JLG Boom Lift E450AJ Parts Manual 31220358

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JLG Boom Lift E450AJ Parts Manual 31220358
Size: 30.57 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Manual
Model: JLG E450AJ Boom Lift
Part Number: 31220358
Publication Date: 2025
Number of Pages: 462 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. BATTERY BOX INSTALLATION - AGM BATTERIES​

FIGURE 1-2. BATTERY BOX INSTALLATION - STANDARD​

FIGURE 1-3. BATTERY CHARGER INSTALLATION (ANSI EXPORT AND CHINA SPECS)​

FIGURE 1-4. BATTERY CHARGER INSTALLATION (ALL SPECS EXCEPT AUSTRALIAN, CE, CHINA, RUSSIAN & UK CA SPECS) (Prior to SN 0300298657, Prior to SN E300017687)​

FIGURE 1-5. BATTERY CHARGER INSTALLATION (ALL SPECS EXCEPT AUSTRALIAN, CE, CHINA, RUSSIAN & UK CA SPECS) (SN 0300298657 to Present, SN E300017687 to Present)​

FIGURE 1-6. BATTERY CHARGER INSTALLATION (AUSTRALIAN SPEC) (Prior to SN 0300298657, Prior to SN E300017687)​

FIGURE 1-7. BATTERY CHARGER INSTALLATION (AUSTRALIAN SPEC) (SN 0300298657 to Present, SN E300017687 to Present)​

FIGURE 1-8. BATTERY CHARGER INSTALLATION (ANSI EXPORT, CE, RUSSIAN & UK CA SPECS) (Prior to SN 0300298657, Prior to SN E300017687)​

FIGURE 1-9. BATTERY CHARGER INSTALLATION (ANSI EXPORT, CE, RUSSIAN & UK CA SPECS) (SN 0300298657 to Present, SN E300017687 to Present)​

FIGURE 1-10. DRIVE INSTALLATION - NON-UL SPECS​

FIGURE 1-11. DRIVE INSTALLATION - UL SPECS​

FIGURE 1-12. DRIVE HUB ASSEMBLY​

FIGURE 1-13. DRIVE MOTOR ASSEMBLY​

FIGURE 1-14. ELECTRICAL PLATE ASSEMBLY - LH (NON-UL SPECS)​

FIGURE 1-15. ELECTRICAL PLATE ASSEMBLY - LH (UL SPECS)​

FIGURE 1-16. ELECTRICAL PLATE ASSEMBLY - RH (NON-UL SPECS)​

FIGURE 1-17. ELECTRICAL PLATE ASSEMBLY - RH (UL SPECS)​

FIGURE 1-18. FRAME COVER INSTALLATION​

FIGURE 1-19. INVERTER INSTALLATION​

FIGURE 1-20. INVERTER INSTALLATION (3000W)​

FIGURE 1-21. MOTOR/PUMP/TANK INSTALLATION - NON-UL SPECS​

FIGURE 1-22. MOTOR/PUMP/TANK INSTALLATION - UL SPECS​

FIGURE 1-23. MOTOR/PUMP/TANK INSTALLATION WITHOUT MOTOR BAND​

FIGURE 1-24. MOTOR/PUMP/TANK INSTALLATION WITH MOTOR BAND​

FIGURE 1-25. HYDRAULIC TANK ASSEMBLY (MACHINES WITH SN STARTING WITH 03)​

FIGURE 1-26. HYDRAULIC TANK ASSEMBLY (MACHINES WITH SN STARTING WITH B3)​

FIGURE 1-27. MOTOR/PUMP ASSEMBLY​

FIGURE 1-28. STEERING INSTALLATION (MACHINES WITH SN STARTING WITH 03)​

FIGURE 1-29. STEERING INSTALLATION (MACHINES WITH SN STARTING WITH B3)​

FIGURE 1-30. HUB - SPINDLE ASSEMBLY - LH​

FIGURE 1-31. HUB - SPINDLE ASSEMBLY - RH​

FIGURE 1-32. TIRE/WHEEL - IN240/55 - 17.5 FOAM FILLED​

FIGURE 1-33. TIRE/WHEEL - IN240/55-17.5 FOAM FILLED NON MARKING​

FIGURE 1-34. TIRE/WHEEL - 26 X 7 X 20 - SOLID NON MARKING​

FIGURE 1-35. VALVE INSTALLATION - FRAME MOUNTED​

FIGURE 1-36. BRAKE/STEER VALVE ASSEMBLY​

FIGURE 1-37. VOLTAGE GUARD 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. TURNTABLE BEARING AND SWING DRIVE INSTALLATION (ZJ MOTOR) (SN 0300299579 to Present, SN B300018364 to Present, Except SN 0300299590 through 0300299593, Excluding 0300299588, B300018377, B300018436, B300018437 and B300018436)​

