JLG EC450AJ Parts Manual (31217105) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG EC450AJ Parts Manual (31217105) – PDF DOWNLOAD
SECTION 1 - FRAME.................................................................... 11 FIGURE 1-1. AXLE INSTALLATION.................................................... 12 FIGURE 1-2. STEER INSTALLATION................................................... 14 FIGURE 1-3. WHEEL DRIVE INSTALLATION (2WD)....................................... 16 FIGURE 1-4. HUB - SPINDLE ASSEMBLY............................................... 18 FIGURE 1-5. DRIVE MOTOR ASSEMBLY................................................. 20 FIGURE 1-6. BATTERY INSTALLATION................................................. 22 FIGURE 1-7. FRAME SHIELD INSTALLATION............................................ 26 FIGURE 1-8. TIRE AND WHEEL INSTALLATION - 33 X 12-20 SOLID NON-MARKING........... 28 FIGURE 1-9. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED................. 30 FIGURE 1-10. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED NON-MARKING.... 32 FIGURE 1-11. CONTROL VALVES INSTALLATION - FRAME MOUNTED......................... 34 FIGURE 1-12. OSCILLATING AXLE VALVE ASSEMBLY..................................... 36 SECTION 2 - TURNTABLE................................................................ 39 FIGURE 2-1. CONTROL VALVES INSTALLATION - TURNTABLE MOUNTED...................... 40 FIGURE 2-2. MAIN VALVE ASSEMBLY.................................................. 42 FIGURE 2-3. AUXILIARY PUMP ASSEMBLY.............................................. 44 FIGURE 2-4. ENCLOSURE INSTALLATION............................................... 46 FIGURE 2-5. SWING DRIVE AND TURNTABLE BEARING INSTALLATION....................... 48 FIGURE 2-6. SWING MOTOR ASSEMBLY................................................. 50 FIGURE 2-7. TURNTABLE BEARING ASSEMBLY........................................... 52 FIGURE 2-8. TURNTABLE COVERS INSTALLATION........................................ 54 FIGURE 2-9. TURNTABLE LOCK INSTALLATION.......................................... 56 FIGURE 2-10. TANK AND PUMPS INSTALLATION......................................... 58 FIGURE 2-11. HYDRAULIC TANK INSTALLATION......................................... 60 FIGURE 2-12. MOTOR ASSEMBLY...................................................... 62 FIGURE 2-13. DRIVE ORIENTATION INSTALLATION...................................... 64 FIGURE 2-14. GROUND CONTROL ASSEMBLY............................................. 66 FIGURE 2-15. ELECTRICAL SYSTEM INSTALLATION...................................... 68 FIGURE 2-16. BATTERY CHARGER INSTALLATION........................................ 72 FIGURE 2-17. BATTERY AND CABLE INSTALLATION...................................... 74 FIGURE 2-18. ALARM WHITE NOISE INSTALLATION...................................... 76 FIGURE 2-19. BEACON LIGHT INSTALLATION - AMBER................................... 78 FIGURE 2-20. BEACON LIGHT INSTALLATION - BLUE.................................... 80 FIGURE 2-21. BEACON LIGHT INSTALLATION - RED..................................... 82 FIGURE 2-22. HOODS INSTALLATION.................................................. 84 FIGURE 2-23. HOOD ASSEMBLY - TANK SIDE........................................... 88 FIGURE 2-24. HOOD ASSEMBLY - ENGINE SIDE......................................... 90 FIGURE 2-25. COVERS INSTALLATION - COUNTERWEIGHT................................. 92 SECTION 3 - BOOM..................................................................... 95 FIGURE 3-1. CYLINDERS INSTALLATION............................................... 96 FIGURE 3-2. BOOM INSTALLATION - WITHOUT AIRLINES................................. 98 FIGURE 3-3. BOOM INSTALLATION - WITH AIRLINE.....................................100 FIGURE 3-4. BOOM AIRLINE INSTALLATION............................................102 FIGURE 3-5. AIRLINE FITTINGS INSTALLATION........................................104 FIGURE 3-6. MAIN BOOM INSTALLATION...............................................106 FIGURE 3-7. MAIN BOOM ASSEMBLY...................................................108 FIGURE 3-8. TOWER BOOM ASSEMBLY..................................................110 FIGURE 3-9. JIB INSTALLATION.....................................................112 FIGURE 3-10. ROTATOR ASSEMBLY....................................................114 FIGURE 3-11. PLATFORM SUPPORT INSTALLATION - WITH 1 CELL LSS.....................116 FIGURE 3-12. BOOM VALVES INSTALLATION............................................118 FIGURE 3-13. BOOM VALVE ASSEMBLY.................................................120 FIGURE 3-14. UPRIGHT VALVE ASSEMBLY..............................................122 SECTION 4 - PLATFORM.................................................................125 FIGURE 4-1. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - SIDE GATE ENTRY......126 FIGURE 4-2. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - SIDE GATE ENTRY......128 FIGURE 4-3. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - SIDE GATE ENTRY......130 FIGURE 4-4. PLATFORM ASSEMBLY - 30IN X 3FT (76CM X .91M) - DROP BAR ENTRY........132 FIGURE 4-5. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - WITH DROP BAR........134 FIGURE 4-6. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - WITH DROP BAR........136 FIGURE 4-7. