JLG E450A, E450AJ, M450A, M450AJ Boom Lift Service Manual
258 pages · Publication 3121127
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What's inside
From the manual's own table of contents: 324 sections, 385 entries. See sample pages (PDF, 594 KB)
General
Hydraulic System Safety
Maintenance12 topics
- Operating specifications
- Capacities
- Tires
- Battery Charger
- Dimensional Data
- Drive System
- Hydraulic Pump/Electric Motor Assembly
- Generator
- Function Speeds
- Pressure Settings
- Torque Specifications
- Lubrication Specifications
Hydraulic Oil6 topics
- Critical Stability Weights
- Cylinder Specifications
- Major Component Weights
- Serial Number Locations
- Operator Maintenance & Lubrication
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventive Maintenance1 topic
- Service and Guidelines
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Lubrication and Servicing1 topic
- SECTION NO. TITLE PAGE NO. Lubrication and Information
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift Test
Show all 324 sections
Platform Drift
Cylinder Drift2 topics
- Pins and Composite Bearing Repair Guidelines
- Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment1 topic
- Tires & Wheels
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation1 topic
- Spindle
Setting Wheel Bearing End Play
Specifications
Checking
Greasing Requirements
Disassembly
Disassembly of Cover
Disassembly of First Stage Planetary Assembly (7)
Disassembly of Second Stage Planet Gears (1)
Assembly of First Stage Planetary Assembly (7)
Assembly of End Cover Unit (8)
Final Assembly
Initial Start-up and After Repairs
Oil Change Interval-Gear Drive
Setting of Tapered Roller Bearings
Securing of the Shaft Nut1 topic
- Drive Brake - Mico
Assembly
Bleeding1 topic
- Speed Sensor Adjustment
Adjustment Procedure
Speed Sensor Installation Verification
Verification w/ Analyzer Procedure1 topic
- SECTION NO. TITLE PAGE NO. Positrac/Tilt module
Preparation Before Disassembly
Disassembly and Inspection
One Piece Stator Construction
Two Piece Stator Construction
Final Checks1 topic
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Replacement of Swing Bearing
Swing Bearing Torque Value
Checking Worm Gear End Play
Adjusting End Play1 topic
- Battery Maintenance and Charging
Battery Maintenance, Quarterly
Optional On Board Generator
Battery Charging (On Board Charger)1 topic
- Battery Charger (S/N 0300059350 to Present)
Operating Instructions
Maintenance Instructions
Battery Charger Fault Codes
Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell
Checking/Changing the Battery Charger Algorithm1 topic
- Generator (Prior to S/N 88539)
Timing Sequences
To Connect the JLG Control System Analyzer to the Generator
Alarms and Fault Flash Codes
Output Current and Voltage Settings
Priming the Fuel Line1 topic
- Generator (S/N 88539 to Present)
Engine
Alternator
Dynamo and Dynamo Voltage Regulator
Dynamo Output Fuse
Control Fuse
Start Battery
Engine Starter
Start Control Relay
Fuel Control Relay
Glow Plug Control Relay
Glow Plug
Fuel Pump
Fuel Solenoid
Engine Low Oil Pressure Switch
Engine Oil Temperature Sensor
Alternator Output Current Sensor
Engine Speed Sensor
SECTION NO. TITLE PAGE NO. RBS Engine/Generator Controller
Warnings and Safety Precautions
System Controls
System Status and Performance Monitoring
System Settings
RBS Start
RBS shutdown
RBS Alarms and Flash Codes
Resetting the RBS Controller
Maintenance Schedule
Troubleshooting
APU Engine Start Battery Boosting1 topic
- Supplementary fuse for apu
Tools And Material
Procedure1 topic
- Boom Maintenance
Removal
Inspection
Installation9 topics
- Upper (Main) Boom Lift Cylinder
- Mid Boom Lift Cylinder
- Lower Boom Lift Cylinder
