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JLG E450A, E450AJ, M450AJ Boom Lift Parts Manual

544 pages · Publication 3121649

$69.63
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Models
E450A, E450AJ, M450AJ
Serial coverage
0300185900, 0300186011, 0300189900, 0300189901-0300208529, Exclude Serial Number Range: 0300202268, 0300202273
Manual type
Parts Manual
Pages
544
Publication
3121649
Condition
Brand new
JLG E450A, E450AJ, M450AJ Boom Lift Parts Manual, publication 3121649

What's inside

From the manual's own table of contents: 89 sections, 209 entries. See sample pages (PDF, 586 KB)

General54 topics
  • SECTION 1 - FRAME
  • FIGURE 1-1. STEERING INSTALLATION
  • FIGURE 1-2. HUB - SPINDLE ASSEMBLY - RH
  • FIGURE 1-3. HUB - SPINDLE ASSEMBLY - LH
  • FIGURE 1-4. WHEEL DRIVE - E450A/E450AJ
  • FIGURE 1-5. WHEEL DRIVE - E450A/E450AJ - UL LISTED
  • FIGURE 1-6. WHEEL DRIVE - M450AJ
  • FIGURE 1-7. HUB - DRIVE ASSEMBLY
  • FIGURE 1-8. DRIVE MOTOR ASSEMBLY
  • FIGURE 1-9. TIRE AND WHEEL - IN240/55-17.5 PNEUMATIC
  • FIGURE 1-11. TIRE AND WHEEL - IN240/55-17.5 PNEUMATIC NON MARKING
  • FIGURE 1-12. TIRE AND WHEEL - 26 X 7 X 20 - SOLID NON MARKING
  • FIGURE 1-13. TIRE AND WHEEL - IN240/55-17.5 FOAM FILL NON MARKING
  • FIGURE 1-14. TIRE AND WHEEL - IN240/55-17.5 PNEUMATIC NON MARKING TS
  • FIGURE 1-15. WHEEL COVER INSTALLATION - IN240/55-17.5 TIRES ONLY
  • FIGURE 1-16. MOTOR/PUMP/TANK INSTALLATION - E450A/E450AJ
  • FIGURE 1-17. MOTOR/PUMP/TANK INSTALLATION - E450A/E450AJ - UL LISTED
  • FIGURE 1-18. MOTOR/PUMP/TANK INSTALLATION - M450AJ
  • FIGURE 1-19. MOTOR/PUMP ASSEMBLY
  • FIGURE 1-20. HYDRAULIC TANK ASSEMBLY - E450A/E450AJ
  • FIGURE 1-21. HYDRAULIC TANK ASSEMBLY - M450AJ
  • FIGURE 1-22. VALVE INSTALLATION - FRAME MOUNTED - E450A
  • FIGURE 1-23. VALVE INSTALLATION - FRAME MOUNTED - E450AJ
  • FIGURE 1-24. VALVE INSTALLATION - FRAME MOUNTED - M450AJ
  • FIGURE 1-25. BRAKE/STEER VALVE ASSEMBLY
  • FIGURE 1-26. BATTERY BOX INSTALLATION (ALL SPECS EXCEPT CE AND AUSTRALIAN SPECS)
  • FIGURE 1-27. BATTERY BOX INSTALLATION - AGM BATTERIES (ALL SPECS EXCEPT CE AND AUSTRALIAN SPECS)
  • FIGURE 1-28. BATTERY BOX INSTALLATION - CE AND AUSTRALIAN SPECS
  • FIGURE 1-29. BATTERY BOX INSTALLATION - AGM BATTERIES (CE AND AUSTRALIAN SPECS)
  • FIGURE 1-31. BATTERY CHARGER INSTALLATION - E450A/E450AJ (AUSTRALIAN SPEC)
  • FIGURE 1-32. BATTERY CHARGER INSTALLATION - E450A/E450AJ (ANSI EXPORT AND CE SPECS)
  • FIGURE 1-34. BATTERY CHARGER INSTALLATION - M450AJ (AUSTRALIAN SPEC)
  • FIGURE 1-35. BATTERY CHARGER INSTALLATION - M450AJ (ANSI EXPORT AND CE SPECS)
  • FIGURE 1-36. INVERTER INSTALLATION - E450A/E450AJ
  • FIGURE 1-37. FRAME COVER INSTALLATION - M450AJ
  • FIGURE 1-38. FRAME COVER INSTALLATION - E450A/E450AJ
  • SECTION 2 - TURNTABLE
