Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
JLG 450A 450AJ PVC 2001 Service & Maintenance Manual (31215022) – PDF DOWNLOAD 
JLG 450A 450AJ PVC 2001 Service & Maintenance Manual (31215022) – PDF DOWNLOAD
JLG 450A 450AJ PVC 2001 Service & Maintenance Manual (31215022) – PDF DOWNLOAD
Original price was: $70.00.$24.95Current price is: $24.95.
JLG 450A 450AJ PVC 2001 Service & Maintenance Manual (31215022) – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
JLG 450A 450AJ PVC 2001 Service & Maintenance Manual (31215022) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 450A 450AJ PVC 2001 Service & Maintenance Manual (31215022) – PDF DOWNLOAD
31215022_B_450A/AJ_JLG_Service_English............................................................. 1 Section A. Introduction - Maintenance Safety Precautions....................................... 3 A General.................................................................................. 3 B Hydraulic System Safety.................................................................. 3 C Maintenance.............................................................................. 3 Table of Contents.............................................................................. 5 List of Figures................................................................................ 12 List of Tables................................................................................. 21 Section 1. Specifications...................................................................... 23 1.1 Operating Specifications............................................................... 23 1.2 Dimensional Data....................................................................... 23 1.3 Capacities............................................................................. 23 1.4 Tires.................................................................................. 23 1.5 Engine Data............................................................................ 24 1.6 Hydraulic Oil.......................................................................... 25 1.7 Major Component Weight................................................................. 26 1.8 Maintenance and Lubrication............................................................ 30 1.9 Threadlocking Compound................................................................. 36 1.10 Torque Charts......................................................................... 37 SAE Fastener Torque Chart.............................................................. 37 SAE Fastener Torque Chart (Continued).................................................. 38 SAE Fastener Torque Chart (Continued).................................................. 39 SAE Fastener Torque Chart (Continued).................................................. 40 SAE Fastener Torque Chart (Continued).................................................. 41 SAE Fastener Torque Chart (Continued).................................................. 42 Metric Fastener Torque Chart........................................................... 43 Metric Fastener Torque Chart (Continued)............................................... 44 Metric Fastener Torque Chart (Continued)............................................... 45 Metric Fastener Torque Chart (Continued)............................................... 46 Section 2. General............................................................................. 47 2.1 Machine Preparation, Inspection, and Maintenance....................................... 47 General................................................................................ 47 Preparation, Inspection, and Maintenance............................................... 47 Pre-Start Inspection................................................................... 47 Pre-Delivery Inspection and Frequent Inspection........................................ 47 Annual Machine Inspection.............................................................. 47 Preventive Maintenance................................................................. 47 2.2 Service and Guidelines................................................................. 48 General................................................................................ 48 Safety and Workmanship................................................................. 48 Cleanliness............................................................................ 48 Components Removal and Installation.................................................... 48 Component Disassembly and Reassembly................................................... 49 Pressure-Fit Parts..................................................................... 49 Bearings............................................................................... 49 Gaskets................................................................................ 49 Bolt Usage and Torque Application...................................................... 49 Hydraulic System....................................................................... 49 Lubrication............................................................................ 49 Battery................................................................................ 49 Lubrication and Servicing.............................................................. 49 2.3 Lubrication and Information............................................................ 50 Hydraulic System....................................................................... 50 Hydraulic Oil.......................................................................... 50 Changing Hydraulic Oil................................................................. 50 Lubrication Specifications............................................................. 50 2.4 Cylinder Drift Test.................................................................... 51 Theory................................................................................. 51 Cylinder Leakage Test.................................................................. 51 Cylinder Thermal Drift................................................................. 51 2.5 Pins and Composite Bearing Repair Guidelines........................................... 52 2.6 Welding on JLG Equipment............................................................... 52 Do the Following When Welding on JLG Equipment......................................... 52 Do NOT Do the Following When Welding on JLG Equipment.................................. 52 Section 3. Chassis & Turntable................................................................. 61 3.1 Tires and Wheels....................................................................... 61 Tire Damage............................................................................ 61 Tire Replacement....................................................................... 61 Wheel Replacement...................................................................... 61 Wheel Installation..................................................................... 61 3.2 Oscillating Axle System................................................................ 62 3.3 Lockout Cylinder Bleeding.............................................................. 62 3.4 Chassis Tilt Indicator System.......................................................... 62 3.5 Oscillating Axle Lockout Test.......................................................... 66 3.6 Cold Start System (Diesel)............................................................. 66 3.7 Drive Orientation System............................................................... 66 3.8 Drive System........................................................................... 67 3.9 Wheel Drive Assembly................................................................... 68 Removal................................................................................ 68 Installation........................................................................... 