JLG E450A, E450AJ, M450A, M450AJ Boom Lift Service Manual
480 pages · Publication 3121714
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What's inside
From the manual's own table of contents: 475 sections, 538 entries. See sample pages (PDF, 576 KB)
General
Hydraulic System Safety
Maintenance6 topics
- Operating Specifications
- Tires
- Capacities
- Dimensional Data
- Torque Specifications
- Lubrication Specifications
Hydraulic Oil5 topics
- Critical Stability Weights
- Major Component Weights
- Serial Number Locations
- Maintenance and Lubrication
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative 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
- Lubrication and Information
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift
Show all 475 sections
Theory
Cylinder Leakage Test
Cylinder Thermal 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 Requirements3 topics
- Tilt Module
- Speed Sensor
- Drive Hub
Roll and Leak Testing
Tightening and Torquing Bolts
Main Disassembly
Output Carrier Disassembly
Input Carrier Disassembly
Hub-spindle Disassembly
Cover Disassembly
Input Carrier Assembly
Output Planet Gear Assembly
Output Carrier Assembly
Hub-spindle Assembly
Cover Assembly
Main Assembly1 topic
- Drive Motor
Removal
Disassembly
Inspection
Assembly
Installation1 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
- Swing Motor
Preparation Before Disassembly
Disassembly and Inspection
One Piece Stator Construction
Two Piece Stator Construction
Final Checks1 topic
- Battery Maintenance and Charging
Battery Maintenance, Quarterly
Optional On Board Generator
Battery Charging (On Board Charger)1 topic
- Battery Charger
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
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
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
- Platform
Support Removal
Support Installation10 topics
- Rotator and Slave Cylinder Removal
- Main Boom Powertrack (E/M450AJ)
- Boom Maintenance
- Wear Pads
- Boom Limit Switches
- Boom Cleanliness Guidelines
- Articulating Jib Boom
- Boom Synchronizing Procedure
- Foot switch Adjustment
- Rotary actuator
Theory Of Operation
Tools Required for Assembly/Disassembly
Installing Counterbalance Valve
Greasing Thrust Washers
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
- Skyguard
Operation
Function Test
Diagnostics & Troubleshooting1 topic
- Lubricating O-Rings in the Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method1 topic
- Hydraulic Connection Assembly and Torque Specification
Tapered Thread Types
Straight Thread Types, Tube and Hose Connections
Straight Thread Types, Port Connections
Flange Connection Types
Tightening Methods
Assembly And Torque Specifications
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections
Assembly Instructions for 37° (JIC) Flare Fittings
Assembly Instructions for 45° SAE Flare Fittings
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
Assembly Instructions for Bulkhead (BH) Fittings
Assembly Instructions for O-Ring Boss (ORB) Fittings
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends
Assembly instructions for Adjustable Port End (BSPP) Fittings
Assembly Instructions for Flange Connections: (FL61 and FL62)
Double Wrench Method
FFWR and TFFT Methods
Adjustable Stud End Assembly
O-ring Installation (Replacement)1 topic
- Hydraulic Cylinders
Platform Level (Slave) Cylinder (E450Aonly)
Platform Level (Slave) Cylinder E/M450AJ
Jib Lift Cylinder (E/M 450AJ Only)
Lower Lift Cylinder
