Jlg M450 Service Manual User Manual

Service and Maintenance ManualModelE450AE450AJM450AM450AJP/N - 3121829March 20, 2014

vi – JLG Lift – 3121829TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-60 – JLG Lift – 31218293.13 GENERATOR (S/N 88539 TO PRESENT)NOTE: Throughout the Generator section, the abbreviat

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-617131012118971211105412631314Figure 3-22. Generator8. Temperature Sensor9. Voltage Regulat

SECTION 3 - CHASSIS & TURNTABLE3-62 – JLG Lift – 3121829Start BatteryThe RBS requires a 12V lead-acid start battery (not sup-plied with the system

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-63Fuel Control RelayThe fuel control relay energizes the hold coil of the fuelsolenoid.The

SECTION 3 - CHASSIS & TURNTABLE3-64 – JLG Lift – 3121829Fuel PumpThe fuel pump runs in parallel with the fuel solenoid holdcoil which is run by th

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-65engine. The signal is also used in determining if the airglow plug should be energized.The

SECTION 3 - CHASSIS & TURNTABLE3-66 – JLG Lift – 3121829Warnings and Safety PrecautionsTHE RBS MAY START WITHOUT WARNING.MORE THAN ONE LIVE CIRCUI

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-67RBS Start RBS shutdownCall to start Manual 48V DC applied to the inputAutomatic 1 Low

SECTION 3 - CHASSIS & TURNTABLE3-68 – JLG Lift – 3121829RBS Alarms and Flash CodesIn the event of an RBS alarm, a flash code will be issuedand an

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-69TroubleshootingTable 3-11. TroubleshootingFlash Code Problem Solution- Unit Off / Disable

3121829 – JLG Lift – vii LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-70 – JLG Lift – 3121829APU Engine Start Battery BoostingAlways connect the POSITIVE (+) of the booster batteryto

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-713.14 SUPPLEMENTARY FUSE FOR APUThe purpose of this section is to describe the procedure to

SECTION 3 - CHASSIS & TURNTABLE3-72 – JLG Lift – 3121829that the cable sleeve can be moved, exposing theconductors of the harness.5. Cut wire 106

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOM MAINTENANCERemoval1. Remove the platform/support as fol

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 31218294. Remove hardware securing telescope cylinder #1 tothe fly boom section, then remove pin from

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-36. Using suitable lifting equipment, slide fly boom sec-tion out to gain access to telescope cy

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 31218294.2 UPPER (MAIN) BOOM LIFT CYLINDERRemoval1. Place the machine on a flat and level surface. Pla

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-5InstallationNOTE: Coat I.D. of bushings with specified lubricant prior toinstalling pins.1. Wit

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 31218294.5 UPPER BOOM TELESCOPE CYLINDERRemoval1. Place machine on flat and level surface, with UpperB

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-74.6 WEAR PADS1. Shim up wear pads until snug to adjacent surface.2. Replace wear pads when worn

viii – JLG Lift – 3121829LIST OF FIGURES FIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 3121829A,B,DC,DABCDTorque to 50 ft.lbs. (68 Nm)Loctite #242Torque 250-270 ft. lbs. (339-366 Nm)Check t

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-9Figure 4-8. Boom Limit Switches

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 3121829Figure 4-9. Platform Components and Attaching Hardware (M450A & E450A)

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-114.8 ARTICULATING JIB BOOMRemoval1. For platform/support removal see platform/supportremoval di

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 31218293. Align bottom tubes with attach holes in rotator sup-port. Using a soft head mallet, install

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-134.12 HELAC ROTARY ACTUATORTheory Of OperationThe rotary actuator is a simple mechanism that us

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 31218291. Housi ng2. Shaft3. Piston Sleeve4. End Ca p109. Lock Pin113. Cap Sc

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-151. Housing2. Shaft3. Piston Sleeve4. End Cap109. Lock Pin113. Cap Scre

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 3121829Disassembly1. Remove the cap screws (113) over end cap lockpins (109).2. Using a 1/8” (3.18mm)

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-177. Remove the stop tube if included. The stop tube isan available option to limit the rotation

3121829 – JLG Lift – ix LIST OF FIGURESFIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 312182912. To remove the piston (3) use a rubber mallet and aplastic mandrel so the piston is no dama

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-1918. Remove the wiper seal (304.1) from its groove in theend cap (4) and shaft (2).19. Remove t

