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JLG E450A E450AJ M450AJ Illustrated Parts Manual - 2018 PDF Parts Catalog
JLG E450A E450AJ M450AJ Illustrated Parts Manual - 2018 PDF Parts Catalog - Image 2
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JLG E450A E450AJ M450AJ Illustrated Parts Manual – 2018 PDF Parts Catalog

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Complete JLG illustrated parts manual for the E450A, E450AJ and M450AJ electric boom lifts. Rev G (2018), document 3121649, covering frame, turntable, engine, boom, platform, cylinders, hydraulics, electrical and decals with exploded views and full part numbers.

SKU: JLG-IPM-3121649-G-HD Category: Tags: , , , Vendor: Loader Manuals
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Description

JLG E450A, E450AJ & M450AJ Illustrated Parts Manual

This JLG E450A E450AJ M450AJ Illustrated Parts Manual is the complete illustrated parts catalog for the JLG E450A, E450AJ and M450AJ electric boom lifts. Published by JLG Industries under document number 3121649, Revision G, dated November 16, 2018, this is the parts reference used to identify and order every serviceable component on these machines. Each figure pairs an exploded illustration with a line-by-line parts list giving item number, JLG part number, quantity, description and revision level.

The content is organised under the standard JLG product hierarchy – Frame, Turntable, Engine, Boom, Platform, Cylinder, Hydraulic, Electrical, Decals, Recommended Service Parts Stock and Special Options – so a technician can move quickly from the machine area being worked on to the exact figure and item needed. Serial-number breakouts are preserved throughout, which matters on these lifts because several assemblies, harnesses and ground control boxes changed between production runs.

File Details

  • Manual type: Illustrated Parts Manual (Parts Catalog)
  • Brand / Models: JLG E450A, E450AJ, M450AJ
  • Language: English
  • Page count: approximately 544 pages
  • File format: PDF
  • Document number: 3121649
  • Revision: G
  • Date: November 16, 2018

Chapters Covered

The JLG E450A E450AJ M450AJ Illustrated Parts Manual is broken into the following top-level sections, each with numbered figures and exploded views:

  • Section 1 – Frame: Steering installation, RH and LH hub-spindle assemblies, wheel drive installations for E450A/E450AJ, E450A/E450AJ UL Listed and M450AJ, hub-drive assembly, drive motor assembly, tire and wheel assemblies (pneumatic, foam fill, solid non-marking, non-marking TS), wheel cover installation, motor/pump/tank installations, motor/pump assembly, hydraulic tank assemblies, frame-mounted valve installations, brake/steer valve assembly, battery box installations (wet and AGM, standard and CE/Australian specs), battery charger installations, inverter installation, frame cover installations
  • Section 2 – Turntable: Turntable-mounted valve installations, main control valve assembly, releveling valve assembly, jib valve assembly, motion alarm installation, turntable bearing and swing drive installation, swing motor assembly, swing bearing assembly, remote bearing lube installation, drive orientation installation, fuel tank and battery installation (M450AJ), ground control box assemblies (standard, CE spec and SKYGUARD variants), motor controls installation, strobe light installation and assembly, beacon light installation, hood installations
  • Section 3 – Engine: Kubota motor/generator installation, motor/generator assembly, and motor/generator components for the M450AJ
  • Section 4 – Boom: Boom and cylinders installations for E450A and E450AJ/M450AJ, main boom assemblies, jib installation, rotator assemblies, platform support with and without load sensing, cables and clamps installations, boom limit switches installation
  • Section 5 – Platform: Platform assemblies in 4 ft/1.22 m, 5 ft/1.52 m and 6 ft/1.83 m sizes with side gate entry, drop bar entry and fall arrest variants, tray assembly, platform console and footswitch installations, platform console assemblies, light panel decal installation, jib switch installation, sealed enclosures (UL Listed), controller assemblies for drive/steer and lift/swing, footswitch assembly, motor controls installation and SKYGUARD system installation
  • Section 6 – Cylinder: Jib cylinder assembly, lower/mid/upper lift cylinder assemblies in both original equipment and service replacement versions, master cylinder assembly, level (platform slave) cylinder assembly, steer cylinder assembly, telescope cylinder assembly, and counterbalance valve assembly
  • Section 7 – Hydraulic: Complete hydraulic diagrams for the E450A, E450AJ and M450AJ with a diagram list
  • Section 8 – Electrical: Electrical diagram list, AC plugs and sockets installations for CEE7 and IEC 60309 configurations, analyzer harness assembly, battery charger assembly and harnesses, beacon light harness, boom limit switch harnesses, breaker box kits, charger cord plug installations, contactor cable kits and contactor plate assemblies, drive orientation harnesses, generator harness, ground control CAN and function switch harnesses, ground control valve harness, horn/beacon harness, indicator lamp harnesses, inverter harnesses, jib harness, LED remote harness, lower/main boom harnesses at 110V and 220V, motor/steer/brake harness, platform CAN bus and function switch harnesses, plug and receptacle installations for 110V and 220V ANSI and CE specs, Posi-Track module CAN harness, SKYGUARD platform sensor and CAN harnesses, steer brake harness, strobe light harnesses, tower boom harness and turntable/frame harness
  • Section 9 – Decals: Decal installations for JLG logo, ANSI spec, Australian spec, CE spec, Japanese spec, Korean spec, Spanish/English, French/English, Chinese/English and Spanish/Portuguese specs, each with its own serial-range breakdown
  • Section 10 – Recommended Service Parts Stock: Standard and variable parts recommended to be kept on hand for field repairs
  • Section 11 – Special Options: Airline installations, ClearSky telematics kits, console covers, cylinder bellows installations, decal kits, electrical connector kits, hydraulic fluids, indicator light installation, LSS override kit, platform entry kits, mesh installations, padding, top rail extensions, worklights, SKYGUARD kits and service tools

