JLG Boom Lift E450AJ Parts Manual 31215014

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JLG Boom Lift E450AJ Parts Manual 31215014
Size: 28.10 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Manual
Model: JLG E450AJ Boom Lift
Part Number: 31215014
Publication Date: 2025
Number of Pages: 418 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. STEERING INSTALLATION (MACHINES WITH SN STARTING WITH 03)​

FIGURE 1-2. STEERING INSTALLATION (MACHINES WITH SN STARTING WITH B3)​

FIGURE 1-3. HUB - SPINDLE ASSEMBLY - RH​

FIGURE 1-4. HUB - SPINDLE ASSEMBLY - LH​

FIGURE 1-5. DRIVE INSTALLATION (NON-UL SPECS)​

FIGURE 1-6. DRIVE INSTALLATION (UL SPECS)​

FIGURE 1-7. DRIVE HUB ASSEMBLY​

FIGURE 1-8. DRIVE MOTOR ASSEMBLY​

FIGURE 1-9. ELECTRICAL PLATE ASSEMBLY - LH (NON-UL SPECS)​

FIGURE 1-10. ELECTRICAL PLATE ASSEMBLY - LH (UL SPECS)​

FIGURE 1-11. ELECTRICAL PLATE ASSEMBLY - RH (NON-UL SPECS)​

FIGURE 1-12. ELECTRICAL PLATE ASSEMBLY - RH (UL SPECS)​

FIGURE 1-13. TIRE/WHEEL - IN240/55 - 17.5 FOAM FILLED​

FIGURE 1-14. TIRE/WHEEL - IN240/55-17.5 FOAM FILLED NON MARKING​

FIGURE 1-15. TIRE/WHEEL - 26 X 7 X 20 - SOLID NON MARKING​

FIGURE 1-16. MOTOR/PUMP/TANK INSTALLATION (NON-UL SPECS)​

FIGURE 1-17. MOTOR/PUMP/TANK INSTALLATION (UL SPECS)​

FIGURE 1-18. MOTOR/PUMP ASSEMBLY​

FIGURE 1-19. HYDRAULIC TANK ASSEMBLY​

FIGURE 1-20. VALVE INSTALLATION - FRAME MOUNTED​

FIGURE 1-21. BRAKE/STEER VALVE ASSEMBLY​

FIGURE 1-22. BATTERY BOX INSTALLATION - STANDARD (ALL SPECS EXCEPT AUSTRALIAN, CE AND CHINA SPECS)​

FIGURE 1-23. BATTERY BOX INSTALLATION - STANDARD (AUSTRALIAN, CE AND CHINA SPECS)​

FIGURE 1-24. BATTERY BOX INSTALLATION - AGM BATTERIES (ALL SPECS EXCEPT AUSTRALIAN, CE AND CHINA SPECS)​

FIGURE 1-25. BATTERY BOX INSTALLATION - AGM BATTERIES (AUSTRALIAN, CE AND CHINA SPECS)​

FIGURE 1-26. BATTERY CHARGER INSTALLATION (ANSI, ANSI EXPORT, CSA, JAPANESE AND UL SPECS) (PVC 2001)​

FIGURE 1-27. BATTERY CHARGER INSTALLATION (ALL SPECS EXCEPT AUSTRALIAN & CE SPECS) (PVC 2007)​

FIGURE 1-28. BATTERY CHARGER INSTALLATION (AUSTRALIAN SPEC) (PVC 2001)​

FIGURE 1-29. BATTERY CHARGER INSTALLATION (AUSTRALIAN SPEC) (PVC 2007)​

FIGURE 1-30. BATTERY CHARGER INSTALLATION (ANSI EXPORT AND CE SPECS) (PVC 2001)​

FIGURE 1-31. BATTERY CHARGER INSTALLATION (ANSI EXPORT, CE AND CHINA SPECS) (PVC 2007)​

FIGURE 1-32. BATTERY CHARGER INSTALLATION (ANSI EXPORT AND CHINA SPECS)​

FIGURE 1-33. BATTERY CHARGER ASSEMBLY​

FIGURE 1-34. INVERTER INSTALLATION​

FIGURE 1-35. VOLTAGE GUARD ASSEMBLY AND INSTALLATION (ANSI EXPORT AND CHINA SPECS)​

FIGURE 1-36. FRAME COVER INSTALLATION​

SECTION 2 - TURNTABLE

FIGURE 2-1. VALVE INSTALLATION - TURNTABLE MOUNTED​

FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY​

FIGURE 2-3. RELEVELING VALVE ASSEMBLY​

FIGURE 2-4. JIB VALVE ASSEMBLY​

FIGURE 2-5. MOTION ALARM INSTALLATION​

FIGURE 2-6. TURNTABLE BEARING AND SWING DRIVE INSTALLATION​

FIGURE 2-7. SWING MOTOR ASSEMBLY​

FIGURE 2-8. SWING BEARING ASSEMBLY​

FIGURE 2-9. REMOTE BEARING LUBE INSTALLATION - OPTIONAL​

FIGURE 2-10. DRIVE ORIENTATION INSTALLATION​

FIGURE 2-11. GROUND CONTROL BOX INSTALLATION (ALL SPECS EXCEPT CE AND CHINA SPECS)​

FIGURE 2-12. GROUND CONTROL BOX INSTALLATION (CE AND CHINA SPECS)​

FIGURE 2-13. GROUND CONTROL BOX ELECTRICAL ASSEMBLY (ALL SPECS EXCEPT CE AND CHINA SPECS)​

FIGURE 2-14. GROUND CONTROL BOX ELECTRICAL ASSEMBLY (CE AND CHINA SPECS)​