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - WITH DROP BAR........138 FIGURE 4-8. CONSOLE BOX INSTALLATION - WITH SKYGUARD.............................140 FIGURE 4-9. PLATFORM CONSOLE BOX ASSEMBLY - WITH SKYGUARD........................142 FIGURE 4-10. CONTROLLER ASSEMBLY - DRIVE AND STEER...............................146 FIGURE 4-11. CONTROLLER ASSEMBLY - LIFT AND SWING................................148 FIGURE 4-12. FOOTSWITCH ASSEMBLY.................................................152 FIGURE 4-13. TRAY ASSEMBLY.......................................................154 FIGURE 4-14. SKYEYE INSTALLATION.................................................156 FIGURE 4-15. SKYGUARD BAR INSTALLATION...........................................158 FIGURE 4-16. SKYLINE INSTALLATION................................................160 FIGURE 4-17. PIPE RACK INSTALLATION..............................................162 SECTION 5 - CYLINDER.................................................................165 FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY.......................................166 FIGURE 5-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY.............................168 FIGURE 5-3. LIFT CYLINDER ASSEMBLY - JIB.........................................170 FIGURE 5-4. LIFT CYLINDER ASSEMBLY - MAIN BOOM...................................172 FIGURE 5-5. LIFT CYLINDER ASSEMBLY - TOWER BOOM..................................174 FIGURE 5-6. MASTER CYLINDER ASSEMBLY.............................................176 FIGURE 5-7. STEER CYLINDER ASSEMBLY..............................................178 FIGURE 5-8. TELESCOPE CYLINDER ASSEMBLY..........................................180 SECTION 6 - HYDRAULIC................................................................183 FIGURE 6-1. BOOM HYDRAULIC SYSTEM INSTALLATION...................................184 FIGURE 6-2. CHASSIS HYDRAULIC SYSTEM INSTALLATION................................188 SECTION 7 - ELECTRICAL...............................................................191 FIGURE 7-1. BEACON LIGHT HARNESS.................................................192 FIGURE 7-2. BMS HARNESS..........................................................194 FIGURE 7-3. BOOM CABLES AND CLAMPS...............................................196 FIGURE 7-4. BOOM HARNESS - MAIN BOOM.............................................200 FIGURE 7-5. BOOM HARNESS - MAIN BOOM AC CABLE....................................202 FIGURE 7-6. BOOM HARNESS - TOWER BOOM............................................204 FIGURE 7-7. BOOM HARNESS - TOWER BOOM AC CABLE...................................206 FIGURE 7-8. BOOM VALVE HARNESS...................................................208 FIGURE 7-9. CHARGER HARNESS......................................................210 FIGURE 7-10. CHASSIS HARNESS ASSEMBLY............................................212 FIGURE 7-11. CONTROLLER BRACKET ASSEMBLY.........................................218 FIGURE 7-12. DRIVE MOTOR HARNESS (RIGHT REAR)....................................220 FIGURE 7-13. DRIVE MOTOR HARNESS (LEFT REAR).....................................222 FIGURE 7-14. FUSE PLATE ASSEMBLY.................................................224 FIGURE 7-15. PLATFORM CONSOLE HARNESS - WITH SKYGUARD............................226 FIGURE 7-16. PLATFORM TO BOOM VALVE HARNESS......................................228 FIGURE 7-17. PLATFORM CONSOLE BOX HARNESS........................................230 FIGURE 7-18. PLATFORM INTERFACE HARNESS..........................................232 FIGURE 7-19. RECEPTACLE BOX KIT - 110V IEC YELLOW................................234 FIGURE 7-20. RECEPTACLE BOX KIT - 220V IEC BLUE..................................236 FIGURE 7-21. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2IN X 4IN BOX............238 FIGURE 7-22. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2IN X 4IN BOX............240 FIGURE 7-23. RECEPTACLE BOX KIT - 220V AFSINT 107................................242 FIGURE 7-24. STEER SENSOR HARNESS................................................244 FIGURE 7-25. SKYEYE INTERMEDIATE HARNESS.........................................246 FIGURE 7-26. SKYEYE RECEIVER HARNESS.............................................248 FIGURE 7-27. SKYEYE EMITTER HARNESS..............................................250 FIGURE 7-28. SKYLINE HARNESS.....................................................252 FIGURE 7-29. SKYGUARD HARNESS....................................................254 FIGURE 7-30. TRACTION HARNESS....................................................256 FIGURE 7-31. WHEEL DRIVE ELECTRICAL HARNESS INSTALLATION (2WD)...................258 SECTION 8 - DECALS...................................................................261 FIGURE 8-1. DECAL INSTALLATION – CE SPECS........................................262 FIGURE 8-2. DECAL INSTALLATION - OPTIONS.........................................264 SECTION 9 - RECOMMENED SERVICE PARTS STOCK...........................................267 FIGURE 9-1. RECOMMENDED SERVICE PARTS STOCK......................................268 SECTION 10 - SPECIAL OPTIONS.........................................................269 FIGURE 10-1. SPECIAL OPTIONS.....................................................270 PART NUMBER INDEX....................................................................271
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