Complete PDF Bookmark Tree

Complete Bookmarks

The complete bookmarks in the “JLG E450A E450AJ M450AJ Illustrated Parts Manual – 2018 PDF Parts Catalog” are as follows:

SECTION 1 – FRAMEp. 13
FIGURE 1-1. STEERING INSTALLATIONp. 14
FIGURE 1-2. HUB – SPINDLE ASSEMBLY – RHp. 16
FIGURE 1-3. HUB – SPINDLE ASSEMBLY – LHp. 18
FIGURE 1-4. WHEEL DRIVE – E450A/E450AJp. 20
FIGURE 1-5. WHEEL DRIVE – E450A/E450AJ – UL LISTEDp. 24
FIGURE 1-6. WHEEL DRIVE – M450AJp. 28
FIGURE 1-7. HUB – DRIVE ASSEMBLYp. 32
FIGURE 1-8. DRIVE MOTOR ASSEMBLYp. 36
FIGURE 1-9. TIRE AND WHEEL – IN240/55-17.5 PNEUMATICp. 38
FIGURE 1-10. TIRE AND WHEEL – IN240/55 – 17.5 FOAM FILLp. 40
FIGURE 1-11. TIRE AND WHEEL – IN240/55-17.5 PNEUMATIC NON MARKINGp. 42
FIGURE 1-12. TIRE AND WHEEL – 26 X 7 X 20 – SOLID NON MARKINGp. 44
FIGURE 1-13. TIRE AND WHEEL – IN240/55-17.5 FOAM FILL NON MARKINGp. 46
FIGURE 1-14. TIRE AND WHEEL – IN240/55-17.5 PNEUMATIC NON MARKING TSp. 48
FIGURE 1-15. WHEEL COVER INSTALLATION – IN240/55-17.5 TIRES ONLYp. 50
FIGURE 1-16. MOTOR/PUMP/TANK INSTALLATION – E450A/E450AJp. 52
FIGURE 1-17. MOTOR/PUMP/TANK INSTALLATION – E450A/E450AJ – UL LISTEDp. 54
FIGURE 1-18. MOTOR/PUMP/TANK INSTALLATION – M450AJp. 56
FIGURE 1-19. MOTOR/PUMP ASSEMBLYp. 58
FIGURE 1-20. HYDRAULIC TANK ASSEMBLY – E450A/E450AJp. 60
FIGURE 1-21. HYDRAULIC TANK ASSEMBLY – M450AJp. 62
FIGURE 1-22. VALVE INSTALLATION – FRAME MOUNTED – E450Ap. 64
FIGURE 1-23. VALVE INSTALLATION – FRAME MOUNTED – E450AJp. 66
FIGURE 1-24. VALVE INSTALLATION – FRAME MOUNTED – M450AJp. 68
FIGURE 1-25. BRAKE/STEER VALVE ASSEMBLYp. 70
FIGURE 1-26. BATTERY BOX INSTALLATION (ALL SPECS EXCEPT CE AND AUSTRALIAN SPECS)p. 72
FIGURE 1-27. BATTERY BOX INSTALLATION – AGM BATTERIES (ALL SPECS EXCEPT CE AND AUSTRALIAN SPECS)p. 74
FIGURE 1-28. BATTERY BOX INSTALLATION – CE AND AUSTRALIAN SPECSp. 76
FIGURE 1-29. BATTERY BOX INSTALLATION – AGM BATTERIES (CE AND AUSTRALIAN SPECS)p. 78
FIGURE 1-30. BATTERY CHARGER INSTALLATION – E450A/E450AJ (ALL SPECS EXCEPED CE AND AUSTRALIAN SPECS)p. 80
FIGURE 1-31. BATTERY CHARGER INSTALLATION – E450A/E450AJ (AUSTRALIAN SPEC)p. 82
FIGURE 1-32. BATTERY CHARGER INSTALLATION – E450A/E450AJ (ANSI EXPORT AND CE SPECS)p. 84
FIGURE 1-33. BATTERY CHARGER INSTALLATION – M450AJ (ALL SPECS EXCEPTED CE, AUSTRALIAN AND UL SPECS)p. 86
FIGURE 1-34. BATTERY CHARGER INSTALLATION – M450AJ (AUSTRALIAN SPEC)p. 88
FIGURE 1-35. BATTERY CHARGER INSTALLATION – M450AJ (ANSI EXPORT AND CE SPECS)p. 90
FIGURE 1-36. INVERTER INSTALLATION – E450A/E450AJp. 92
FIGURE 1-37. FRAME COVER INSTALLATION – M450AJp. 94
FIGURE 1-38. FRAME COVER INSTALLATION – E450A/E450AJp. 96
SECTION 2 – TURNTABLEp. 99
FIGURE 2-1. VALVE INSTALLATION – TURNTABLE MOUNTED – E450Ap. 100
FIGURE 2-2. VALVE INSTALLATION – TURNTABLE MOUNTED – E450AJp. 102
FIGURE 2-3. VALVE INSTALLATION – TURNTABLE MOUNTED – M450AJp. 104