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 3121829Assembly1. Gather all the components and tools into one loca-tion prior to re-assembly. Use th

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-216. Install the inner T-seal (200) into the piston (3) usinga circular motion. Install the oute

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 312182910. Looking from the opposite end of the housing (1)you can see if your timing marks are linin

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-2316. Install the O-ring (204) and back-up ring (207) intothe inner seal groove on the end cap (

SECTION 4 - BOOM & PLATFORM4-24 – JLG Lift – 3121829Installing Counterbalance ValveRefer to Figure 4-14., Rotator Counterbalance Valve.1. Make sur

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-25Figure 4-14. Rotator Counterbalance Valve

SECTION 4 - BOOM & PLATFORM4-26 – JLG Lift – 3121829Installation and BleedingAfter installation of the actuator on the equipment, it isimportant t

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-27TroubleshootingTable 4-1. TroubleshootingProblem Cause Solution1. Shaft rotates slowly or not

x – JLG Lift – 3121829LIST OF TABLES TABLE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-28 – JLG Lift – 31218294.13 POWERTRACK MAINTENANCERemoving a LinkNOTE: Hoses shown in the powertrack are for example

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-293. To remove a link, the rivets holding the links togethermust be removed. Use a right-angle p

SECTION 4 - BOOM & PLATFORM4-30 – JLG Lift – 31218295. After grinding it may be neccesary to help the rivetout by using a center punch with a hamm

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-317. Remove the link from the other section of the pow-ertrack using a screwdriver. Installing a

SECTION 4 - BOOM & PLATFORM4-32 – JLG Lift – 31218292. Spread apart the half-shear (female) end of the newlink and slide the peanut end of the tra

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-334. Pull the moving end out over the track so that thenew connection is positioned in the curve

SECTION 4 - BOOM & PLATFORM4-34 – JLG Lift – 31218297. Install the snap ring in the groove on the pin. Repeatthe pin installation steps for all ce

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-35NOTE: Maximum tightening torque is 18-20 in-lbs. 9. Pull up on the other end of the round bar

SECTION 4 - BOOM & PLATFORM4-36 – JLG Lift – 312182910. Install a new 8-32 x 0.500 self threading screw onthe other side. NOTE: When tightening sc

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-372. Parts used: Bracket Center Pin and Center Pin SnapRing. 3. Take the new bracket and install

SECTION 1 - SPECIFICATIONS3121829 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 OPERATING SPECIFICATIONS1.2 CAPACITIES1.3 TIRES1.4 BATTERY CHARGER1.5

SECTION 4 - BOOM & PLATFORM4-38 – JLG Lift – 3121829Replacing Moving End Brackets1. Remove existing pins and center rivet. Remove therivet the sam

SECTION 4 - BOOM & PLATFORM3121829 – JLG Lift – 4-393. Install radius pins into their original locations andinstall snap rings. Repeat with other

SECTION 4 - BOOM & PLATFORM4-40 – JLG Lift – 3121829NOTES:

SECTION 5 - HYDRAULICS3121829 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 LUBRICATING O-RINGS IN THE HYDRAULIC SYSTEMWhen assembling connectors in the h

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 3121829Dip MethodNOTE: This method works best with Face Seal o-rings, butwill work for all o-ring fitting types

SECTION 5 - HYDRAULICS3121829 – JLG Lift – 5-35.2 CYLINDERS - THEORY OF OPERATIONDouble Acting Cylinder(Upper Boom Lift, Mid Boom Lift, Lower Boom Lif

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 3121829Cylinders With Dual Counterbalance Valve(Lower Lift, Mid Lift, Telescope, and Slave Cylinders)OPERATE AL

SECTION 5 - HYDRAULICS3121829 – JLG Lift – 5-5the cylinder head retainer cap screws, and removecap screws from cylinder barrel.NOTE: Steps 6 applies o

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 31218297. Inspect threaded portion of piston for damage.Dress threads as necessary.8. Inspect seal and o-ring g

SECTION 5 - HYDRAULICS3121829 – JLG Lift – 5-7wear ring into the applicable cylinder head glandgroove.3. Place a new o-ring and back-up seal in the ap

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31218291.6 DRIVE SYSTEM1.7 HYDRAULIC PUMP/ELECTRIC MOTOR ASSEMBLY1.8 GENERATOR1.9 FUNCTION SPEEDSTable 1-6.