  • FIGURE 2-1. VALVE INSTALLATION - TURNTABLE MOUNTED - E450A
  • FIGURE 2-2. VALVE INSTALLATION - TURNTABLE MOUNTED - E450AJ
  • FIGURE 2-3. VALVE INSTALLATION - TURNTABLE MOUNTED - M450AJ
  • FIGURE 2-4. MAIN CONTROL VALVE ASSEMBLY
  • FIGURE 2-5. RELEVELING VALVE ASSEMBLY
  • FIGURE 2-6. JIB VALVE ASSEMBLY
  • FIGURE 2-7. MOTION ALARM INSTALLATION
  • FIGURE 2-8. TURNTABLE BEARING AND SWING DRIVE INSTALLATION
  • FIGURE 2-9. SWING MOTOR ASSEMBLY
  • FIGURE 2-10. SWING BEARING ASSEMBLY
  • FIGURE 2-11. REMOTE BEARING LUBE INSTALLATION - OPTIONAL
  • FIGURE 2-12. DRIVE ORIENTATION INSTALLATION
  • FIGURE 2-13. FUEL TANK AND BATTERY INSTALLATION - M450AJ
  • FIGURE 2-14. GROUND CONTROL BOX ASSEMBLY - E450A
  • FIGURE 2-17. GROUND CONTROL BOX ASSEMBLY - E450AJ/M450AJ
  • FIGURE 2-20. MOTOR CONTROLS INSTALLATION - M450AJ
  • FIGURE 2-21. STROBE LIGHT INSTALLATION (AMBER) - OPTIONAL
FIGURE 2-22. STROBE LIGHT INSTALLATION - UL LISTED - OPTIONAL
FIGURE 2-23. STROBE LIGHT ASSEMBLY
FIGURE 2-26. HOOD INSTALLATION - E450A/E450AJ
FIGURE 2-27. HOOD INSTALLATION - M450AJ
SECTION 3 - ENGINE
FIGURE 3-1. KUBOTA MOTOR/GENERATOR INSTALLATION - M450AJ
FIGURE 3-2. KUBOTA MOTOR/GENERATOR ASSEMBLY - M450AJ
FIGURE 3-3. KUBOTA MOTOR/GENERATOR COMPONENTS
SECTION 4 - BOOM
FIGURE 4-1. BOOM AND CYLINDERS INSTALLATION - E450A
FIGURE 4-2. BOOM AND CYLINDERS INSTALLATION - E450AJ/M450AJ
FIGURE 4-3. MAIN BOOM ASSEMBLY - E450A
FIGURE 4-4. MAIN BOOM ASSEMBLY - E450AJ/M450AJ
FIGURE 4-5. JIB INSTALLATION
FIGURE 4-6. ROTATOR ASSEMBLY - E450A
FIGURE 4-7. ROTATOR ASSEMBLY - E450AJ/M450AJ
FIGURE 4-8. PLATFORM SUPPORT WITHOUT LOAD SENSING
FIGURE 4-9. PLATFORM SUPPORT INSTALLATION - WITH LSS - E450AJ/M450AJ
FIGURE 4-10. PLATFORM SUPPORT INSTALLATION - WITH LSS - E450A
FIGURE 4-11. CABLES AND CLAMPS INSTALLATION - E450A
FIGURE 4-12. CABLES AND CLAMPS INSTALLATION - E450AJ/M450AJ
FIGURE 4-13. BOOM LIMIT SWITCHES INSTALLATION
SECTION 5 - PLATFORM
Show all 90 sections
FIGURE 5-18. TRAY ASSEMBLY
FIGURE 5-19. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION
FIGURE 5-20. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - UL LISTED
FIGURE 5-22. PLATFORM CONSOLE ASSEMBLY
FIGURE 5-23. PLATFORM CONSOLE ASSEMBLY - UL LISTED
FIGURE 5-24. PLATFORM CONSOLE ASSEMBLY - WITH SKYGUARD (SN 0300200790 through 0300208529)
FIGURE 5-25. LIGHT PANEL DECAL INSTALLATION
FIGURE 5-26. JIB SWITCH INSTALLATION - E450AJ/M450AJ
FIGURE 5-27. SEALED ENCLOSURES - UL LISTED
FIGURE 5-28. CONTROLLER ASSEMBLY - DRIVE AND STEER
FIGURE 5-29. CONTROLLER ASSEMBLY - LIFT AND SWING
FIGURE 5-30. FOOTSWITCH ASSEMBLY
FIGURE 5-31. MOTOR CONTROLS INSTALLATION - M450AJ59 topics
  • FIGURE 5-34. CROSS RAIL INSTALLATION
  • FIGURE 5-35. PIPE RACK INSTALLATION
  • SECTION 6 - CYLINDER
  • FIGURE 6-1. JIB CYLINDER ASSEMBLY - E450AJ/M450AJ
