Oshkosh Corporation JLG E450AJ Manuals

Manuals and User Guides for Oshkosh Corporation JLG E450AJ. We have 3 Oshkosh Corporation JLG E450AJ manuals available for free PDF download: Service And Maintenance Manual

Oshkosh Corporation JLG E450AJ Service And Maintenance Manual (487 pages)

Brand: Oshkosh Corporation | Category: Boom Lifts | Size: 59 MB

Oshkosh Corporation JLG E450AJ Service And Maintenance Manual (262 pages)

Brand: Oshkosh Corporation | Category: Boom Lifts | Size: 19 MB

Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Section 1 - Specifications
16
Operating Specifications
16
Capacities
16
Tires
16
Battery Charger
16
Dimensional Data
16
Drive System
17
Hydraulic Pump/Electric Motor Assembly
17
Generator
17
Function Speeds
17
Pressure Settings
18
Torque Specifications
19
Lubrication Specifications
19
Hydraulic Oil
19
Critical Stability Weights
19
Cylinder Specifications
20
Major Component Weights
20
Serial Number Locations
20
Operator Maintenance & Lubrication
22
Section 2 - General
33
Machine Preparation, Inspection, and Maintenance
33
General
33
Preparation, Inspection, and Maintenance
33
Pre-Start Inspection
33
Pre-Delivery Inspection and Frequent Inspection
33
Annual Machine Inspection
33
Preventive Maintenance
33
Service and Guidelines
34
General
34
Safety and Workmanship
34
Cleanliness
34
Components Removal and Installation
34
Component Disassembly and Reassembly
35
Pressure-Fit Parts
35
Bearings
35
Gaskets
35
Bolt Usage and Torque Application
35
Hydraulic Lines and Electrical Wiring
35
Hydraulic System
35
Lubrication
35
Battery
35
Lubrication and Servicing
35
Hydraulic Oil
36
Changing Hydraulic Oil
36
Lubrication Specifications
36
Cylinder Drift Test
36
Platform Drift
36
Cylinder Drift
36
Pins and Composite Bearing Repair Guidelines
37
Welding on JLG Equipment
37
Do the Following When Welding on JLG Equipment
37
Do NOT Do the Following When Welding on JLG Equipment
37
Section 3 - Chassis & Turntable
43
Tires & Wheels
43
Tire Inflation
43
Tire Damage
43
Tire Replacement
43
Wheel Replacement
43
Wheel Installation
43
Spindle
44
Setting Wheel Bearing End Play
44
Specifications
44
Checking
44
Greasing Requirements
44
Drive Hub
46
Disassembly
46
Disassembly of Cover
47
Disassembly of First Stage Planetary Assembly (7)
47
Disassembly of Second Stage Planet Gears (1)
47
Assembly of First Stage Planetary Assembly (7)
47
Assembly of End Cover Unit (8)
47
Final Assembly
48
Initial Start-Up and after Repairs
48
Maintenance
48
Oil Change Interval-Gear Drive
48
Setting of Tapered Roller Bearings
48
Securing of the Shaft Nut
48
Drive Brake - Mico
50
Disassembly
50
Assembly
50
Bleeding
50
Speed Sensor Adjustment
53
Adjustment Procedure
53
Speed Sensor Installation Verification
58
Verification W/ Analyzer Procedure
58
Positrac/Tilt Module
61
Swing Motor - S/N 0300135649 to Present
63
Preparation before Disassembly
66
Disassembly and Inspection
66
Assembly
72
One Piece Stator Construction
79
Two Piece Stator Construction
80
Final Checks
80
Swing Bearing
81
Turntable Bearing Mounting Bolt Condition Check
81
Wear Tolerance
82
Replacement of Swing Bearing
83
Swing Bearing Torque Value
85
Checking Worm Gear End Play
