JLG E450A Service And Maintenance Manual
  1. Manuals
  2. Brands
  3. JLG Manuals
  4. Lifting Systems
  5. E450A
  6. Service and maintenance manual

JLG E450A Service And Maintenance Manual

Electric boom lift
Hide thumbs Also See for E450A:
Table of Contents

Advertisement

Quick Links

Download this manual See also: Service Maintenance Manual
Service and Maintenance Manual
Model
E450A
E450AJ
M450A
M450AJ
P/N - 3121127
January 26, 2009

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the E450A and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for JLG E450A

Summary of Contents for JLG E450A

  • Page 1 Service and Maintenance Manual Model E450A E450AJ M450A M450AJ P/N - 3121127 January 26, 2009...

  • Page 3: Bhydraulic System Safety

    Every effort should be made to relieve any system • KEEP ALL SUPPORT EQUIPMENT AND ATTACH- pressure prior to disconnecting or removing any portion of MENTS STOWED IN THEIR PROPER PLACE. the system. • USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS. 3121127 – JLG Lift –...
  • Page 4 INTRODUCTION REVISON LOG Original Issue - August 15, 1999 Revised - April 5, 2001 Revised - May 25, 2004 Revised - July 30, 2007 Revised - January 24, 2008 Revised - January 26, 2009 – JLG Lift – 3121127...

  • Page 5: Table Of Contents

    Lubrication and Servicing ........... 2-3 3121127 – JLG Lift –...
  • Page 6 Welding on JLG Equipment ............2-5 Do the Following When Welding on JLG Equipment ......2-5 Do NOT Do the Following When Welding on JLG Equipment .
  • Page 7 Timing Sequences ............3-29 To Connect the JLG Control System Analyzer to the Generator ..... 3-30 Alarms and Fault Flash Codes .
  • Page 8 Assembly ..............4-20 – JLG Lift –...
  • Page 9 To Connect the JLG Control System Analyzer ........
  • Page 10 HD30/HDP20 Series Disassembly..........7-28 – JLG Lift –...
  • Page 11 Boom Limit Switches............4-9 4-9. Platform Components and Attaching Hardware (M450A & E450A) ......4-10 4-10.
  • Page 12 Connector Assembly Figure 1 ........... .7-23 viii – JLG Lift – 3121127...
  • Page 13 Hydraulic Schematic - M450A/E450A - Sheet 1 of 2 ....... .
  • Page 14 JLG Control System Flash Codes........

  • Page 15: Section 1 - Specifications

    Horizontal Reach @ Maximum E450A/M450A 13,100 lb. (5942 kg) Up and Over E450AJ/M450AJ 15,100 lb. (6804 kg) M450 A, E450A 23 ft. 1 in. (7.0 m) M450AJ, E450AJ 23 ft. 9 in. (7.24 m) CAPACITIES Machine Width 5 ft. 9 in. (1.75 m) Table 1-2.

  • Page 16: Drive System

    Platform Rotate - Right & Left 180° - E450AJ, M450AJ 20-24** Pump 0.098 in.[3]/rev. (1.6 cm[3]/rev.) Platform Rotate - Right & Left 180° - E450A, M450A 17-14** Pump Output 2.96 gpm (11.2 lpm) @ 3200 psi (222 Bar) Jib Up...

  • Page 17: Pressure Settings

    1500 Platform Level Up Relief 3000 Brake/Steer Valve Platform Level Down Relief 1200 Steer Relief 2300 Brake/Steer Valve Main Relief - E450A/M450A 3200 Steer Relief 2300 Main Relief - E450AJ/M450AJ 3400 Main Relief - E450A/M450A 3200 Jib Valve Main Relief - E450AJ/M450AJ...

  • Page 18: Lubrication Specifications

    DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS of comparable viscosities. If use of hydraulic oil OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BAT- other than Mobil DTE 11M is desired, contact JLG TERIES, FILLED TIRES, PLATFORM) DO NOT MODIFY UNIT IN Industries for proper recommendations.

  • Page 19: Cylinder Specifications

    Mid Lift Cylinder Lower Lift Cylinder Telescope Cylinder 38.5 Upper Upright Lower Upright Turntable Battery Box (incl. batteries) Chassis (w/ pneu. tires) 4,295 1948 Chassis (w/ foam-filled tires) 4,695 2130 Counterweight 3850 1746 Machine Complete 11,800 5352 3121127 – JLG Lift –...

  • Page 20: Operator Maintenance & Lubrication Diagram

    SECTION 1 - SPECIFICATIONS Figure 1-2. Operator Maintenance & Lubrication Diagram – JLG Lift – 3121127...

  • Page 21: Operator Maintenance & Lubrication

    Comments - If necessary install grease fittings into pound. (JLG Part No. 3020027) worm gear housing and grease bearings. Bearing Grease (JLG Part No. 3020029) Mobilith SHA 460. Synthetic Lithium Lubricant, Gredag 741 Grease. (JLG Part No. 3020022) DO NOT OVERGREASE BEARINGS. OVERGREASING BEARINGS Engine (crankcase) Oil.
  • Page 22 Lube Point(s) - Level/Fill Plug Capacity - 17 oz. (1/2 Full) Lube - EPGL Interval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation – JLG Lift – 3121127...
  • Page 23 9. Engine Lube Point(s) - Fill Cap Capacity - Refer to Engine Manual Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accor- dance with engine manual. 3121127 – JLG Lift –...

  • Page 24: Torque Chart (Sae Fasteners - Sheet 1 Of 3)

    SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 3) 1-10 – JLG Lift – 3121127...

  • Page 25: Torque Chart (Sae Fasteners - Sheet 2 Of 3))

    SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 3)) 3121127 – JLG Lift – 1-11...

  • Page 26: Torque Chart (Sae Fasteners - Sheet 3 Of 3)

    SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 3) 1-12 – JLG Lift – 3121127...

  • Page 27: Torque Chart (Metric Fasteners - Sheet 1 Of 3)

    SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 1 of 3) 3121127 – JLG Lift – 1-13...

  • Page 28: Torque Chart (Metric Fasteners - Sheet 2 Of 3)

    SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 2 of 3) 1-14 – JLG Lift – 3121127...

  • Page 29: Torque Chart (Metric Fasteners - Sheet 3 Of 3)

    SECTION 1 - SPECIFICATIONS Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 3 of 3) 3121127 – JLG Lift – 1-15...
  • Page 30 SECTION 1 - SPECIFICATIONS NOTES: 1-16 – JLG Lift – 3121127...

