JLG E450AJ Operation & Safety Manual
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JLG E450AJ Operation & Safety Manual

JLG E450AJ Operation & Safety Manual

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Operation & Safety
Manual
Original Instructions -
Keep this manual with the machine at all times.
E450AJ
PVC 2501
3122337200
January 13, 2025 - Rev A
Copyright ©
ANSI
AS/NZS MOL70
English (en-US)

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  • Page 1 Operation & Safety Manual Original Instructions - Keep this manual with the machine at all times. E450AJ PVC 2501 3122337200 January 13, 2025 - Rev A Copyright © ANSI AS/NZS MOL70 English (en-US)
  • Page 2 WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other repro- ductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing.

  • Page 3: Foreword

    Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.

  • Page 4: Safety Alert Symbols And Safety Signal Words

    Indicates a potentially hazardous situation. If not avoided, may result in minor or moderate injury. It may also alert against unsafe practices. This decal will have a yellow background. NOTICE Indicates information or a company policy that relates directly or indirectly to the safety of personnel or protection of property. 3122337200 E450AJ...
  • Page 5 NOTICE JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate.
  • Page 6 Questions Regarding Product Modifications Contact: Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 or Visit www.jlg.com to find your local JLG office. In USA: Toll Free: 877-JLG-SAFE (877-554-7233) Outside USA: Phone: 240-420-2661 Fax: 301-745-3713 E-mail: ProductSafety@JLG.com...

  • Page 7: Revision Log

    REVISION LOG Description Date Revision January 13, 2025 Original Issue Other Publications Available Publication Publication Number Service & Maintenance Manual 31223373 Illustrated Parts Manual 31223374 E450AJ 3122337200...
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  • Page 9: Table Of Contents

    Walk-Around Inspection ............30 Function Check ..............31 SkyGuard® Function Check ..........32 SECTION 3 MACHINE CONTROLS AND INDICATORS......35 General ................35 Controls and Indicators .............35 Ground Control Station .............36 Platform Control Station ............39 Platform Control Indicator Panel ........43 Battery Charger..............45 Beacons ................47 E450AJ 3122337200...
  • Page 10 4.18 Shut Down and Park ............61 4.19 Lifting and Tie Down ............62 4.20 Lifting Chart ..............63 4.21 E450AJ Safety Decals ............64 SECTION 5 EMERGENCY PROCEDURES ........... 69 General ................69 Incident Notification ............69 Emergency Operation ............69 Emergency Towing Procedures .........70 Manual Descent System ...........71 Manual Swing Override.............71...
  • Page 11 Battery Maintenance and Charging (Lead Acid/AGM)..100 Tires and Wheels............102 7.10 Radio Frequency (RF) Information ........104 7.11 Supplemental Information Only Applicable to CE/UKCA Machines ............... 106 7.12 EC Declaration of Conformity .......... 107 7.13 UKCA Declaration of Conformity........108 E450AJ 3122337200...
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  • Page 13: Safety Precautions

    Read, understand, and study the Operation and Safety Manual in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc. • Only personnel who have received proper training regarding the inspection, application and operation of MEWPs (including recognizing and avoiding hazards associated with their operation) shall be authorized to operate a MEWP.
  • Page 14 • Check the work area for hazardous locations. Do not operate the machine in hazardous environments unless approved for that purpose by JLG. • Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel.

