Jlg E45A_AJ ANSI Service Manual User Manual

SERVICE & MAINTENANCE Models M45A M45AJ E45A E45AJ 3120765 February 15, 2000 AUSTRALIAN OFFICE JLG INDUSTRIES, INC. P.O. Box 5119 11 Bolwarra Ro

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 3120765Ground Bearing PressureM45A, E45A - 95 psi (6.2 Bar)M45AJ, E45AJ - 110 psi (7.6 Bar)Machine Height (

SECTION 3 - TROUBLESHOOTING3-4 – JLG Lift – 3120765.Table 3-2.Boom Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYCONTROL VALVESValve spool st

SECTION 3 - TROUBLESHOOTING3120765 – JLG Lift – 3-5Restricted or broken supply line on valve bank or hydraulic pump.Clean or replace line.Directional

SECTION 3 - TROUBLESHOOTING3-6 – JLG Lift – 3120765Function Speed and Drive Speed does not operate below horizontal.Damaged wiring on level limit swit

SECTION 3 - TROUBLESHOOTING3120765 – JLG Lift – 3-7Boom extends and retracts erratically.Hydraulic system oil low. Replenish oil as necessary.Wear pad

SECTION 3 - TROUBLESHOOTING3-8 – JLG Lift – 3120765Boom swings erratically in either direction.Hydraulic system oil low. Replenish oil as necessary.La

SECTION 3 - TROUBLESHOOTING3120765 – JLG Lift – 3-9.Table 3-3.Turntable Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYCONTROL VALVE.Valve Spo

SECTION 3 - TROUBLESHOOTING3-10 – JLG Lift – 3120765.Table 3-4.Chassis Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYGENERATOR.Engine will no

SECTION 3 - TROUBLESHOOTING3120765 – JLG Lift – 3-11FRONT FRAME AXLE AREA.One or both wheels will not steer.Steering link or tie rod broken or attachi

SECTION 3 - TROUBLESHOOTING3-12 – JLG Lift – 3120765Joystick not functioning properly. Replace joystick/Run System Test.Charger plugged in. Check help

SECTION 3 - TROUBLESHOOTING3120765 – JLG Lift – 3-13Proportional Flow Valve not functioning properly. Repair or replace valve.Hydraulic pump not funct

SECTION 1 - SPECIFICATIONS3120765 – JLG Lift – 1-31.6 TORQUE SPECIFICATIONS1.7 LUBRICATIONHydraulic OilNOTE: Hydraulic oils must have anti-wear qualit

SECTION 3 - TROUBLESHOOTING3-14 – JLG Lift – 3120765Brake Drags or runs hot.Low actuation pressure. Place pressure gauge in bleed port & check pre

SECTION 3 - TROUBLESHOOTING3120765 – JLG Lift – 3-15.Table 3-5.Hydraulic System - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYHYDRAULIC SYSTEMS - GENE

SECTION 3 - TROUBLESHOOTING3-16 – JLG Lift – 3120765Function sluggish during operation. (System pressure too low.)Main relief valve set too low. Reset

SECTION 3 - TROUBLESHOOTING3120765 – JLG Lift – 3-17.Table 3-6.Electrical System - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYPLATFORM CONTROLS.No po

SECTION 3 - TROUBLESHOOTING3-18 – JLG Lift – 3120765Hourmeter inoperative.Damaged wiring in hourmeter circuit. Repair or replace wiring.Inoperative ho

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SECTION 3 - TROUBLESHOOTING3-20 – JLG Lift – 3120765Figure 3-1. Electrical Components Installation - Sheet 1

SECTION 3 - TROUBLESHOOTING3120765 – JLG Lift – 3-21Figure 3-2. Electrical Components Installation - Sheet 2

SECTION 3 - TROUBLESHOOTING3-22 – JLG Lift – 3120765Figure 3-3. Platform Electrical Schematic - Sheet 1 of 2

SECTION 3 - TROUBLESHOOTING3120765 – JLG Lift – 3-23Figure 3-4. Platform Electrical Schematic - Sheet 2 of 21870072D

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31207651.8 PRESSURE SETTINGSMain ValveUpper Lift Down Relief - 550 psi (38 bar)Mid/Lower Lift Down Relief -

SECTION 3 - TROUBLESHOOTING3-24 – JLG Lift – 31207651870072DFigure 3-5. Turntable Electrical Schematic

SECTION 3 - TROUBLESHOOTING3120765 – JLG Lift – 3-251870072DFigure 3-6. Frame Electrical Schematic

SECTION 3 - TROUBLESHOOTING3-26 – JLG Lift – 3120765Figure 3-7. On Board Generator Electrical Schematic1870072D