  • Page 31: Section 2 - General

    JLG Service It is important to establish and conform to a comprehen- Training School for the subject JLG product model. Refer- sive inspection and preventive maintenance program. The ence the machine Service and Maintenance Manual and...

  • Page 32: Service And Guidelines

    Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Service and Maintenance Inspection rental delivery. Mechanic Manual and applicable JLG inspection form. Frequent Inspection In service for 3 months or 150 hours, which- Owner, Dealer, or User Qualified JLG Service and Maintenance ever comes first;...

  • Page 33: Component Disassembly And Reassembly

    (See Hydraulic system filters should checked, Torque Chart Section 1.) cleaned, and/or replaced as necessary, at the speci- 3121127 – JLG Lift –...

  • Page 34: Hydraulic Oil

    Maximum allowable drift is 2 inches (5 cm) in 10 minutes. ranges. If the machine does not pass this test, proceed with the following. 2. JLG recommends Mobil DTE-11 hydraulic oil, which has an SAE viscosity of 10W and a viscosity index of Cylinder Drift 140.

  • Page 35: Pins And Composite Bearing Repair Guidelines

    1. Pinned joints should disassembled inspected if the following occurs: Do the Following When Welding on JLG a. Excessive sloppiness in joints. Equipment b. Noise originating from the joint during operation. • Disconnect the battery. 2. Filament wound bearings should be replaced if any •...

  • Page 36: Inspection And Preventive Maintenance Schedule

    Hood, Hood Props, Hood Latches 1,2,5 Chassis Assembly Tires 16,17 16,17,18 16,17,18 Wheel Nuts/Bolts Wheel Bearings 14,24 Oscillating Axle/Lockout Cylinder Systems Outrigger or Extendable Axle Systems Steer Components Drive Motors Drive Hubs Functions/Controls Platform Controls – JLG Lift – 3121127...
  • Page 37 Hydraulic Fluid 7,11 7,11 Electrical Connections Instruments, Gauges, Switches, Lights, Horn 5,23 General Operators and Safety Manuals in Storage Box ANSI and EMI Manuals/Handbooks Installed Capacity Decals Installed, Secure, Legible All Decals/Placards Installed, Secure, Legible 3121127 – JLG Lift –...
  • Page 38 Function Test of All Systems 21, 22 Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership Footnotes: Prior to use each day; or at each Operator change Prior to each sale, lease, or delivery In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used...

  • Page 39: Engine Operating Temperature Specifications - Kubota

    180° F(82° C) (HYD. OIL TANK TEMP.) IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC AMBIENT AIR OIL COOLER (CONSULT JLG SERVICE TEMPERATURE 120° F (49° C) NO OPERATION ABOVE THIS PROLONGED OPERATION IN AMBIENT TEMPERATURE 110°...
  • Page 40 SECTION 2 - GENERAL NOTES: 2-10 – JLG Lift – 3121127...

  • Page 41: Section 3 - Chassis & Turntable

    JLG. Due to size variations between the air pressure that is stenciled on the side of the JLG tire brands, both tires on the same axle should be the product or rim decal for safe and proper operational same.

  • Page 42: Drive Hub

    PART NO. 2780236 19. The second stage planetary gears (1) must be changed as a complete set of four and JLG recom- The final drive consists of two planetary stages with an mends changing the sun gear (3) along with this set integrated disconnect mechanism.

  • Page 43: Disassembly Of Cover

    4. Install the cover (51) into cover (8) and fix cover (51) 1. Press cylindrical roller bearings out of planet gears with hex bolts (53). Tighten bolts with torque wrench (1). to 6.3 ft. lbs. (8.5 Nm). 3121127 – JLG Lift –...

  • Page 44: Final Assembly

    (24) 0.04 to 0.05 inches (1.1 pressure and speed before running at full speed. After 4 to 1.3 mm) into the spindle thread. Then set ball (24) hours of operation, recheck oil level. in position by punching in expander (25). – JLG Lift – 3121127...

  • Page 45: Drive Hub - Cutaway

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-1. Drive Hub - Cutaway 3121127 – JLG Lift –...

  • Page 46: Drive Brake - Mico

    1. Clean all parts thoroughly before assembly. 2. Press new rotary seal (22) into cover (21). Note direction of seal 3. Install new bearing (18) and retaining ring (19) on shaft (10). 4. Install shaft assembly and retaining ring (17) in – JLG Lift – 3121127...

  • Page 47: Drive Brake

    21. Cover 4. Case Seal 10. Shaft 16. Spring Retainer 22. Rotary Oil Seal 5. O-ring 11. Stator Disc 17. Retaining Ring 23. Gasket 6. Backup Ring 12. Sensor Ring 18. Bearing Figure 3-2. Drive Brake 3121127 – JLG Lift –...

  • Page 48: Drive Brake Diagnosis

    Replace o-rings. release. Discs frozen These brakes are designed for only limited dynamic Replace disc stack. braking. A severe emergency stop or prolonged reduced release pressure operation may result in this type of damage. – JLG Lift – 3121127...

  • Page 49: Speed Sensor Adjustment

    IF ONLY ONE SENSOR IS INSTALLED WRONG, THE CONTROLLER SENSES A PROBLEM AND THE MACHINE WILL ONLY DRIVE AT CREEP SPEED. IF BOTH SENSORS ARE ADJUSTED TOO FAR OUT, THE CONTROL SYSTEM CONTROLLER WILL NOT DRIVE THE MACHINE. 3121127 – JLG Lift –...

  • Page 50: Speed Sensor Orientation

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-3. Speed Sensor Orientation 3-10 – JLG Lift – 3121127...
  • Page 51 SECTION 3 - CHASSIS & TURNTABLE 3121127 – JLG Lift – 3-11...
  • Page 52 SECTION 3 - CHASSIS & TURNTABLE 3-12 – JLG Lift – 3121127...
  • Page 53 SECTION 3 - CHASSIS & TURNTABLE 3121127 – JLG Lift – 3-13...

  • Page 54: Speed Sensor Installation Verification

    OBSTRUCTIONS. THE OPERATOR SHOULD BE FAMILIAR WITH JLG EQUIPMENT AND BE PREPARED TO USE THE FOOTSWITCH 15. Use the right left cursor keys on the analyzer to high- TO STOP THE MACHINE. READ AND UNDERSTAND THIS ENTIRE light diagnostics and press enter.
  • Page 55 21. Adjust the left speed sensor using the preceding analyzer display should match direction Adjustment Procedure until the analyzer displays selected. "SPEED 20% FWD" when forward is selected in the platform. The percentage displayed is not critical, just the direction. 3121127 – JLG Lift – 3-15...
  • Page 56 SECTION 3 - CHASSIS & TURNTABLE 3-16 – JLG Lift – 3121127...