  • Page 15: Operation

    Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency. • Do not carry materials directly on platform railing unless approved by JLG. • When two or more persons are in the platform, the operator shall be responsible for all machine operations.
  • Page 16 • Enter and exit only through gate area. Use extreme caution when entering or leaving platform. Ensure that the platform assembly is fully lowered. Face the platform when entering or leaving the platform. Always maintain “three point 3122337200 E450AJ...
  • Page 17 25 (8) Over 350 KV to 500 KV 35 (11) Over 500 KV to 750 KV 45 (14) Over 750 KV to 1000 KV Note: This requirement shall apply except where employer, local or governmental regulations are more stringent. E450AJ 3122337200...
  • Page 18 Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces. • Never exceed the maximum platform capacity as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG. 3122337200 E450AJ...
  • Page 19 Wind motion visible in smoke 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion 13-18 5.5-7.9 Moderate Dust and loose paper raised. Small breeze branches begin to move. E450AJ 3122337200...
  • Page 20 • Be aware of stopping distances in all drive speeds. When driving in high speed, reduce drive speed before stopping. Travel grades in low speed only. 3122337200 E450AJ...

  • Page 21: Towing, Lifting, And Hauling

    • DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the machine is powered on or when the hydraulic system is under pressure. E450AJ 3122337200...
  • Page 22 Wear gloves to help protect hands from spraying fluid. • Use only replacement parts or components that are approved by JLG. To be considered approved, replacement parts or components must be identical or equivalent to original parts or components.

  • Page 23: Long-Term Storage

    3 months) with an internal combustion engine, refer to the engine manufacturer’s guidance regarding fuel degradation. • For long-term storage of battery-electric machines, store machines in a cool, dry place away from direct sunlight and heat sources. Avoid storing batteries in a fully discharged or fully charged state. E450AJ 3122337200...
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  • Page 25: User Responsibilities, Machine Preparation, And Inspection

    2.1.3 Operator Responsibility The operator must be instructed that they have the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site. E450AJ 3122337200...

  • Page 26: Preparation, Inspection, And Maintenance

    6. Accessories and optional equipment. PREPARATION, INSPECTION, AND MAINTENANCE The following table covers machine inspections and maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for MEWPs. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.
  • Page 27 Mechanic tenance Manual Service & Main- tenance Manual Note: Inspection forms are available from JLG. Use the Service & Maintenance Manual to perform inspections. NOTICE JLG Industries, Inc. recognizes a factory trained service technician as a person who has successfully completed the JLG Service Training School for the specified JLG product model.

  • Page 28: Machine Components

    1. Cleanliness — Check all surfaces for leakage (oil or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel. 2. Structure — Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies. 3122337200 E450AJ...
  • Page 29 Attach only one (1) lanyard per lanyard anchorage point. WARNING If the machine does not operate properly, turn off the machine immediately! Report the problem to the proper maintenance personnel. Do not operate the machine until it is declared safe for operation. E450AJ 3122337200...

  • Page 30: Walk-Around Inspection

    4. Platform Rotator - See Inspection Note. 5. Jib Assembly and Jib Rotator - See Inspection Note. 6. All Hydraulic Cylinders - No visible damage; pivot pins and hydraulic hoses undamaged, not leaking. 7. Boom Sections/Uprights/Turntable - See Inspection Note. 3122337200 E450AJ...

  • Page 31: Function Check

    WARNING To avoid a collision and injury if platform does not stop when a control switch or lever is released, remove foot from footswitch or use emergency stop to stop machine. Perform the Function Check as follows: E450AJ 3122337200...

  • Page 32: Skyguard® Function Check

    SKYGUARD® FUNCTION CHECK From the Platform Control Station in an area free from obstructions: 1. Operate the telescope-out function. 2. Activate the SkyGuard SkyLine® sensor by pressing rod to break connection between the rod and the right bracket. 3122337200 E450AJ...
  • Page 33 Make sure normal operation is available. If SkyGuard remains activated after function reversal or cutout, press and hold the SkyGuard Override Switch to allow normal use of machine functions until the sensor is deactivated. Refer to the SkyGuard Activation/Deactivation section for additional information. E450AJ 3122337200...
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  • Page 35: Machine Controls And Indicators

    This indicator will be yellow. Indicates important information regarding the oper- ating condition, i.e. procedures essential for safe op- eration. This indicator will be green with the exception of the capacity indicator which will be yellow. E450AJ 3122337200...