FIGURE 2-4. MAIN CONTROL VALVE ASSEMBLYp. 106
FIGURE 2-5. RELEVELING VALVE ASSEMBLYp. 110
FIGURE 2-6. JIB VALVE ASSEMBLYp. 112
FIGURE 2-7. MOTION ALARM INSTALLATIONp. 114
FIGURE 2-8. TURNTABLE BEARING AND SWING DRIVE INSTALLATIONp. 116
FIGURE 2-9. SWING MOTOR ASSEMBLYp. 118
FIGURE 2-10. SWING BEARING ASSEMBLYp. 120
FIGURE 2-11. REMOTE BEARING LUBE INSTALLATION – OPTIONALp. 122
FIGURE 2-12. DRIVE ORIENTATION INSTALLATIONp. 124
FIGURE 2-13. FUEL TANK AND BATTERY INSTALLATION – M450AJp. 126
FIGURE 2-14. GROUND CONTROL BOX ASSEMBLY – E450Ap. 128
FIGURE 2-15. GROUND CONTROL BOX ASSEMBLY – E450A – CE SPEC (SN 0300189898 through 0300200789)p. 130
FIGURE 2-16. GROUND CONTROL BOX ASSEMBLY – E450A – CE SPEC (SN 0300200790 through 0300208529)p. 132
FIGURE 2-17. GROUND CONTROL BOX ASSEMBLY – E450AJ/M450AJp. 134
FIGURE 2-18. GROUND CONTROL BOX ASSEMBLY – E450AJ/M450AJ – CE SPEC (SN 0300189898 through 0300200789)p. 136
FIGURE 2-19. GROUND CONTROL BOX ASSEMBLY – E450AJ/M450AJ – CE SPEC (SN 0300200790 through 0300208529)p. 138
FIGURE 2-20. MOTOR CONTROLS INSTALLATION – M450AJp. 140
FIGURE 2-21. STROBE LIGHT INSTALLATION (AMBER) – OPTIONALp. 142
FIGURE 2-22. STROBE LIGHT INSTALLATION – UL LISTED – OPTIONALp. 144
FIGURE 2-23. STROBE LIGHT ASSEMBLYp. 146
FIGURE 2-24. BEACON LIGHT INSTALLATION – BLUE (SN 0300189898 through 0300200789)p. 148
FIGURE 2-25. BEACON LIGHT INSTALLATION – BLUE (SN 0300200790 through 0300208529)p. 150
FIGURE 2-26. HOOD INSTALLATION – E450A/E450AJp. 152
FIGURE 2-27. HOOD INSTALLATION – M450AJp. 154
SECTION 3 – ENGINEp. 157
FIGURE 3-1. KUBOTA MOTOR/GENERATOR INSTALLATION – M450AJp. 158
FIGURE 3-2. KUBOTA MOTOR/GENERATOR ASSEMBLY – M450AJp. 160
FIGURE 3-3. KUBOTA MOTOR/GENERATOR COMPONENTSp. 162
SECTION 4 – BOOMp. 165
FIGURE 4-1. BOOM AND CYLINDERS INSTALLATION – E450Ap. 166
FIGURE 4-2. BOOM AND CYLINDERS INSTALLATION – E450AJ/M450AJp. 168
FIGURE 4-3. MAIN BOOM ASSEMBLY – E450Ap. 172
FIGURE 4-4. MAIN BOOM ASSEMBLY – E450AJ/M450AJp. 176
FIGURE 4-5. JIB INSTALLATIONp. 178
FIGURE 4-6. ROTATOR ASSEMBLY – E450Ap. 180
FIGURE 4-7. ROTATOR ASSEMBLY – E450AJ/M450AJp. 182
FIGURE 4-8. PLATFORM SUPPORT WITHOUT LOAD SENSINGp. 184
FIGURE 4-9. PLATFORM SUPPORT INSTALLATION – WITH LSS – E450AJ/M450AJp. 186
FIGURE 4-10. PLATFORM SUPPORT INSTALLATION – WITH LSS – E450Ap. 190
FIGURE 4-11. CABLES AND CLAMPS INSTALLATION – E450Ap. 194
FIGURE 4-12. CABLES AND CLAMPS INSTALLATION – E450AJ/M450AJp. 196
FIGURE 4-13. BOOM LIMIT SWITCHES INSTALLATIONp. 198
SECTION 5 – PLATFORMp. 201
FIGURE 5-1. PLATFORM ASSEMBLY – 4FT/1.22M – SIDE GATE ENTRY (SN 0300189898 through 0300200789)p. 202
FIGURE 5-2. PLATFORM ASSEMBLY – 4FT/1.22M – SIDE GATE ENTRY (SN 0300200790 through 0300208529)p. 204
FIGURE 5-3. PLATFORM ASSEMBLY – 5FT/1.52M – SIDE GATE ENTRY (SN 0300189898 through 0300200789)p. 206