  • Page 57: Positrac/Tilt Module

    When installing a new positrac/tilt module, always ensure 6. Verify that the tilt reading is now "0.0; 0.0". that it is calibrated using the JLG Control System analyzer before operating the machine. Refer to Section 6, JLG Control System Analyzer Kit Instructions. Use a standard...

  • Page 58: Swing Bearing

    Turntable Bearing Mounting Bolt Condition Check NOTE: This check is designed to replace the existing bear- ing bolt torque checks on JLG Lifts in service. This check must be performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter.

  • Page 59: Wear Tolerance

    Metal particles in the grease. b. Increased drive power. c. Noise. d. Rough rotation. 5. If bearing inspection shows no defects, reassemble bearing and return to service. 3121127 – JLG Lift – 3-19...

  • Page 60: Replacement Of Swing Bearing

    Remove the two capscrews securing the bear- ing upon installation. Remove bolts, nuts and ing to the rotation box to separate the two for washers which attach the turntable to the bear- inspection. ing inner race. Discard nuts and bolts. 3-20 – JLG Lift – 3121127...

  • Page 61: Swing Bearing Torquing Sequence

    SECTION 3 - CHASSIS & TURNTABLE 2. Installation. a. Install bearing to rotation box with two cap- JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED GRADE 8 screws, so that fill plug of bearing is as close to BEARING NUTS AND BOLTS BE DISCARDED AND REPLACED gear as bolt pattern will allow.

  • Page 62: Swing Bearing Torque Value

    Checking Worm Gear End Play 5. Replace end plate and torque bolts to 90 ft. lbs. (122 Nm). NOTE: JLG Industries requires that a annual inspection be 6. Recheck end play. performed on the worm gear end play. 1. Using a dial indicator, measure end play of worm Fig 2 Adjusting End Play.

  • Page 63: Swing Components

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-14. Swing Components 3121127 – JLG Lift – 3-23...

  • Page 64: Battery Maintenance And Charging

    5. When all cables and terminal posts have been cleaned, ensure all cables are properly positioned and do not get pinched. Close battery compartment cover. 6. Start hydraulic system and ensure that it functions properly. 3-24 – JLG Lift – 3121127...
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 3121127 – JLG Lift – 3-25...

  • Page 66: Battery Charging (On Board Charger)

    Charge the batteries at available times between charging. d. Be sure the battery fluid covers the battery plates before charging, but to avoid overflow, do not top off the fluid level until charging. Figure 3-16. Batteries and Battery Charger 3-26 – JLG Lift – 3121127...

  • Page 67: Generator (Prior To S/N 88539)

    14.2 psi (1 Electrical power for the starter is provided by the start bat- Bar). tery. The starter is energized by the start control relay. 3121127 – JLG Lift – 3-27...

  • Page 68: Generator Components

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-17. Generator Components 3-28 – JLG Lift – 3121127...

  • Page 69: Timing Sequences

    The RBS will attempt to start the engine up until the Table 3-5. RBS Shutdown Sequence number of crank cycles is reached. If the RBS does Remove CTS not start, an Overcrank fault is indicated. TDER Engine Run TDC Cooldown Engine Stop 3121127 – JLG Lift – 3-29...

  • Page 70: To Connect The Jlg Control System Analyzer To The Generator

    In the event of an RBS alarm, a flash code will be issued and an alarm indicated on the analyzer. The JLG Control System Analyzer can be used to monitor generator settings and conditions. Connect the analyzer NOTE: Alarms must be reset once the fault has been cor- as follows: rected.
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE 3121127 – JLG Lift – 3-31...

  • Page 72: Output Current And Voltage Settings

    CTS after a low battery voltage CTS. If the charging current falls below the finish charging current while another CTS is active, the RBS will continue to oper- ate at the normal/extended output voltage until all CTS’s are removed. 3-32 – JLG Lift – 3121127...

  • Page 73: Priming The Fuel Line

    10. Engine might run rough for 20 seconds or so, but it will clean out. 4. When fuel starts to flow out of the rubber line, re- connect the fuel line to the fuel injector pump. 3121127 – JLG Lift – 3-33...

  • Page 74: Generator (S/N 88539 To Present)

    Voltage regulation and current limiting is provided by the RBS Engine/Generator Controller. glow plug. Rating: 15ADC The rectifier diodes and output current sensor are located in the alternator endbell. This fuse is located on the right side of the engine. 3-34 – JLG Lift – 3121127...

  • Page 75: Generator

    3. Start Control Relay 10. Alternator 4. Fuel Solenoid 11. Starter 5. Fuel Pump 12. Starter Solenoid 6. Low Oil Pressure Switch 13. Oil Filter 7. Glow Plug 14. Fuel Filter Figure 3-19. Generator 3121127 – JLG Lift – 3-35...

  • Page 76: Start Battery

    The engine is equipped with a 12VDC starter, which pro- vides the mechanical power to crank the engine. Electrical power for the starter is provided by the start battery. The starter is energized by the start control relay. 3-36 – JLG Lift – 3121127...

  • Page 77: Fuel Control Relay

    The glow plug is a resistive heating element located in the combustion chamber. It is used during starting at temper- atures below 32°F (0°C). The heater is energized by the glow plug control relay. 3121127 – JLG Lift – 3-37...

  • Page 78: Fuel Pump

    This sensor provides an analog signal to the engine/gen- The fuel solenoid is located on the right side of the engine. erator controller. The primary use of this signal is for high engine temperature shutdown 248°F (120°C) for the 3-38 – JLG Lift – 3121127...

  • Page 79: Alternator Output Current Sensor

    The engine speed sensor is located inside the recoil Pre-heat starter cover at the front of the engine. Inhibit run Engine temp. switch + Output voltage Speed sensing + 5V Output current sense Not used Not used Field Drive 3121127 – JLG Lift – 3-39...

  • Page 80: Warnings And Safety Precautions

    SPEED TIME AND GLOW PLUG SETTINGS TD no speed signal TD DC sensing fault Starter disconnect 1000 Hz Overspeed shutdown 3800 RPM Underspeed shutdown 2000 RPM Glow plug on temperature 5°C Glow plug on time 3-40 – JLG Lift – 3121127...