  • FIGURE 6-2. LIFT CYLINDER ASSEMBLY - LOWER - E450A (ORIGINAL EQUIPMENT)
  • FIGURE 6-3. LIFT CYLINDER ASSEMBLY - E450A (SERVICE REPLACEMENT)
  • FIGURE 6-4. LIFT CYLINDER ASSEMBLY - LOWER - E450AJ/M450AJ (ORIGINAL EQUIPMENT)
  • FIGURE 6-5. LIFT CYLINDER ASSEMBLY - LOWER - E450AJ/M450AJ (SERVICE REPLACEMENT)
  • FIGURE 6-6. LIFT CYLINDER ASSEMBLY - MID - E450A (ORIGINAL EQUIPMENT)
  • FIGURE 6-7. LIFT CYLINDER ASSEMBLY - MID - E450A (SERVICE REPLACEMENT)
  • FIGURE 6-8. LIFT CYLINDER ASSEMBLY - MID - E450AJ/M450AJ (ORIGINAL EQUIPMENT)
  • FIGURE 6-9. LIFT CYLINDER ASSEMBLY - MID - E450AJ/M450AJ (SERVICE REPLACEMENT)
  • FIGURE 6-10. LIFT CYLINDER ASSEMBLY - UPPER - E450A (ORIGINAL EQUIPMENT)
  • FIGURE 6-11. LIFT CYLINDER ASSEMBLY - UPPER - E450A (SERVICE REPLACEMENT)
  • FIGURE 6-12. LIFT CYLINDER ASSEMBLY - UPPER - E450AJ/M450AJ (ORIGINAL EQUIPMENT)
  • FIGURE 6-13. LIFT CYLINDER ASSEMBLY - UPPER - E450AJ/M450AJ (SERVICE REPLACEMENT)
  • FIGURE 6-14. MASTER CYLINDER ASSEMBLY - E450A
  • FIGURE 6-15. MASTER CYLINDER ASSEMBLY - E450AJ/M450AJ
  • FIGURE 6-16. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY - E450A
  • FIGURE 6-17. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY - E450AJ/M450AJ
  • FIGURE 6-18. STEER CYLINDER ASSEMBLY
  • FIGURE 6-19. TELESCOPE CYLINDER ASSEMBLY - E450A (ORIGINAL EQUIPMENT)
  • FIGURE 6-20. TELESCOPE CYLINDER ASSEMBLY - E450A (SERVICE REPLACEMENT)
  • FIGURE 6-21. TELESCOPE CYLINDER ASSEMBLY - E450AJ/M450AJ (ORIGINAL EQUIPMENT)
  • FIGURE 6-22. TELESCOPE CYLINDER ASSEMBLY - E450AJ/M450AJ (SERVICE REPLACEMENT)
  • FIGURE 6-23. COUNTERBALANCE VALVE ASSEMBLY
  • SECTION 7 - HYDRAULIC
  • FIGURE 7-1. HYDRAULIC DIAGRAM - E450A
  • FIGURE 7-2. HYDRAULIC DIAGRAM - E450AJ
  • FIGURE 7-3. HYDRAULIC DIAGRAM - M450AJ
  • FIGURE 7-4. HYDRAULIC DIAGRAM LIST
  • SECTION 8 - ELECTRICAL
  • FIGURE 8-1. ELECTRICAL DIAGRAM LIST
  • FIGURE 8-2. AC PLUGS AND SOCKETS INSTALLATION - CEE7 POST GROUND - 2 X 4 BOX (CE SPEC)
  • FIGURE 8-3. AC PLUGS AND SOCKETS INSTALLATION - CEE7 SIDE GROUND - 2 X 4 BOX (CE SPEC)
  • FIGURE 8-4. AC PLUGS AND SOCKETS INSTALLATION - AFSINT 107-2-01 KEYED GROUND - 2 X 4 BOX (CE SPEC)
  • FIGURE 8-5. AC PLUGS AND SOCKETS INSTALLATION - IEC 60309 YELLOW (CE SPEC)
  • FIGURE 8-6. AC PLUGS AND SOCKETS INSTALLATION - IEC 60309 BLUE (CE SPEC)
  • FIGURE 8-7. AC PLUGS AND SOCKETS INSTALLATION - CEE7 POST GROUND (CE SPEC)
  • FIGURE 8-8. AC PLUGS AND SOCKETS INSTALLATION - CEE 7 SIDE GROUND (CE SPEC)
  • FIGURE 8-9. ANALYZER HARNESS ASSEMBLY
  • FIGURE 8-10. BATTERY CHARGER ASSEMBLY
  • FIGURE 8-12. BATTERY CHARGER INDICATOR HARNESS - CE SPEC (SN 0300200790 through 0300208529)
  • FIGURE 8-13. BEACON LIGHT HARNESS (BLUE BEACON ONLY)
  • FIGURE 8-14. BOOM LIMIT SWITCH HARNESS - LOWER