- Upper Boom Telescope Cylinder
- Mid and Lower Lift Cylinder Bleeding Procedure
- Wear Pads
- Boom Limit Switches
- Articulating Jib Boom
- load sensing system
Calibration3 topics
- Boom Synchronizing Procedure
- Footswitch Adjustment
- SECTION NO. TITLE PAGE NO. Helac Rotary actuator
Theory Of Operation
Tools Required for Assembly/Disassembly
Installing Counterbalance Valve
Testing the Actuator
Installation and Bleeding1 topic
- Powertrack Maintenance
Removing a Link
Installing a New Link
Replacing Fixed End Brackets
Replacing Moving End Brackets1 topic
- Lubricating O-Rings in the Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method1 topic
- Cylinders - Theory of Operation
Double Acting Cylinder1 topic
- Cylinder Checking Procedures
Cylinder Without Counterbalance Valves
Cylinders With Single Counterbalance Valve
Cylinders With Dual Counterbalance Valve1 topic
- Cylinder Repair
Cleaning and Inspection1 topic
- Pressure Setting Procedures
Main Relief
Upper Lift Down Relief
Lower Lift Down Relief
Telescope Relief
Platform Level Up Relief
Platform Level Down Relief
Steer Relief
Jib Lift (Up and Down) Relief
Releveling Valve Relief1 topic
- JLG Control System Analyzer Kit Instructions
Introduction
To Connect the JLG Control System Analyzer
Using the Analyzer
Changing the Access Level of the Hand Held Analyzer
Adjusting Parameters Using the Hand Held Analyzer
Machine Setup
Machine Personality Settings
Machine Configuration Programming Information
Level Vehicle Description
Help Descriptions and Fault Flash Codes
Analyzer Diagnostics Menu Structure
System Self Test3 topics
- General
- Troubleshooting
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement1 topic
- Checking Switches
Basic Check
Limit Switches
Automatic Switches
Switch Wiring - Low Side, High Side2 topics
- Applying Silicone Dielectric Compound to Electrical Connections
- AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
Wedge Lock
Service - Voltage Reading1 topic
- Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
Serial Number Locations
Operator Maintenance & Lubrication Diagram
Torque Chart (SAE Fasteners - Sheet 1 of 7)
Torque Chart (SAE Fasteners - Sheet 2 of 7)
Torque Chart (SAE Fasteners - Sheet 3 of 7)
Torque Chart (SAE Fasteners - Sheet 4 of 7)
Torque Chart (METRIC Fasteners - Sheet 5 of 7)
Torque Chart (METRIC Fasteners - Sheet 6 of 7)
Torque Chart (METRIC Fasteners - Sheet 7 of 7)
Engine Operating Temperature Specifications - Kubota
Spindle Assembly
Drive Hub - Cutaway
Drive Brake
Speed Sensor Orientation
Frame Mounted Electrical Components - Sheet 1 of 2
Frame Mounted Electrical Components - Sheet 2 of 2
Voltage Checks
Steering Components and Spindles
Drive Components
Tilt Sensor Location
Swing Motor - Cutaway
Swing Motor - Exploded View
Swing Bearing Feeler Gauge Check
Swing Bearing Tolerance Boom Placement
Swing Bearing Tolerance Measuring Point
Swing Bearing Torquing Sequence
Swing Components
On Board Generator
Batteries and Battery Charger (Prior to S/N 0300059350)
Battery Charger ((S/N 0300059350 to Present)
Generator Components
Generator System Analyzer Flow Chart
Generator
Location of Components - Boom Removal
Upper Boom Lift Cylinder Removal
Mid Boom Lift Cylinder Removal
Lower Boom Lift Cylinder Removal
Upper Telescope Cylinder Removal
Wear Pad Thickness
Platform Support Torque Values
Boom Limit Switches
Platform Components and Attaching Hardware (M450A & E450A)
Location of Components - Articulating Jib Boom
Load Sensing System
Rotary Actuator (Exploded View)
Rotary Actuator (Cutaway View)
Rotator Counterbalance Valve
Cylinder Barrel Support
Capscrew Removal
Cylinder Rod Support
Tapered Bushing Removal
Gar-Max Bearing Installation
Rod Seal Installation
Wiper Seal Installation