FIGURE 5-4. PLATFORM ASSEMBLY – 5FT/1.52M – SIDE GATE ENTRY (SN 0300200790 through 0300208529)p. 208
FIGURE 5-5. PLATFORM ASSEMBLY – 5FT/1.52M – SIDE GATE ENTRY – WITH STOP (SN 0300189898 through 0300195136)p. 210
FIGURE 5-6. PLATFORM ASSEMBLY – 6FT/1.83M – SIDE GATE ENTRY (SN 0300195137 through 0300200789)p. 212
FIGURE 5-7. PLATFORM ASSEMBLY – 6FT/1.83M – SIDE GATE ENTRY (SN 0300200790 through 0300208529)p. 214
FIGURE 5-8. PLATFORM ASSEMBLY – 4FT/1.22M – DROP BAR ENTRY (SN 0300189898 through 0300200789)p. 216
FIGURE 5-9. PLATFORM ASSEMBLY – 4FT/1.22M – DROP BAR ENTRY (SN 0300200790 through 0300208529)p. 218
FIGURE 5-10. PLATFORM ASSEMBLY – 5FT/1.52M – DROP BAR ENTRY (SN 0300189898 through 0300200789)p. 220
FIGURE 5-11. PLATFORM ASSEMBLY – 5FT/1.52M – DROP BAR ENTRY (SN 0300200790 through 0300208529)p. 222
FIGURE 5-12. PLATFORM ASSEMBLY – 6FT/1.83M – DROP BAR ENTRY (SN 0300189898 through 0300200789)p. 224
FIGURE 5-13. PLATFORM ASSEMBLY – 6FT/1.83M – DROP BAR ENTRY (SN 0300200790 through 0300208529)p. 226
FIGURE 5-14. PLATFORM ASSEMBLY – 5FT/1.52M – FALL ARREST (ANSI EXPORT SPEC) (SN 0300189898 through 0300200789)p. 228
FIGURE 5-15. PLATFORM ASSEMBLY – 5FT/1.52M – FALL ARREST (ANSI EXPORT SPEC) (SN 0300200790 through 0300208529)p. 230
FIGURE 5-16. PLATFORM ASSEMBLY – 6FT/1.83M – FALL ARREST (SN 0300189898 through 0300200789)p. 232
FIGURE 5-17. PLATFORM ASSEMBLY – 6FT/1.83M – FALL ARREST (SN 0300200790 through 0300208529)p. 234
FIGURE 5-18. TRAY ASSEMBLYp. 236
FIGURE 5-19. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATIONp. 238
FIGURE 5-20. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION – UL LISTEDp. 240
FIGURE 5-21. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION – WITH SKYGUARD (SN 0300200790 through 0300208529)p. 242
FIGURE 5-22. PLATFORM CONSOLE ASSEMBLYp. 244
FIGURE 5-23. PLATFORM CONSOLE ASSEMBLY – UL LISTEDp. 248
FIGURE 5-24. PLATFORM CONSOLE ASSEMBLY – WITH SKYGUARD (SN 0300200790 through 0300208529)p. 252
FIGURE 5-25. LIGHT PANEL DECAL INSTALLATIONp. 256
FIGURE 5-26. JIB SWITCH INSTALLATION – E450AJ/M450AJp. 258
FIGURE 5-27. SEALED ENCLOSURES – UL LISTEDp. 260
FIGURE 5-28. CONTROLLER ASSEMBLY – DRIVE AND STEERp. 262
FIGURE 5-29. CONTROLLER ASSEMBLY – LIFT AND SWINGp. 264
FIGURE 5-30. FOOTSWITCH ASSEMBLYp. 266
FIGURE 5-31. MOTOR CONTROLS INSTALLATION – M450AJp. 268
FIGURE 5-32. SKYGUARD SYSTEM INSTALLATION (SN 0300189898 through 0300200789)p. 270
FIGURE 5-33. SKYGUARD SYSTEM INSTALLATION (SN 0300200790 through 0300208529)p. 272
FIGURE 5-34. CROSS RAIL INSTALLATIONp. 274
FIGURE 5-35. PIPE RACK INSTALLATIONp. 276
SECTION 6 – CYLINDERp. 279
FIGURE 6-1. JIB CYLINDER ASSEMBLY – E450AJ/M450AJp. 280
FIGURE 6-2. LIFT CYLINDER ASSEMBLY – LOWER – E450A (ORIGINAL EQUIPMENT)p. 282
FIGURE 6-3. LIFT CYLINDER ASSEMBLY – E450A (SERVICE REPLACEMENT)p. 284
