Function Speed
339
Control Module Location - Sheet 1 of 2
340
Control Module Location - Sheet 2 of 2
341
Analyzer Connecting Points
342
Power Module - LH
343
Power Module - RH
344
Ground Control Module - Sheet 1 of 3
345
Ground Control Module - Sheet 2 of 3
346
Ground Control Module - Sheet 3 of 3
347
Platform Module - Sheet 1 of 2
348
Platform Module - Sheet 2 of 2
349
Help Descriptions and Fault Flash Codes
350
Help Descriptions and Fault Flash Codes
351
Analyzer Diagnostics Menu Structure
356
System Self Test
362
System Test Messages
363
Calibrating Steer
367
Calibrating Tilt Sensor
369
Calibrating Load Sensing
371
LSS System
374
Diagnostic Menu
375
Calibration Procedure
376
Accessory Weights
377
Skyglazier Capacity Reductions
379
Testing & Evaluation
381
Troubleshooting
382
Resetting the MSSO System
383
Diagnostic Trouble Codes
385
Basic Electrical Information & Electrical Schematics
403
General
403
Multimeter Basics
403
Grounding
403
Backprobing
403
Min/Max
403
Polarity
403
Scale
403
Voltage Measurement
403
Resistance Measurement
404
Continuity Measurement
404
Current Measurement
405
Checking Switches
405
Basic Check
405
Limit Switches
405
Automatic Switches
406
Switch Wiring - Low Side, High Side
406
Installation of Dielectric Grease
407
Deutsch HD, DT, DTM, DRC Series
407
AWP Seal
407
AMP Mate-N-Lok
408
DIN Connectors
408
Exclusions
408
AMP Connector
410
Applying Silicone Dielectric Compound to AMP Connectors
410
Assembly
410
Connector Assembly Figure 2
411
Disassembly
412
Wedge Lock
412
Service - Voltage Reading
412
Connector Installation
413
DEUTSCH Connectors
414
DT/DTP Series Assembly
414
DT/DTP Series Disassembly
414
HD30/HDP20 Series Assembly
415
HD30/HDP20 Series Disassembly
415
Wiring Harness Connector Lables
416
Component Labels
416
Connector Labels
416
Platform Console Harness - Sheet 2 of 4
419
Platform Console Harness - Sheet 3 of 4
420
Platform Console Harness - Sheet 4 of 4
421
Load Sensing System Harness - Sheet 2 of 2
425
Main Valve Harness - Sheet 2 of 3
427
Main Valve Harness - Sheet 3 of 3
428
Turntable Harness - Sheet 2 of 3
431
Turntable Harness - Sheet 3 of 3
432
Ground Control Panel Harness - Sheet 2 of 3
435
Ground Control Panel Harness - Sheet 3 of 3
436
Chassis Traction Harness - Sheet 2 of 4
439
Chassis Traction Harness - Sheet 3 of 4
440
Chassis Traction Harness - Sheet 4 of 4
441
Chassis Steer/Brake Harness - Sheet 2 of 2
445
Chassis Head /Tail Light Harness - Sheet 2 of 2
447
Generator IGN Harness - Sheet 2 of 2
451
Skyguard Harness Sheet - 2 of 2
453
Soft Touch Harness - Sheet 2 of 2
455
Platform Console Harness with Skyguard and 1 Cell LSS - Sheet 2 of 4
457
Platform Console Harness with Skyguard and 1 Cell LSS - Sheet 3 of 4
458
Platform Console Harness with Skyguard and 1 Cell LSS - Sheet 4 of 4
459
Electrical Schematic - Sheet 1 of 18
461
Electrical Schematic - Sheet 2 of 18
462
Electrical Schematic - Sheet 3 of 18
463
Electrical Schematic - Sheet 4 of 18
464
Electrical Schematic - Sheet 5 of 18
465
Electrical Schematic - Sheet 6 of 18
466
Electrical Schematic - Sheet 7 of 18
467
Electrical Schematic - Sheet 8 of 18
468
Electrical Schematic - Sheet 9 of 18
469
Electrical Schematic - Sheet 10 of 18
470
Electrical Schematic - Sheet 11 of 18
471
Electrical Schematic - Sheet 12 of 18
472
Electrical Schematic - Sheet 13 of 18
473
Electrical Schematic - Sheet 14 of 18
474
Electrical Schematic - Sheet 15 of 18
475
Electrical Schematic - Sheet 16 of 18
476
Electrical Schematic - Sheet 17 of 18
477
Gen 2 Plat Interface Harness
478
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JLG E450AJ Specifications
General
Platform Height
45 ft
Weight
13, 400 lb
Power Source
Electric
Platform Capacity
500 lbs
Platform Capacity - Unrestricted
500 lbs
Tire Type
Solid
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