JLG 450A 450AJ Series II Service & Maintenance Manual (3121180) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 450A 450AJ Series II Service & Maintenance Manual (3121180) – PDF DOWNLOAD
Section A. Introduction - Maintenance Safety Precautions.......................... 3
A. General.................................................................... 3
B. Hydraulic System Safety.................................................... 3
C. Maintenance................................................................ 3
Section 1. Specifications..................................................... 17
1.1 Capacities............................................................ 17
1.2 Tires................................................................. 17
1.3 Engine................................................................ 17
1.4 Specifications and Performance Data................................... 18
Reach Specifications.................................................. 18
Dimensional Data...................................................... 18
Chassis............................................................... 18
1.5 Function Speeds....................................................... 19
Machine Orientation When Doing Speed Tests............................ 19
Test Notes............................................................ 19
1.6 Torque Requirements................................................... 19
1.7 Lubrication........................................................... 21
Hydraulic Oil......................................................... 21
1.8 Major Component Weights............................................... 22
1.9 Pressure Settings - PSI (BAR)......................................... 22
1.10 Serial Number Location............................................... 22
1.11 Operator Maintenance................................................. 23
1.12 Draining Propane Regulator Oil Build Up (Prior to S/N 0300137808).... 27
1.13 Propane Fuel Filter Replacement...................................... 28
Removal............................................................... 28
Installation.......................................................... 28
1.14 Propane System Pressure Relief....................................... 28
Section 2. General................................................................ 37
General....................................................................... 37
Preparation, Inspection, and Maintenance...................................... 37
Pre-Start Inspection.......................................................... 37
Pre-Delivery Inspection and Frequent Inspection............................... 37
Annual Machine Inspection..................................................... 37
Preventative Maintenance...................................................... 37
2.2 Service and Guidelines.................................................... 38
General................................................................... 38
Safety and Workmanship.................................................... 38
Cleanliness............................................................... 38
Components Removal and Installation....................................... 38
Component Disassembly and Reassembly...................................... 39
Pressure-Fit Parts........................................................ 39
Bearings.................................................................. 39
Gaskets................................................................... 39
Bolt Usage and Torque Application......................................... 39
Hydraulic Lines and Electrical Wiring..................................... 39
Hydraulic System.......................................................... 39
Lubrication............................................................... 39
Battery................................................................... 39
Lubrication and Servicing................................................. 39
2.3 Lubrication and Information............................................... 40
Hydraulic System.......................................................... 40
Hydraulic Oil............................................................. 40
Changing Hydraulic Oil.................................................... 40
Lubrication Specifications................................................ 40
2.4 Cylinder Drift Test....................................................... 41
Platform Drift............................................................ 41
Cylinder Drift............................................................ 41
2.5 Pins and Composite Bearing Repair Guidelines.............................. 41
2.6 Welding on JLG Equipment.................................................. 42
DO the Following When Welding on JLG Equipment............................ 42
DO NOT Do the Following When Welding on JLG Equipment..................... 42
Section 3. Chassis & Turntable.................................................... 51
3.1 Tires & Wheels............................................................ 51
Tire Inflation............................................................ 51
Tire Damage............................................................... 51
Pneumatic Tires........................................................... 51
Polyurethane Foam Filled Tires............................................ 51
Solid Flex Tires.......................................................... 51
Tire Replacement.......................................................... 51
Wheel Replacement......................................................... 51
Wheel Installation........................................................ 52
3.2 Torque Hub (Machines Built Before S/N 0300071527)......................... 53
Roll, Leak, and Brake Testing............................................. 53
Tightening and Torquing Bolts............................................. 53
Main Disassembly.......................................................... 54
Input Carrier Disassembly................................................. 56
Output Carrier Disassembly................................................ 57
Housing-Spindle Disassembly............................................... 58
Spindle-Brake Disassembly................................................. 59
Input Carrier Sub-Assembly................................................ 60
Output Carrier Sub-Assembly............................................... 62
Spindle-Brake Sub-Assembly................................................ 64
Housing-Spindle Sub-Assembly.............................................. 66
DW2B INTEGRAL BRAKE CHECK................................................. 66