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 3121829screws) through the drilled holes in the bushing andinto the tapped holes in the piston. 12. Tighten the

SECTION 5 - HYDRAULICS3121829 – JLG Lift – 5-917. Position the cylinder barrel in a suitable holding fix-ture.EXTREME CARE SHOULD BE TAKEN WHEN INSTAL

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 3121829121126618 195192518 1410162022179233*,4*,242127131388771683779-E*Prior to S/N 03001065181. Loctite #242

SECTION 5 - HYDRAULICS3121829 – JLG Lift – 5-111. Barrel2. Cylinder Rod3. Retainer4. Piston5. Cylinder Head6. Hex Nut7. Tube Spacer8. Holding Valve9.

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 31218291. Loctite #2422. Primer #74713. Socket Head Bolt4. Tapered Bushing5. Bushing6. Cylinder Head7. Cylinde

SECTION 5 - HYDRAULICS3121829 – JLG Lift – 5-13161446131112132022151718752321231010891A1D1E1C1BE/M 450 AE/M 450AJ8923231683826-A1683711-A1683939-B1. B

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 31218291817715461314131220221619208523232511111091D1E1A1B1C9102525E/M 450AE/M 450AJ1683825-A1683713-A1683942-C

SECTION 5 - HYDRAULICS3121829 – JLG Lift – 5-1517154613111014132021161819752322923231232312201683813-A1683708-B1683945-C1684061-C1. Barrel2. Cylinder

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 31218291. Barrel2. Cylinder Rod3. Retainer4. Piston5. Cylinder Head6. Hex Nut7. Tube Spacer8. Setscrew9. T-Sea

SECTION 5 - HYDRAULICS3121829 – JLG Lift – 5-171. Loctite #2422. Locking Primer3. Bolt4. Tapered Bushing5. Bushing6. Piston7. Washer8. Head9. Barrel10

SECTION 1 - SPECIFICATIONS3121829 – JLG Lift – 1-31.10 PRESSURE SETTINGSTable 1-10. Pressure Settings - Prior to S/N 0300062642Circuit PSI BarMain Co

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 31218291. Wiper2. Spanner Nut3. Retaining Ring4. Lip Seal5. Wear Ring6. Backup Ring7. O-ring8. Guide9. Barrel1

SECTION 5 - HYDRAULICS3121829 – JLG Lift – 5-191. Barrel 2. Rod3. Piston4. Head5. Spacer6. Counterbalance Valve7. Bolt8. Plug 9. Setscrew10. Locknut11

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 31218295.5 PRESSURE SETTING PROCEDURESCold temperatures have a significant impact on pressurereadings.JLG Indu

SECTION 5 - HYDRAULICS3121829 – JLG Lift – 5-21Platform Level Down Relief1. On machines prior to S/N 0300062642, install thepressure gauge at the “G”

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 3121829Table 5-4. Pressure Settings - Prior to S/N 0300062642Circuit PSI BarMain Control ValveLift Down Relie

SECTION 5 - HYDRAULICS3121829 – JLG Lift – 5-23Figure 5-25. Brake/Steer Valve Components

SECTION 5 - HYDRAULICS5-24 – JLG Lift – 3121829Figure 5-26. Main Valve Components Prior to S/N 62642

SECTION 5 - HYDRAULICS3121829 – JLG Lift – 5-25EMERGENCY DESCENT HAND PUMPEMERGENCY DESCENT VALVELOWER LIFTDOWN RELIEFRELEVELING RELIEFRELEVELINGVALVE

SECTION 5 - HYDRAULICS5-26 – JLG Lift – 3121829NOTES:

SECTION 6 - JLG CONTROL SYSTEM3121829 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONSIntroductionWHEN I

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31218291.11 TORQUE SPECIFICATIONS1.12 LUBRICATION SPECIFICATIONSRefer to Section 1.17, Operator Maintenance

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 3121829The JLG designed Control System is a 48 volt basedmotor control unit installed on the boom lift.