Mid Lift Cylinder
Upper Lift Cylinder
Master Cylinder (E450A only)
Master Cylinder E/M450AJ
Steer Cylinder
Telescope Cylinder (E450A only)
Telescope Cylinder E/M450AJ1 topic
- Cylinder Removal And Installation
Main Boom Lift Cylinder Removal
Main Boom Lift Cylinder Installation
Mid Boom Lift Cylinder Removal
Mid Boom Lift Cylinder Installation
Lower Boom Lift Cylinder Removal
Lower Boom Lift Cylinder Installation
Main Boom Telescope Cylinder Removal
Main Boom Telescope Cylinder Installation2 topics
- Mid and Lower Lift Cylinder Bleeding Procedure
- Pressure Setting Procedures
Main Relief
Main 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
Level Vehicle Description2 topics
- Machine Personality Settings
- Machine Orientation When performing test
Test Notes1 topic
- Function Speed
Help Descriptions and Fault Flash Codes
Analyzer Diagnostics Menu Structure
System Self Test4 topics
- Calibrating Steer
- Calibrating Tilt Sensor
- Calibrating Load Sensing
- LSS System
Diagnostic Menu
Calibration Procedure
Testing & Evaluation3 topics
- Resetting The MSSO System
- General
- 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 Side1 topic
- Applying Silicone Dielectric Compound to Electrical Connections
Installation of Dielectric Grease
Deutsch HD, DT, DTM, DRC Series
AWP Seal
AMP Mate-N-Lok
DIN Connectors
Exclusions1 topic
- 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 Disassembly1 topic
- Wiring Harness Connector Lables
Connector Labels
Component Labels
Serial Number Locations
Maintenance & Lubrication Diagram
Torque Chart (SAE Fasteners - Sheet 1 of 5)
Torque Chart (SAE Fasteners - Sheet 2 of 5)
Torque Chart (SAE Fasteners - Sheet 3 of 5)
Torque Chart (METRIC Fasteners - Sheet 4 of 5)
Torque Chart (METRIC Fasteners - Sheet 5 of 5)
Engine Operating Temperature Specifications - Kubota
Spindle Assembly
Chassis Component Location
Drive Components
Cable Routing
Relay
System Fuses
Ignition Relay Fuse
Drive Fuses
Drive Limit Switch
Steering Installation and spindle
Main Assembly - Sheet 1 of 2
Main Assembly - Sheet 2 of 2
Output Carrier
Planet Gear
Input Carrier
Hub Spindle
Drive Hub - Sheet 1 of 2
Drive Hub - Sheet 2 of 2
Drive Motor
Swing Bearing Feeler Gauge Check
Swing Bearing Tolerance Boom Placement
Swing Bearing Tolerance Measuring Point
Swing Bearing Torquing Sequence
Swing Bearing Removal - E450A
Swing Bearing Removal - E450AJ, M450AJ
Swing Components
Swing Motor - Cutaway
Swing Motor - Exploded View
On Board Generator
Battery Charger (E450A/AJ)
Battery Charger (M450AJ)
Generator
Location of Components Platform Support
Platform Support Torque Values
Wear Pad Thickness
Boom Limit Switches
Platform Components and Attaching Hardware (M450A & E450A)
Location of Components - Articulating Jib Boom
Rotary Actuator (Exploded View)
Rotator- Assembly Drawing
Rotator Counterbalance Valve
NPTF Thread
BSPT Thread
JIC Thread
SAE Thread
ORFS Thread
MTBL-MBTS Thread
Bulkhead Thread
ORB-MPP Thread
MFF-BSPP Thread
Torque Wrench Angle
FFWR Method
Cylinder Barrel Support
Cylinder Rod Support
Platform Level (Slave) Cylinder (E450A only)
Composite Bearing Installation
Rod Seal Installation
Cylinder Head Seal Installation
Wiper Seal Installation
Installation of Head Seal Kit
Piston Seal Kit Installation
Cylinder Head Removal
Platform Level (Slave) Cylinder - E/M450AJ (SN B300002487 to Present)
Jib Lift Cylinder (SN B300002487 to Present)
Cylinder Cap Removal
Lower Lift Cylinder - E450A (SN 0300239756 to Present)
Lower Lift Cylinder - E450AJ/M450AJ (SN B300002487 to Present)