FIGURE 6-4. LIFT CYLINDER ASSEMBLY – LOWER – E450AJ/M450AJ (ORIGINAL EQUIPMENT)p. 286
FIGURE 6-5. LIFT CYLINDER ASSEMBLY – LOWER – E450AJ/M450AJ (SERVICE REPLACEMENT)p. 288
FIGURE 6-6. LIFT CYLINDER ASSEMBLY – MID – E450A (ORIGINAL EQUIPMENT)p. 290
FIGURE 6-7. LIFT CYLINDER ASSEMBLY – MID – E450A (SERVICE REPLACEMENT)p. 292
FIGURE 6-8. LIFT CYLINDER ASSEMBLY – MID – E450AJ/M450AJ (ORIGINAL EQUIPMENT)p. 294
FIGURE 6-9. LIFT CYLINDER ASSEMBLY – MID – E450AJ/M450AJ (SERVICE REPLACEMENT)p. 296
FIGURE 6-10. LIFT CYLINDER ASSEMBLY – UPPER – E450A (ORIGINAL EQUIPMENT)p. 298
FIGURE 6-11. LIFT CYLINDER ASSEMBLY – UPPER – E450A (SERVICE REPLACEMENT)p. 300
FIGURE 6-12. LIFT CYLINDER ASSEMBLY – UPPER – E450AJ/M450AJ (ORIGINAL EQUIPMENT)p. 302
FIGURE 6-13. LIFT CYLINDER ASSEMBLY – UPPER – E450AJ/M450AJ (SERVICE REPLACEMENT)p. 304
FIGURE 6-14. MASTER CYLINDER ASSEMBLY – E450Ap. 306
FIGURE 6-15. MASTER CYLINDER ASSEMBLY – E450AJ/M450AJp. 308
FIGURE 6-16. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY – E450Ap. 310
FIGURE 6-17. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY – E450AJ/M450AJp. 312
FIGURE 6-18. STEER CYLINDER ASSEMBLYp. 314
FIGURE 6-19. TELESCOPE CYLINDER ASSEMBLY – E450A (ORIGINAL EQUIPMENT)p. 316
FIGURE 6-20. TELESCOPE CYLINDER ASSEMBLY – E450A (SERVICE REPLACEMENT)p. 318
FIGURE 6-21. TELESCOPE CYLINDER ASSEMBLY – E450AJ/M450AJ (ORIGINAL EQUIPMENT)p. 320
FIGURE 6-22. TELESCOPE CYLINDER ASSEMBLY – E450AJ/M450AJ (SERVICE REPLACEMENT)p. 322
FIGURE 6-23. COUNTERBALANCE VALVE ASSEMBLYp. 324
SECTION 7 – HYDRAULICp. 327
FIGURE 7-1. HYDRAULIC DIAGRAM – E450Ap. 328
FIGURE 7-2. HYDRAULIC DIAGRAM – E450AJp. 332
FIGURE 7-3. HYDRAULIC DIAGRAM – M450AJp. 336
FIGURE 7-4. HYDRAULIC DIAGRAM LISTp. 340
SECTION 8 – ELECTRICALp. 341
FIGURE 8-1. ELECTRICAL DIAGRAM LISTp. 342
FIGURE 8-2. AC PLUGS AND SOCKETS INSTALLATION – CEE7 POST GROUND – 2 X 4 BOX (CE SPEC)p. 344
FIGURE 8-3. AC PLUGS AND SOCKETS INSTALLATION – CEE7 SIDE GROUND – 2 X 4 BOX (CE SPEC)p. 346
FIGURE 8-4. AC PLUGS AND SOCKETS INSTALLATION – AFSINT 107-2-01 KEYED GROUND – 2 X 4 BOX (CE SPEC)p. 348
FIGURE 8-5. AC PLUGS AND SOCKETS INSTALLATION – IEC 60309 YELLOW (CE SPEC)p. 350
FIGURE 8-6. AC PLUGS AND SOCKETS INSTALLATION – IEC 60309 BLUE (CE SPEC)p. 352
FIGURE 8-7. AC PLUGS AND SOCKETS INSTALLATION – CEE7 POST GROUND (CE SPEC)p. 354
FIGURE 8-8. AC PLUGS AND SOCKETS INSTALLATION – CEE 7 SIDE GROUND (CE SPEC)p. 356
FIGURE 8-9. ANALYZER HARNESS ASSEMBLYp. 358
FIGURE 8-10. BATTERY CHARGER ASSEMBLYp. 360
FIGURE 8-11. BATTERY CHARGER HARNESS (SN 0300189898 through 0300196080)p. 362
FIGURE 8-12. BATTERY CHARGER INDICATOR HARNESS – CE SPEC (SN 0300200790 through 0300208529)p. 364
FIGURE 8-13. BEACON LIGHT HARNESS (BLUE BEACON ONLY)p. 366
FIGURE 8-14. BOOM LIMIT SWITCH HARNESS – LOWERp. 368
