JLG Boom Lift E450AJ Parts Manual 3122558700

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JLG Boom Lift E450AJ Parts Manual 3122558700
Size: 30.74 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Manual
Model: JLG E450AJ Boom Lift
Part Number: 3122558700
Publication Date: 2025
Number of Pages: 468 Pages

Contents:
SECTION 1 - FRAME

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

FIGURE 1-2. BATTERY BOX INSTALLATION - AGM BATTERIES (6V)​

FIGURE 1-3. BATTERY BOX INSTALLATION - STANDARD​

FIGURE 1-4. BATTERY CHARGER INSTALLATION (ANSI EXPORT AND CHINA SPECS)​

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

FIGURE 1-6. BATTERY CHARGER INSTALLATION (AUSTRALIAN SPEC)​

FIGURE 1-7. BATTERY CHARGER INSTALLATION (GREEN POWER)​

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

FIGURE 1-9. DRIVE INSTALLATION - NON-UL SPECS​

FIGURE 1-10. DRIVE INSTALLATION - UL SPECS​

FIGURE 1-11. DRIVE HUB ASSEMBLY​

FIGURE 1-12. DRIVE MOTOR ASSEMBLY​

FIGURE 1-13. ELECTRICAL PLATE ASSEMBLY - LH (NON-UL SPECS)​

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

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

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

FIGURE 1-17. FRAME COVER INSTALLATION​

FIGURE 1-18. INVERTER INSTALLATION​

FIGURE 1-19. INVERTER (2000W/60HZ) 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​

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 OR C3)​

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 (Except SN B300029590 through B300029593, Except SN B300029624 through B300029628, Excluding C300001330, C300001363 and C300001343)​

FIGURE 1-36. VALVE INSTALLATION - FRAME MOUNTED (Except SN 0300332981 through 0300332983, Excluding 0300332992 and 0300332993)​

FIGURE 1-37. BRAKE/STEER VALVE ASSEMBLY​

FIGURE 1-38. VOLTAGE GUARD INSTALLATION​

SECTION 2 - TURNTABLE

FIGURE 2-1. VALVE INSTALLATION - TURNTABLE MOUNTED (Except SN B300029590 through B300029593, Except SN B300029624 through B300029628, Excluding C300001330, C300001363 and C300001343)​

FIGURE 2-2. VALVE INSTALLATION - TURNTABLE MOUNTED (Except SN 0300332981 through 0300332983, Excluding 0300332992 and 0300332993)​

FIGURE 2-3. MAIN CONTROL VALVE ASSEMBLY​

FIGURE 2-4. RELEVELING VALVE ASSEMBLY (Except SN B300029590 through B300029593, Except SN B300029624 through B300029628, Excluding C300001330, C300001363 and C300001343)​

FIGURE 2-5. JIB VALVE ASSEMBLY (Except SN B300029590 through B300029593, Except SN B300029624 through B300029628, Excluding C300001330, C300001363 and C300001343)​

FIGURE 2-6. JIB VALVE ASSEMBLY (Except SN 0300332981 through 03003322983, Excluding 0300332992 and 0300332993)​

FIGURE 2-7. MOTION ALARM INSTALLATION​

FIGURE 2-8. TURNTABLE BEARING AND SWING DRIVE INSTALLATION​

FIGURE 2-9. SWING BEARING ASSEMBLY​

FIGURE 2-10. SWING MOTOR 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)​

FIGURE 2-14. GROUND CONTROL BOX ELECTRICAL ASSEMBLY - DISPLAY WITHOUT BUTTONS (ALL SPECS EXCEPT CE, CHINA, RUSSIAN & UK CA SPECS)​