  • Page 81: Rbs Start

    Overcrank fault to cool down. is indicated after 3 failed crank cycles. Time delay bypass RBS waits until normal engine operating conditions are reached before Low oil pressure and Underspeed faults are moni- tored. 3121127 – JLG Lift – 3-41...

  • Page 82: Rbs Alarms And Flash Codes

    Change engine oil and filter every 150 hours The RBS can be reset using the analyzer or by disabling and re-enabling the RBS controller. This will clear any cur- rent fault condition with the controller. 3-42 – JLG Lift – 3121127...

  • Page 83: Troubleshooting

    Refer to the Kubota OC60 Engine Manual for further checks. If the ambient temperature is low, verify that the heater and/or glow plug are operating. No Speed Signal Check wiring connections. Overvoltage Check alternator output voltage. 3121127 – JLG Lift – 3-43...

  • Page 84: Apu Engine Start Battery Boosting

    THE MAIN BATTERY OF THE LIFT MUST NEVER BE USED TO BOOST THE APU. DAMAGE TO SENSITIVE ELECTRONIC COMPO- IMPROPER USE OF A BOOSTER BATTERY TO START AN APU MAY NENTS WILL RESULT. CAUSE AN EXPLOSION. 3-44 – JLG Lift – 3121127...

  • Page 85: Supplementary Fuse For Apu

    • - Weather proof fuse holder - JLG P/N 2400081 • - AGC1, 1 Amp fuse - JLG P/N 2400080 • - 45 cm of #16 AWG wire - JLG P/N 4920019 • - 2 X insulated butt splice connectors - JLG P/N 4460035 •...
  • Page 86 5. Cut wire 106 going to the Engine/Generator Control- ler after the existing connection point and install the conductors that lead to the new inline fuse holder. Use insulated butt splice connectors for these con- ductors. 3-46 – JLG Lift – 3121127...

  • Page 87: Section 4. Boom & Platform

    There will be initial weeping of hydraulic remove pin #1 from the base boom. fluid which can be caught in a suitable container. After initial discharge, there should be no further leakage from the retract port. 3121127 – JLG Lift –...

  • Page 88: Inspection

    16. Remove hardware securing powertrack to the base 5. Attach the power track to the aft end of fly boom boom section. Remove powertrack. section. Secure power track with hardware. – JLG Lift – 3121127...

  • Page 89: Installation

    14. Retract boom section fully. Adjust wear pads at aft end of boom section to zero clearance. Adjust pads alternately side to side, so that fly boom section is centered in base boom section. 15. Disconnect auxiliary power source from telescope cylinder. 3121127 – JLG Lift –...

  • Page 90: Upper (Main) Boom Lift Cylinder

    #2 through the mounting holes in the lift cylinder and upright. Secure in place with pin retaining hard- ware. 3. Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports. – JLG Lift – 3121127...

  • Page 91: Installation

    5. Remove boom prop and overhead crane. Take the lift cylinder through one complete cycle to assure correct functioning. Place boom in stowed position. Check hydraulic fluid and adjust accordingly. 3121127 – JLG Lift –...

  • Page 92: Upper Boom Telescope Cylinder

    7. Using a suitable brass drift, carefully drive the tele- scope cylinder pin from the base boom. 8. Attach a suitable sling to the telescope cylinder. Using a suitable lifting device attached to the sling carefully pull the telescope cylinder from the boom assembly. – JLG Lift – 3121127...

  • Page 93: Wear Pads

    3. Adjust wear pads as follows: a. Loosen jam nut on adjustment bolt, turn bolt CW until wear pad is snug to adjacent surface. b. After adjustments have been made, tighten the jam nuts on wear pad bolts. 3121127 – JLG Lift –...

  • Page 94: Platform Support Torque Values

    NOTE: If any rotator bolts are replaced, all bolts A,B,D on the rotator should be retorqued. Torque to 50 ft.lbs. (68 Nm) Loctite #242 Torque 250-270 ft. lbs. (339-366 Nm) Check torque every 150 hours of operation Figure 4-7. Platform Support Torque Values – JLG Lift – 3121127...

  • Page 95: Boom Limit Switches

    SECTION 4 - BOOM & PLATFORM Figure 4-8. Boom Limit Switches 3121127 – JLG Lift –...

  • Page 96: Platform Components And Attaching Hardware (M450A & E450A)

    SECTION 4 - BOOM & PLATFORM Figure 4-9. Platform Components and Attaching Hardware (M450A & E450A) 4-10 – JLG Lift – 3121127...

  • Page 97: Articulating Jib Boom

    #7. Using a suitable brass drift and hammer, remove jib boom. Using a soft head mallet, install rotator the cylinder pin from articulating jib boom. support pin #6 into articulating jib boom and secure with mounting hardware. 3121127 – JLG Lift – 4-11...

  • Page 98: Load Sensing System

    12. Verify that the overload lamp lights continuously and the alarm sounds continuously during an overload condition. 13. Remove weight from the basket. 14. Adjust P2 until the load = 0%. 15. Place 455 LBS. in the center of the basket. 4-12 – JLG Lift – 3121127...

  • Page 99: Helac Rotary Actuator

    Once the radius is achieved round off all sharp twice that of the piston. edges of the heated end by using a grinder. There may be some slight modifications for your own personal prefer- ence. 3121127 – JLG Lift – 4-13...

  • Page 100: Rotary Actuator (Exploded View)

    3. Piston Sleeve 204. O-Ring 400. Stop Tube (Optional) 4. End Cap 205. Cup Seal 401. Counterbalance Valve 109. Lock Pin 207. Back-Up 113. Cap Screw 302. Wear Guide Figure 4-12. Rotary Actuator (Exploded View) 4-14 – JLG Lift – 3121127...

  • Page 101: Rotary Actuator (Cutaway View)

    3. Piston Sleeve 204. O-Ring 400. Stop Tube (Optional) 4. End Cap 205. Cup Seal 401. Counterbalance Valve 109. Lock Pin 207. Back-Up 113. Cap Screw 302. Wear Guide Figure 4-13. Rotary Actuator (Cutaway View) 3121127 – JLG Lift – 4-15...

  • Page 102: Disassembly

    3. Remove the lock pins using an “Easy Out” (a size #2 is shown). If the pin will not come out with the “Easy Out”, use 5/16” drill bit to a depth of 1/2” (12.7mm)todrill out the entire pin. 4-16 – JLG Lift – 3121127...
  • Page 103 11. Before removing the piston (3), mark the housing (1) ring gear in relation to the piston O.D. gear. There should now be timing marks on the housing (1) ring gear, the piston (3) and the shaft (2). 3121127 – JLG Lift – 4-17...
  • Page 104 14. Remove the o-ring (204) and backup ring (207) from 17. Remove the thrust washers (304), from the end cap end cap (4) and set aside for inspection. (4) and shaft (2). 4-18 – JLG Lift – 3121127...