  • Page 36: Ground Control Station

    7. Power/Emergency Stop 14. Rotate 3.3.1 Ground Control Station Functions WARNING To avoid serious injury, do not operate machine if any control levers or toggle switches controlling platform movement do not return to the off or neutral position when released. 3122337200 E450AJ...
  • Page 37 Platform Leveling Override A three position switch allows the operator to adjust the automatic self leveling system. This switch is used to adjust platform level in situations such as ascending/descending a grade. E450AJ 3122337200...
  • Page 38 The Swing control switch provides 350 degrees non-continuous turntable rotation. System Distress Indicator The system distress indicator lights to signify an electrical system fault. Telescope Provides for extension and retraction of Upper Boom. Upper Boom Lift Provides for raising and lowering of Upper Boom. 3122337200 E450AJ...

  • Page 39: Platform Control Station

    WARNING Only use the platform leveling override function for slight leveling of the platform. Incorrect use could cause the load/occupants to shift or fall. Failure to do so could result in death or serious injury. E450AJ 3122337200...
  • Page 40 This also occurs when Function Speed Control is clicked on creep. WARNING To avoid serious injury, do not operate machine if any control levers or toggle switches controlling platform movement do not return to the off or neutral position when released. 3122337200 E450AJ...
  • Page 41 Provides main lift and swing. Push forward to lift up, pull backward to boom down. Move right to swing right, move left to swing left. Moving the joystick activates switches to provide the functions selected. Note: Lower lift will not function when operating main lift. E450AJ 3122337200...
  • Page 42 The switch also enables the functions cut out by the SkySense system to operate again at creep speed, allowing the operator to move the platform closer to the obstacle that caused the shutdown situation if desired. Telescope Provides extension and retraction of the main boom. 3122337200 E450AJ...

  • Page 43: Platform Control Indicator Panel

    Restricted capacities are permitted at restricted platform positions (shorter boom lengths and higher boom angles). Creep Speed When the Function Speed Control is turned to the creep position, the indicator acts as a reminder that all functions are set to the slowest speed. E450AJ 3122337200...
  • Page 44 System Distress The light indicates that the JLG Control System has detected an abnormal condition and a Diagnostic Trouble Code has been set in the system memory. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval.

  • Page 45: Battery Charger

    • External Error Condition Caution: Amber LED flashing 2. LED Indicator on Ground Control Station • Full Charge (100%): LED is green • Charge Cycle in Process: LED is amber • Abnormal Battery Condition/Charger Fault: LED is red E450AJ 3122337200...
  • Page 46 Electric quantity – 100% Fast flashing green Electric quantity – 75% to 99% Fast flashing amber Electric quantity – 50% to 75% Slow flashing amber Electric quantity – less than 50% Flashing red Error Solid red Communication Outage 3122337200 E450AJ...

  • Page 47: Beacons

    Blue or Red SkyGuard® Beacon The SkyGuard beacon is available in blue or red lamp options. The beacon will flash in conjunction with an audible alarm when the SkyGuard sensor is activated. Refer to the SkyGuard Operation section for more information. E450AJ 3122337200...
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  • Page 49: Machine Operation

    2. Load is within manufacturer’s rated capacity. 3. All machine systems are functioning properly. 4. Machine is as originally equipped from JLG. 4.2.2 Platform Load Sensing System (LSS) The Platform Load Sensing System (LSS) measures platform load from a sensor in the platform support.
  • Page 50 3. Upper boom fully elevated and retracted. 4. Platform rotated 90°. Machine will tip over in this direction if overloaded or operated beyond the limits of the maximum operating slope. BM000523A Figure 4. Position of Least Backward Stability 3122337200 E450AJ...