FIGURE 2-15. GROUND CONTROL BOX ELECTRICAL ASSEMBLY - DISPLAY WITHOUT BUTTONS (CE, CHINA, RUSSIAN & UK CA SPECS)​

FIGURE 2-16. GROUND CONTROL BOX ELECTRICAL ASSEMBLY - DISPLAY WITHOUT BUTTONS (ALL SPECS EXCEPT CE & UK CA SPECS)​

FIGURE 2-17. STROBE LIGHT INSTALLATION - AMBER​

FIGURE 2-18. BEACON LIGHT INSTALLATION (BLUE)​

FIGURE 2-19. BEACON LIGHT INSTALLATION (RED)​

FIGURE 2-20. HOOD PLUGS INSTALLATION​

FIGURE 2-21. 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. BOOM AND CYLINDERS INSTALLATION (CHINA SPEC)​

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

FIGURE 4-5. MAIN BOOM ASSEMBLY (MACHINES WITH SN STARTING WITH B3)​

FIGURE 4-6. MAIN BOOM ASSEMBLY (CHINA SPEC)​

FIGURE 4-7. JIB INSTALLATION (MACHINES WITH SN STARTING WITH B3)​

FIGURE 4-8. JIB INSTALLATION (MACHINES WITH SN STARTING WITH 03)​

FIGURE 4-9. ROTATOR ASSEMBLY - PLATFORM​

FIGURE 4-10. BOOM LIMIT SWITCHES INSTALLATION​

SECTION 5 - PLATFORM

FIGURE 5-1. TRADITIONAL PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH FALL ARREST (ALL SPECS EXCEPT CE ,AUSTRALIAN, JAPANESE, CIS SPECS) (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-2. TRADITIONAL PLATFORM ASSEMBLY - 30IN X 5FT (76.2CM X 1.52M) WITH FALL ARREST (ALL SPECS EXCEPT CE, JAPANESE, CIS, & AUSTRALIAN SPECS) (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-3. TRADITIONAL PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH FALL ARREST (ANSI EXPORT OR CSA SPECS) (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-4. TRADITIONAL PLATFORM ASSEMBLY - 30IN X 5FT (76.2CM X 1.52M) WITH FALL ARREST (ANSI EXPORT AND CSA SPECS) (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-5. RAPID REPLACEABLE PLATFORM (30IN X 4FT (76.2CM X 1.22M) (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-6. RAPID REPLACEABLE PLATFORM (30IN X 5FT (76.2CM X 1.52M) (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-7. RAPID REPLACEABLE PLATORM (30IN X 6FT) (76.2CM X 1.82M) (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-8. RAPID REPLACEABLE PLATFORM SUPPORT (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-9. RAPID REPLACEABLE PLATFORM SUPPORT (MACHINES WITH SN STARTING WITH B3 & C3)​

FIGURE 5-10. RAPID REPLACEABLE PLATFORM (30IN X 4FT (76.2CM X 1.22M) (MACHINES WITH SN STARTING WITH B3 & C3)​

FIGURE 5-11. RAPID REPLACEABLE PLATFORM (30IN X 5FT (76.2CM X 1.52M) (MACHINES WITH SN STARTING WITH B3 OR C3)​

FIGURE 5-12. RAPID REPLACEABLE PLATFORM (30IN X 6FT) (76.2CM X 1.83M) (MACHINES WITH SN STARTING WITH B3 OR C3)​

FIGURE 5-13. PLATFORM - SWING GATE INSTALLATION (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-14. PLATFORM - DROP BAR INSTALATION (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-15. PLATFORM SWING GATE INSTALLATION (MACHINES WITH SN STARTING WITH B3 OR C3)​

FIGURE 5-16. PLATFORM DROP BAR INSTALLATION (MACHINES WITH SN STARTING WITH B3 OR C3)​

FIGURE 5-17. PLATFORM CONTROL AND FOOTSWITH INSTALLATION - NON-UL LISTED​

FIGURE 5-18. PLATFORM CONTROL AND FOOTSWITH INSTALLATION - UL LISTED (MACHINES WITH SN STARTING WITH 03)​

FIGURE 5-19. PLATFORM CONSOLE ASSEMBLY - NON UL LISTED​

FIGURE 5-20. PLATFORM CONSOLE ASSEMBLY - UL LISTED​

FIGURE 5-21. PLATFORM BEACON INSTALLATION​

FIGURE 5-22. LIGHT PANEL INSTALLATION​

FIGURE 5-23. JIB SWITCH INSTALLATION​

FIGURE 5-24. FOOTSWITCH ASSEMBLY​

FIGURE 5-25. USB CHARGER INSTALLATION​

FIGURE 5-26. TRAY ASSEMBLY​

FIGURE 5-27. SKYEYE INSTALLATION​

FIGURE 5-28. SKYGUARD BAR INSTALLATION​

FIGURE 5-29. SKYLINE INSTALLATION​

FIGURE 5-30. SKYSENSE MID TUBE SENSOR ASSEMBLY​

FIGURE 5-31. SKYSENSE OVERHEAD SENSOR ASSEMBLY​

FIGURE 5-32. SOFT-TOUCH INSTALLATION​

SECTION 6 - CYLINDER

FIGURE 6-1. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH B3)​

FIGURE 6-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH 03)​

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)​

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

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

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

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

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

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

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

FIGURE 6-17. 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. BREAKER BOX KIT WITH ONE BREAKER​