  • Page 105: Inspection

    2.34 mm). 20. Remove the piston I.D. seal (200). You may now pro- ceed to the inspection process. 3. Inspect the wear guide condition and measure thick- ness (not less than 0.123” or 3.12 mm). 3121127 – JLG Lift – 4-19...

  • Page 106: Assembly

    2. Install the thrust washer (304) onto shaft (2) and end cap (4). 3. Install the wiper seal (304.1/green O-ring) into it’s groove on the shaft (2) and end cap (4) around the outside edge of the thrust washer (304). 4-20 – JLG Lift – 3121127...
  • Page 107 Make sure the wedged ends the point where the gear teeth meet. overlap correctly. Repeat this step for the outer seal (202). 3121127 – JLG Lift – 4-21...
  • Page 108 (2) with the gear teeth on the inside of the piston (3). Now tap the flange end of the shaft with a rubber mallet until the gear teeth engage. 4-22 – JLG Lift – 3121127...
  • Page 109 (1). Tighten them to 25 in. lbs. (2.825 Nm). 18. Tighten the end cap (4). In most cases the original holes for the lock pins will line up. 3121127 – JLG Lift – 4-23...
  • Page 110 SECTION 4 - BOOM & PLATFORM NOTES: 4-24 – JLG Lift – 3121127...

  • Page 111: Section 5 - Hydraulics

    1. Hold the fitting in one hand while using the brush with the other hand to dip into the container. Remove excess hydraulic oil from the brush so an even film of oil is applied on the o-ring. 3121127 – JLG Lift –...

  • Page 112: Dip Method

    3. O-ring Boss type fittings will require more pressure even coat of oil. in able to immerse more of the fitting into the satu- rated sponge. This will also cause more oil to be dis- persed from the sponge. – JLG Lift – 3121127...

  • Page 113: Cylinders - Theory Of Operation

    6. Activate hydraulic system and activate cylinder retract function. Check extend port for leakage. 7. If extend port leakage is less than 6-8 drops per minute, carefully reconnect hose to extend port, then activate cylinder through one complete cycle 3121127 – JLG Lift –...

  • Page 114: Cylinders With Dual Counterbalance Valve

    5. Mark cylinder head and barrel with a center punch the appropriate ports. for easy realignment. Using an allen wrench, loosen 7. Remove boom prop/overhead crane, activate hydraulic system and run cylinder through complete cycle to check for leaks and operation. – JLG Lift – 3121127...

  • Page 115: Cleaning And Inspection

    5. Inspect threaded portion of barrel for damage. Dress Figure 5-3. Cylinder Rod Support threads as necessary. 9. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible. 3121127 – JLG Lift –...

  • Page 116: Assembly

    Dress applicable surfaces as nec- NOTE: Prior to cylinder assembly, ensure that the proper essary. cylinder seal kit is used. See your JLG Parts Manual. 9. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace Apply a light film of hydraulic oil to all components as necessary.

  • Page 117: Wiper Seal Installation

    NOTE: When installing the tapered bushing, piston and mat- ing end of rod must be free of oil. WHEN REBUILDING THE STEER, LOWER LIFT, LEVEL CYLINDER, OR UPPER LIFT CYLINDER, APPLY LOCTITE #242 TO TAPERED BUSHING BOLTS, THEN TIGHTEN SECURELY. 3121127 – JLG Lift –...

  • Page 118: Tapered Bushing Installation

    11. Assemble the tapered bushing loosely into the pis- b. Tap each space once; this means the tapered ton and insert JLG capscrews (not vendor cap- bushing is tapped 3 times as there are 3 spaces screws) through the drilled holes in the bushing and between the capscrews.

  • Page 119: Rod Assembly Installation

    THAT THE OUTER END OF THE ROD IS SUPPORTED. USE EITHER A TRAVELING OVERHEAD HOIST, FORK-LIFT, OR OTHER MEANS RACINE - 1 7/8 HEX 1 5/8 - 12 THDS. 100-110 ft. lbs. TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING (136-149 Nm) ROD. 3121127 – JLG Lift –...

  • Page 120: Jib Cylinder

    4. Loctite RC 609 10. Barrel 16. Backup Ring 22. O-ring 5. Bolt 11. Cylinder Rod 17. Backup Ring 23. Seal 6. Tapered Bushing 12. Washer Ring 18. Seal Ring 24. Wiper Figure 5-14. Jib Cylinder 5-10 – JLG Lift – 3121127...

  • Page 121: Level Cylinder - A Models

    10. Pipe Plug 16. Rod Seal 22. Holding Valve 5. Cylinder Head 11. T-Seal 17. Wiper 23. Plug 6. Hex Nut 12. Wear Ring 18. Locking Primer Figure 5-15. Level Cylinder - A Models 3121127 – JLG Lift – 5-11...

  • Page 122: Level Cylinder - Aj & Ajp Models

    4. Tapered Bushing 10. Piston 16. O-ring 22. Valve Cartridge 5. Bushing 11. Not Used 17. Wiper 23. Bolt 6. Cylinder Head 12. Lock Ring 18. Seal Figure 5-16. Level Cylinder - AJ & AJP Models 5-12 – JLG Lift – 3121127...

  • Page 123: Lower Lift Cylinder

    21. Loctite #222 4. Piston 10. Pipe Plug 16. O-ring 22. Locking Primer 5. Cylinder Head 11. Setscrew 17. Rod Seal 23. Bushing 6. Hex Nut 12. Piston Seal 18. Wiper Figure 5-17. Lower Lift Cylinder 3121127 – JLG Lift – 5-13...

  • Page 124: Mid Lift Cylinder

    23. Locking Primer 4. Piston 9. Holding Valve 14. Piston Seal 19. Rod Seal 24. Not Used 5. Cylinder Head 10. Holding Valve 15. Not Used 20. Rod Wiper 25. Bushing Figure 5-18. Mid Lift Cylinder 5-14 – JLG Lift – 3121127...

  • Page 125: Upper Lift Cylinder

    8. Not Used 13. Wear Ring 18. Seal 23. Bushing 4. Piston 9. Holding Valve 14. Seal 19. Wiper 5. Cylinder Head 10. O-ring Plug 15. O-ring 20. Loctite #242 Figure 5-19. Upper Lift Cylinder 3121127 – JLG Lift – 5-15...

