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JLG E450A E450AJ M450A M450AJ Service Manual S/N 0300208529 to Present

August 23, 2017

S/N 0300208529 to Present
P/N - 3121714

Content:
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General
B Hydraulic System Safety
C Maintenance

SECTION 1 - SPECIFICATIONS
1.1 Operating Specifications
1.2 Tires
1.3 Capacities
1.4 Function Speed
1.5 Dimensional Data
1.6 Torque Specifications
1.7 Lubrication Specifications
Hydraulic Oil
1.8 Critical Stability Weights
1.9 Major Component Weights
1.10 Serial Number Locations
1.11 Maintenance and Lubrication

SECTION 2 - GENERAL
2.1 Machine Preparation, Inspection, and Maintenance
General
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance
2.2 Service and Guidelines
General
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Lubrication and Servicing
2.3 Lubrication and Information
Hydraulic System
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications
2.4 Cylinder Drift
Theory
Cylinder Leakage Test
Cylinder Thermal Drift
2.5 Pins and Composite Bearing Repair Guidelines
2.6 Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment

SECTION 3 - CHASSIS & TURNTABLE
3.1 Tires & Wheels
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation
3.2 Spindle
Setting Wheel Bearing End Play
Specifications
Checking
Greasing Requirements
3.3 Tilt Module
3.4 Speed Sensor
3.5 Drive Hub
Roll and Leak Testing
Tightening and Torquing Bolts
Main Disassembly
Output Carrier Disassembly
Input Carrier Disassembly
Hub-spindle Disassembly
Cover Disassembly
Input Carrier Assembly
Output Planet Gear Assembly
Output Carrier Assembly
Hub-spindle Assembly
Cover Assembly
Main Assembly
3.6 Drive Motor
Removal
Disassembly
Inspection
Assembly
Installation
3.7 Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Replacement of Swing Bearing
Swing Bearing Torque Value
Checking Worm Gear End Play
Adjusting End Play
3.8 Swing Motor
Preparation Before Disassembly
Disassembly and Inspection
Assembly
One Piece Stator Construction
Two Piece Stator Construction
Final Checks
3.7 Battery Maintenance and Charging
Battery Maintenance, Quarterly
Optional On Board Generator
Battery Charging (On Board Charger)
3.8 Battery Charger
Operating Instructions
Maintenance Instructions
Battery Charger Fault Codes
Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell
Checking/Changing the Battery Charger Algorithm
3.9 Generator
Engine
Alternator
Dynamo and Dynamo Voltage Regulator
Dynamo Output Fuse
Control Fuse
Start Battery
Engine Starter
Start Control Relay
Fuel Control Relay
Glow Plug Control Relay
Glow Plug
Fuel Pump
Fuel Solenoid
Engine Low Oil Pressure Switch
Engine Oil Temperature Sensor
Alternator Output Current Sensor
Engine Speed Sensor
RBS Engine/Generator Controller
Warnings and Safety Precautions
System Controls
System Status and Performance Monitoring
System Settings
RBS Start
RBS shutdown
RBS Alarms and Flash Codes
Resetting the RBS Controller
Maintenance Schedule
Troubleshooting
APU Engine Start Battery Boosting
3.10 Supplementary fuse for apu
Tools And Material
Procedure

SECTION 4 - BOOM & PLATFORM
4.1 Platform
Support Removal
Support Installation
4.2 Rotator and Slave Cylinder Removal
Removal
Installation
4.3 Main Boom Powertrack (E/M450AJ)
Removal
Installation
4.4 Boom Maintenance
Removal
Disassembly
Inspection
Assembly
Installation
4.5 Wear Pads
4.6 Boom Limit Switches
4.7 Boom Cleanliness Guidelines
4.8 Articulating Jib Boom
Removal
Disassembly
Inspection
Assembly
4.9 Boom Synchronizing Procedure
4.10 Foot switch Adjustment
4.11 Rotary actuator
Theory Of Operation
Tools Required for Assembly/Disassembly
Disassembly
Inspection
Assembly
Installing Counterbalance Valve
Greasing Thrust Washers
Testing the Actuator
Installation and Bleeding
Troubleshooting
4.12 Powertrack Maintenance
Removing a Link
Installing a New Link
Replacing Fixed End Brackets
Replacing Moving End Brackets
4.13 Skyguard
Operation
Functional Test
Diagnostic & Troubleshooting

SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS
5.1 Lubricating O-Rings in the Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method
5.2 Hydraulic Cylinders
Slave Cylinder (E450Aonly)
Slave Cylinder (E/M450AJ only)
Jib Lift Cylinder
Lower Lift Cylinder
Mid Lift Cylinder
Main Lift Cylinder
Master Cylinder (E450A only)
Master Cylinder (E/M450AJ only)
Steer Cylinder
Telescope Cylinder (E450A only)
Telescope Cylinder (E/M450AJ only)
5.3 Cylinder Removal And Installation
Main Boom Lift Cylinder Removal
Main Boom Lift Cylinder Installation
Mid Boom Lift Cylinder Removal
Mid Boom Lift Cylinder Installation
Lower Boom Lift Cylinder Removal
Lower Boom Lift Cylinder Installation
Main Boom Telescope Cylinder Removal
Main Boom Telescope Cylinder Installation
5.4 Mid and Lower Lift Cylinder Bleeding Procedure
5.5 Pressure Setting Procedures
Main Relief
Main Lift Down Relief
Lower Lift Down Relief
Telescope Relief
Platform Level Up Relief
Platform Level Down Relief
Steer Relief
Jib Lift (Up and Down) Relief
Releveling Valve Relief

SECTION 6 - JLG CONTROL SYSTEM
6.1 JLG Control System Analyzer Kit Instructions
Introduction
To Connect the JLG Control System Analyzer
Using the Analyzer
Changing the Access Level of the Hand Held Analyzer
Adjusting Parameters Using the Hand Held Analyzer
Machine Setup
Level Vehicle Description
6.2 Machine Personality Settings
6.3 Machine Orientation When performing test
Test Notes
6.4 Function Speed
Help Descriptions and Fault Flash Codes
Analyzer Diagnostics Menu Structure
System Self Test
6.5 Calibrating Steer
6.6 Calibrating Tilt Sensor
6.7 Calibrating Load Sensing
6.8 LSS System
Diagnostic Menu
Calibration Procedure
Testing & Evaluation
Troubleshooting
6.9 Resetting The MSSO System

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS
7.1 General
7.2 Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement
7.3 Checking Switches
Basic Check
Limit Switches
Automatic Switches
Switch Wiring - Low Side, High Side
7.4 Applying Silicone Dielectric Compound to Electrical Connections
Installation of Dielectric Grease
Deutsch HD, DT, DTM, DRC Series
AWP Seal
AMP Mate-N-Lok
DIN Connectors
Exclusions
7.5 AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
Assembly
Disassembly
Wedge Lock
Service - Voltage Reading
7.6 DEUTSCH Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
7.7 Wiring Harness Connector Lables
Connector Labels
Component Labels
File Data

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