FIGURE 2-8. SWING MOTOR ASSEMBLY​

FIGURE 2-9. SWING MOTOR ASSEMBLY (ZJ MOTOR)​

FIGURE 2-10. SWING BEARING ASSEMBLY​

FIGURE 2-11. REMOTE BEARING LUBE INSTALLATION - OPTIONAL​

FIGURE 2-12. DRIVE ORIENTATION INSTALLATION​

FIGURE 2-13. GROUND CONTROL BOX INSTALLATION (ALL SPECS EXCEPT CE, CHINA, RUSSIAN & UK CA SPECS) (Prior to SN 0300298657, Prior to SN E300017687)​

FIGURE 2-14. GROUND CONTROL BOX INSTALLATION (ALL SPECS EXCEPT CE, CHINA, RUSSIAN & UK CA SPECS) (SN 0300298657 to Present, SN E300017687 to Present)​

FIGURE 2-15. GROUND CONTROL BOX INSTALLATION (CE, CHINA, RUSSIAN & UK CA SPECS) (Prior to SN 0300298657, Prior to SN E300017687)​

FIGURE 2-16. GROUND CONTROL BOX INSTALLATION (CE, CHINA, RUSSIAN & UK CA SPECS) (SN 0300298657 to Present, SN E300017687 to Present)​

FIGURE 2-17. GROUND CONTROL BOX ELECTRICAL ASSEMBLY - DISPLAY WITH BUTTONS (ALL SPECS EXCEPT CE, CHINA, RUSSIAN & UK CA SPECS)​

FIGURE 2-18. GROUND CONTROL BOX ELECTRICAL ASSEMBLY - DISPLAY WITHOUT BUTTONS (ALL SPECS EXCEPT CE, CHINA, RUSSIAN & UK CA SPECS)​

FIGURE 2-19. GROUND CONTROL BOX ELECTRICAL ASSEMBLY - DISPLAY WITH BUTTONS (CE, CHINA, RUSSIAN & UK CA SPECS)​

FIGURE 2-20. GROUND CONTROL BOX ELECTRICAL ASSEMBLY - DISPLAY WITHOUT BUTTONS (CE, CHINA, RUSSIAN & UK CA SPECS)​

FIGURE 2-21. STROBE LIGHT INSTALLATION - AMBER (WITHOUT CLEARSKY BEACON) (Prior to SN 0300298657, Prior to SN E300017687)​

FIGURE 2-22. STROBE LIGHT INSTALLATION - AMBER (WITHOUT CLEARSKY BEACON) (SN 0300298657 to Present, SN E300017687 to Present)​

FIGURE 2-23. 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 (NON-UL SPECS)​

FIGURE 5-10. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION (UL SPECS)​

FIGURE 5-11. PLATFORM CONSOLE ASSEMBLY (NON-UL SPECS)​

FIGURE 5-12. PLATFORM CONSOLE ASSEMBLY (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. USB CHARGER 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. SKYSENSE MID TUBE SENSOR ASSEMBLY​

FIGURE 5-24. SKYSENSE OVERHEAD SENSOR ASSEMBLY​

FIGURE 5-25. SOFT-TOUCH 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) (Prior to SN 0300292776, SN 0300321238 through 0300321245, SN 0300321447 through 0300321781, Prior to SN B300002463, Except SN 0300286744 through 0300286748, Including 0300...​

FIGURE 6-6. LIFT CYLINDER ASSEMBLY - LOWER (MACHINES WITH SN STARTING WITH 03) (SN 0300286744 through 0300286748, SN 0300293054 through 0300320938, SN 0300320940 through 0300320945, SN 0300321246 through 0300321248, SN 0300321250 to Present, SN B30000...​