FIGURE 2-15. STROBE LIGHT INSTALLATION - AMBER​

FIGURE 2-16. BEACON LIGHT INSTALLATION - BLUE​

FIGURE 2-17. BEACON LIGHT INSTALLATION - RED​

FIGURE 2-18. HOOD INSTALLATION​

SECTION 3 - ENGINE

FIGURE 3-1. KUBOTA MOTOR/GENERATOR ASSEMBLY​

FIGURE 3-2. KUBOTA ENGINE COMPONENTS​

SECTION 4 - BOOM

FIGURE 4-1. BOOM AND CYLINDERS INSTALLATION (MACHINES WITH SN STARTING WITH 03)​

FIGURE 4-2. BOOM AND CYLINDERS INSTALLATION (MACHINES WITH SN STARTING WITH B3)​

FIGURE 4-3. MAIN BOOM ASSEMBLY (MACHINES WITH SN STARTING WITH 03)​

FIGURE 4-4. MAIN BOOM ASSEMBLY (MACHINES WITH SN STARTING WITH B3)​

FIGURE 4-5. JIB INSTALLATION (MACHINES WITH SN STARTING WITH 03)​

FIGURE 4-6. JIB INSTALLATION (MACHINES WITH SN STARTING WITH B3)​

FIGURE 4-7. ROTATOR ASSEMBLY​

FIGURE 4-8. PLATFORM SUPPORT INSTALLATION​

FIGURE 4-9. BOOM LIMIT SWITCHES INSTALLATION​

SECTION 5 - PLATFORM

FIGURE 5-1. PLATFORM ASSEMBLY - 4FT/1.22M - SIDE GATE ENTRY​

FIGURE 5-2. PLATFORM ASSEMBLY - 5FT/1.52M - SIDE GATE ENTRY​

FIGURE 5-3. PLATFORM ASSEMBLY - 4FT/1.22M - DROP BAR ENTRY​

FIGURE 5-4. PLATFORM ASSEMBLY - 5FT/1.52M - DROP BAR ENTRY​

FIGURE 5-5. PLATFORM ASSEMBLY - 30IN X 3FT (76CM X .91M) - DROP BAR ENTRY​

FIGURE 5-6. PLATFORM ASSEMBLY - 6FT/1.83M - DROP BAR ENTRY​

FIGURE 5-7. PLATFORM ASSEMBLY - 5FT/1.52M - FALL ARREST​

FIGURE 5-8. PLATFORM ASSEMBLY - 6FT/1.83M - FALL ARREST​

FIGURE 5-9. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - WITH 1 CELL LSS AND WITH SKYGUARD (NON-UL SPECS)​

FIGURE 5-10. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - WITH 1 CELL LSS AND WITH SKYGUARD (UL SPECS)​

FIGURE 5-11. PLATFORM CONSOLE ASSEMBLY - WITH 1 CELL LSS AND WITH SKYGUARD (NON-UL SPECS)​

FIGURE 5-12. PLATFORM CONSOLE ASSEMBLY - WITH 1 CELL LSS AND WITH SKYGUARD (UL SPECS)​

FIGURE 5-13. LIGHT PANEL INSTALLATION​

FIGURE 5-14. JIB SWITCH INSTALLATION​

FIGURE 5-15. CONTROLLER ASSEMBLY - DRIVE AND STEER​

FIGURE 5-16. CONTROLLER ASSEMBLY - LIFT AND SWING​

FIGURE 5-17. FOOTSWITCH ASSEMBLY​

FIGURE 5-18. MOTOR CONTROLS INSTALLATION​

FIGURE 5-19. TRAY ASSEMBLY​

FIGURE 5-20. SKYEYE INSTALLATION​

FIGURE 5-21. SKYGUARD BAR INSTALLATION​

FIGURE 5-22. SKYLINE INSTALLATION​

FIGURE 5-23. PIPE RACK INSTALLATION​

SECTION 6 - CYLINDER

FIGURE 6-1. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH 03)​

FIGURE 6-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH B3)​

FIGURE 6-3. LIFT CYLINDER ASSEMBLY - JIB (MACHINES WITH SN STARTING WITH 03)​

FIGURE 6-4. LIFT CYLINDER ASSEMBLY - JIB (MACHINES WITH SN STARTING WITH B3)​

FIGURE 6-5. LIFT CYLINDER ASSEMBLY - LOWER (MACHINES WITH SN STARTING WITH 03)​

FIGURE 6-6. LIFT CYLINDER ASSEMBLY - LOWER (MACHINES WITH SN STARTING WITH B3)​

FIGURE 6-7. LIFT CYLINDER ASSEMBLY - MID (MACHINES WITH SN STARTING WITH 03)​

FIGURE 6-8. LIFT CYLINDER ASSEMBLY - MID (MACHINES WITH SN STARTING WITH B3)​

FIGURE 6-9. LIFT CYLINDER ASSEMBLY - UPPER (MACHINES WITH SN STARTING WITH 03) (PRIOR TO PVC 2001)​

FIGURE 6-10. LIFT CYLINDER ASSEMBLY - UPPER (MACHINES WITH SN STARTING WITH 03) (PVC 2001)​

FIGURE 6-11. LIFT CYLINDER ASSEMBLY - UPPER (MACHINES WITH SN STARTING WITH B3)​

FIGURE 6-12. TELESCOPE CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH 03) (PRIOR TO PVC 2001)​

FIGURE 6-13. TELESCOPE CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH 03) (PVC 2001)​

FIGURE 6-14. TELESCOPE CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH B3)​