Installation of Head Seal Kit
Piston Seal Kit Installation
Tapered Bushing Installation
Seating the Tapered Bearing
Poly-Pak Piston Seal Installation
Rod Assembly Installation
Jib Cylinder
Level Cylinder - A Models
Level Cylinder - AJ & AJP Models
Lower Lift Cylinder
Mid Lift Cylinder
Upper Lift Cylinder
Master Cylinder - A Models
Master Cylinder - AJ Models
Steer Cylinder
Telescope Cylinder
Jib Valve Location
Brake/Steer Valve Components
Main Valve Components Prior to S/N 62642
Main Valve Components S/N 62642 to Present
Control Module Location
Power Controller - Sheet 1 of 4
Power Controller - Sheet 2 of 4
Power Controller - Sheet 3 of 4
Power Controller - Sheet 4 of 4
Analyzer Flow Chart (Software Version 3.x) - Sheet 1 of 3
Analyzer Flow Chart (Software Version 3.x) - Sheet 2 of 3
Analyzer Flow Chart (Software Version 3.x) - Sheet 3 of 3
Voltage Measurement (DC)
Current Measurement (DC)
Connector Assembly Figure 1
AMP Connector
Connector Assembly Figure 2
Connector Assembly Figure 3
Connector Assembly Figure 4
Connector Disassembly
Connector Installation
DT/DTP Contact Installation
DT/DTP Contact Removal
HD/HDP Contact Installation
HD/HDP Locking Contacts Into Position
HD/HDP Contact Removal
HD/HDP Unlocking Contacts
Electrical Components Installation - Sheet 1
Electrical Components Installation - Sheet 2
Electrical Schematic - Sheet 1 of 6
Electrical Schematic - Sheet 2 of 6
Electrical Schematic - Sheet 3 of 6
Electrical Schematic - Sheet 4 of 6
Electrical Schematic - Sheet 5 of 6
Electrical Schematic - Sheet 6 of 6
Hydraulic Schematic - M450A/E450A - Sheet 1 of 2
Hydraulic Schematic - M450A/E450A - Sheet 2 of 2
Hydraulic Schematic - M450AJ/E450AJ - Sheet 1 of 2
Hydraulic Schematic - M450AJ/E450AJ - Sheet 2 of 2
Hydraulic Schematic Component List
Operating Specifications
Capacities
Tire Specifications
Dimensional Data
Drive System
Hydraulic Pump/Electric Motor
Function Speeds
Pressure Settings - Prior to S/N 0300062642
Pressure Settings - S/N 0300062642 to Present
Torque Requirements
Mobil DTE 11M Specs
Mobil EAL 224H Specs
Critical Stability Weights
Cylinder Specifications
Major Component Weights
Inspection and Maintenance
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Drive Brake Diagnosis
Swing Motor Troubleshooting
Battery Charger Fault Codes (Delta-Q)
Battery Algorithms
RBS Prestart Sequence
RBS Startup Sequence
RBS Shutdown Sequence
Generator System Flash Codes
Controller Interface Pin Assignments
Cylinder Head and Tapered Bushing Torque Specifications
Cylinder Piston Nut Torque Specifications)
Holding Valve Torque Specifications
Personality Ranges/Defaults
Machine Setup Descriptions
JLG Control System Flash Codes
DIAGNOSTICS - Menu Descriptions
System Test Descriptions
System Test Messages
Diagnostic Fault Codes
Platform Assembly - Troubleshooting
Boom Assembly - Troubleshooting
Turntable Assembly - Troubleshooting
Chassis Assembly - Troubleshooting
Hydraulic System - Troubleshooting
Electrical System - Troubleshooting
Inside this manual
Real pages from this service manual (258 pages). Open the sample pages (PDF, 593 KB)
- Specifications, page 19: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 229: SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS
- Diagram, page 250: SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS
- Color page, page 145: SECTION 4 - BOOM & PLATFORM
- Color page, page 225: SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS
Other manuals for this machine
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 258 pages
Quantity one is the manual described above.
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Other editions and similar models
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