85
Adjusting End Play
85
Battery Maintenance and Charging
87
Battery Maintenance, Quarterly
87
Optional on Board Generator
87
Battery Charging (on Board Charger)
89
Battery Charger (S/N 0300059350 to Present)
90
Operating Instructions
90
Maintenance Instructions
90
Battery Charger Fault Codes
90
Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell
93
Checking/Changing the Battery Charger Algorithm
94
Generator (Prior to S/N 88539)
95
Timing Sequences
97
To Connect the JLG Control System Analyzer to the Generator
98
Alarms and Fault Flash Codes
98
Output Current and Voltage Settings
100
Priming the Fuel Line
101
Generator (S/N 88539 to Present)
102
Engine
102
Alternator
102
Dynamo and Dynamo Voltage Regulator
102
Dynamo Output Fuse
102
Control Fuse
102
Start Battery
104
Engine Starter
104
Start Control Relay
104
Fuel Control Relay
105
Glow Plug Control Relay
105
Glow Plug
105
Fuel Pump
106
Fuel Solenoid
106
Engine Low Oil Pressure Switch
106
Engine Oil Temperature Sensor
106
Alternator Output Current Sensor
107
Engine Speed Sensor
107
RBS Engine/Generator Controller
107
Warnings and Safety Precautions
108
System Controls
108
System Status and Performance Monitoring
108
System Settings
108
RBS Start
109
RBS Shutdown
109
RBS Alarms and Flash Codes
110
Resetting the RBS Controller
110
Maintenance Schedule
110
Troubleshooting
111
APU Engine Start Battery Boosting
112
Supplementary Fuse for Apu
113
Tools and Material
113
Procedure
113
Section 4 - Boom & Platform
116
Boom Maintenance
116
Removal
116
Disassembly
116
Inspection
117
Assembly
117
Installation
118
Upper (Main) Boom Lift Cylinder
119
Removal
119
Installation
119
MID Boom Lift Cylinder
119
Installation
120
Lower Boom Lift Cylinder
120
Removal
120
Upper Boom Telescope Cylinder
121
Removal
121
Installation
121
MID and Lower Lift Cylinder Bleeding Procedure
122
Wear Pads
122
Boom Limit Switches
123
Articulating Jib Boom
126
Removal
126
Disassembly
126
Inspection
126
Assembly
126
Load Sensing System
127
Calibration
127
Boom Synchronizing Procedure
127
Footswitch Adjustment
127
Helac Rotary Actuator
128
Theory of Operation
128
Tools Required for Assembly/Disassembly
128
Disassembly
131
Inspection
134
Assembly
135
Installing Counterbalance Valve
139
Testing the Actuator
139
Installation and Bleeding
141
Troubleshooting
142
Powertrack Maintenance
143
Removing a Link
143
Installing a New Link
146
Replacing Fixed End Brackets
151
Replacing Moving End Brackets
153
Section 5 - Hydraulics
156
Lubricating O-Rings in the Hydraulic System
156
Cup and Brush
156
Dip Method
157
Spray Method
157
Brush-On Method
157
Cylinders - Theory of Operation
158
Double Acting Cylinder
158
Cylinder Checking Procedures
158
Cylinder Without Counterbalance Valves
158
Cylinders with Single Counterbalance Valve
158
Cylinders with Dual Counterbalance Valve
159
Cylinder Repair
159
Disassembly
159
Cleaning and Inspection
160
Assembly
161
Pressure Setting Procedures
175
Main Relief
175
Upper Lift down Relief
175
Lower Lift down Relief
175
Telescope Relief
175
Platform Level up Relief
175
Platform Level down Relief
176
Steer Relief
176
Jib Lift (up and Down) Relief
176
Releveling Valve Relief
176