Main Assembly............................................................. 68
3.3 Torque Hub (Machines built after S/N 0300071527).......................... 80
Roll and Leak Testing..................................................... 80
Tightening and Torquing Bolts............................................. 80
Oil Information........................................................... 80
MAIN DISASSEMBLY for “B” Drives........................................... 80
Hub-Spindle Disassembly................................................... 81
Cover Disassembly......................................................... 81
Carrier Disassembly....................................................... 81
Assemble Carrier.......................................................... 82
Cover Sub-Assembly........................................................ 84
Hub-Spindle Sub-Assembly.................................................. 85
Main Assembly............................................................. 87
Tool List................................................................. 92
3.4 Re-Aligning Torque Hub Input Coupling..................................... 93
Equipment Required........................................................ 93
Procedure................................................................. 93
3.5 Drive Motor............................................................... 93
Disassembly............................................................... 93
Inspection................................................................ 94
Assembly.................................................................. 96
Drive Motor Troubleshooting............................................... 96
3.6 Drive Motor............................................................... 97
Description............................................................... 97
Shaft Seal Replacement.................................................... 97
Loop Flushing Valve....................................................... 98
Troubleshooting........................................................... 99
Disassembly...............................................................100
Inspection................................................................104
Assembly..................................................................106
Initial Start-up Procedures...............................................111
3.7 Adjustment Procedure For Lockout Valve....................................114
3.8 Oscillating Axle Bleeding Procedure and Lockout Test......................114
Lockout Cylinder Bleeding (Early Cylinders)...............................114
Lockout Cylinder Bleeding (Ram Cylinders).................................114
Oscillating Axle Lockout Test.............................................115
3.9 Swing Bearing.............................................................115
Description...............................................................115
Removal...................................................................115
Disassembly...............................................................117
Assembly..................................................................119
Installation..............................................................119
Turntable Bearing Mounting Bolt Condition Check...........................120
Check Frame To Bearing Bolts..............................................120
Wear Tolerance............................................................121
3.10 Swing Motor..............................................................122
Preparation Before Disassembly............................................122
Removal...................................................................124
Preparation Before Disassembly............................................124
Disassembly and Inspection................................................125
Assembly..................................................................132
One Piece Stator Assembly.................................................138
Two Piece Stator Assembly.................................................139
Final Checks..............................................................139
Installation..............................................................139
3.11 Semi-Track...............................................................140
Testing...................................................................140
Removing..................................................................140
Normal Wear...............................................................140
Adjustment................................................................140
3.12 Generator................................................................144
Every 250 hours...........................................................144
Every 500 hours...........................................................144
Overload Protection.......................................................144
Brushes and Slip Rings....................................................144
3.13 Ford EFI Engine..........................................................146
Performing Diagnostics....................................................146
EFI Diagnostics...........................................................146
ECM and Sensors...........................................................146
Intake Air Temperature (IAT) Sensor.......................................150
Manifold Absolute Pressure (MAP) Sensor...................................150
Engine Control Module (ECM)...............................................150
ECM Inputs/Outputs........................................................151
Throttle Position (TP) Sensor.............................................151
3.14 Circuit Testing Tools....................................................152
Electrostatic Discharge Damage............................................152
Fuel System...............................................................152
3.15 Deutz Engine.............................................................156
Checking Oil Level........................................................156
Changing Engine Oil.......................................................156
Changing Oil Filter.......................................................157
Replacing Fuel Filter.....................................................157
Cleaning Fuel Strainer....................................................157
3.16 Deutz EMR 2 (S/N 85332 to Present).......................................158
3.17 GM Engine General Maintenance............................................170
Drive Belt Maintenance....................................................170