SECTION 6 - JLG CONTROL SYSTEM3121829 – JLG Lift – 6-3The top level menus are as follows:HELPDIAGNOSTICSACTIVATE TESTACCESS LEVELPERSONALITIESMACHINE

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 3121829Once the correct password is displayed, press ENTER.The access level should display the followin

SECTION 6 - JLG CONTROL SYSTEM3121829 – JLG Lift – 6-5Machine SetupWhen a machine digit item is selected, press the UP orDOWN arrow keys to adjust its

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3121829Machine Personality Settings NOTE: Personality settings can be adjusted within theadjustment ran

SECTION 6 - JLG CONTROL SYSTEM3121829 – JLG Lift – 6-7SWING ACCELeration 0.5 to 5.0s 2.7DECELeration 0.0 to 3.0s 1.8MINimum LEFT speed 0 to 10% 1MAXim

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 3121829JIB ACCELeration 0.5 to 5.0 1.5DECELeration 0.5 to 3.0 0.5MINimum UP speed 0 to 50 9MAXimum UP

SECTION 6 - JLG CONTROL SYSTEM3121829 – JLG Lift – 6-9Machine Configuration Programming Information4150286-9NOTE: The following information is to be u

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 31218293= Motion Alarm - Sounds when any function isactive (Option)7. PLATFORM ALARM0= Sounds continuo

SECTION 6 - JLG CONTROL SYSTEM3121829 – JLG Lift – 6-11Table 6-4. Help Descriptions and Fault Flash CodesFlash Code DescriptionNo flash code is indica

SECTION 1 - SPECIFICATIONS3121829 – JLG Lift – 1-51.14 CYLINDER SPECIFICATIONSNOTE: All dimensions are given in inches (in.), with the met-ric equival

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 31218292/2Flash code 2/2 indicates problems with drive & steer selection.DRIVE JOYSTICK FAULTYThe

SECTION 6 - JLG CONTROL SYSTEM3121829 – JLG Lift – 6-132/5Flash code 2/5 indicates that a function is prevented due to a cutout.BOOM PREVENTED - DRIVE

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 31218293/3Flash code 3/3 indicates that a contactor coil is short-circuited.OVERLOADED VALVE SUPPLY-CH

SECTION 6 - JLG CONTROL SYSTEM3121829 – JLG Lift – 6-156/6Flash code 6/6 indicates problems with the CANbus.48V PROTECTION TRIPPED - CHECK INTER-MODUL

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 31218299/9Flash code 9/9 indicates problems with the controller.POWER MODULE FAILURE: CONTACTOR DRIVE

SECTION 6 - JLG CONTROL SYSTEM3121829 – JLG Lift – 6-17MENU: HELP:PRESS ENTERHELP: (001) SYSTEM OKLOG: (XXX)XX:XXXXXXXXXXXXXMENU:

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 3121829MENU:ACTIVATE TESTSACTIVATE TESTS: YES:ENTER,NO:ESCMENU:ACCESS LEVEL 1ACCESS LEVEL: CODE 0000

SECTION 6 - JLG CONTROL SYSTEM3121829 – JLG Lift – 6-19MENU: MACHINE SETUPMODEL NUMBER: 1=3002TILT: 1=5Deg2DRIVE CUTOUT: 0=CHA

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 3121829Analyzer Diagnostics Menu Structure In the following structure descriptions, an intended item i

SECTION 6 - JLG CONTROL SYSTEM3121829 – JLG Lift – 6-21TILT . . . Displays measured vehicle tilt The first value indicates tilt in die forwards revers

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 3121829Figure 1-2. Operator Maintenance & Lubrication Diagram

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 3121829System Self TestThe system self test is utilized to locate typical problems.See Table 6-6, Syst

SECTION 6 - JLG CONTROL SYSTEM3121829 – JLG Lift – 6-23Table 6-7. System Test MessagesRUNNING Initial display when system test is run; certain "

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 3121829TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized

SECTION 6 - JLG CONTROL SYSTEM3121829 – JLG Lift – 6-25CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure t

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 3121829TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed, the system

SECTION 6 - JLG CONTROL SYSTEM3121829 – JLG Lift – 6-27 Table 6-8. Diagnostic Fault CodesDTCFlash CodeFault Message Description 001 00 EVERYTHING OK T

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 31218292252 22 FUNCTION PROBLEM - TELESCOPE OUT PERMANENTLY SELECTEDInput was CLOSED during startup225

SECTION 6 - JLG CONTROL SYSTEM3121829 – JLG Lift – 6-292514 25 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible while the vehicle is be

SECTION 6 - JLG CONTROL SYSTEM6-30 – JLG Lift – 312182933364 33 FORWARD CONTACTOR COIL - OPEN CIRCUIT Traction point A did not go HIGH when forward co