Oshkosh Corporation JLG E450AJ Service And Maintenance Manual (153 pages)

Brand: Oshkosh Corporation | Category: Boom Lifts | Size: 24 MB

Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Specifications
20
Operating Specifications
20
Tires
20
Capacities
20
Dimensional Data
20
Torque Specifications
21
Lubrication Specifications
21
Hydraulic Oil
21
Critical Stability Weights
22
Major Component Weights
22
Serial Number Locations
22
Maintenance and Lubrication
24
Threadlocking Compound
27
Torque Charts
28
SAE Fastener Torque Chart
28
SAE Fastener Torque Chart (Continued)
29
SAE Fastener Torque Chart (Continued)
31
SAE Fastener Torque Chart (Continued)
33
Metric Fastener Torque Chart
34
Metric Fastener Torque Chart (Continued)
35
Metric Fastener Torque Chart (Continued)
37
General
38
Machine Preparation, Inspection, and Maintenance
38
Preparation, Inspection, and Maintenance
38
Pre-Start Inspection
38
Pre-Delivery Inspection and Frequent Inspection
38
Annual Machine Inspection
38
Preventative Maintenance
38
Service and Guidelines
39
General
39
Safety and Workmanship
39
Cleanliness
39
Components Removal and Installation
39
Component Disassembly and Assembly
40
Pressure-Fit Parts
40
Bearings
40
Gaskets
40
Bolt Usage and Torque Application
40
Hydraulic Lines and Electrical Wiring
40
Hydraulic System
40
Lubrication
40
Battery
40
Lubrication and Servicing
40
Lubrication and Information
41
Hydraulic System
41
Hydraulic Oil
41
Changing Hydraulic Oil
41
Lubrication Specifications
41
Cylinder Drift
42
Theory
42
Cylinder Leakage Test
42
Cylinder Thermal Drift
42
Pins and Composite Bearing Repair Guidelines
43
Welding on JLG Equipment
43
Do the Following When Welding on JLG Equipment
43
Do NOT Do the Following When Welding on JLG Equipment
43
Chassis & Turntable
49
Tires & Wheels
49
Tire Damage
49
Tire Replacement
49
Wheel Replacement
49
Wheel Installation
49
Spindle
50
Setting Wheel Bearing End Play
50
Specifications
50
Checking
50
Greasing Requirements
50
Tilt Module
53
Speed Sensor
54
Drive Hub
61
Roll and Leak Testing
61
Tightening and Torquing Bolts
61
Main Disassembly
62
Output Carrier Disassembly
64
Input Carrier Disassembly
66
Hub-Spindle Disassembly
67
Cover Disassembly
68
Input Carrier Assembly
69
Output Planet Gear Assembly
69
Output Carrier Assembly
70
Hub-Spindle Assembly
70
Cover Assembly
71
Main Assembly
71
Drive Motor
74
Removal
74
Disassembly
74
Inspection
74
Assembly
75
Installation
75
Swing Bearing
77
Turntable Bearing Mounting Bolt Condition Check
77
Wear Tolerance
78
Replacement of Swing Bearing
79
Swing Bearing Torque Value
82
Checking Worm Gear End Play
82
Adjusting End Play
82
Swing Motor
84
Preparation before Disassembly
87
Disassembly and Inspection
87
Assembly
94
One Piece Stator Construction
100
Two Piece Stator Construction
101
Final Checks
101
Battery Maintenance and Charging
102
Battery Maintenance, Quarterly
102
Optional on Board Generator
102
Battery Charging (on Board Charger)
102
Battery Charger
104
Operating Instructions
104
Maintenance Instructions
105
Battery Charger Fault Codes
105
Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell
108
Checking/Changing the Battery Charger Algorithm
108
Generator
109
Engine
109
Alternator
109
Dynamo and Dynamo Voltage Regulator
109
Dynamo Output Fuse
109
Control Fuse
109
Start Battery
111
Engine Starter
111
Start Control Relay
111
Fuel Control Relay
112
Glow Plug Control Relay
112
Glow Plug
112
Fuel Pump
113
Fuel Solenoid
113
Engine Low Oil Pressure Switch
113
Engine Oil Temperature Sensor
113
Alternator Output Current Sensor
114
Engine Speed Sensor
114
RBS Engine/Generator Controller
114
Warnings and Safety Precautions
115
System Controls
115
System Status and Performance Monitoring
115
System Settings
115
RBS Start
116
RBS Shutdown
116
RBS Alarms and Flash Codes
117
Resetting the RBS Controller
117
Maintenance Schedule
117
Troubleshooting
118
APU Engine Start Battery Boosting
119
Supplementary Fuse for APU
120
Tools and Material
120
Procedure
120
Boom & Platform
123
Platform
123
Support Removal
123
Support Installation
124
Rotator and Platform Level Cylinder Removal
126
Removal
126
Installation
126
Main Boom Powertrack
127
Removal
127
Installation
127
Boom Maintenance
128
Removal
128
Disassembly
129
Inspection
129
Assembly
129
Installation
130
Wear Pads
131
Boom Limit Switches
131
Boom Cleanliness Guidelines
131
Articulating Jib Boom
133
Removal
133
Disassembly
133
Inspection
133
Assembly
133
Boom Synchronizing Procedure
134
Foot Switch Adjustment
134
Rotary Actuator
135
Theory of Operation
135
Tools Required for Assembly/Disassembly
135
Disassembly
138
Inspection
141
Assembly
142
Installing Counterbalance Valve
146
Greasing Thrust Washers
147
Testing the Actuator
147
Installation and Bleeding
148
Troubleshooting
149
Powertrack Maintenance
150
Removing a Link
150

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