  • Page 126: Master Cylinder - A Models

    17. Loctite #242 3. Retainer 8. Setscrew 13. Wear Ring 18. Loctite #222 4. Piston 9. T-Seal 14. Rod Seal 5. Cylinder Head 10. Wear Ring 15. Rod Wiper Figure 5-20. Master Cylinder - A Models 5-16 – JLG Lift – 3121127...

  • Page 127: Master Cylinder - Aj Models

    8. Head 13. Wear Ring 18. Seal 4. Tapered Bushing 9. Barrel 14. Backup Ring 19. Backup Ring 5. Bushing 10. Cylinder Rod 15. O-ring 20. Seal Figure 5-21. Master Cylinder - AJ Models 3121127 – JLG Lift – 5-17...

  • Page 128: Steer Cylinder

    2. Spanner Nut 7. O-ring 12. Wear Ring 17. Rod 3. Retaining Ring 8. Guide 13. Seal 4. Lip Seal 9. Barrel 14. O-ring 5. Wear Ring 10. Tube 15. O-ring Figure 5-22. Steer Cylinder 5-18 – JLG Lift – 3121127...

  • Page 129: Telescope Cylinder

    22. Cap 5. Spacer 11. Retaining Ring 17. Rod Seal 23. O-Ring Plug 6. Counterbalance Valve 12. Wear Ring 18. Wiper 24. Bolt * Torque to 150 foot-pounds (203 Nm) Figure 5-23. Telescope Cylinder 3121127 – JLG Lift – 5-19...

  • Page 130: Pressure Setting Procedures

    Cold temperatures have a significant impact on pressure 1. On machines prior to S/N 0300062642, install the readings.JLG Industries Inc. recommends operating the pressure gauge at the “G” port on Main Control machine until hydraulic system has warmed to normal valve, activate and bottom out Platform Level Up.

  • Page 131: Platform Level Down Relief

    2. Adjust Platform Level Down Relief to value given in Table 5-4, Pressure Settings - Prior to S/N 0300062642 or Table 5-5, Pressure Settings - S/N 0300062642 to Present. 3121127 – JLG Lift – 5-21...

  • Page 132: Jib Valve Location

    Telescope Relief (AJP) 3000 Brake/Steer Valve Platform Level Up Relief 3000 Steer Relief 2300 Platform Level Down Relief 1200 Main Relief - E450A/M450A 3200 Brake/Steer Valve Main Relief - E450AJ/M450AJ 3400 Steer Relief 2300 Jib Valve Main Relief - E450A/M450A...

  • Page 133: Brake/Steer Valve Components

    SECTION 5 - HYDRAULICS Figure 5-25. Brake/Steer Valve Components 3121127 – JLG Lift – 5-23...

  • Page 134: Main Valve Components Prior To S/N 62642

    SECTION 5 - HYDRAULICS Figure 5-26. Main Valve Components Prior to S/N 62642 5-24 – JLG Lift – 3121127...

  • Page 135: Main Valve Components S/N 62642 To Present

    HAND PUMP UPPER LIFT DOWN RELIEF LOWER LIFT DOWN RELIEF GAUGE PORT TELESCOPE RELIEF RELEVELING VALVE PLATFORM LEVEL RELIEF (BACKWARD) RELEVELING RELIEF PLATFORM LEVEL RELIEF (FORWARD) Figure 5-27. Main Valve Components S/N 62642 to Present 3121127 – JLG Lift – 5-25...
  • Page 136 SECTION 5 - HYDRAULICS NOTES: 5-26 – JLG Lift – 3121127...

  • Page 137: Section 6 - Jlg Control System

    SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM 6.1 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONS Figure 6-1. Control Module Location Introduction IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC- TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE- WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON...

  • Page 138: To Connect The Jlg Control System Analyzer

    The motor control- ler also features an adjustable time limit for positive trac- tion. The JLG Control System controller has a built in LED to HELP: PRESS ENTER indicate any faults. The system stores recent faults which may be accessed for troubleshooting.

  • Page 139: Changing The Access Level Of The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM The top level menus are as follows: Pressing ENTER with any of the above displayed menus, will display additional sub-menus within the selected HELP menu. In some cases, such as DRIVE, the next level is the DIAGNOSTICS parameter or information to be changed.

  • Page 140: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Once the correct password is displayed, press ENTER. The access level should display the following, if the pass- Analyzer word was entered correctly: Once you have gained access to level 1, and a personality...

  • Page 141: Machine Setup

    SECTION 6 - JLG CONTROL SYSTEM Machine Setup There is a setting that JLG strongly recommends that you do not change. This setting is so noted below: When a machine digit item is selected, press the UP or ELEVATION CUTBACK...

  • Page 142: Machine Personality Settings

    SECTION 6 - JLG CONTROL SYSTEM Machine Personality Settings NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS DRIVE ACCELeration 0.5s to 5.0s DECELeration 0.1s to 2.0s...
  • Page 143 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS SWING ACCELeration 0.5 to 5.0s DECELeration 0.0 to 3.0s MINimum LEFT speed 0 to 10% MAXimum LEFT speed 0 to 60% CREEP maximum LEFT speed 0 to 35%...
  • Page 144 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS ACCELeration 0.5 to 5.0 DECELeration 0.5 to 3.0 MINimum UP speed 0 to 50 MAXimum UP speed 0 to 100 MINimum DOWN speed 0 to 25...

  • Page 145: Machine Configuration Programming Information

    SECTION 6 - JLG CONTROL SYSTEM 2. TILT SWITCH Table 6-2. Machine Setup Descriptions When tilted the tilt light is lit (continuously) and drive speed is reduced to the creep speed setting MODEL NUMBER... Displays/adjusts machine model NOTE: all personalities reset to default...

  • Page 146: Level Vehicle Description

    7. PLATFORM ALARM Help Descriptions and Fault Flash Codes 0= Sounds continuously when above elevation and tilted only. Table 6-3. JLG Control System Flash Codes 1= Sounds continuously when above elevation and tilted, and in conjunction with fault code flashes Code...