SECTION 6 - JLG CONTROL SYSTEM3121829 – JLG Lift – 6-3177 6 77 STA LLED P UMP MOTOR OR PO WER WI RING ERROR T he p owe r mo dul e pu mp M OSF ET prot

SECTION 1 - SPECIFICATIONS3121829 – JLG Lift – 1-71.17 OPERATOR MAINTENANCE & LUBRICATIONNOTE: The following numbers correspond to those in Fig-ur

SECTION 6 - JLG CONTROL SYSTEM6-32 – JLG Lift – 312182999133 99 POWER MODULE FAILURE - HWFS CODE 15 Hardware failsafe tests failed because the hardwar

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-1SECTION 7. BASIC TROUBLESHOOTING, ELECTRICAL INFOR

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-2 – JLG Lift – 3121829.Table 7-1. Platform Assembly - TroubleshootingTRO

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-3Proportional Flow Regulator not powered. Check wiri

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-4 – JLG Lift – 3121829.Table 7-2. Boom Assembly - TroubleshootingTROUBLE

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-5Restricted or broken supply line on valve bank or h

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-6 – JLG Lift – 3121829Function Speed and Drive Speed does not operate bel

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-7Boom extends and retracts erratically.Hydraulic sys

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-8 – JLG Lift – 3121829Boom swings erratically in either direction.Hydraul

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-9.Table 7-3. Turntable Assembly - TroubleshootingTR

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 31218294. Hydraulic Return FilterInterval - Change after first 50 hrs. and every 6months or 300 hrs. therea

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-10 – JLG Lift – 3121829.Table 7-4. Chassis Assembly - TroubleshootingTRO

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-11FRONT FRAME AXLE AREA.One or both wheels will not

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-12 – JLG Lift – 3121829Joystick not functioning properly. Replace joystic

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-13Proportional Flow Valve not functioning properly.

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-14 – JLG Lift – 3121829Brake Drags or runs hot.Low actuation pressure. Pl

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-15.Table 7-5. Hydraulic System - TroubleshootingTRO

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-16 – JLG Lift – 3121829Function sluggish during operation. (System pressu

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-17.Table 7-6. Electrical System - TroubleshootingTR

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-18 – JLG Lift – 3121829Hourmeter inoperative.Damaged wiring in hourmeter

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-197.3 MULTIMETER BASICSA wide variety of multimeters

SECTION 1 - SPECIFICATIONS3121829 – JLG Lift – 1-99. EngineLube Point(s) - Fill CapCapacity - Refer to Engine ManualLube - EOInterval - 3 Months or 15

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-20 – JLG Lift – 3121829Resistance Measurement• First test meter and leads

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-21Current Measurement• Set up the meter for the expe

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-22 – JLG Lift – 3121829Automatic SwitchesIf the switch is actuated automa

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-237.6 AMP CONNECTORApplying Silicone Dielectric Comp

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-24 – JLG Lift – 31218293. After all required contacts have been inserted,

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-25Disassembly1. Insert a 4.8 mm (3/16") wide sc

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-26 – JLG Lift – 3121829Figure 7-11. Connector Installation

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-277.7 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Gra

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-28 – JLG Lift – 3121829HD30/HDP20 Series Assembly1. Grasp contact about 2

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-29This page left blank intentionally.

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3121829Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 7)REFERENCE JLG ANEROBIC THREAD LOCKING COMPO

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-30 – JLG Lift – 3121829Figure 7-18. Electrical Components Installation -

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-31Figure 7-19. Electrical Components Installation -

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-32 – JLG Lift – 3121829Figure 7-20. Electrical Schematic - Sheet 1 of 6

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-331870227EFigure 7-21. Electrical Schematic - Sheet

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-34 – JLG Lift – 3121829Figure 7-22. Electrical Schematic - Sheet 3 of 6

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-351870227EFigure 7-23. Electrical Schematic - Sheet

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-36 – JLG Lift – 3121829Figure 7-24. Electrical Schematic - Sheet 5 of 6

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-371870227 EFigure 7-25. Electrical Schematic - Shee

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-38 – JLG Lift – 3121829Figure 7-26. Hydraulic Schematic - M450A/E450A -

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-392792505EFigure 7-27. Hydraulic Schematic - M450A/

