JLG 450A 450AJ PVC 2007 Service & Maintenance Manual (31217149) – PDF DOWNLOAD

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JLG 450A 450AJ PVC 2007 Service & Maintenance Manual (31217149) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 450A 450AJ PVC 2007 Service & Maintenance Manual (31217149) – PDF DOWNLOAD

31217149_A_450A, 450AJ_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...................................................................... 76
			Carrier Disassembly.................................................................... 76
			Assemble Carrier....................................................................... 76
			Cover Sub-Assembly..................................................................... 78
			Hub-Spindle Sub-Assembly............................................................... 79
			Main Assembly.......................................................................... 81
			Tool List.............................................................................. 86
		3.11 Re-Align Torque Hub Input Coupling.................................................... 87
			Equipment Required..................................................................... 87
			Procedure.............................................................................. 87
		3.12 Drive Motor........................................................................... 87
			Description............................................................................ 87
			Shaft Seal Replacement................................................................. 88
			Loop Flushing Valve.................................................................... 88
			Troubleshooting........................................................................ 89
			Disassembly............................................................................ 90
			Inspection............................................................................. 94
			Assembly............................................................................... 96
			Initial Start-Up Procedures............................................................100
		3.13 Drive Brake...........................................................................101
			Disassembly............................................................................101
			Inspection.............................................................................101
			Assembly...............................................................................101
		3.14 Swing Bearing.........................................................................104
			Removal................................................................................104
			Installation...........................................................................104
			Turntable Bearing Mounting Bolt Condition Check........................................106
			Wear Tolerance.........................................................................106
		3.15 Swing Motor...........................................................................110
			Removal................................................................................112
			Preparation Before Disassembly.........................................................114
			Disassembly and Inspection.............................................................114
			Assembly...............................................................................121
			One Piece Stator Construction..........................................................127
			Two Piece Stator Construction..........................................................128
			Final Checks...........................................................................129
			Installation...........................................................................129
		3.16 Generator.............................................................................129
			Maintenance Schedule...................................................................129
			Overload Protection....................................................................130
			Inspecting Brushes, Replacing Brushes and Cleaning Slip Rings..........................130
			Troubleshooting........................................................................132
			Generator Disassembly and Assembly.....................................................133
			Lead Connection List for Generator.....................................................140
			Generator Pulley.......................................................................141
			Removal................................................................................141
			Installation...........................................................................141
			Removal................................................................................142
			Installation...........................................................................142
			Removal................................................................................143
			Installation...........................................................................143
			Removal................................................................................144
			Installation...........................................................................144
			Removal................................................................................145
			Installation...........................................................................145
		3.17 Deutz Engine..........................................................................146
		3.18 Kubota Engine.........................................................................150
		3.19 Deutz Engine - D2.9L4.................................................................152
			Check Oil Level........................................................................152
			Replacing Engine Oil...................................................................152
			Replacing the Oil Filter...............................................................152
			Replacing the Fuel Filters.............................................................153
		3.20 Deutz Engine - D2011L03...............................................................154
			Check Oil Level........................................................................154
			Replacing Engine Oil...................................................................155
			Replacing the Oil Filter...............................................................155
			Replacing the Fuel Filter..............................................................156
			Deutz EMR 2............................................................................157
		3.21 Kubota Engine General Maintenance.....................................................194
			Checking Oil Level.....................................................................194
			Replacing Engine Oil...................................................................194
			Replacing the Oil Filter...............................................................195
			Maintenance of the Drive Belt..........................................................195
			Replacing Oil Separator................................................................196
		3.22 Deutz Engine D2.9L4 (Stage V).........................................................200
			General Maintenance....................................................................202
			Check Oil Level........................................................................202
			Replacing Engine Oil...................................................................202
			Replacing the Oil Filter...............................................................202
			Replacing the Fuel Filters.............................................................203
			Deutz EMR5.............................................................................204
		3.23 HRC Engine Emission Characteristics...................................................231
			Terminology for Removing Soot..........................................................231
		3.24 Diesel Particulate Filter (If Equipped)...............................................232
			Standstill Cleaning....................................................................233
			Maintenance Standstill Cleaning Initiation Methods.....................................234
			Canceling Maintenance Standstill.......................................................234
			Unsuccessful Cleaning Event............................................................234
			DPF Filter Replacement due to Ash Load.................................................234
			Ash Load...............................................................................237
		3.26 Counterweight.........................................................................238
	Section 4. Boom & Platform.....................................................................241
		4.1 Boom Systems...........................................................................241
			Platform Control Enable System.........................................................241
			Transport Position Sensing System......................................................241
			Platform Load Sensing System (LSS).....................................................241
			Beyond Transport Position - Drive Speed Cutback System.................................241
			Drive/Steer –Boom Function Interlock System............................................241
			Jib Lift End of Stroke Dampening (if equipped).........................................241
			Main Boom Lift End of Stroke Dampening.................................................241
			Emergency Decent System................................................................241
		4.2 Platform...............................................................................242
			Platform/Support Removal...............................................................242
			Platform/Support Installation..........................................................243
		4.3 Rotator................................................................................245
			Removal................................................................................245
			Installation...........................................................................245
		4.4 Jib....................................................................................246
			Removal................................................................................246
			Disassembly............................................................................246
			Inspection.............................................................................246
			Assembly...............................................................................247
			Installation...........................................................................247
		4.5 Platform Level Cylinder................................................................248
			Removal................................................................................248
			Installation...........................................................................248
		4.6 Main Boom Powertrack...................................................................249
			Removal................................................................................249
			Installation...........................................................................249
		4.7 Powertrack Maintenance.................................................................250
			Remove Link............................................................................250
			Install New Link.......................................................................253
			Replace Fixed End Brackets.............................................................256
			Replace Moving End Brackets............................................................257
		4.8 Boom Cleanliness Guidelines............................................................264
		4.9 Boom Shimming Procedure................................................................265
		4.10 Boom Assembly.........................................................................274
			Upper Boom Removal.....................................................................274
			Mid Boom Removal.......................................................................275
			Lower Boom Removal.....................................................................277
			Upper Boom Disassembly.................................................................277
			Inspection.............................................................................279
			Upper Boom Assembly....................................................................279
			Lower Boom Installation................................................................280
			Mid Boom Installation..................................................................281
			Upper Boom Installation................................................................282
		4.11 Rotator Assembly......................................................................284
			Theory of Operation....................................................................284
			Required Tools.........................................................................285
			Before Disassembly.....................................................................285
			Disassembly............................................................................288
			Inspection.............................................................................292
			Assembly...............................................................................292
			Installing Counterbalance Valve........................................................298
			Greasing Thrust Washers................................................................299
			Testing the Actuator...................................................................299
			Installation and Bleeding..............................................................300
		4.12 Foot Switch Adjustment................................................................300
			Troubleshooting........................................................................301
		4.13 Skyguard..............................................................................302
			Operation..............................................................................302
			Function Test..........................................................................302
			Diagnostics & Troubleshooting..........................................................303
		4.14 Bolt-on External Fall Arrest..........................................................304
			Inspection Before Use..................................................................304
			Installation...........................................................................304
	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........................................................538
			Connector Labels.......................................................................538
			Component Labels.......................................................................538
		7.9 Electrical Installation................................................................540
		7.10 Wiring Harness........................................................................551
		7.11 Electrical Schematics.................................................................665

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