JLG 450A Series II 450AJ Series II Service & Maintenance Manual (3121290) – PDF DOWNLOAD

Description

JLG 450A Series II 450AJ Series II Service & Maintenance Manual (3121290) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 450A Series II 450AJ Series II Service & Maintenance Manual (3121290) – 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 Operating specifications and Performance Data............................. 17
	1.1 Reach Specifications...................................................... 17
	1.2 Dimensional Data.......................................................... 17
	1.3 Chassis................................................................... 17
	1.4 Capacities................................................................ 17
	1.5 Tires..................................................................... 18
	1.6 Engine.................................................................... 18
	1.7 Major Component Weights...................................................  0
	1.8 Hydraulic Oil............................................................. 19
	1.9 Serial Number Location.................................................... 20
	1.10 Operator Maintenance..................................................... 22
Section 2. General................................................................ 33
	2.1 Machine Preparation, Inspection, and Maintenance.......................... 33
		General................................................................... 33
		Preparation, Inspection, and Maintenance.................................. 33
		Pre-Start Inspection...................................................... 33
		Pre-Delivery Inspection and Frequent Inspection........................... 33
		Annual Machine Inspection................................................. 33
		Preventative Maintenance.................................................. 33
	2.2 Service and Guidelines.................................................... 34
		General................................................................... 34
		Safety and Workmanship.................................................... 34
		Cleanliness............................................................... 34
		Components Removal and Installation....................................... 34
		Component Disassembly and Reassembly...................................... 35
		Pressure-Fit Parts........................................................ 35
		Bearings.................................................................. 35
		Gaskets................................................................... 35
		Battery................................................................... 35
		Bolt Usage and Torque Application......................................... 35
		Hydraulic Lines and Electrical Wiring..................................... 35
		Hydraulic System.......................................................... 35
		Lubrication............................................................... 35
	2.3 Lubrication and Information............................................... 36
		Hydraulic System.......................................................... 36
		Hydraulic Oil............................................................. 36
		Changing Hydraulic Oil.................................................... 36
		Lubrication Specifications................................................ 36
	2.4 Cylinder Drift Test....................................................... 36
		Platform Drift............................................................ 36
		Cylinder Drift............................................................ 36
	2.5 Pins and Composite Bearing Repair Guidelines.............................. 37
	2.6 Welding on JLG Equipment.................................................. 37
		Do the Following When Welding on JLG Equipment............................ 37
		Do NOT Do the Following When Welding on JLG Equipment..................... 37
Section 3. Chassis & Turntable.................................................... 41
	3.1 Tires And Wheels.......................................................... 41
		Tire Inflation............................................................ 41
		Tire Damage............................................................... 41
		Tire Replacement.......................................................... 41
		Wheel Replacement......................................................... 41
		Wheel Installation........................................................ 42
	3.2 Torque Hub................................................................ 43
		Oil Information........................................................... 43
		Roll and Leak Testing..................................................... 43
		Tightening and Torquing Bolts............................................. 43
		MAIN DISASSEMBLY for “B” Drives........................................... 48
		Hub-Spindle Disassembly................................................... 48
		Cover Disassembly......................................................... 49
		Carrier Disassembly....................................................... 49
		Assemble Carrier.......................................................... 49
		Cover Sub-Assembly........................................................ 51
		Hub-Spindle Sub-Assembly.................................................. 52
		Main Assembly............................................................. 54
		Tool List................................................................. 59
	3.3 Re-Align Torque Hub Input Coupling........................................ 60
		Equipment Required........................................................ 60
		Procedure................................................................. 60
	3.4 Drive Motor............................................................... 60
		Description............................................................... 60
		Shaft Seal Replacement.................................................... 61
		Loop Flushing Valve....................................................... 61
		Troubleshooting........................................................... 62
		Disassembly............................................................... 63
		Inspection................................................................ 67
		Assembly.................................................................. 69
		Initial Start-Up Procedures............................................... 73
	3.5 Adjustment Procedure For Lockout Valve.................................... 75
	3.6 Oscillating Axle Bleeding Procedure and Lockout Test...................... 75
		Lockout Cylinder Bleeding (Ram Cylinders)................................. 75
		Oscillating Axle Lockout Test............................................. 76
	3.7 Swing Bearing............................................................. 76
		Description............................................................... 76