FIGURE 6-15. MASTER CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH 03)​

FIGURE 6-16. MASTER CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH 03)​

FIGURE 6-17. STEER CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH 03)​

FIGURE 6-18. STEER CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH B3)​

FIGURE 6-19. COUNTERBALANCE VALVE ASSEMBLY​

SECTION 7 - HYDRAULIC

FIGURE 7-1. HYDRAULIC DIAGRAM​

FIGURE 7-2. HYDRAULIC DIAGRAM LIST​

SECTION 8 - ELECTRICAL

FIGURE 8-1. ELECTRICAL DIAGRAM LIST​

FIGURE 8-2. AC PLUGS AND SOCKETS INSTALLATION - AFSINT 107-2-01 KEYED GROUND - 2 X 4 BOX (CE SPEC)​

FIGURE 8-3. AC PLUGS AND SOCKETS INSTALLATION - CEE7 POST GROUND (CE SPEC)​

FIGURE 8-4. AC PLUGS AND SOCKETS INSTALLATION - CEE 7 SIDE GROUND (CE SPEC)​

FIGURE 8-5. AC PLUGS AND SOCKETS INSTALLATION - CEE7 POST GROUND - 2 X 4 BOX (CE SPEC)​

FIGURE 8-6. AC PLUGS AND SOCKETS INSTALLATION - CEE7 SIDE GROUND - 2 X 4 BOX (CE SPEC)​

FIGURE 8-7. AC PLUGS AND SOCKETS INSTALLATION - IEC 60309 BLUE (CE SPEC)​

FIGURE 8-8. AC PLUGS AND SOCKETS INSTALLATION - IEC 60309 YELLOW (CE SPEC)​

FIGURE 8-9. BATTERY CABLE KIT (NON-UL SPECS)​

FIGURE 8-10. BATTERY CABLE KIT (UL SPECS)​

FIGURE 8-11. BLUETOOTH MODULE INSTALLATION​

FIGURE 8-12. BLUETOOTH MODULE HARNESS​

FIGURE 8-13. BOOM CABLE - LOWER​

FIGURE 8-14. BOOM CABLE - UPPER​

FIGURE 8-15. BOOM LIMIT SWITCH HARNESS - LOWER​

FIGURE 8-16. BOOM LIMIT SWITCH HARNESS - UPPER​

FIGURE 8-17. BREAKER BOX KIT WITH ONE BREAKERS - CE SPEC​

FIGURE 8-18. BREAKER BOX KIT WITH TWO BREAKERS - CE SPEC​

FIGURE 8-19. CABLES AND CLAMPS INSTALLATION​

FIGURE 8-20. CHARGER CORD PLUG INSTALLATION - 110V - IEC 60309 - YELLOW (CE SPEC)​

FIGURE 8-21. CHARGER CORD PLUG INSTALLATION - 220V - AFSINT 107 KEYED GROUND (CE SPEC)​

FIGURE 8-22. CHARGER CORD PLUG INSTALLATION - 220V - CEE7 POST GROUND (CE SPEC)​

FIGURE 8-23. CHARGER CORD PLUG INSTALLATION - 220V - CEE7 SIDE GROUND (CE SPEC)​

FIGURE 8-24. CHARGER CORD PLUG INSTALLATION - 220V - IEC 60309 - BLUE (CE SPEC)​

FIGURE 8-25. CHASSIS TO TURNTABLE HARNESS​

FIGURE 8-26. GENERATOR HARNESS​

FIGURE 8-27. GROUND CONTROL PANEL HARNESS​

FIGURE 8-28. INVERTER HARNESS​

FIGURE 8-29. INVERTER IGNITION HARNESS​

FIGURE 8-30. LOWER BOOM 110V HARNESS ASSEMBLY​

FIGURE 8-31. LOWER BOOM 220V HARNESS ASSEMBLY​

FIGURE 8-32. PLATFORM CONSOLE HARNESS - WITH 1 CELL LSS​

FIGURE 8-33. PLUG AND RECEPTACLE INSTALLATION - SUPPLIED LOCALLY​