68 3.10 Torque Hub............................................................................ 69 Roll and Leak Testing.................................................................. 69 Tightening and Torquing Bolts.......................................................... 69 Main Disassembly for “B” Drives........................................................ 70 Hub-Spindle Disassembly................................................................ 70 Cover Disassembly...................................................................... 77 Carrier Disassembly.................................................................... 77 Assemble Carrier....................................................................... 77 Cover Sub-Assembly..................................................................... 79 Hub-Spindle Sub-Assembly............................................................... 80 Main Assembly.......................................................................... 82 Tool List.............................................................................. 87 3.11 Re-Align Torque Hub Input Coupling.................................................... 88 Equipment Required..................................................................... 88 Procedure.............................................................................. 88 3.12 Drive Motor........................................................................... 88 Description............................................................................ 88 Shaft Seal Replacement................................................................. 89 Loop Flushing Valve.................................................................... 89 Troubleshooting........................................................................ 90 Disassembly............................................................................ 91 Inspection............................................................................. 95 Assembly............................................................................... 97 Initial Start-Up Procedures............................................................101 3.13 Drive Brake...........................................................................102 Disassembly............................................................................102 Inspection.............................................................................102 Assembly...............................................................................102 3.14 Swing Bearing.........................................................................105 Removal................................................................................105 Installation...........................................................................105 Turntable Bearing Mounting Bolt Condition Check........................................107 Wear Tolerance.........................................................................107 3.15 Swing Motor...........................................................................111 Removal................................................................................113 Preparation Before Disassembly.........................................................115 Disassembly and Inspection.............................................................115 Assembly...............................................................................122 One Piece Stator Construction..........................................................128 Two Piece Stator Construction..........................................................129 Final Checks...........................................................................130 Installation...........................................................................130 3.16 Generator.............................................................................130 Maintenance Schedule...................................................................130 Overload Protection....................................................................131 Inspecting Brushes, Replacing Brushes and Cleaning Slip Rings..........................131 Troubleshooting........................................................................133 Generator Disassembly and Assembly.....................................................134 Lead Connection List for Generator.....................................................142 Generator Pulley.......................................................................143 Removal................................................................................143 Installation...........................................................................143 Removal................................................................................144 Installation...........................................................................144 Removal................................................................................145 Installation...........................................................................145 Removal................................................................................146 Installation...........................................................................146 Removal................................................................................147 Installation...........................................................................147 3.17 Deutz Engine..........................................................................148 3.18 Kubota Engine.........................................................................152 3.19 Deutz Engine - D2.9L4.................................................................154 Check Oil Level........................................................................154 Replacing Engine Oil...................................................................154 Replacing the Oil Filter...............................................................154 Replacing the Fuel Filters.............................................................155 3.20 Deutz Engine - D2011L03...............................................................156 Check Oil Level........................................................................156 Replacing Engine Oil...................................................................157 Replacing the Oil Filter...............................................................157 Replacing the Fuel Filter..............................................................158 Deutz EMR 2............................................................................159 3.21 Kubota Engine General Maintenance.....................................................196 Checking Oil Level.....................................................................196 Replacing Engine Oil...................................................................196 Replacing the Oil Filter...............................................................197 Maintenance of the Drive Belt..........................................................197 REPLACING OIL SEPARATOR................................................................198 3.22 Deutz Engine D2.9L4 (STAGE V).........................................................202 General Maintenance....................................................................204 Check Oil Level........................................................................204 Replacing Engine Oil...................................................................204 Replacing the Oil Filter...............................................................204 Replacing the Fuel Filters.............................................................205 Deutz EMR5.............................................................................206 3.23 HRC Engine Emission Characteristics...................................................233 Terminology for Removing Soot..........................................................233 3.24 Diesel Particulate Filter (If Equipped)...............................................234 Standstill Cleaning....................................................................235 