JLG M45A, M45AJ, E45A & E45AJ Articulating Boom Lift Service and Maintenance Manual (ANSI) - 3120765

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This service manual PDF download for the M45A, M45AJ, E45A & E45AJ JLG Articulating Boom Lift has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

JLG Lift M45A
JLG Lift M45AJ
JLG Lift E45A
JLG Lift E45AJ


TABLE OF CONTENTS :

SECTION 1 - SPECIFICATIONS
1.1 Capacities 
1.2 Component Data 
1.3 Performance Data 
1.4 Function Speeds (M45A/E45A)
1.5 Function Speeds (M45AJ/E45AJ) 
1.6 Torque Specifications 
1.7 Lubrication
1.8 Pressure Settings 
1.9 Cylinder Specifications 
1.10 Major Component Weights 
1.11 Critical Stability Weights 
1.12 Serial Number Locations

SECTION 2 - PROCEDURES
2.1 General 
2.2 Servicing and Maintenance Guidelines 
2.3 Lubrication Information 
2.4 Battery Maintenance and Charging 
2.5 Cylinders - Theory of Operation 
2.6 Cylinder Checking Procedures 
2.7 Cylinder Repair
2.8 Cylinder Removal and Installation 
2.9 Wear Pads 
2.10 Boom Maintenance 
2.11 Rotator - Helac
2.12 Boom Limit Switches
2.13 Articulating Jib Boom 
2.14 Swing Bearing 
2.15 Mid and Lower Lift Cylinder Bleeding Procedure
2.16 Boom Synchronizing Procedure
2.17 Drive Hub
2.18 Drive Brake - Mico 
2.19 Pins and Gar-max Bearing Repair Guidelines 
2.20 Speed Sensor Adjustment 
2.21 Footswitch Adjustment 
2.22 Positrac/Tilt module
2.23 Pressure Setting Procedures 
2.24 JLG Control System Analyzer Kit Instructions 
2.25 Generator
2.26 Preventive Maintenance and Inspection Schedule

SECTION 3 - TROUBLESHOOTING
3.1 General 
3.2 Troubleshooting
3.3 Hydraulic Circuit Checks

LIST OF FIGURES
LIST OF TABLES


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Part Number : 3120765
Total Pages : 130


This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General 
B Hydraulic System Safety 
C Maintenance 

SECTION 1 - SPECIFICATIONS
1.1 Capacities 
1.2 Component Data 
1.3 Performance Data 
1.4 Function Speeds (M45A/E45A)
1.5 Function Speeds (M45AJ/E45AJ) 
1.6 Torque Specifications 
1.7 Lubrication
1.8 Pressure Settings 
1.9 Cylinder Specifications 
1.10 Major Component Weights 
1.11 Critical Stability Weights 
1.12 Serial Number Locations

SECTION 2 - PROCEDURES
2.1 General 
2.2 Servicing and Maintenance Guidelines 
2.3 Lubrication Information 
2.4 Battery Maintenance and Charging 
2.5 Cylinders - Theory of Operation 
2.6 Cylinder Checking Procedures 
2.7 Cylinder Repair
2.8 Cylinder Removal and Installation 
2.9 Wear Pads 
2.10 Boom Maintenance 
2.11 Rotator - Helac
2.12 Boom Limit Switches
2.13 Articulating Jib Boom 
2.14 Swing Bearing 
2.15 Mid and Lower Lift Cylinder Bleeding Procedure
2.16 Boom Synchronizing Procedure
2.17 Drive Hub
2.18 Drive Brake - Mico 
2.19 Pins and Gar-max Bearing Repair Guidelines 
2.20 Speed Sensor Adjustment 
2.21 Footswitch Adjustment 
2.22 Positrac/Tilt module
2.23 Pressure Setting Procedures 
2.24 JLG Control System Analyzer Kit Instructions 
2.25 Generator
2.26 Preventive Maintenance and Inspection Schedule

SECTION 3 - TROUBLESHOOTING
3.1 General 
3.2 Troubleshooting
3.3 Hydraulic Circuit Checks

LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. Serial Number Locations
1-2. Torque Chart 
1-3. Lubrication Diagram 
2-1. On Board Generator 
2-2. Batteries and Battery Charger
2-3. Cylinder Barrel Support
2-4. Capscrew Removal 
2-5. Cylinder Rod Support 
2-6. Tapered Bushing Removal 
2-7. Gar-Max Bearing Installation
2-8. Rod Seal Installation 
2-9. Wiper Seal Installation
2-10. Installation of Head Seal Kit
2-11. Piston Seal Kit Installation
2-12. Tapered Bushing Installation 
2-13. Seating the Tapered Bearing 
2-14. Poly-Pak Piston Seal Installation
2-15. Rod Assembly Installation
2-16. Upper Boom Lift Cylinder Removal 
2-17. Mid Boom Lift Cylinder Removal
2-18. Lower Boom Lift Cylinder Removal
2-19. Upper Telescope Cylinder Removal
2-20. Wear Pad Thickness 
2-21. Platform Components and Attaching Hardware (M45A & E45A)
2-22. Location of Components - Boom Removal
2-23. Rotator Assembly (Helac) 
2-24. Removing End Cap 
2-25. Removing Shaft from Housing 
2-26. Removing Sleeve from Housing 
2-27. Actuator Timing 
2-28. Boom Limit Switches
2-29. Location of Components - Articulating Jib Boom
2-30. Swing Bearing Feeler Gauge Check
2-32. Swing Bearing Tolerance Measuring Point
2-31. Swing Bearing Tolerance Boom Placement
2-33. Swing Bearing Torquing Sequence 
2-34. Swing Components
2-35. Drive Hub - Cutaway
2-36. Drive Brake - Mico
2-37. Speed Sensor Orientation
2-38. Frame Mounted Electrical Components
2-39. Steering Components and Spindles
2-40. Drive Components 
2-41. Tilt Sensor Location
2-42. Jib Valve Location 
2-43. Brake/Steer Valve Components 
2-44. Main Valve Components 
2-45. Control Module Location
2-46. Analyzer Flow Chart - Sheet 1 of 2 
2-47. Analyzer Flow Chart - Sheet 2 of 2 
2-48. Generator Components 
2-49. Generator System Analyzer Flow Chart
3-1. Electrical Components Installation - Sheet 1 
3-2. Electrical Components Installation - Sheet 2
3-3. Platform Electrical Schematic - Sheet 1 of 2
3-4. Platform Electrical Schematic - Sheet 2 of 2
3-5. Turntable Electrical Schematic 
3-6. Frame Electrical Schematic 
3-7. On Board Generator Electrical Schematic 
3-8. Hydraulic Schematic - M45A/E45A - Sheet 1 of 2 
3-9. Hydraulic Schematic - M45A/E45A - Sheet 2 of 2 
3-10. Hydraulic Schematic - M45AJ/E45AJ - Sheet 1 of 2
3-11. Hydraulic Schematic - M45AJ/E45AJ - Sheet 2 of 2

LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Torque Requirements 
1-2 Hydraulic Oil 
1-3 Lubrication Specifications
1-4 Mobil DTE 11M Specs
1-5 Cylinder Specifications
1-6 Major Component Weights 
1-7 Critical Stability Weights 
1-8 Lubrication Chart 
2-1 Cylinder Head and Tapered Bushing Torque Specifications
2-2 Cylinder Piston Nut Torque Specifications) 
2-3 Holding Valve Torque Specifications 
2-4 Wear Pad Thickness 
2-4 Pressure Settings 
2-5 Personality Ranges/Defaults 
2-6 Machine Setup Descriptions 
2-7 JLG Control System Flash Codes
2-8 Help Descriptions and Fault Flash Codes 
2-9 DIAGNOSTICS - Menu Descriptions
2-10 System Test Descriptions 
2-11 System Test Messages 
2-12 RBS Prestart Sequence
2-13 RBS Startup Sequence 
2-14 RBS Shutdown Sequence
2-15 Generator System Flash Codes 
2-16 Preventive Maintenance and Inspection Schedule
3-1 Platform Assembly - Troubleshooting
3-2 Boom Assembly - Troubleshooting
3-3 Turntable Assembly - Troubleshooting
3-4 Chassis Assembly - Troubleshooting 
3-5 Hydraulic System - Troubleshooting
3-6 Electrical System - Troubleshooting 

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