  • FIGURE 8-15. BOOM LIMIT SWITCH HARNESS - UPPER
  • FIGURE 8-16. BREAKER BOX KIT WITH TWO BREAKERS - CE SPEC
  • FIGURE 8-17. BREAKER BOX KIT WITH THREE BREAKERS - CE SPEC
  • FIGURE 8-18. CHARGER CORD PLUG INSTALLATION - 220V - CEE7 POST GROUND (CE SPEC)
  • FIGURE 8-19. CHARGER CORD PLUG INSTALLATION - 220V - CEE7 SIDE GROUND (CE SPEC)
  • FIGURE 8-20. CHARGER CORD PLUG INSTALLATION - 220V - AFSINT 107 KEYED GROUND (CE SPEC)
  • FIGURE 8-21. CHARGER CORD PLUG INSTALLATION - 110V - IEC 60309 - YELLOW (CE SPEC)
  • FIGURE 8-22. CHARGER CORD PLUG INSTALLATION - 220V - IEC 60309 - BLUE (CE SPEC)
  • FIGURE 8-23. CONTACTOR CABLE KIT - E450A/E450AJ
  • FIGURE 8-24. CONTACTOR CABLE KIT - M450AJ
  • FIGURE 8-25. CONTACTOR PLATE ASSEMBLY AND HARNESSES
  • FIGURE 8-26. CONTACTOR PLATE ASSEMBLY AND HARNESSES - UL LISTED
  • FIGURE 8-27. CONTACTOR PLATE KIT - E450A/E450AJ - UL/EE
  • FIGURE 8-28. DRIVE ORIENTATION HARNESS
FIGURE 8-29. DRIVE ORIENTATION SWITCH HARNESS ASSEMBLY
FIGURE 8-30. GENERATOR HARNESS TO GROUND CONTROL BOX
FIGURE 8-31. GROUND CONTROL CAN HARNESS ASSEMBLY
FIGURE 8-32. GROUND CONTROL FUNCTION SWITCH HARNESS ASSEMBLY
FIGURE 8-35. GROUND CONTROL VALVE HARNESS ASSEMBLY
FIGURE 8-36. HORN/BEACON HARNESS ASSEMBLY
FIGURE 8-37. INDICATOR LAMP HARNESS ASSEMBLY
FIGURE 8-38. INDICATOR LAMP HARNESS ASSEMBLY - WITH SKYGUARD
FIGURE 8-41. JIB HARNESS - AJ MODELS ONLY
FIGURE 8-42. LED REMOTE HARNESS
FIGURE 8-43. LOWER BOOM 110V HARNESS ASSEMBLY
FIGURE 8-44. LOWER BOOM 220V HARNESS ASSEMBLY - CE SPEC
FIGURE 8-45. MAIN BOOM HARNESS ASSEMBLY
FIGURE 8-46. MAIN BOOM 110V HARNESS ASSEMBLY
FIGURE 8-47. MAIN BOOM 220V HARNESS ASSEMBLY - CE SPEC
FIGURE 8-48. MAIN BOOM HARNESS ASSEMBLY - E450AJ/M450AJ
FIGURE 8-49. MOTOR/STEER/BRAKE HARNESS - M450AJ
FIGURE 8-50. PLATFORM CAN BUS HARNESS ASSEMBLY
FIGURE 8-51. PLATFORM FUNCTION SWITCH HARNESS ASSEMBLY
FIGURE 8-52. PLATFORM FUNCTION SWITCH HARNESS ASSEMBLY - WITH SKYGUARD
FIGURE 8-53. PLUG AND RECEPTACLE INSTALLATION - SUPPLIED LOCALLY
FIGURE 8-54. PLUG AND RECEPTACLE INSTALLATION - 110V - ANSI SPEC
FIGURE 8-55. PLUG AND RECEPTACLE 110V INSTALLATION - IEC 60309 - YELLOW (CE SPEC)
FIGURE 8-56. PLUG AND RECEPTACLE 220V INSTALLATION - IEC 60309 - BLUE (CE SPEC)
FIGURE 8-58. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 SIDE GROUND - 70MM X 70MM BOX (CE SPEC)
FIGURE 8-59. PLUG AND RECEPTACLE 220V INSTALLATION - ANSI SPEC
FIGURE 8-60. PLUG AND RECEPTACLE 220 INSTALLATION - CEE7 SIDE GROUND - 2 X 4 BOX (CE SPEC)
FIGURE 8-61. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 POST GROUND - 2 X 4 BOX (CE SPEC)
FIGURE 8-62. PLUG AND RECEPTACLE 220V INSTALLATION - AFSINT 107 KEYED GROUND - 2 X 4 BOX (CE SPEC)
FIGURE 8-63. POSI-TRACK MODULE CAN HARNESS ASSEMBLY
FIGURE 8-64. SKYGUARD PLATFORM SENSOR HARNESS (SN 0300189898 through 0300200789)