Mid Lift Cylinder - E450AJ/M450AJ (SN B300002487 to Present)
Upper Lift Cylinder - E450A (SN 0300239756 to Present)
Upper Lift Cylinder - E450AJ/M450AJ (SN B300002487 to Present)
Master Cylinder E/M450AJ (SN B3000024867 to Present)
Spanner Nut Removal
Telescope Cylinder - E450AJ/M450AJ (SN B300002487 to Present)
Components Boom
Main Telescope Cylinder Removal
Jib Valve Location
Hydraulic Component Location
Steer Valve Pressure Adjustment
Steer Valve Component
Steer Valve Torque Specification
Main Valve Pressure Adjustment
Main Valve Components
Main Control Valve Torque Specification
Releveling Valve Torque Specification
Jib Valve Torque Specification (SN 0300233452 to Present, SN B300002533 to Present)
Hydraulic Schematic (SN 0300233452 to Present, SN B300002533 to Present) - Sheet 1 of 7
Hydraulic Schematic (SN 0300233452 to Present, SN B300002533 to Present) - Sheet 2 of 7
Hydraulic Schematic (SN 0300233452 to Present, SN B300002533 to Present) - Sheet 3 of 7
Hydraulic Schematic (SN 0300233452 to Present, SN B300002533 to Present) - Sheet 4 of 7
Hydraulic Schematic (SN 0300233452 to Present, SN B300002533 to Present) - Sheet 5 of 7
Hydraulic Schematic (SN 0300233452 to Present, SN B300002533 to Present) - Sheet 6 of 7
Hydraulic Schematic (SN 0300233452 to Present, SN B300002533 to Present) - Sheet 7 of 7
Hand Held Analyzer
Analyzer Software P1.4 - Sheet 1 of 5
Analyzer Software P1.4 - Sheet 2 of 5
Analyzer Software P1.4 - Sheet 3 of 5
Analyzer Software P1.4 - Sheet 4 of 5
Analyzer Software P1.4 - Sheet 5 of 5
Control Module Location - Sheet 1 of 2
Control Module Location - Sheet 2 of 2
Analyzer Connecting Points
Power Module - LH
Power Module - RH
Ground Control Module - Sheet 1 of 3
Ground Control Module - Sheet 2 of 3
Ground Control Module - Sheet 3 of 3
Platform Module - Sheet 1 of 2
Platform Module - Sheet 2 of 2
Voltage Measurement (DC)
Current Measurement (DC)
Application to Female Contacts
Use of Seal Plugs
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
Platform Console Harness - Sheet 1 of 4
Platform Console Harness - Sheet 2 of 4
Platform Console Harness - Sheet 3 of 4
Platform Console Harness - Sheet 4 of 4
Platform Beacon Harness
Load Sensing System Harness (LSS) - Sheet 1 of 2
Load Sensing System Harness - Sheet 2 of 2
Main Valve Harness - Sheet 1 of 3
Main Valve Harness - Sheet 2 of 3
Main Valve Harness - Sheet 3 of 3
Turntable Harness - Sheet 1 of 3
Turntable Harness - Sheet 2 of 3
Turntable Harness - Sheet 3 of 3
Ground Control Panel Harness - Sheet 1 of 3
Ground Control Panel Harness - Sheet 2 of 3
Ground Control Panel Harness - Sheet 3 of 3
Chassis Traction Harness - Sheet 1 of 4
Chassis Traction Harness - Sheet 2 of 4
Chassis Traction Harness - Sheet 3 of 4
Chassis Traction Harness - Sheet 4 of 4
Chassis to Turntable Harness
Chassis Steer/Brake Harness - Sheet 1 of 2
Chassis Steer/Brake Harness - Sheet 2 of 2
Chassis Head /Tail Light Harness - Sheet 1 of 2
Chassis Head /Tail Light Harness - Sheet 2 of 2
Inverter IGN Harness
Platform Work Light Harness
Generator IGN Harness - Sheet 1 of 2
Generator IGN Harness - Sheet 2 of 2
SkyGuard Harness - Sheet 1 of 2
SkyGuard Harness Sheet - 2 of 2
Soft Touch Harness - Sheet 1 of 2
Soft Touch Harness - Sheet 2 of 2
Platform Console Harness with SkyGuard and 1 Cell LSS - Sheet 1 of 4
Platform Console Harness with SkyGuard and 1 Cell LSS - Sheet 2 of 4
Platform Console Harness with SkyGuard and 1 Cell LSS - Sheet 3 of 4