Engine Electrical System Maintenance......................................170
Checking/Filling Engine Oil Level.........................................170
Changing Engine Oil.......................................................171
Coolant Fill Procedure - Dual Fuel Engine.................................171
3.18 GM Engine Dual Fuel System...............................................172
Fuel Filter...............................................................172
Electric Lock Off.........................................................172
EPR Assembly..............................................................173
Low Pressure Regulator (LPR)..............................................173
Air Fuel Mixer............................................................174
Electronic Throttle Control (ETC).........................................174
Engine Control Module.....................................................175
Heated Exhaust Gas Oxygen Sensor..........................................175
Gasoline Multi Point Fuel Injection System (MPFI).........................175
Gasoline Fuel Pump........................................................176
Gasoline Pressure And Temperature Sensor Manifold.........................176
Fuel Filter...............................................................176
Fuel Injector Rail........................................................176
Fuel Injector.............................................................176
3.19 GM Engine Fuel System Repair.............................................176
Propane Fuel System Pressure Relief.......................................176
Propane Fuel System Leak Test.............................................177
Propane Fuel Filter Replacement...........................................177
Removal...................................................................177
Installation..............................................................177
Electronic Pressure Regulator (EPR) Assembly Replacement..................178
Temperature Manifold Absolute Pressure (TMAP) Sensor......................179
Electronic Throttle Control Replacement...................................179
MIXER REPLACEMENT.........................................................180
Coolant Hose Replacement..................................................180
Vapor Hose Replacement....................................................181
Engine Control Module Replacement.........................................181
Heated Exhaust Gas Oxygen Sensor Replacement..............................181
3.20 GM Engine LPG Fuel System Diagnosis......................................182
Fuel System Description...................................................182
Diagnostic Aids...........................................................182
3.21 Perkins Engine General Maintenance.......................................197
Replacing the Engine Crankcase Breather...................................197
Engine Oil Level - Check..................................................197
Engine Oil and Filter - Change............................................197
Fuel Filter/Water Separator...............................................199
Setting Actuator..........................................................200
Speed Sensor Installation.................................................201
3.22 Engine Radiator Fill Procedure - Perkins & Caterpillar...................201
3.23 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS......................203
Section Layout............................................................203
Fault Code Broadcast......................................................205
Diagnostic Trouble Codes..................................................205
CAN.......................................................................205
MIL Output................................................................205
Diagnostic Calibration Configuration and Corrective Actions...............206
Fault/Diagnostic Trouble Code Interaction.................................207
DBW Diagnostic Test.......................................................209
3.24 Diagnostic Trouble Code Fault Descriptions...............................212
DTC 116- ECT Higher Than Expected Stage 1.................................212
DTC 117- ECT/CHT Low Voltage..............................................213
DTC 118- ECT/CHT High Voltage.............................................215
DTC 122- TPS1 Signal Voltage Low..........................................217
DTC 123- TPS1 Signal Voltage High.........................................219
DTC 217- ECT Higher Than Expected 2.......................................221
DTC 219- RPM Higher Than Max Allowed Governed Speed.......................222
DTC 336- Crank Signal Input Noise.........................................223
DTC 337- Loss of Crank Input Signal.......................................225
DTC 521- Oil Pressure Sender/Switch High Pressure.........................226
DTC 524- Oil Pressure Low.................................................229
DTC 562- Battery Voltage (VBat) Low.......................................233
DTC 563- Battery Voltage (VBat) High......................................235
DTC 601- Microprocessor Failure - FLASH...................................237
DTC 604- Microprocessor Failure - RAM.....................................239
DTC 606- Microprocessor Failure - COP.....................................241
DTC 642- 5 Volt External Low Voltage......................................243
DTC 643- 5 Volt External High Voltage.....................................244
DTC 1612- Microprocessor Failure - RTI 1..................................245
DTC 1613- Microprocessor Failure - RTI 2..................................245
DTC 1614- Microprocessor Failure - RTI 3..................................247
DTC 1615- Microprocessor Failure - A/D....................................249
DTC 1616- Microprocessor Failure - interrupt..............................251
DTC 1625- CAN J1939 Shutdown Request......................................253
DTC 1626- CAN J1939 Transmit (Tx) Fault...................................254
DTC 1627- CAN J1939 Receive (Rx) Fault....................................255
DTC 1628- CAN Address Conflict Failure....................................256
DTC 1629- J1939 TSC1 Message Receipt Loss.................................258
DTC 1652- TPS1 Loss of Communications.....................................259
DTC 2111- Unable to Reach Lower TPS.......................................260
DTC 2112- Unable to Reach Higher TPS......................................262
DTC 9999- Throttle Actuator Failsafe Spring Failure.......................263