FIGURE 8-65. SKYGUARD PLATFORM SENSOR HARNESS (SN 0300200790 through 0300208529)
FIGURE 8-67. STEER BRAKE HARNESS - E450A/E450AJ
FIGURE 8-68. STROBE LIGHT HARNESS
FIGURE 8-69. STROBE LIGHT - AMBER - HARNESS
FIGURE 8-70. TOWER BOOM HARNESS ASSEMBLY - E450A/E450AJ/M450AJ
FIGURE 8-71. TURNTABLE/FRAME HARNESS ASSEMBLY
SECTION 9 - DECALS
FIGURE 9-1. DECAL INSTALLATION - JLG LOGO
FIGURE 9-2. DECAL INSTALLATION - ANSI SPEC - M450AJ
FIGURE 9-3. DECAL INSTALLATION - ANSI SPEC - E450A/E450AJ
FIGURE 9-4. DECAL INSTALLATION - AUSTRALIAN SPEC - M450AJ
FIGURE 9-7. DECAL INSTALLATION - AUSTRALIAN SPEC - E450AJ
FIGURE 9-10. DECAL INSTALLATION - JAPANESE SPEC - M450AJ
FIGURE 9-11. DECAL INSTALLATION - JAPANESE SPEC - E450A/E450AJ
FIGURE 9-12. DECAL INSTALLATION - KOREAN SPEC - M450AJ
FIGURE 9-13. DECAL INSTALLATION - KOREAN SPEC - E450A/E450AJ
FIGURE 9-14. DECAL INSTALLATION - SPANISH/ENGLISH SPECS - M450AJ
FIGURE 9-15. DECAL INSTALLATION - SPANISH/ENGLISH SPECS - E450A/E450AJ
FIGURE 9-16. DECAL INSTALLATION - FRENCH/ENGLISH SPECS - M450AJ
FIGURE 9-17. DECAL INSTALLATION - FRENCH/ENGLISH SPECS - E450A/E450AJ
FIGURE 9-18. DECAL INSTALLATION - CHINESE/ENGLISH SPEC - M450AJ
FIGURE 9-19. DECAL INSTALLATION - CHINESE/ENGLISH SPEC - E450A/E450AJ7 topics
  • FIGURE 9-20. DECAL INSTALLATION - SPANISH/PORTUGUESE SPECS - M450AJ
  • FIGURE 9-21. DECAL INSTALLATION - SPANISH/PORTUGUESE SPECS - E450A/E450AJ
  • SECTION 10 - RECOMMENDED SERVICE PARTS STOCK
  • FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK
  • SECTION 11 - SPECIAL OPTIONS
  • FIGURE 11-1. SPECIAL OPTIONS
  • PART NUMBER INDEX

Inside this manual

Real pages from this parts manual (544 pages). Open the sample pages (PDF, 586 KB)

Sample pages from the JLG E450A, E450AJ, M450AJ Boom Lift Parts Manual: Parts illustration, Parts illustration, Parts illustration
  • Parts illustration, page 192: SECTION 4 - BOOM
  • Parts illustration, page 472: FIGURE 8-66. SKYGUARD CAN HARNESS (SN 0300200790 through 0300208529)
  • Parts illustration, page 496: SECTION 9 - DECALS

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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.

This manual

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

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, 544 pages

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Other editions and similar models

JLG E400A, E400AJP, E400AJP narrow, E400A narrow, E450A, E450AJ, M400A, M4Parts Manual · 3121128 · $69.61JLG E400A, E400AJP, E400AJP narrow, E400A narrow, E450A, E450AJ, M400A, M4Parts Manual · 3121830 · $69.71JLG E450A, E450AJ, M450AJParts Manual · 3121715 · $69.85JLG E450AJParts Manual · 31215014 · $69.73JLG E450AJParts Manual · 31215014_Rev_B · $69.63

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