FIGURE 6-7. LIFT CYLINDER ASSEMBLY - LOWER (MACHINES WITH SN STARTING WITH B3)​

FIGURE 6-8. LIFT CYLINDER ASSEMBLY - MID (MACHINES WITH SN STARTING WITH 03) (Prior to SN 0300291339, SN 0300291343 through 0300291672, SN 0300291677 through 0300291682, Prior to SN B300002463, Except SN 0300286741 through 0300286748, Including 030029...​

FIGURE 6-9. LIFT CYLINDER ASSEMBLY - MID (MACHINES WITH SN STARTING WITH 03) (SN 0300286741 through 0300286748, SN 0300291676 to Present, SN B300002463 to Present, Except SN 0300291677 through 0300291682, Including 0300291339, 0300291342 and 0300291673)​

FIGURE 6-10. LIFT CYLINDER ASSEMBLY - MID (MACHINES WITH SN STARTING WITH B3)​

FIGURE 6-11. LIFT CYLINDER ASSEMBLY - UPPER (MACHINES WITH SN STARTING WITH 03)​

FIGURE 6-12. LIFT CYLINDER ASSEMBLY - UPPER (MACHINES WITH SN STARTING WITH B3)​

FIGURE 6-13. MASTER CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH 03)​

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

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

FIGURE 6-16. STEER CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH B3)​

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

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

FIGURE 6-19. COUNTERBALANCE VALVE ASSEMBLY​

SECTION 7 - HYDRAULIC

FIGURE 7-1. HYDRAULIC DIAGRAM​

SECTION 8 - ELECTRICAL

FIGURE 8-1. AC PLUGS AND SOCKETS INSTALLATION - AFSINT 107-2-01 KEYED GROUND - 2 X 4 BOX (CE & UK CA SPEC)​

FIGURE 8-2. AC PLUGS AND SOCKETS INSTALLATION - CEE7 POST GROUND (CE & UK CA SPEC)​

FIGURE 8-3. AC PLUGS AND SOCKETS INSTALLATION - CEE 7 SIDE GROUND (CE & UK CA SPEC)​

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

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

FIGURE 8-6. AC PLUGS AND SOCKETS INSTALLATION - IEC 60309 BLUE (CE & UK CA SPEC)​

FIGURE 8-7. AC PLUGS AND SOCKETS INSTALLATION - IEC 60309 YELLOW (CE & UK CA SPEC)​

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

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

FIGURE 8-10. BOOM CABLE - LOWER​

FIGURE 8-11. BOOM CABLE - UPPER​

FIGURE 8-12. BOOM LIMIT SWITCH HARNESS - LOWER​

FIGURE 8-13. BOOM LIMIT SWITCH HARNESS - UPPER​

FIGURE 8-14. BREAKER BOX KIT WITH ONE BREAKERS - CE & UK CA SPEC​

FIGURE 8-15. BREAKER BOX KIT WITH TWO BREAKERS - CE & UK CA SPEC​

FIGURE 8-16. CABLES AND CLAMPS INSTALLATION​

FIGURE 8-17. CHARGER HARNESS (Prior to SN 0300298657, Prior to SN E300017687)​

FIGURE 8-18. CHARGER HARNESS (SN 0300298657 to Present, SN E300017687 to Present)​

FIGURE 8-19. CHARGER CORD PLUG INSTALLATION - 110V - IEC 60309 - YELLOW (CE & UK CA SPEC)​

FIGURE 8-20. CHARGER CORD PLUG INSTALLATION - 220V - AFSINT 107 KEYED GROUND (CE & UK CA SPEC)​

FIGURE 8-21. CHARGER CORD PLUG INSTALLATION - 220V - CEE7 POST GROUND (CE & UK CA SPEC)​

FIGURE 8-22. CHARGER CORD PLUG INSTALLATION - 220V - CEE7 SIDE GROUND (CE & UK CA SPEC)​

FIGURE 8-23. CHARGER CORD PLUG INSTALLATION - 220V - IEC 60309 - BLUE (CE & UK CA SPEC)​

FIGURE 8-24. CHARGER DC CONNECTION HARNESS​

FIGURE 8-25. CHARGER EBOOM HARNESS (Prior to SN 0300298657, Prior to SN E300017687)​