Maintenance Standstill Cleaning Initiation Methods.....................................236 Canceling Maintenance Standstill.......................................................236 Unsuccessful Cleaning Event............................................................236 DPF Filter Replacement due to Ash Load.................................................236 Ash Load...............................................................................239 3.26 Counterweight.........................................................................240 Section 4. Boom & Platform.....................................................................243 4.1 Boom Systems...........................................................................243 Platform Control Enable System.........................................................243 Transport Position Sensing System......................................................243 Platform Load Sensing System (LSS).....................................................243 Beyond Transport Position - Drive Speed Cutback System.................................243 Drive/Steer –Boom Function Interlock System............................................243 Jib Lift End of Stroke Dampening (if equipped).........................................243 Main Boom Lift End of Stroke Dampening.................................................243 Emergency Decent System................................................................243 4.2 Platform...............................................................................244 Platform/Support Removal...............................................................244 Platform/Support Installation..........................................................245 4.3 Rotator................................................................................247 Removal................................................................................247 Installation...........................................................................247 4.4 Jib....................................................................................248 Removal................................................................................248 Disassembly............................................................................248 Inspection.............................................................................248 Assembly...............................................................................249 Installation...........................................................................249 4.5 Platform Level Cylinder................................................................250 Removal................................................................................250 Installation...........................................................................250 4.6 Main Boom Powertrack...................................................................251 Removal................................................................................251 Installation...........................................................................251 4.7 Powertrack Maintenance.................................................................252 Remove Link............................................................................252 Install New Link.......................................................................255 Replace Fixed End Brackets.............................................................258 Replace Moving End Brackets............................................................259 4.8 Boom Cleanliness Guidelines............................................................266 4.9 Boom Shimming Procedure................................................................267 4.10 Boom Assembly.........................................................................276 Upper Boom Removal.....................................................................276 Mid Boom Removal.......................................................................277 Lower Boom Removal.....................................................................279 Upper Boom Disassembly.................................................................279 Inspection.............................................................................281 Upper Boom Assembly....................................................................281 Lower Boom Installation................................................................282 Mid Boom Installation..................................................................283 Upper Boom Installation................................................................284 4.11 Rotator Assembly......................................................................286 Theory of Operation....................................................................286 Required Tools.........................................................................287 Before Disassembly.....................................................................287 Disassembly............................................................................290 Inspection.............................................................................294 Assembly...............................................................................294 Installing Counterbalance Valve........................................................300 Greasing Thrust Washers................................................................301 Testing the Actuator...................................................................301 Installation and Bleeding..............................................................302 4.12 Foot Switch Adjustment................................................................302 Troubleshooting........................................................................303 4.13 Skyguard..............................................................................304 Operation..............................................................................304 Function Test..........................................................................304 Diagnostics & Troubleshooting..........................................................305 Section 5. Basic Hydraulics Information & Schematics...........................................307 5.1 Lubricating O-rings In The Hydraulic System............................................307 Cup and Brush..........................................................................307 Dip Method.............................................................................308 Spray Method...........................................................................308 Brush-on Method........................................................................308 5.2 Hydraulic Connection Assembly And Torque Specification.................................309 Tapered Thread Types...................................................................309 Straight Thread Types, Tube and Hose Connections.......................................309 Straight Thread Types, Port Connections................................................310 Flange Connection Types................................................................310 Tightening Methods.....................................................................310 Assembly And Torque Specifications.....................................................311 Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections.....312 Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections......313 Assembly Instructions for 37° (JIC) Flare Fittings.....................................314 Assembly Instructions for 45° SAE Flare Fittings.......................................318 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings.............................320 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS).............322 Assembly Instructions for Bulkhead (BH) Fittings.......................................324 Assembly Instructions for O-Ring Boss (ORB) Fittings...................................328 Assembly Instructions for Adjustable Port End Metric (MFF) Fittings....................336 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends................344 Assembly instructions for Adjustable Port End (BSPP) Fittings..........................348 Assembly Instructions for Flange Connections: (FL61 and FL62)..........................356 Double Wrench Method...................................................................359 FFWR and TFFT Methods..................................................................360 Adjustable Stud End Assembly...........................................................360 O-ring Installation (Replacement)......................................................361 5.3 Hydraulic Cylinders....................................................................362 Axle Lockout Cylinder..................................................................362 Platform Level Cylinder................................................................364 Jib Lift Cylinder......................................................................369 Main Lift Cylinder.....................................................................374 Tower Boom Lift Cylinder...............................................................379 Master Cylinder........................................................................384 Steer Cylinder.........................................................................389 Telescope Cylinder.....................................................................392 5.4 Pressure Setting Procedure.............................................................425 Main System Relief.....................................................................425 Steer Left Relief......................................................................425 Steer Right Relief.....................................................................425 Swing Relief...........................................................................426 Jib Lift Down Relief...................................................................426 Platform Level Up Relief...............................................................426 Platform Level Down Relief.............................................................427 5.5 Drive Pump Pre-Fill Procedure..........................................................427 5.6 Hydraulic Schematics...................................................................434 Section 6. JLG Control System..................................................................439 6.1 JLG Control System Analyzer Kit Instructions...........................................439 Introduction...........................................................................439 To Connect the JLG Control System Analyzer.............................................440 Using the Analyzer.....................................................................440 Changing the Access Level of the Hand Held Analyzer....................................441 Adjusting Parameters Using the Hand Held Analyzer......................................442 Machine Setup..........................................................................443 Tilt Sensor Calibration................................................................444 Ground Control Console Display Gauge...................................................447 6.2 LSS System.............................................................................477 Diagnostic Menu........................................................................478 Calibration Procedure..................................................................479 Testing & Evaluation...................................................................483 Troubleshooting........................................................................484 6.3 Resetting The MSSO System..............................................................485 6.4 Function Speed Control System..........................................................486 6.5 Fuel Reserve / Cut-out System..........................................................486 6.6 Machine Model Adjustment...............................................................487 Adjustment Notes.......................................................................487 Machine Orientation When Performing Test...............................................487 Section 7. Basic Electrical Information & Schematics...........................................521 7.1 General................................................................................521 7.2 Multimeter Basics......................................................................521 Grounding..............................................................................521 Backprobing............................................................................521 Min/Max................................................................................521 Polarity...............................................................................521 Scale..................................................................................521 Voltage Measurement....................................................................521 Resistance Measurement.................................................................522 Continuity Measurement.................................................................522 Current Measurement....................................................................523 7.3 Applying Silicone Dielectric Compound to Electrical Connections........................523 7.4 Dielectric Grease Application..........................................................524 Installation...........................................................................524 AMP Mate-N-Lok.........................................................................524 AMP Faston.............................................................................524 AMP Micro-Fit..........................................................................524 AMP Mini Fit Jr........................................................................525 Mini Fit Sr............................................................................525 DIN Connectors.........................................................................525 Exceptions.............................................................................525 7.5 AMP Connector..........................................................................526 Applying Silicone Dielectric Compound to AMP Connectors................................526 Assembly...............................................................................526 Disassembly............................................................................528 Wedge Lock.............................................................................528 Service - Voltage Reading..............................................................528 7.6 Deutsch Connectors.....................................................................530 DT/DTP Series Assembly.................................................................530 DT/DTP Series Disassembly..............................................................530 HD30/HDP20 Series Assembly.............................................................531 HD30/HDP20 Series Disassembly..........................................................531 7.7 Telematics Gateway.....................................................................532 Telematics-Ready (TCU) Plug............................................................532 7.8 Wiring Harness Connector Labels........................................................536 Connector Labels.......................................................................536 Component Labels.......................................................................536 7.9 Electrical Installation................................................................538 7.10 Wiring Harness........................................................................549 7.11 Electrical Schematics.................................................................663
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.M