  • Page 51: Motor Operation

    Emergency Stop switch is pulled out (on), the Platform/ Ground select switch is in the appropriate position and the Footswitch is depressed. CAUTION If a motor malfunction necessitates unscheduled shutdown, determine and correct cause before resuming any operation. BATTERY CHARGING Note: Park the machine in a well-ventilated area before charging. E450AJ 3122337200...

  • Page 52: Inverter

    Note: Refer to the Operating Specifications table for gradeability and side slope ratings. All ratings for gradeability and side slope are based upon the machine’s boom being in the stowed position, fully lowered, and retracted. Traveling is limited by two factors: 3122337200 E450AJ...

  • Page 53: Traveling (Driving)

    Note: When lower boom is raised above horizontal, or the upper boom is raised ap- proximately 16 inches (40.6 cm) above boom rest, the high drive function will automatically be in low drive. E450AJ 3122337200...
  • Page 54 Drive/Steer in the opposite direction from the movement of the controls. If the indicator is illuminated, operate the Drive function in the following manner: 3122337200 E450AJ...

  • Page 55: Steering

    Left for steering left. 4.10 PLATFORM JLG offers multiple platform sizes to accommodate a variety of applications. Refer to the Illustrated Parts Manual for available platforms. Not all platform options may be of adequate size to allow for the maximum number of rated occupants shown on the machine's capacity decal.
  • Page 56 4.10.5 Jib Swing To rotate jib and platform to the left, jib swing control switch is positioned to the left and held until desired posi- tion is reached. 3122337200 E450AJ...

  • Page 57: Boom

    4.11.1 Swinging the Boom To swing boom, use Swing control to select Right or Left direction. NOTICE When swinging the boom make sure there is ample room for the boom to clear surrounding walls, partitions and equipment. E450AJ 3122337200...

  • Page 58: Function Speed Control

    Turning the knob all the way counterclockwise until it clicks puts the machine into Creep Mode. Creep Mode puts the functions listed above, as well as the Drive/Steer and Main Lift/Swing functions into the slowest speed setting. 4.13 USB CHARGING PORT The machine is equipped with a USB charging port for the operator. 3122337200 E450AJ...

  • Page 59: Clearsky Smart Fleet

    (if available) restrictions. Refer to the Access Control and Beacons sections of this manual for more information. Visit the ClearSky section of the JLG website for more resources and information about accessing web portal or mobile app data. 4.15 ACCESS CONTROL - CLEARSKY SMART FLEET™...

  • Page 60: Skyguard Activation/Deactivation

    Note: Restricted functionality may occur if the CS550 (ClearSky® LED Motion / Amber Beacon) is damaged or removed. A protective cage is available through JLG. Machines equipped with ClearSky Smart Fleet Access Control are also equipped with the CS550. Refer to the ClearSky Smart Fleet and Beacons sections of this manual for more information.

  • Page 61: Boom Synchronizing Procedure

    5. Activate Lower Boom Down, fully lower boom. 6. Repeat step 1 through 5 if necessary. 4.18 SHUT DOWN AND PARK Note: When parking battery powered units overnight, batteries should be charged properly to ensure readiness for following workday. E450AJ 3122337200...

  • Page 62: Lifting And Tie Down

    4.19 LIFTING AND TIE DOWN 4.19.1 Lifting 1. Refer to the Machine Serial Number Plate, call JLG Industries, or weigh the individual unit to find out the Gross Vehicle Weight. 2. Place the boom in the stowed position. 3. Remove all loose items from the machine.

  • Page 63: Lifting Chart

    4. Ensure the platform is lowered so the wear pad on the bottom rests on the surface of the transportation vehicle. Note: Secure through the tie downs on the boom using straps or chains of ad- equate strength. OAC014470 4.20 LIFTING CHART BM001111A E450AJ 3122337200...