FIGURE 8-15. BOOM LIMIT SWITCH HARNESS – UPPERp. 370
FIGURE 8-16. BREAKER BOX KIT WITH TWO BREAKERS – CE SPECp. 372
FIGURE 8-17. BREAKER BOX KIT WITH THREE BREAKERS – CE SPECp. 374
FIGURE 8-18. CHARGER CORD PLUG INSTALLATION – 220V – CEE7 POST GROUND (CE SPEC)p. 376
FIGURE 8-19. CHARGER CORD PLUG INSTALLATION – 220V – CEE7 SIDE GROUND (CE SPEC)p. 378
FIGURE 8-20. CHARGER CORD PLUG INSTALLATION – 220V – AFSINT 107 KEYED GROUND (CE SPEC)p. 380
FIGURE 8-21. CHARGER CORD PLUG INSTALLATION – 110V – IEC 60309 – YELLOW (CE SPEC)p. 382
FIGURE 8-22. CHARGER CORD PLUG INSTALLATION – 220V – IEC 60309 – BLUE (CE SPEC)p. 384
FIGURE 8-23. CONTACTOR CABLE KIT – E450A/E450AJp. 386
FIGURE 8-24. CONTACTOR CABLE KIT – M450AJp. 388
FIGURE 8-25. CONTACTOR PLATE ASSEMBLY AND HARNESSESp. 390
FIGURE 8-26. CONTACTOR PLATE ASSEMBLY AND HARNESSES – UL LISTEDp. 392
FIGURE 8-27. CONTACTOR PLATE KIT – E450A/E450AJ – UL/EEp. 394
FIGURE 8-28. DRIVE ORIENTATION HARNESSp. 396
FIGURE 8-29. DRIVE ORIENTATION SWITCH HARNESS ASSEMBLYp. 398
FIGURE 8-30. GENERATOR HARNESS TO GROUND CONTROL BOXp. 400
FIGURE 8-31. GROUND CONTROL CAN HARNESS ASSEMBLYp. 402
FIGURE 8-32. GROUND CONTROL FUNCTION SWITCH HARNESS ASSEMBLYp. 404
FIGURE 8-33. GROUND CONTROL FUNCTION SWITCH HARNESS ASSEMBLY – CE SPEC (SN 0300189898 through 0300200789)p. 406
FIGURE 8-34. GROUND CONTROL FUNCTION SWITCH HARNESS ASSEMBLY – CE SPEC (SN 0300200790 through 0300208529)p. 408
FIGURE 8-35. GROUND CONTROL VALVE HARNESS ASSEMBLYp. 410
FIGURE 8-36. HORN/BEACON HARNESS ASSEMBLYp. 412
FIGURE 8-37. INDICATOR LAMP HARNESS ASSEMBLYp. 414
FIGURE 8-38. INDICATOR LAMP HARNESS ASSEMBLY – WITH SKYGUARDp. 416
FIGURE 8-39. INVERTER HARNESS (SN 0300189898 through 0300193792)p. 418
FIGURE 8-40. INVERTER HARNESS (SN 0300193793 through 0300208529)p. 420
FIGURE 8-41. JIB HARNESS – AJ MODELS ONLYp. 422
FIGURE 8-42. LED REMOTE HARNESSp. 424
FIGURE 8-43. LOWER BOOM 110V HARNESS ASSEMBLYp. 426
FIGURE 8-44. LOWER BOOM 220V HARNESS ASSEMBLY – CE SPECp. 428
FIGURE 8-45. MAIN BOOM HARNESS ASSEMBLYp. 430
FIGURE 8-46. MAIN BOOM 110V HARNESS ASSEMBLYp. 432
FIGURE 8-47. MAIN BOOM 220V HARNESS ASSEMBLY – CE SPECp. 434
FIGURE 8-48. MAIN BOOM HARNESS ASSEMBLY – E450AJ/M450AJp. 436
FIGURE 8-49. MOTOR/STEER/BRAKE HARNESS – M450AJp. 438
FIGURE 8-50. PLATFORM CAN BUS HARNESS ASSEMBLYp. 440
FIGURE 8-51. PLATFORM FUNCTION SWITCH HARNESS ASSEMBLYp. 442
FIGURE 8-52. PLATFORM FUNCTION SWITCH HARNESS ASSEMBLY – WITH SKYGUARDp. 444
FIGURE 8-53. PLUG AND RECEPTACLE INSTALLATION – SUPPLIED LOCALLYp. 446
FIGURE 8-54. PLUG AND RECEPTACLE INSTALLATION – 110V – ANSI SPECp. 448
FIGURE 8-55. PLUG AND RECEPTACLE 110V INSTALLATION – IEC 60309 – YELLOW (CE SPEC)p. 450
FIGURE 8-56. PLUG AND RECEPTACLE 220V INSTALLATION – IEC 60309 – BLUE (CE SPEC)p. 452
FIGURE 8-57. PLUG AND RECEPTACLE 220V INSTALLATION – CEE7 POST GROUND – 70MM X 70MM BOX (CE SPEC)p. 454