		Removal................................................................... 76
		Disassembly............................................................... 78
		Assembly.................................................................. 80
		Installation.............................................................. 80
		Turntable Bearing Mounting Bolt Checks.................................... 82
		Check Frame To Bearing Bolts.............................................. 82
		Check Turntable To Bearing Bolts.......................................... 82
		Wear Tolerance............................................................ 82
	3.8 Swing Motor............................................................... 83
		Preparation Before Disassembly............................................ 83
		Removal................................................................... 84
		Preparation Before Disassembly............................................ 84
		Disassembly and Inspection................................................ 86
		Assembly.................................................................. 93
		One Piece Stator Assembly................................................. 99
		Two Piece Stator Assembly.................................................100
		Final Checks..............................................................100
		Installation..............................................................100
	3.9 Generator.................................................................102
		Every 250 hours...........................................................102
		Every 500 hours...........................................................102
		Overload Protection.......................................................102
		Brushes and Slip Rings....................................................102
	3.10 Deutz Engine.............................................................104
		Check Oil Level...........................................................104
		Change Engine Oil.........................................................104
		Change Oil Filter.........................................................104
		Replace Fuel Filter.......................................................105
		Clean Fuel Strainer (D2011 L03 Only)......................................105
	3.11 Deutz EMR 2..............................................................106
	3.12 Bio Fuel in Deutz Engines................................................118
		General...................................................................118
		Bio Fuel..................................................................118
		Biological Contamination In Fuels.........................................119
	3.13 GM Engine General Maintenance............................................120
		Drive Belt Maintenance....................................................120
		Engine Electrical System Maintenance......................................120
		Checking/Filling Engine Oil Level.........................................120
		Change Engine Oil.........................................................121
		Coolant Fill Procedure - Dual Fuel Engine.................................121
	3.14 GM Engine Dual Fuel System...............................................122
		Fuel Filter...............................................................122
		Direct Electronic Pressure Regulator (DEPR)...............................124
		Air Fuel Mixer............................................................124
		Electronic Throttle Control (ETC).........................................125
		Electric Lock Off.........................................................125
		Engine Control Module (ECM)...............................................125
		Heated Exhaust Gas Oxygen Sensor..........................................126
		Gasoline Multi Point Fuel Injection System (MPFI).........................126
		Gasoline Fuel Pump........................................................126
		Gasoline Pressure And Temperature Sensor Manifold.........................126
		Fuel Filter...............................................................127
		Fuel Injector Rail........................................................127
		Fuel Injector.............................................................127
	3.15 GM Engine Fuel System Repair.............................................127
		Propane Fuel System Pressure Relief.......................................127
		Propane Fuel System Leak Test.............................................127
		Propane Fuel Filter Replacement...........................................128
		Direct Electronic Pressure Regulator (DEPR) Maintenance And Inspection....128
		Check/Drain Oil Build-Up In 2-Stage Vaporizer.............................129
		Air Fuel Mixer/Throttle Control Device Maintenance And Inspection.........129
		Exhaust System And Catalytic Converter Inspection And Maintenance.........130
		Temperature Manifold Absolute Pressure (TMAP) Sensor......................130
		Throttle Body (ETC) Replacement...........................................130
		Mixer Replacement.........................................................130
		Electronic Pressure Regulator (EPR) Replacement...........................131
		Regulator Replacement.....................................................131
		Coolant Hose Replacement..................................................131
		Vapor Hose Replacement....................................................131
		Engine Control Module Replacement.........................................132
		Heated Exhaust Gas Oxygen Sensor Replacement..............................132
	3.16 GM Engine LPG Fuel System Diagnosis......................................133
		Fuel System Description...................................................133
		Diagnostic Aids...........................................................133
	3.17 DGC Diagnostic Support And Trouble Code Definitions......................148
		Section Layout............................................................148
		Fault Code Broadcast......................................................150
		Diagnostic Trouble Codes..................................................150
		CAN.......................................................................150
		MIL Output................................................................150
		Diagnostic Calibration Configuration and Corrective Actions...............150
		Fault/Diagnostic Trouble Code Interaction.................................151
		DBW Diagnostic Test.......................................................154
	3.18 Diagnostic Trouble Code Fault Descriptions...............................157
		DTC 116- ECT Higher Than Expected Stage 1.................................157
		DTC 117- ECT/CHT Low Voltage..............................................158
		DTC 118- ECT/CHT High Voltage.............................................160
		DTC 122- TPS1 Signal Voltage Low..........................................162