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SECTION 3 - TROUBLESHOOTING3-28 – JLG Lift – 3120765Figure 3-8. Hydraulic Schematic - M45A/E45A - Sheet 1 of 2

SECTION 3 - TROUBLESHOOTING3120765 – JLG Lift – 3-292792337CFigure 3-9. Hydraulic Schematic - M45A/E45A - Sheet 2 of 2

SECTION 3 - TROUBLESHOOTING3-30 – JLG Lift – 31207652792337AFigure 3-10. Hydraulic Schematic - M45AJ/E45AJ - Sheet 1 of 2

SECTION 3 - TROUBLESHOOTING3120765 – JLG Lift – 3-312792337CFigure 3-11. Hydraulic Schematic - M45AJ/E45AJ - Sheet 2 of 2

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SECTION 1 - SPECIFICATIONS3120765 – JLG Lift – 1-51.12 SERIAL NUMBER LOCATIONSFor machine identification, a serial number plate is affixedto the left

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Customer Support Toll Free:

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 3120765Figure 1-2. Torque Chart

SECTION 1 - SPECIFICATIONS3120765 – JLG Lift – 1-7Figure 1-3. Lubrication Diagram

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 3120765Table 1-8. Lubrication ChartComponentsNumber/TypeLube PointsCapacity LubeInterval HoursComments3 Mon

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-1SECTION 2. PROCEDURES2.1 GENERALThis section provides information necessary to performmaintenance on th

SECTION 2 - PROCEDURES2-2 – JLG Lift – 3120765Bearings1. When a bearing is removed, cover it to keep out dirtand abrasives. Clean bearings in nonflamm

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-32.3 LUBRICATION INFORMATIONHydraulic System1. The primary enemy of a hydraulic system is contam-ination.

SECTION 2 - PROCEDURES2-4 – JLG Lift – 31207652.4 BATTERY MAINTENANCE AND CHARGINGBattery Maintenance, Quarterly1. Open battery compartment cover to a

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-5Figure 2-1. On Board Generator

SECTION 2 - PROCEDURES2-6 – JLG Lift – 3120765NOTE: The engine will automatically shut down under thefollowing conditions:High Engine Oil TemperatureL

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-7Holding valves are used in the Lift circuits to preventretraction of the cylinder rod should a hydraulic

SECTION 2 - PROCEDURES2-8 – JLG Lift – 31207652. When working on the platform slave cylinder, strokeplatform slave level cylinder forward until platfo

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-9EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL-INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OF

SECTION 2 - PROCEDURES2-10 – JLG Lift – 31207659. Inspect cylinder head inside diameter for scoring orother damage and for ovality and tapering. Repla

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-113. Place a new o-ring and back-up seal in the applica-ble outside diameter groove of the cylinder head.

SECTION 2 - PROCEDURES2-12 – JLG Lift – 312076511. Assemble the tapered bushing loosely into the pis-ton and insert JLG capscrews (not vendor cap-scre

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-1317. Position the cylinder barrel in a suitable holding fix-ture.EXTREME CARE SHOULD BE TAKEN WHEN INSTA

INTRODUCTION3120765 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 2 - PROCEDURES2-14 – JLG Lift – 31207652.8 CYLINDER REMOVAL AND INSTALLATIONUpper (Main) Boom Lift Cylinder Removal1. Place the machine on a f

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-15Mid Boom Lift Cylinder Installation.NOTE: Coat I.D. of bushings with specified lubricant prior toinstal

SECTION 2 - PROCEDURES2-16 – JLG Lift – 3120765Upper Boom Telescope Cylinder Removal1. Place machine on flat and level surface, with UpperBoom in the

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-172.9 WEAR PADS1. Shim up wear pads until snug to adjacent surface.2. Replace wear pads when worn to thic

SECTION 2 - PROCEDURES2-18 – JLG Lift – 3120765Figure 2-21. Platform Components and Attaching Hardware (M45A & E45A)

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-19d. Remove hardware securing the lift cylinder pin#1. Using a suitable brass drift and hammer,remove pin

SECTION 2 - PROCEDURES2-20 – JLG Lift – 31207657. Using a piece of tape, mark the length of hoses andwires from front of fly boom and bottom of basebo

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-216. Using suitable lifting equipment, slide fly boom sec-tion out to gain access to telescope cylinder a

SECTION 2 - PROCEDURES2-22 – JLG Lift – 3120765Figure 2-23. Rotator Assembly (Helac)

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-234. Place two (2) 3/8"x16NC bolts in threaded holes inbottom of the actuator. Using a suitable bar,