FIGURE 8-26. CHASSIS TO TURNTABLE HARNESS​

FIGURE 8-27. CLEARSKY 3-WIRE TELEMATICS INSTALLATION (ALL SPECS UL & CHINA SPECS)​

FIGURE 8-28. CLEARSKY 3G CANBUS TELEMATICS INSTALLATION (ANSI EXPORT, CE & UK CA SPECS)​

FIGURE 8-29. CLEARSKY 3G CANBUS TELEMATICS INSTALLATION (AUSTRALIAN SPECS)​

FIGURE 8-30. CLEARSKY 4G CANBUS TELEMATICS INSTALLATION (ALL SPECS EXCEPT CHINA SPECS)​

FIGURE 8-31. CLEARSKY 4G CANBUS TELEMATICS INSTALLATION (CHINA SPECS)​

FIGURE 8-32. CLEARSKY CS550 BEACON INSTALLATION​

FIGURE 8-33. CLEARSKY HARNESS - 3-WIRE TELEMATICS​

FIGURE 8-34. CLEARSKY HARNESS - CANBUS TELEMATICS​

FIGURE 8-35. GROUND CONTROL PANEL HARNESS (Prior to SN 0300298657, Prior to SN E300017687)​

FIGURE 8-36. GROUND CONTROL PANEL HARNESS (SN 0300298657 to Present, SN E300017687 to Present)​

FIGURE 8-37. INVERTER HARNESS​

FIGURE 8-38. INVERTER IGNITION HARNESS​

FIGURE 8-39. LOWER BOOM 110V HARNESS ASSEMBLY​

FIGURE 8-40. LOWER BOOM 220V HARNESS ASSEMBLY​

FIGURE 8-41. PLATFORM CONSOLE HARNESS - WITH 1 CELL LSS (UL SPECS)​

FIGURE 8-42. PLUG AND RECEPTACLE INSTALLATION - SUPPLIED LOCALLY​

FIGURE 8-43. PLUG AND RECEPTACLE INSTALLATION - 110V​

FIGURE 8-44. PLUG AND RECEPTACLE INSTALLATION - 220V​

FIGURE 8-45. PLUG AND RECEPTACLE 110V INSTALLATION - IEC 60309 - YELLOW (CE & UK CA SPEC)​

FIGURE 8-46. PLUG AND RECEPTACLE 220V INSTALLATION - AFSINT 107 KEYED GROUND - 2 X 4 BOX (CE & UK CA SPEC)​

FIGURE 8-47. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 POST GROUND - 2 X 4 BOX (CE & UK CA SPEC)​

FIGURE 8-48. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 POST GROUND - 70MM X 70MM BOX (CE & UK CA SPEC)​

FIGURE 8-49. PLUG AND RECEPTACLE 220 INSTALLATION - CEE7 SIDE GROUND - 2 X 4 BOX (CE & UK CA SPEC)​

FIGURE 8-50. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 SIDE GROUND - 70MM X 70MM BOX (CE & UK CA SPEC)​

FIGURE 8-51. PLUG AND RECEPTACLE 220V INSTALLATION - IEC 60309 - BLUE (CE & UK CA SPEC)​

FIGURE 8-52. SKYEYE INTERMEDIATE HARNESS​

FIGURE 8-53. SKYEYE RECEIVER HARNESS​

FIGURE 8-54. SKYEYE EMITTER HARNESS​

FIGURE 8-55. SKYGUARD HARNESS - WITH 1 CELL LSS​

FIGURE 8-56. SKYLINE HARNESS​

FIGURE 8-57. STEER/BRAKE HARNESS​

FIGURE 8-58. STROBE LIGHT JUMPER HARNESS​

FIGURE 8-59. TRACTION HARNESS​

FIGURE 8-60. TURNTABLE HARNESS (Prior to SN 0300298657, Prior to SN E300017687)​

FIGURE 8-61. TURNTABLE HARNESS (SN 0300298657 to Present, SN E300017687 to Present)​

FIGURE 8-62. UPPER BOOM 110V HARNESS ASSEMBLY​

FIGURE 8-63. UPPER BOOM 220V HARNESS ASSEMBLY​

FIGURE 8-64. VALVE HARNESS (Prior to SN 0300298657, Prior to SN E300017687)​

FIGURE 8-65. VALVE HARNESS (SN 0300298657 to Present, SN E300017687 to Present)​

SECTION 9 - DECALS

FIGURE 9-1. DECAL INSTALLATION - ANSI, ANSI EXPORT 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, CHINA & & UK CA 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/ACCESORIES/KITS​

PART NUMBER INDEX