DTC to SPN/FMI Table......................................................264
Section 4. Boom & Platform........................................................267
4.1 Boom Maintenance..........................................................267
Removal of Boom Assembly..................................................267
Disassembly of Main Boom..................................................268
Inspection................................................................268
Assembly of Main Boom.....................................................269
Installation of Boom Assembly.............................................269
4.2 Rotator...................................................................274
Theory of Operation.......................................................274
Disassembly and Inspection................................................274
Assembly and Testing......................................................274
4.3 Rotary Actuator (S/N 0300130812 and 1300006433 to Present)................277
Theory of Operation.......................................................277
Required Tools............................................................277
Disassembly...............................................................280
Inspection................................................................284
Assembly..................................................................284
Installing Counterbalance Valve...........................................289
Section 5. Hydraulics.............................................................291
5.1 Cylinder Repair -USA Manufactured Only....................................291
Disassembly...............................................................291
Cleaning and Inspection...................................................312
Assembly..................................................................313
5.2 Hydraulic Pump (Gear).....................................................316
Disassembly...............................................................316
Inspect Parts For Wear....................................................318
General Information.......................................................319
Reverse Shaft Rotation of Pump............................................319
Assembly..................................................................319
Placing Pump Back Into Service............................................322
5.3 Variable Pump.............................................................322
Ports and Pressure Gauges.................................................322
NFPE Control..............................................................322
Removal and Installation of FNR and NFPE Modules..........................323
Removal and Installation of FNR and NFPE Control Orifices.................323
Charge Relief Valve.......................................................323
Shaft Seal and Shaft Replacement..........................................326
Charge Pump...............................................................328
5.4 Hydraulic Component Start-Up Procedures and Recommendations...............330
5.5 Pressure Setting Procedure................................................332
Bang-Bang Main Relief.....................................................332
Steer.....................................................................332
Platform Level Up.........................................................332
Platform Level Down.......................................................332
Articulating Jib..........................................................332
Proportional Main Relief..................................................332
Lift Down.................................................................332
Swing.....................................................................332
Section 6. JLG Control System.....................................................337
6.1 Introduction..............................................................337
6.2 Connect JLG Control System Analyzer.......................................339
6.3 Using Analyzer............................................................339
6.4 Changing Hand Held Analyzer Access Level..................................341
6.5 Adjusting Parameters Using the Hand Held Analyzer.........................343
6.6 Machine Setup.............................................................343
6.7 Machine Personality Settings..............................................355
6.8 System Test...............................................................375
Test from Platform........................................................375
Test from the Ground Station..............................................377
Section 7. Basic Electrical Information & Schematics..............................417
7.1 General...................................................................417
7.1 Multimeter Basics.........................................................417
Grounding.................................................................417
Backprobing...............................................................417
Min/Max...................................................................417
Polarity..................................................................417
Scale.....................................................................417
Voltage Measurement.......................................................417
Resistance Measurement....................................................418
Continuity Measurement....................................................418
Current Measurement.......................................................419
7.2 Applying Silicone Dielectric Compound to Electrical Connections...........419
7.3 AMP Connector.............................................................420
Applying Silicone Dielectric Compound to AMP Connectors...................420
Assembly..................................................................420
Disassembly...............................................................422
Wedge Lock................................................................422
7.4 Deutsch Connectors........................................................424
DT/DTP Series Assembly....................................................424
DT/DTP Series Disassembly.................................................424
HD30/HDP20 Series Assembly................................................425
HD30/HDP20 Series Disassembly.............................................425
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JLG 450A 450AJ Series II Service & Maintenance Manual (3121180) – PDF DOWNLOAD
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