Platform Console Harness with SkyGuard and 1 Cell LSS - Sheet 4 of 4
Gen 2 Plat Interface Harness
Electrical Schematic - Sheet 1 of 18
Electrical Schematic - Sheet 2 of 18
Electrical Schematic - Sheet 3 of 18
Electrical Schematic - Sheet 4 of 18
Electrical Schematic - Sheet 5 of 18
Electrical Schematic - Sheet 6 of 18
Electrical Schematic - Sheet 7 of 18
Electrical Schematic - Sheet 8 of 18
Electrical Schematic - Sheet 9 of 18
Electrical Schematic - Sheet 10 of 18
Electrical Schematic - Sheet 11 of 18
Electrical Schematic - Sheet 12 of 18
Electrical Schematic - Sheet 13 of 18
Electrical Schematic - Sheet 14 of 18
Electrical Schematic - Sheet 15 of 18
Electrical Schematic - Sheet 16 of 18
Electrical Schematic - Sheet 17 of 18
Electrical Schematic - Sheet 18 of 18
Operating Specifications
Tire Specifications
Capacities
Dimensional Data
Torque Requirements
Mobil DTE 10 Excel 15 Specs
Mobil EAL 224H Specs
Critical Stability Weights
Major Component Weights
Inspection and Maintenance
Cylinder Drift
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Swing Motor Troubleshooting
Battery Charger Fault Codes (Delta-Q)
Battery Algorithms
Controller Interface Pin Assignments
SkyGuard Function Table
NPTF Pipe Thread
BSPT Pipe Thread
37° Flare (JIC) Thread - Steel
37° Flare (JIC) Thread - Aluminum/Brass
45° Flare (SAE) - Steel
45° Flare (SAE) - Aluminum/Brass
O-ring Face Seal (ORFS) - Steel
O-ring Face Seal (ORFS) - Aluminum/Brass
DIN 24° Cone (MBTL & MBTS)
Bulkhead Fittings (BH) - INCH
Bulkhead Fittings (BH) - METRIC
O-ring Boss (ORB) - Table 1 of 6
O-ring Boss (ORB) - Table 2 of 6
O-ring Boss (ORB) - Table 3 of 6
O-ring Boss (ORB) - Table 4 of 6
O-ring Boss (ORB) - Table 5 of 6
O-ring Boss (ORB) - Table 6 of 6
Metric Flat Face Port (MFF) - L Series - Table 1 of 3
Metric Flat Face Port (MFF) - L Series - Table 2 of 3
Metric Flat Face Port (MFF) - L Series - Table 3 of 3
Metric Flat Face Port (MFF) - S Series - Table 1 of 3
Metric Flat Face Port (MFF) - S Series - Table 2 of 3
Metric Flat Face Port (MFF) - S Series - Table 3 of 3
Metric Pipe Parallel O-Ring Boss (MPP)
British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3
British Standard Parallel Pipe Port (BSPP) - L Series - Table 3 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3
Flange Code (FL61 & FL62) -Inch Fasteners
Flange Code (FL61 & FL62) - Metric Fasteners
Cartridge Torque Values
Coil Torque Values
Analyzer Abbreviations
Machine Configuration Programming Information
Machine Configuration Programming Settings
Personality Ranges/Defaults
Function Speeds
Machine Setup Descriptions
JLG Control System Flash Codes
DIAGNOSTICS - Menu Descriptions
System Test Descriptions
System Test Messages
Diagnostic Menu Descriptions
Accessory Weights
SkyGlazier Capacity Reductions
Pipe Rack Capacity Reductions
LSS Troubleshooting Chart
Diagnostic Trouble Codes
Wiring Harness Connector Labels
Inside this manual
Real pages from this service manual (480 pages). Open the sample pages (PDF, 573 KB)
- Troubleshooting, page 78: SECTION 3 - CHASSIS & TURNTABLE
- Specifications, page 379: SECTION 6 - JLG CONTROL SYSTEM
- Diagram, page 456: SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS
- Color page, page 150: SECTION 4 - BOOM & PLATFORM
- Color page, page 409: SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS
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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, 480 pages
Quantity one is the manual described above.
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