  • Page 147: Help Descriptions And Fault Flash Codes

    SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash Code Description No flash code is indicated for the following help messages; they are intended to hint at a possible problem if the vehicle is not behaving as expected.
  • Page 148 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash code 2/2 indicates problems with drive & steer selection. DRIVE JOYSTICK FAULTY The drive joystick center tap is out of valid range, or the wiper is wire-off.
  • Page 149 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash code 2/5 indicates that a function is prevented due to a cutout. BOOM PREVENTED - DRIVE SELECTED A boom function is selected while a drive function is selected and drive cutout is configured to prevent simultaneous drive &...
  • Page 150 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash code 3/3 indicates that a contactor coil is short-circuited. OVERLOADED VALVE SUPPLY-CHECK WIRING. There is a high current draw from the valve supply when no valve is energized; this is probably due to a wir- ing error at the ground module.
  • Page 151 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash code 6/6 indicates problems with the CANbus. 48V PROTECTION TRIPPED - CHECK INTER-MODULE WIRING The power module is not receiving acknowledgments from the platform or ground modules to transmitted data, and the protection circuit which supplies the platform and ground modules has tripped.
  • Page 152 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Descriptions and Fault Flash Codes Flash code 9/9 indicates problems with the controller. POWER MODULE FAILURE: CONTACTOR DRIVE CODE 1 A contactor remained energized when turned off. POWER MODULE FAILURE: HWFS CODE 2 The hardware failsafe tests did not complete because traction point A is not safe, or the hardware failsafe is permanently tripped.
  • Page 153 SECTION 6 - JLG CONTROL SYSTEM 3121127 – JLG Lift – 6-17...
  • Page 154 SECTION 6 - JLG CONTROL SYSTEM 6-18 – JLG Lift – 3121127...

  • Page 155: Analyzer Diagnostics Menu Structure

    SECTION 6 - JLG CONTROL SYSTEM Analyzer Diagnostics Menu Structure the next outer level. The LEFT/RIGHT arrow keys move between items in the same level. The UP/DOWN arrow In the following structure descriptions, an intended item is keys alter a value if allowed selected by pressing ENTER;...
  • Page 156 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. DIAGNOSTICS - Menu Descriptions TILT . . . Displays measured vehicle tilt The first value indicates tilt in die forwards reverse direction (pitch) The second value indicates tilt in the left/ right direction (roll) DATALOG MAX.TEMP .

  • Page 157: System Self Test

    SECTION 6 - JLG CONTROL SYSTEM System Self Test switch. When the controller sees that the lower lift up switch has been closed, it will move on to the next The system self test is utilized to locate typical problems.

  • Page 158: System Test Messages

    SECTION 6 - JLG CONTROL SYSTEM Table 6-7. System Test Messages RUNNING Initial display when system test is run; certain "critical" checks are made. Problems which can be reported include: ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test.
  • Page 159 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. System Test Messages TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized and de-energized; checks are made for open-and short- circuit valve coils. The valves are tested in the order: PROP (main proportional), LL U, LL D, UL U, UL D, SWING L,...
  • Page 160 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. System Test Messages CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it is in its "normal" position; function switches should be open, cutout switches should be closed, joysticks should be in neutral.
  • Page 161 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. System Test Messages TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed, the system test ends. If ENTER is pressed, each operator input is prompted for in turn.
  • Page 162 SECTION 6 - JLG CONTROL SYSTEM NOTES: 6-26 – JLG Lift – 3121127...

  • Page 163: Section 7 - Basic Troubleshooting, Electrical Information, & Schematics

    For aid in troubleshooting, refer to It should be noted that there is no substitute for a thor- the Illustrated Parts Manual for hydraulic diagrams of the ough knowledge of the equipment and related systems. various circuits 3121127 – JLG Lift –...

  • Page 164: Platform Assembly - Troubleshooting

    Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting. Slave cylinder not functioning properly. Repair or replace cylinder. Electrical failure. See proper wiring diagram/Run System Test. Orifice plugged. Clean orifice. – JLG Lift – 3121127...
  • Page 165 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Table 7-1. Platform Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Proportional Flow Regulator not powered. Check wiring/Run System Test. Personalities not set correctly Check settings. 3121127 – JLG Lift –...

  • Page 166: Boom Assembly - Troubleshooting

    Lift cylinder holding valve inoperative. Repair or replace holding valve. Bypass valve not operating. Determine cause and repair or replace valve. Electrical malfunction. See wiring diagram/Run System Test. Hydraulic system oil low. Replenish oil as necessary. – JLG Lift – 3121127...
  • Page 167 Directional valve not functioning properly. Repair or replace valve. Worn seals in lift cylinder. Replace seals. Cylinder not functioning properly. Repair or replace cylinder. Boom drifts down. Worn seals in lift cylinder. Replace seals. 3121127 – JLG Lift –...
  • Page 168 Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting. Pressure setting incorrect. Check pressure/re-adjust as necessary. Telescope cylinder not functioning properly. Repair or replace cylinder. Personality Setting incorrect. Set to Factory Default. – JLG Lift – 3121127...
  • Page 169 Repair or replace valve. Foreign object(s) wedged between swing motor Remove object(s), check for damage and repair pinion and swing gear. or replace component(s) as required. Swing Joystick not functioning properly. Repair or replace swing joystick/Run System Test. 3121127 – JLG Lift –...
  • Page 170 Swing motor not functioning properly. Repair or replace swing control switch. Worn or broken teeth on swing gear or swing Replace gear(s) as required. motor pinion. Restrictor valves(s) plugged. Clean or replace restrictor valve. – JLG Lift – 3121127...

  • Page 171: Turntable Assembly - Troubleshooting

    Valve spool scored. Repair or replace valve. Excessive back pressure caused by restricted Remove line and clear obstruction or replace line return line to reservoir. as necessary. Damaged valve seals. Repair or replace valve as necessary. 3121127 – JLG Lift –...

  • Page 172: Chassis Assembly - Troubleshooting

    Check fuel tank and immediately wipe up spilled fuel. Fuel tank damaged. Drain all fuel from tank and remove tank for replacement or repair. Fuel line from tank damaged. Replace fuel line. Carburetor flooding. Repair, replace or adjust carburetor. 7-10 – JLG Lift – 3121127...
  • Page 173 Restricted or broken line on valve bank. Clean, repair or replace line. Air in wheel brake circuit. Bleed circuit, determine and correct cause. Damaged wiring on joystick. Repair or replace wiring /Run System Test. 3121127 – JLG Lift – 7-11...
  • Page 174 Hydraulic system oil low. Replenish oil as necessary. Restricted hydraulic line or fitting. Clean, repair or replace line or fitting. Steer system pressure low. Adjust pressure. Bent linkage (tie rods). Repair or replace linkage as required. 7-12 – JLG Lift – 3121127...
  • Page 175 DRIVE BRAKE. Brake Slips Excessive pressure in hydraulic system. Check hydraulic filter, restrictions in other hydraulic components. Disc plates worn. Check disc thickness. Springs broken or have taken a permanent set. Check release pressure. 3121127 – JLG Lift – 7-13...
  • Page 176 Replace bearing. Brake will not release. Stuck or clogged valve. Place pressure gauge in bleed port - check for adequate pressure. Replace defective line or component. Bad o-rings. Replace o-rings. Discs frozen. Replace disc stack. 7-14 – JLG Lift – 3121127...