FIGURE 8-17. CABLES AND CLAMPS INSTALLATION​

FIGURE 8-18. CLEARSKY CS550 BEACON INSTALLATION​

FIGURE 8-19. CHARGER HARNESS​

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

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

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

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

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

FIGURE 8-25. CHARGER DC CONNECTION HARNESS​

FIGURE 8-26. CHASSIS TO TURNTABLE HARNESS​

FIGURE 8-27. GROUND CONTROL PANEL HARNESS​

FIGURE 8-28. STROBE LIGHT JUMPER HARNESS​

FIGURE 8-29. VALVE HARNESS​

FIGURE 8-30. INVERTER HARNESS​

FIGURE 8-31. INVERTER IGNITION HARNESS​

FIGURE 8-32. INVERTER IGNITION HARNESS​

FIGURE 8-33. LOWER BOOM 110V HARNESS ASSEMBLY​

FIGURE 8-34. LOWER BOOM 220V HARNESS ASSEMBLY​

FIGURE 8-35. PLATFORM CONSOLE HARNESS - WITH 1 CELL LSS (UL SPECS)​

FIGURE 8-36. PLATFORM BEACON HARNESS​

FIGURE 8-37. PLUG AND RECEPTACLE INSTALLATION - SUPPLIED LOCALLY​

FIGURE 8-38. PLUG AND RECEPTACLE INSTALLATION - 110V​

FIGURE 8-39. PLUG AND RECEPTACLE INSTALLATION - 220V​

FIGURE 8-40. PLUG AND RECEPTACLE 110V INSTALLATION - IEC 60309 - YELLOW (CE & UK CA SPEC)​

FIGURE 8-41. PLUG AND RECEPTACLE 220V INSTALLATION - AFSINT 107 KEYED GROUND - 2 X 4 BOX (CE & UK CA SPEC)​

FIGURE 8-42. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 POST GROUND - 2 X 4 BOX (CE & UK CA SPEC)​

FIGURE 8-43. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 POST GROUND - 70MM X 70MM BOX (CE & UK CA SPEC)​

FIGURE 8-44. PLUG AND RECEPTACLE 220 INSTALLATION - CEE7 SIDE GROUND - 2 X 4 BOX (CE & UK CA SPEC)​

FIGURE 8-45. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 SIDE GROUND - 70MM X 70MM BOX (CE & UK CA SPEC)​

FIGURE 8-46. PLUG AND RECEPTACLE 220V INSTALLATION - IEC 60309 - BLUE (CE & UK CA SPEC)​

FIGURE 8-47. PLUG & RECEPTACLE 220V - CEE7 POST GROUND 2X4 BOX (CE, GB, & CIS SPECS)​

FIGURE 8-48. PLUG & RECEPTACLE 220V - AFSINT 107 KEYED GROUND 2X4 BOX (CE, GB, & CIS SPECS)​

FIGURE 8-49. SKYEYE INTERMEDIATE HARNESS​

FIGURE 8-50. SKYEYE RECEIVER HARNESS​

FIGURE 8-51. SKYEYE EMITTER HARNESS​

FIGURE 8-52. SKYGUARD HARNESS - WITH 1 CELL LSS​

FIGURE 8-53. SKYLINE HARNESS​

FIGURE 8-54. STEER/BRAKE HARNESS​

FIGURE 8-55. TRACTION HARNESS​

FIGURE 8-56. TURNTABLE HARNESS​

FIGURE 8-57. UPPER BOOM 110V HARNESS ASSEMBLY​

FIGURE 8-58. UPPER BOOM 220V HARNESS ASSEMBLY​

FIGURE 8-59. USB HARNESS​

FIGURE 8-60. WORKLIGHT HARNESS​

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​

FIGURE 9-15. DROP BAR - FALL ARREST DECAL INSTALLATION​

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