FIGURE 8-34. PLUG AND RECEPTACLE INSTALLATION - 110V​

FIGURE 8-35. PLUG AND RECEPTACLE INSTALLATION - 220V​

FIGURE 8-36. PLUG AND RECEPTACLE 110V INSTALLATION - IEC 60309 - YELLOW (CE SPEC)​

FIGURE 8-37. PLUG AND RECEPTACLE 220V INSTALLATION - AFSINT 107 KEYED GROUND - 2 X 4 BOX (CE SPEC)​

FIGURE 8-38. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 POST GROUND - 2 X 4 BOX (CE SPEC)​

FIGURE 8-39. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 POST GROUND - 70MM X 70MM BOX (CE SPEC)​

FIGURE 8-40. PLUG AND RECEPTACLE 220 INSTALLATION - CEE7 SIDE GROUND - 2 X 4 BOX (CE SPEC)​

FIGURE 8-41. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 SIDE GROUND - 70MM X 70MM BOX (CE SPEC)​

FIGURE 8-42. PLUG AND RECEPTACLE 220V INSTALLATION - IEC 60309 - BLUE (CE SPEC)​

FIGURE 8-43. SKYEYE INTERMEDIATE HARNESS​

FIGURE 8-44. SKYEYE RECEIVER HARNESS​

FIGURE 8-45. SKYEYE EMITTER HARNESS​

FIGURE 8-46. SKYGUARD HARNESS - WITH 1 CELL LSS​

FIGURE 8-47. SKYLINE HARNESS​

FIGURE 8-48. STEER/BRAKE HARNESS​

FIGURE 8-49. TRACTION HARNESS​

FIGURE 8-50. TURNTABLE HARNESS​

FIGURE 8-51. UPPER BOOM 110V HARNESS ASSEMBLY​

FIGURE 8-52. UPPER BOOM 220V HARNESS ASSEMBLY​

FIGURE 8-53. VALVE HARNESS​

SECTION 9 - DECALS

FIGURE 9-1. DECAL INSTALLATION - ANSI, ANSI EXPORT, CSA AND UL SPECS - ENGLISH (MACHINES WITH SN STARTING WITH 03)​

FIGURE 9-2. DECAL INSTALLATION - ANSI EXPORT SPEC - ENGLISH (MACHINES WITH SN STARTING WITH B3)​

FIGURE 9-3. DECAL INSTALLATION - AUSTRALIAN SPEC​

FIGURE 9-4. DECAL INSTALLATION - CE AND CHINA SPECS​

FIGURE 9-5. DECAL INSTALLATION - CHINESE/ENGLISH (MACHINES WITH SN STARTING WITH 03)​

FIGURE 9-6. DECAL INSTALLATION - CHINESE/ENGLISH (MACHINES WITH SN STARTING WITH B3)​

FIGURE 9-7. DECAL INSTALLATION - FRENCH/ENGLISH SPECS​

FIGURE 9-8. DECAL INSTALLATION - JAPANESE SPEC (MACHINES WITH SN STARTING WITH 03)​

FIGURE 9-9. DECAL INSTALLATION - JAPANESE SPEC (MACHINES WITH SN STARTING WITH B3)​

FIGURE 9-10. DECAL INSTALLATION - KOREAN SPEC (MACHINES WITH SN STARTING WITH 03)​

FIGURE 9-11. DECAL INSTALLATION - KOREAN SPEC (MACHINES WITH SN STARTING WITH B3)​

FIGURE 9-12. DECAL INSTALLATION - SPANISH/ENGLISH SPECS​

FIGURE 9-13. DECAL INSTALLATION - SPANISH/PORTUGUESE SPECS​

FIGURE 9-14. DECAL INSTALLATION - OPTIONS​

SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK​

SECTION 11 - SPECIAL OPTIONS

FIGURE 11-1. SPECIAL OPTIONS​

PART NUMBER INDEX