  • Page 64: E450Aj Safety Decals

    Machine Operation 4.21 E450AJ SAFETY DECALS 4.21.1 Safety Decals Location and Legend Figure 8. Safety Decals - 1 of 6 BM001176A Figure 9. Safety Decals - 2 of 6 3122337200 E450AJ...
  • Page 65 Machine Operation Figure 10. Safety Decals - 3 of 6 BM001178A Figure 11. Safety Decals - 4 of 6 E450AJ 3122337200...
  • Page 66 Machine Operation BM001179A Figure 12. Safety Decals - 5 of 6 Figure 13. Safety Decals - 6 of 6 3122337200 E450AJ...
  • Page 67 Machine Operation E450AJ 3122337200...
  • Page 68 Machine Operation 3122337200 E450AJ...

  • Page 69: Emergency Procedures

    This section explains the steps to be taken in case of an emergency situation during operation. INCIDENT NOTIFICATION JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details.

  • Page 70: Emergency Towing Procedures

    3. Connect suitable equipment, remove chocks, and move machine. After moving machine, complete the following procedures: 1. Position machine on a firm and level surface. 2. Chock wheels securely. 3. Engage drive hubs by reversing disconnect caps on hubs. 4. Remove chocks from wheels as needed. 3122337200 E450AJ...

  • Page 71: Manual Descent System

    If the CS550 (ClearSky® LED Motion / Amber Beacon) is removed from a machine or disconnected from the control system through damage, the machine may also be placed into a Locked Out state. NOTICE Contact the ClearSky Smart Fleet™ account owner if the machine is in a Locked Out state. E450AJ 3122337200...
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  • Page 73: Accessories

    Top Rail ✔ ✔ ✔ ✔ (30” x 48”) Platform Top Rail Extension ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ (30” x 48”) (30” x 60”) Platform Work ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ Lights E450AJ 3122337200...
  • Page 74 ✔ Surface SkySense® ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ SkySense® Platform ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ Bumper Padding Soft Touch ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ (30” x 60”) 3122337200 E450AJ...
  • Page 75 Accessories E450AJ 3122337200...
  • Page 76 Accessories 3122337200 E450AJ...

  • Page 77: Bolt-On External Fall Arrest

    If the external fall arrest system is used to arrest a fall or is otherwise damaged, the entire system must be replaced and the platform fully inspected before returning to service. Refer to the service manual for removal and installation procedures. E450AJ 3122337200...
  • Page 78 Attachment Ring: No cracks or signs of wear are acceptable. Any signs of corrosion requires replacement. • Attaching Hardware: Inspect all attaching hardware to ensure there are no missing components and hardware is properly tightened. • Platform Rails: No visible damage is acceptable. 3122337200 E450AJ...

  • Page 79: Fall Arrest Platform

    Accessories FALL ARREST PLATFORM Note: See the JLG External Fall Arrest System manual (PN 3128935) for more de- tailed information. The external fall arrest system is designed to provide a lanyard attach point while allowing the operator to access areas outside the platform. Exit/enter the platform through the gate area only.
  • Page 80 Return racks to the stowed position when not in use. • Use this option only on approved models. 6.4.3 Preparation and Inspection • Ensure racks are secured to the platform rails. • Replace torn or frayed tie-down straps. 3122337200 E450AJ...

  • Page 81: Platform Work Lights

    Note: Reinstall tie-down straps across any remaining material before continuing machine operations. PLATFORM WORK LIGHTS OAC04000 Figure 18. Platform Work Lights The Platform Work Lights accessory consists of two 12V lights mounted to the platform railing. E450AJ 3122337200...

  • Page 82: Platform Work Surface

    Accessories PLATFORM WORK SURFACE BM000276A Figure 19. Platform Work Surface The platform work surface option consists of a corner tray bolted onto the top and mid rails of the platform. 3122337200 E450AJ...