INTRODUCTIONA-2 – JLG Lift – 3120765REVISON LOGMay 15, 1999 - Original IssueJuly 1, 1999 - RevisedAugust 1, 1999 - Revised2-40 - Updated 8-30-991-1 an

SECTION 2 - PROCEDURES2-24 – JLG Lift – 3120765AssemblyNOTE: Lubricate all seals and o-rings with clean hydraulicoil prior to assembly.1. Install new

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-25Figure 2-28. Boom Limit Switches

SECTION 2 - PROCEDURES2-26 – JLG Lift – 31207652.13 ARTICULATING JIB BOOMRemoval1. For platform/support removal see platform/supportremoval diagram. S

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-27mallet, install pivot pin #2 into fly boom assemblyand secure with mounting hardware.7. Align the slave

SECTION 2 - PROCEDURES2-28 – JLG Lift – 31207654. If a difference less than 0.057 in. (1.40 mm) is deter-mined, and any of the following conditions ex

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-29attach the outer race of the bearing to the frame.Discard the bolts. Use suitable lifting equipmentto r

SECTION 2 - PROCEDURES2-30 – JLG Lift – 31207652. If tolerance exceeds .010", reduce end play to lessthan .005". Refer to Adjusting End Play

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-31Figure 2-34. Swing Components

SECTION 2 - PROCEDURES2-32 – JLG Lift – 31207652.15 MID AND LOWER LIFT CYLINDER BLEEDING PROCEDURENOTE: Bleeding procedure should only be necessary if

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-33Figure 2-35. Drive Hub - Cutaway

3120765 – JLG Lift – i TABLE OF CONTENTSTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION A - INTRODUCTION - MAINTENANCE SA

SECTION 2 - PROCEDURES2-34 – JLG Lift – 31207652.18 DRIVE BRAKE - MICODisassembly1. Remove pressure plate (3) from cover (21) byremoving cap screws (1

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-35Figure 2-36. Drive Brake - Mico

SECTION 2 - PROCEDURES2-36 – JLG Lift – 31207652.19 PINS AND GAR-MAX BEARING REPAIR GUIDELINESFilament wound bearings.1. Pinned joints should be disas

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-37Figure 2-37. Speed Sensor Orientation

SECTION 2 - PROCEDURES2-38 – JLG Lift – 3120765Figure 2-38. Frame Mounted Electrical Components

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-39Figure 2-39. Steering Components and Spindles

SECTION 2 - PROCEDURES2-40 – JLG Lift – 31207652.21 FOOTSWITCH ADJUSTMENTAdjust switch so that functions will operate when pedal isat center of travel

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-414. Use Up/Down arrow keys to enter the followingpassword "33271". Depress Enter.5. Use the ri

SECTION 2 - PROCEDURES2-42 – JLG Lift – 3120765Platform Level Up Relief1. With pressure gauge at “G” port on main valve, acti-vate and bottom out Plat

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-43Figure 2-43. Brake/Steer Valve Components

ii – JLG Lift – 3120765TABLE OF CONTENTS LIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. Serial Number Locations. . . . .

SECTION 2 - PROCEDURES2-44 – JLG Lift – 3120765Figure 2-44. Main Valve Components

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-452.24 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONSIntroductionWHEN INSTALLING A NEW POWER MODULE CONTROL

SECTION 2 - PROCEDURES2-46 – JLG Lift – 3120765The upper lift, swing, and drive are controlled by individualjoysticks, with steering being controlled

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-47The top level menus are as follows:HELPDIAGNOSTICSACTIVATE TESTACCESS LEVELPERSONALITIESMACHINE SETUPLE

SECTION 2 - PROCEDURES2-48 – JLG Lift – 3120765Once the correct password is displayed, press ENTER.The access level should display the following, if t

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-49Machine SetupWhen a machine digit item is selected, press the UP orDOWN arrow keys to adjust its value,

SECTION 2 - PROCEDURES2-50 – JLG Lift – 3120765Machine Personality Settings NOTE: Personality settings can be adjusted within theadjustment range in o

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-51SWING ACCELeration 0.5 to 5.0s 2.7DECELeration 0.0 to 3.0s 1.8MINimum LEFT speed 0 to 10% 1MAXimum LEFT

SECTION 2 - PROCEDURES2-52 – JLG Lift – 3120765JIB ACCELeration 0.5 to 5.0 1.5DECELeration 0.5 to 3.0 0.5MINimum UP speed 0 to 50 9MAXimum UP speed 0

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-53Machine Configuration Programming InformationNOTE: The following information is to be used when working