FIGURE 8-58. PLUG AND RECEPTACLE 220V INSTALLATION – CEE7 SIDE GROUND – 70MM X 70MM BOX (CE SPEC)p. 456
FIGURE 8-59. PLUG AND RECEPTACLE 220V INSTALLATION – ANSI SPECp. 458
FIGURE 8-60. PLUG AND RECEPTACLE 220 INSTALLATION – CEE7 SIDE GROUND – 2 X 4 BOX (CE SPEC)p. 460
FIGURE 8-61. PLUG AND RECEPTACLE 220V INSTALLATION – CEE7 POST GROUND – 2 X 4 BOX (CE SPEC)p. 462
FIGURE 8-62. PLUG AND RECEPTACLE 220V INSTALLATION – AFSINT 107 KEYED GROUND – 2 X 4 BOX (CE SPEC)p. 464
FIGURE 8-63. POSI-TRACK MODULE CAN HARNESS ASSEMBLYp. 466
FIGURE 8-64. SKYGUARD PLATFORM SENSOR HARNESS (SN 0300189898 through 0300200789)p. 468
FIGURE 8-65. SKYGUARD PLATFORM SENSOR HARNESS (SN 0300200790 through 0300208529)p. 470
FIGURE 8-66. SKYGUARD CAN HARNESS (SN 0300200790 through 0300208529)p. 472
FIGURE 8-67. STEER BRAKE HARNESS – E450A/E450AJp. 474
FIGURE 8-68. STROBE LIGHT HARNESSp. 476
FIGURE 8-69. STROBE LIGHT – AMBER – HARNESSp. 478
FIGURE 8-70. TOWER BOOM HARNESS ASSEMBLY – E450A/E450AJ/M450AJp. 480
FIGURE 8-71. TURNTABLE/FRAME HARNESS ASSEMBLYp. 482
SECTION 9 – DECALSp. 485
FIGURE 9-1. DECAL INSTALLATION – JLG LOGOp. 486
FIGURE 9-2. DECAL INSTALLATION – ANSI SPEC – M450AJp. 488
FIGURE 9-3. DECAL INSTALLATION – ANSI SPEC – E450A/E450AJp. 490
FIGURE 9-4. DECAL INSTALLATION – AUSTRALIAN SPEC – M450AJp. 492
FIGURE 9-5. DECAL INSTALLATION – CE SPEC – M450AJ (SN 0300189898 through 0300200789)p. 494
FIGURE 9-6. DECAL INSTALLATION – CE SPEC – M450AJ (SN 0300200790 through 0300208529)p. 496
FIGURE 9-7. DECAL INSTALLATION – AUSTRALIAN SPEC – E450AJp. 498
FIGURE 9-8. DECAL INSTALLATION – CE SPEC – E450AJ (SN 0300189898 through 0300200789)p. 500
FIGURE 9-9. DECAL INSTALLATION – CE SPEC – E450AJ (SN 0300200790 through 0300208529)p. 502
FIGURE 9-10. DECAL INSTALLATION – JAPANESE SPEC – M450AJp. 504
FIGURE 9-11. DECAL INSTALLATION – JAPANESE SPEC – E450A/E450AJp. 506
FIGURE 9-12. DECAL INSTALLATION – KOREAN SPEC – M450AJp. 508
FIGURE 9-13. DECAL INSTALLATION – KOREAN SPEC – E450A/E450AJp. 510
FIGURE 9-14. DECAL INSTALLATION – SPANISH/ENGLISH SPECS – M450AJp. 512
FIGURE 9-15. DECAL INSTALLATION – SPANISH/ENGLISH SPECS – E450A/E450AJp. 514
FIGURE 9-16. DECAL INSTALLATION – FRENCH/ENGLISH SPECS – M450AJp. 516
FIGURE 9-17. DECAL INSTALLATION – FRENCH/ENGLISH SPECS – E450A/E450AJp. 518
FIGURE 9-18. DECAL INSTALLATION – CHINESE/ENGLISH SPEC – M450AJp. 520
FIGURE 9-19. DECAL INSTALLATION – CHINESE/ENGLISH SPEC – E450A/E450AJp. 522
FIGURE 9-20. DECAL INSTALLATION – SPANISH/PORTUGUESE SPECS – M450AJp. 524
FIGURE 9-21. DECAL INSTALLATION – SPANISH/PORTUGUESE SPECS – E450A/E450AJp. 526
SECTION 10 – RECOMMENDED SERVICE PARTS STOCKp. 529
FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCKp. 530
SECTION 11 – SPECIAL OPTIONSp. 531
FIGURE 11-1. SPECIAL OPTIONSp. 532
PART NUMBER INDEXp. 535