  • Page 83: Skysense

    (left LED for left sensor bar; right LED for right sensor bar; both LEDs for center sensor bar or overhead sensor) should be red. 5. Recycle the footswitch and press the override button on the platform control console. E450AJ 3122337200...
  • Page 84 LED Flashing Yellow: Machine is in SkySense warning zone and will reduce function speed to creep. Flash frequency correlates to proximity of object. • LED Red: Machine is in SkySense stop zone and all machine functions will cease. 3122337200 E450AJ...
  • Page 85 Note: Override is only required to be engaged if the operator desires to move the platform closer to an object that is in or entering the stop zone. E450AJ 3122337200...
  • Page 86 SkyGuard will function normally. 6.7.6 SkySense Coverage Areas BM000009A BM000010A Figure 20. SkySense Coverage Level Figure 21. SkySense Coverage Level 1 Areas (2– Bar) 2 Areas (3 — Bar) Note: Sensor Cones shown are approximations for reference only. 3122337200 E450AJ...

  • Page 87: Skysense® Platform Bumper Padding

    A padding kit is mounted to the platform rails and to a frame suspended below the platform. Limit switches deactivate platform functions when the padded framework contacts an adjacent structure. A button on the platform console allows override of the system. E450AJ 3122337200...
  • Page 88 Accessories BM000011A Figure 23. Soft Touch System 1. Override Indicator Light 2. Override Button 3. Rail Bumper 4. Limit Switch 5. Suspended Frame and Rail Bumper 6. Limit Switch 3122337200 E450AJ...

  • Page 89: General Specifications And Operator Maintenance

    Maximum Wind Speed 28 mph (12.5 m/s) Maximum Tire Load 6,900 lb (3130 kg) Ground Bearing Pressure 75 psi (5.2 kg/cm System Voltage 48 volts Battery Life per Charge 7 hours continuous Battery Recharge Time 17 hours from full discharge E450AJ 3122337200...
  • Page 90 51 ft (15.54 m) Platform Height 45 ft (13.72 m) Track Width 5 ft (1.51 m) Tail Swing (Any Position) Ground Clearance 8 in (20 m) 7.2.4 Critical Stability Weights Component Counter weight 3,850 1746 Tire & Wheel (foam-filled) 3122337200 E450AJ...

  • Page 91: Serial Number Location

    BM000802A Figure 24. Serial Number Locations BATTERY CHARGER Battery Charger Type Delta-Q Electrical System Voltage (DC) 48V (960 W) Input AC Input Voltage 85-270V AC E450AJ 3122337200...

  • Page 92: Hydraulic Oil Specifications

    GL-3 and sufficient chemical stability for mobile hydraulic system service. JLG Industries recommends standard UTTO. Note: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities.
  • Page 93 Note: When temperatures remain consistently below 20° F (-7° C), JLG Industries recommends the use of a premium “cold weather” hydraulic fluid (Viscosity Gr. 32).
  • Page 94 ** Readily biodegradeable classification indicates one of the following: CO2 Conversion > 60% per EPA 560/6-82-003 CO2 Conversion > 80% per CEC-L-33-A-93 † Virtually Non-toxic classification indicates a LC50 > 5000 ppm per OECD 203 ‡ Fire Resistant classification indicates Factory Mutual Research Corp. (FMRC) Approval 3122337200 E450AJ...

  • Page 95: Operator Maintenance And Lubrication Diagram

    Extreme Pressure Gear Lube (oil) meeting API Service Classification GL-5 orMil- Spec Mil-L-2105. Hydraulic Oil. API Ser vice Classification GL-3 Open Gear Lube - Tribol Molub-Alloy 936 Open Gear Compound. (JLG PartNo. 3020027) Bearing Grease (JLG Part No. 3020029) Mobilith SHA 460.
  • Page 96 Note: OG will allow better cycle times than Mobiltac375NC, however Mobil- tac375NC must be used in dusty environments. If the swing function be- comes noisy and/or rough lubricate the bearing teeth. CAUTION Do not overgrease bearings. Overgreasing bearings will result in blowing outer seal in housing. 3122337200 E450AJ...
  • Page 97 Interval - Check Level daily; Change every 2 years or 1200 hours of operation. Comments - On new machines, those recently overhauled, or after changing hydraulic oil, operate all systems a minimum of two complete cycles and recheck oil level in reservoir. E450AJ 3122337200...
  • Page 98 5. Wheel Drive Hub 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 3122337200 E450AJ...
  • Page 99 Interval - Every 2 years or 1200 hours of operation 7. Spindles/Bushing Capacity - A/R Lube - Lithium Lubricant Interval - Every 2 years or 1200 hours of operation Comments - At Spindle/Bushing Replacement; Coat I. D. of bushings prior to installing king pins. E450AJ 3122337200...