3120765 – JLG Lift – iii TABLE OF CONTENTSLIST OF FIGURES (continued)FIGURE NO. TITLE PAGE NO.3-1. Electrical Components Installation

SECTION 2 - PROCEDURES2-54 – JLG Lift – 31207653= Motion Alarm - Sounds when any function isactive (Option)7. PLATFORM ALARM0= Sounds continuously whe

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-55Table 2-8. Help Descriptions and Fault Flash CodesFlash Code DescriptionNo flash code is indicated for

SECTION 2 - PROCEDURES2-56 – JLG Lift – 31207652/2Flash code 2/2 indicates problems with drive & steer selection.DRIVE JOYSTICK FAULTYThe drive jo

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-572/5Flash code 2/5 indicates that a function is prevented due to a cutout.BOOM PREVENTED - DRIVE SELECTE

SECTION 2 - PROCEDURES2-58 – JLG Lift – 31207653/3Flash code 3/3 indicates that a contactor coil is short-circuited.OVERLOADED VALVE SUPPLY-CHECK WIRI

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-596/6Flash code 6/6 indicates problems with the CANbus.48V PROTECTION TRIPPED - CHECK INTER-MODULE WIRING

SECTION 2 - PROCEDURES2-60 – JLG Lift – 31207659/9Flash code 9/9 indicates problems with the controller.POWER MODULE FAILURE: CONTACTOR DRIVE CODE 1 A

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-61Figure 2-46. Analyzer Flow Chart - Sheet 1 of 2

SECTION 2 - PROCEDURES2-62 – JLG Lift – 3120765Figure 2-47. Analyzer Flow Chart - Sheet 2 of 2

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-63Analyzer Diagnostics Menu Structure In the following structure descriptions, an intended item isselecte

iv – JLG Lift – 3120765TABLE OF CONTENTS This Page Left Blank Intentionally.

SECTION 2 - PROCEDURES2-64 – JLG Lift – 3120765TILT . . . Displays measured vehicle tilt The first value indicates tilt in die forwards reverse direct

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-65System Self TestThe system self test is utilized to locate typical problems.See Table 2-10, System Test

SECTION 2 - PROCEDURES2-66 – JLG Lift – 3120765Table 2-11. System Test MessagesRUNNING Initial display when system test is run; certain "critica

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-67TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized and de-e

SECTION 2 - PROCEDURES2-68 – JLG Lift – 3120765CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it i

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-69TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed, the system test end

SECTION 2 - PROCEDURES2-70 – JLG Lift – 31207652.25 GENERATORNOTE: Throughout the Generator section, the abbreviationsRBS and CTS are used. RBS stands

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-71Figure 2-48. Generator Components

SECTION 2 - PROCEDURES2-72 – JLG Lift – 3120765Timing Sequences• RBS Prestart Sequence1. Time Delay Engine Start (TDES)TDES is the period which the RB

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-73To Connect the JLG Control System Analyzer to the GeneratorThe JLG Control System Analyzer can be used

SECTION 1 - SPECIFICATIONS3120765 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESHydraulic Oil Tank5 gallons (19 liters)Generator Fuel Tank4

SECTION 2 - PROCEDURES2-74 – JLG Lift – 3120765Figure 2-49. Generator System Analyzer Flow Chart

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-75• OverspeedIf the engine speed exceeds the overspeed limit, theengine will stop immediately and an over

SECTION 2 - PROCEDURES2-76 – JLG Lift – 31207652.26 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULEThe preventive maintenance and inspection checks are

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-77Table 2-16.Preventive Maintenance and Inspection ScheduleAREADAILY WEEKLYINTERVALMONTHLY 3 MONTH 6 MONT

SECTION 2 - PROCEDURES2-78 – JLG Lift – 3120765TURNTABLE1.Engine Oil (see mfg. manual)352.Battery353.Radiator354.Air Cleaner1145.Exhaust System11,56.S

SECTION 2 - PROCEDURES3120765 – JLG Lift – 2-79 CHASSIS1.Wheel and Tire Assembly18,9,152.Drive Motors1,5,63.Drive Torque Hubs**1,5,6 34.Drive Brakes1

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SECTION 3 - TROUBLESHOOTING3120765 – JLG Lift – 3-1SECTION 3. TROUBLESHOOTING3.1 GENERALThis section contains troubleshooting information to beused f

SECTION 3 - TROUBLESHOOTING3-2 – JLG Lift – 3120765.Table 3-1.Platform Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYAutomatic leveling inope

SECTION 3 - TROUBLESHOOTING3120765 – JLG Lift – 3-3Proportional Flow Regulator not powered. Check wiring/Run System Test.Personalities not set correct