What makes this JLG E450A E450AJ M450AJ Illustrated Parts Manual genuinely useful is the level of granularity. Every figure is cross-referenced to a parts table that identifies not just the assembly but each individual bushing, seal, cartridge valve, fitting, harness pin and decal, with the correct JLG part number for the specific model and serial range. The hydraulics section gives complete hose and fitting identification for all three models. The electrical section breaks harnesses down to connector, pin and socket level. The cylinder section separates original equipment cylinders from service replacement cylinders, so a technician working on an older machine can tell at a glance which breakdown applies.

Who This Parts Manual Is For

This is the reference for anyone maintaining, repairing or rebuilding a JLG E450A, E450AJ or M450AJ. Whether you are replacing a worn wear pad on the main boom, ordering a new swing motor seal kit, chasing a hydraulic leak through a hose diagram, identifying the correct ground control box for a CE-spec machine, matching a decal set to the serial number, or simply looking up the exact part number before calling a supplier, the answer is in these pages. Parts managers and rebuild shops use it to quote and order accurately the first time. Owners who do their own maintenance use it to avoid the wrong part arriving and the machine sitting idle.

IMAGES PREVIEW

JLG E450A E450AJ M450AJ Illustrated Parts Manual - 2018 PDF Parts Catalog — PDF page 36 preview
JLG E450A E450AJ M450AJ Illustrated Parts Manual - 2018 PDF Parts Catalog — PDF page 118 preview
JLG E450A E450AJ M450AJ Illustrated Parts Manual - 2018 PDF Parts Catalog — PDF page 282 preview

Because the manual covers serial-number breakouts (covering ranges from 0300189898 through 0300208529 and the intermediate sub-ranges), it takes the guesswork out of model-year changes. Several assemblies – ground control boxes, harnesses, inverters, hood mounts, hoses, joystick controllers and platform consoles – differ within those ranges, and this manual tells you which one belongs to your machine.

Why It Matters

Working from the wrong parts reference on a boom lift costs time and money. A mis-identified hydraulic cartridge, an incorrect seal kit or a harness that does not match the serial number all lead to downtime. The JLG E450A E450AJ M450AJ Illustrated Parts Manual removes that risk by giving the exact part number, the exact figure and the exact revision level that JLG specified for these machines.

Instant PDF Delivery

This parts manual is delivered as an instant PDF download – no shipping, no waiting. Open it on any laptop, tablet or phone in the workshop, or print the figure pages you need for the job. The file is identical to the document referenced by its JLG part number 3121649, Revision G, so the figures, tables and part numbers line up with what you see on the machine.

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