  • Page 177: Hydraulic System - Troubleshooting

    Broken pump drive shaft/pump coupling. Repair or replace pump/pump coupling. Note: Any time pump or pump drive coupling is removed coat pump and drive coupling splines with Lithium Soap Base Grease (TEX- ACO CODE 1912 OR EQUIVALENT). 3121127 – JLG Lift – 7-15...
  • Page 178 Replace filter. Amperage too low on controller. Correctly adjust controller. Low voltage in electrical system. Correct low voltage problem. System(s) operate erratically. Sticking or binding valve spools, pistons. Clean, repair, or replace components as required. 7-16 – JLG Lift – 3121127...

  • Page 179: Electrical System - Troubleshooting

    Faulty start switch. Replace switch. INSTRUMENTS AND INDICATORS. Travel warning horn inoperative. Machine set-up incorrect. Adjust control module settings properly. Damaged wiring in horn circuit. Repair or replace wiring/Run System Test. Damaged horn. Replace horn. 3121127 – JLG Lift – 7-17...
  • Page 180 REMEDY Hourmeter inoperative. Damaged wiring in hourmeter circuit. Repair or replace wiring. Inoperative hourmeter. Replace hourmeter. Platform alarm circuit. Platform alarm inoperative. Check platform alarm/Run System Test. Defective bulb in tilt light. Replace bulb. 7-18 – JLG Lift – 3121127...

  • Page 181: Multimeter Basics

    Also check that the lead on the "COM" port goes to the Ground or negative side of the sig- 3121127 – JLG Lift – 7-19...

  • Page 182: Resistance Measurement

    • First test meter and leads by touching leads • If meter is not auto ranging, set it to the correct together. Meter should produce an audible alarm, range (See multimeter’s operation manual) indicating continuity 7-20 – JLG Lift – 3121127...

  • Page 183: Current Measurement

    Figure 7-4. Current Measurement (DC) Another type of limit switch used by JLG is the inductive • Set up the meter for the expected current range proximity switch, also referred to as a "prox switch". Induc- •...

  • Page 184: Automatic Switches

    NOTE: Curing-type sealants might also be used to prevent shorting and would be less messy, but would make • Main Boom Rotary sensor connections (on Celesco Sensor), future pin removal more difficult. 7-22 – JLG Lift – 3121127...

  • Page 185: Amp Connector

    3. Install a hole plug into this and/or any unused wire lbs. to be sure the retention fingers are holding the seal that has silicone dielectric compound escaping contact (See Figure 7-7.). from it. Figure 7-6. AMP Connector 3121127 – JLG Lift – 7-23...

  • Page 186: Connector Assembly Figure 2

    (See Figure 7-9.). wedge lock must be closed to its locked position. Release the locking latches by squeezing them inward (See Figure 7-8.). Figure 7-9. Connector Assembly Figure 4 Figure 7-8. Connector Assembly Figure 3 7-24 – JLG Lift – 3121127...

  • Page 187: Disassembly

    The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick. 3121127 – JLG Lift – 7-25...

  • Page 188: Connector Installation

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-11. Connector Installation 7-26 – JLG Lift – 3121127...

  • Page 189: Deutsch Connectors

    The wedgelock will snap into place. Rectangular 3. Hold the rear seal in place, as removing the contact wedges are not oriented. Thy may go in either way. may displace the seal. 3121127 – JLG Lift – 7-27...

  • Page 190: Hd30/Hdp20 Series Assembly

    Figure 7-17. HD/HDP Unlocking Contacts Figure 7-15. HD/HDP Locking Contacts Into Position NOTE: Do Not twist or insert tool at an angle. NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing 7-28 – JLG Lift – 3121127...
  • Page 191 SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS This page left blank intentionally. 3121127 – JLG Lift – 7-29...

  • Page 192: Electrical Components Installation - Sheet 1

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-18. Electrical Components Installation - Sheet 1 7-30 – JLG Lift – 3121127...

  • Page 193: Electrical Components Installation - Sheet 2

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-19. Electrical Components Installation - Sheet 2 3121127 – JLG Lift – 7-31...

  • Page 194: Electrical Schematic - Sheet 1 Of 4

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-20. Electrical Schematic - Sheet 1 of 4 7-32 – JLG Lift – 3121127...

  • Page 195: Electrical Schematic - Sheet 2 Of 4

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 1870227 B Figure 7-21. Electrical Schematic - Sheet 2 of 4 3121127 – JLG Lift – 7-33...

  • Page 196: Electrical Schematic - Sheet 3 Of 4

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-22. Electrical Schematic - Sheet 3 of 4 7-34 – JLG Lift – 3121127...

  • Page 197: Electrical Schematic - Sheet 4 Of 4

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 1870227 B Figure 7-23. Electrical Schematic - Sheet 4 of 4 3121127 – JLG Lift – 7-35...

  • Page 198: Hydraulic Schematic - M450A/E450A - Sheet 1 Of 2

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-24. Hydraulic Schematic - M450A/E450A - Sheet 1 of 2 7-36 – JLG Lift – 3121127...

  • Page 199: Hydraulic Schematic - M450A/E450A - Sheet 2 Of 2

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 2792505D Figure 7-25. Hydraulic Schematic - M450A/E450A - Sheet 2 of 2 3121127 – JLG Lift – 7-37...

  • Page 200: Hydraulic Schematic - M450Aj/E450Aj - Sheet 1 Of 2

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-26. Hydraulic Schematic - M450AJ/E450AJ - Sheet 1 of 2 7-38 – JLG Lift – 3121127...

  • Page 201: Hydraulic Schematic - M450Aj/E450Aj - Sheet 2 Of 2

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS 2792505D Figure 7-27. Hydraulic Schematic - M450AJ/E450AJ - Sheet 2 of 2 3121127 – JLG Lift – 7-39...

  • Page 202: Hydraulic Schematic Component List

    SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS Figure 7-28. Hydraulic Schematic Component List 7-40 – JLG Lift – 3121127...
  • Page 204 JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu...

This manual is also suitable for:

E450ajM450aM450aj

Table of Contents

Save PDF