  • Page 100: Battery Maintenance And Charging (Lead Acid/Agm)

    Comments - Check level daily/Change in accordance with engine manual. BATTERY MAINTENANCE AND CHARGING (LEAD ACID/AGM) WARNING To avoid injury from an explosion, do not smoke or allow sparks or a flame near battery during servicing. Always wear eye and hand protection when servicing batteries. 3122337200 E450AJ...
  • Page 101 Note: To avoid electrolyte overflow, add distilled water to batteries after charging. When adding water to the battery, fill only to level indicated or 3/8'' above separators. 1. Open battery compartment cover to allow access to battery terminals and vent caps. E450AJ 3122337200...

  • Page 102: Tires And Wheels

    JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for a particular machine model. If not using a JLG approved...
  • Page 103 When selecting and installing a replacement tire, ensure that all tires are inflated to the pressure recommended by JLG. Due to size variations between tire brands, both tires on the same axle should be the same.

  • Page 104: Torque Sequence

    Sky Smart Fleet telematics must be received by countries that are certified to have ClearSky Smart Fleet. For a full listing of ClearSky Smart Fleet certified countries, please refer to the ClearSky webpage on the JLG website. 7.10.1 Federal Communications Commission (FCC)
  • Page 105 JLG Industries, Inc. declares that the radio equipment ClearSky Smart Fleet CS550 Connectivity Module complies with Directive 2014/53/EU. Full details can be found on the declaration of conformity. The CS550 is intended to be mounted on JLG machines and has integrated beacon functionality. Additionally, it provides telematics data via WiFi or Cell, and provides local diagnostic data exchange with a mobile device connected via WiFi and BLE.

  • Page 106: Supplemental Information Only Applicable To Ce/Ukca Machines

    The vibration highest root mean square value of weighted acceleration to which the whole body is subjected during driving or lifting does not exceed 0.5 m/s JLG declares that machines included in this manual, before placing on the market, have been subjected to the required tests in accordance with EN280-1:2022, clause 5.3.

  • Page 107: Ec Declaration Of Conformity

    EN 61000-6-2:2005 • EN 60204-1:2018 • EN 280–1:2022 • EN ISO 12100:2010 JLG Industries, Inc. hereby declares that the above mentioned machine conforms with the requirements of: • 2006/42/EC — Machinery Directive • 2014/30/EU — EMC Directive • 2014/53/EU — RED Directive (If fitted with optional equipment) Note: This declaration conforms with the requirements of annex II-A of the council directive 2006/42/EC.

  • Page 108: Ukca Declaration Of Conformity

    EN 60204-1:2018 • EN 280–1:2022 • EN ISO 12100:2010 JLG Industries, Inc. hereby declares that the above mentioned machine conforms with the requirements of: • 2008 No. 1597 - Supply of Machinery (Safety) Regulations 2008 • 2016 No. 1091 - Electromagnetic Compatibility Regulations 20165 •...
  • Page 109 Inspection, Maintenance and Repair Log Serial Number ___________________________________ Any additional required certificates can be attached to the rear cover of this manual or stored in the manual box. Date Comments...
  • Page 110 Inspection, Maintenance and Repair Log...
  • Page 112 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...

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