SECTION 1 - SPECIFICATIONS3121829 – JLG Lift – 1-11Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-40 – JLG Lift – 3121829Figure 7-28. Hydraulic Schematic - M450A/E450A -

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-412792505EFigure 7-29. Hydraulic Schematic - M450A/

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-42 – JLG Lift – 3121829Figure 7-30. Hydraulic Schematic - M450AJ/E450AJ

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121829 – JLG Lift – 7-432792505EFigure 7-31. Hydraulic Schematic - M450AJ

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-44 – JLG Lift – 3121829Figure 7-32. Hydraulic Schematic Component List

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (Au

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121829Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS3121829 – JLG Lift – 1-13Figure 1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121829Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 1 - SPECIFICATIONS3121829 – JLG Lift – 1-15Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7)Size PITCHTensile Stress AreaClamp LoadT

INTRODUCTION3121829 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 1 - SPECIFICATIONS1-16 – JLG Lift – 3121829Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 2 - GENERAL3121829 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 2 - GENERAL2-2 – JLG Lift – 31218292.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 2 - GENERAL3121829 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

SECTION 2 - GENERAL2-4 – JLG Lift – 3121829fied intervals required in the Lubrication Chart inSection 1. Always examine filters for evidence ofmetal p

SECTION 2 - GENERAL3121829 – JLG Lift – 2-52.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINESFilament wound bearings.1. Pinned joints should be disassem

SECTION 2 - GENERAL2-6 – JLG Lift – 3121829 Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveM

SECTION 2 - GENERAL3121829 – JLG Lift – 2-7Ground Controls 55 66Function Control Locks, Guards, or Detents 1,5 1,5 5 5Footswitch 1,5 5 5Emergency Stop

SECTION 2 - GENERAL2-8 – JLG Lift – 3121829Walk-Around Inspection Performed 21Annual Machine Inspection Due 21No Unauthorized Modifications or Additio

SECTION 2 - GENERAL3121829 – JLG Lift – 2-9-40 F(-40 C)-30 F(-34 C)-20 F(-29 C)-10 F(-23 C) 0 F(-18 C) 10 F(-12 C) 20 F(-7 C) 30 F(-1 C) 40 F(4 C) 50

INTRODUCTIONA-2 – JLG Lift – 3121829REVISON LOGOriginal Issue - August 15, 1999Revised - April 5, 2001Revised - May 25, 2004Revised - July 31, 2007Rev

SECTION 2 - GENERAL2-10 – JLG Lift – 3121829NOTES:

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES & WHEELSTire InflationThe air pressure for

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 31218292. Tighten nuts in the following sequence:3. The tightening of the nuts should be done in s

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-31. Dust Cap2. Cotter Pin3. Spindle Nut4. Spindle Washer5. Stud Nut6. Bearing Cone7. Hub8. B

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 31218293.3 DRIVE HUBPART NO. 2780236The final drive consists of two planetary stages with anintegr

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-5Disassembly of Cover1. Loosen and remove hex head bolts (53) to removecover (51).2. Remove

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 3121829Final Assembly1. Install thrust washer (29) in spindle (60).2. Install o-ring (19) into gro

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-71. Planet Gear2. Planet Gear 3. Sun Gear4. Shaft Nut5. Planet Bolt6. Support Ring7. Planet

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 31218293.4 DRIVE BRAKE - MICODisassembly1. Remove pressure plate (3) from cover (21) byremoving th

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-92322192118171615201211109876542331131421. Capscrew2. Washer3. Pressure Plate4. Case Seal5.

3121829 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 3121829Table 3-2. Drive Brake DiagnosisProblem Cause ExplanationCorrectiveActionBrake slips Exces

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-113.5 SPEED SENSOR ADJUSTMENTFor proper drive operation, the speed sensors must beproperly i

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 3121829Figure 3-3. Speed Sensor Orientation

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-13Figure 3-4. Frame Mounted Electrical Components - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 3121829Figure 3-5. Frame Mounted Electrical Components - Sheet 2 of 2

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-15Should read 0-7 Volts. Anything over 7 volts should flash Error Code 7-7, Open Pump Circui

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 3121829Speed Sensor Installation VerificationThe motor controller averages the readings from the

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-1718. while watching the analyzer display, select drive for-ward. Be ready to remove your fo

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 3121829Figure 3-7. Steering Components and Spindles

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-193.6 POSITRAC/TILT MODULEWhen installing a new positrac/tilt module, always ensurethat it i

ii – JLG Lift – 3121829TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 3121829Figure 3-9. Tilt Sensor Location

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-213.7 SWING MOTOR - S/N 0300135649 TO PRESENTIF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATE

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 3121829Table 3-3. Swing Motor TroubleshootingTrouble Cause RemedyOil Leakage 1. Hose fittings loo

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-23123444888E8A8C8B48D9445761012131414151625171819201. Bolt2. End Cover3. Seal Ring4. Seal Ri

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 3121829Preparation Before Disassembly• Before you disassemble the motor unit or any of itscompone

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-253. Remove the special ring head bolts (1) using anappropriate 1/2 or 9/16 inch size socket

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 31218297. Remove commutator (5) and seal ring (3) Removeseal ring from commutator, using an air h

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-279. Remove commutator (5) and seal ring (3) Removeseal ring from commutator, using an air h

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 312182912. Check exposed portion of coupling shaft (12) to besure you have removed all signs of r

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-2915. Remove thrust bearing (15) and thrust washer (14).Inspect for wear, brinelling, corros

3121829 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 3121829replaced. If the housing has passed this inspectionthe disassembly of the motor is complet

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-31SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHENUSING ANY SOLVENT. EVEN A SMALL EXPLOSI

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 31218293. Press a new dirt and water seal (20) into the housing(18) outer bearing counterbore. Th

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-338. Be sure that a generous amount of clean corrosionresistant grease has been applied to t

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 312182911. Assemble wear plate (9) over the drive link (10) andalignment studs onto the housing (

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-3515. Assemble the manifold (7) over the alignment studsand drive link (10) and onto the rot

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 3121829NOTE: If the end cover has a valve (24) or has five boltholes, use the line you previously

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-37One Piece Stator ConstructionA disassembled rotor stator and vanes that cannot bereadily a

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 3121829Two Piece Stator ConstructionA disassembled rotor set (8) that cannot be readily assem-ble

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-393.8 SWING BEARINGTurntable Bearing Mounting Bolt Condition CheckNOTE: This check is design

iv – JLG Lift – 3121829TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 3121829Wear Tolerance1. With the boom positioned over the side of themachine, the Upper Boom hori

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-413. If a difference greater than 0.057 in. (1.40 mm) isdetermined, the swing bearing should

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 3121829IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACTWRENCH IS USED FOR TIGHTENING THE BEARING

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-43Swing Bearing Torque ValueInstall with Loctite - 190 ft. lbs. (260 Nm).Checking Worm Gear

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 3121829Figure 3-16. Swing Components

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-453.9 BATTERY MAINTENANCE AND CHARGINGBattery Maintenance, Quarterly1. Open battery compartm

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 3121829Figure 3-17. On Board Generator

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-47NOTE: The engine will automatically shut down under thefollowing conditions:High Engine Oi

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 31218293.10 BATTERY CHARGER (S/N 0300059350 TO PRESENT)LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-4912341. AC Voltage - Input Cable2. Charger Interlock Cable3. DC Power Cable to Batteries4.

3121829 – JLG Lift – v TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 3121829NO LIGHTS AT ALLNo Lights at all indicate that AC power to the charger isnot connected or

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-51[5 Flashes] - Over TemperatureThis fault indicates the charger has become too hot duringop

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 3121829Checking/Changing the Battery Charger AlgorithmThe charger is pre-loaded with programming

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-533.12 GENERATOR (PRIOR TO S/N 88539)NOTE: Throughout the Generator section, the abbreviatio

SECTION 3 - CHASSIS & TURNTABLE3-54 – JLG Lift – 3121829Figure 3-20. Generator Components

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-55Timing Sequences• RBS Prestart Sequence1. Time Delay Engine Start (TDES)TDES is the period

SECTION 3 - CHASSIS & TURNTABLE3-56 – JLG Lift – 3121829To Connect the JLG Control System Analyzer to the GeneratorThe JLG Control System Analyzer

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-57Figure 3-21. Generator System Analyzer Flow Chart

SECTION 3 - CHASSIS & TURNTABLE3-58 – JLG Lift – 3121829•OverspeedIf the engine speed exceeds the overspeed limit, theengine will stop immediately

SECTION 3 - CHASSIS & TURNTABLE3121829 – JLG Lift – 3-59Priming the Fuel LineThe following procedure is for re-priming the fuel line onthe generat