		DTC 123- TPS1 Signal Voltage High.........................................164
		DTC 217- ECT Higher Than Expected 2.......................................166
		DTC 219- RPM Higher Than Max Allowed Governed Speed.......................167
		DTC 336- Crank Signal Input Noise.........................................168
		DTC 337- Loss of Crank Input Signal.......................................170
		DTC 521- Oil Pressure Sender/Switch High Pressure.........................171
		DTC 524- Oil Pressure Low.................................................174
		DTC 562- Battery Voltage (VBat) Low.......................................178
		DTC 563- Battery Voltage (VBat) High......................................180
		DTC 601- Microprocessor Failure - FLASH...................................182
		DTC 604- Microprocessor Failure - RAM.....................................184
		DTC 606- Microprocessor Failure - COP.....................................186
		DTC 642- 5 Volt External Low Voltage......................................188
		DTC 643- 5 Volt External High Voltage.....................................189
		DTC 1612- Microprocessor Failure - RTI 1..................................190
		DTC 1613- Microprocessor Failure - RTI 2..................................191
		DTC 1614- Microprocessor Failure - RTI 3..................................193
		DTC 1615- Microprocessor Failure - A/D....................................195
		DTC 1616- Microprocessor Failure - interrupt..............................197
		DTC 1625- CAN J1939 Shutdown Request......................................199
		DTC 1626- CAN J1939 Transmit (Tx) Fault...................................200
		DTC 1627- CAN J1939 Receive (Rx) Fault....................................201
		DTC 1628- CAN Address Conflict Failure....................................202
		DTC 1629- J1939 TSC1 Message Receipt Loss.................................204
		DTC 1652- TPS1 Loss of Communications.....................................205
		DTC 2111- Unable to Reach Lower TPS.......................................206
		DTC 2112- Unable to Reach Higher TPS......................................208
		DTC 9999- Throttle Actuator Failsafe Spring Failure.......................209
		DTC to SPN/FMI Table......................................................210
Section 4. Boom & Platform........................................................213
	4.1 Boom Maintenance..........................................................213
		Remove Boom Assembly......................................................213
		Main Boom Disassembly.....................................................214
		Inspection................................................................214
		Main Boom Assembly........................................................215
		Install Boom Assembly.....................................................215
	4.2 Rotary Actuator...........................................................219
		Theory of Operation.......................................................219
		Required Tools............................................................219
		Disassembly...............................................................221
		Inspection................................................................224
		Assembly..................................................................225
		Installing Counterbalance Valve...........................................230
	4.3 Powertrack Maintenance....................................................232
		Remove Link...............................................................232
		Install New Link..........................................................235
		Replace Fixed End Brackets................................................238
		Replace Moving End Brackets...............................................239
Section 5. Hydraulics.............................................................241
	5.1 O-Ring Lubrication........................................................241
		Cup and Brush.............................................................241
		Dip.......................................................................242
		Spray.....................................................................242
		Brush-On..................................................................242
	5.2 Hydraulic Cylinders.......................................................243
		Tower Lift Cylinder.......................................................244
		Main Lift Cylinder........................................................249
		Master Cylinder (450 A/AJ) Without Arctic Package.........................253
		Master Cylinder (450 A/AJ) With Arctic Package............................258
		Telescope Cylinder........................................................263
		Slave (Platform Level) Cylinder Without Arctic Pkg........................267
		Platform Level (Slave) Cylinder With Arctic Package.......................272
		Jib Lift Cylinder (AJ Only) Without Arctic Package........................277
		Jib Lift Cylinder (AJ Only) With Arctic Package...........................282
		Steer Cylinder............................................................287
		Axle Lockout Cylinder.....................................................291
	5.3 Hydraulic Pump (Gear).....................................................293
		Disassembly...............................................................293
		Inspect Parts For Wear....................................................295
		General Information.......................................................296
		Reverse Shaft Rotation of Pump............................................296
		Assembly..................................................................296
		Placing Pump Back Into Service............................................299
	5.4 Variable Pump.............................................................299
		Ports and Pressure Gauges.................................................299
		NFPE Control..............................................................299
		Remove and Install FNR and NFPE Modules...................................300
		Remove and Install FNR and NFPE Control Orifices..........................300
		Charge Relief Valve.......................................................300
		Shaft Seal and Shaft Replacement..........................................303
		Charge Pump...............................................................305
	5.5 Hydraulic Component Start-Up..............................................306
	5.6 Main Valve Block Pressure Setting Procedures..............................307
		Telescope.................................................................307
		Main Relief...............................................................307
		Steer.....................................................................307
		Lift Down.................................................................307
		Swing.....................................................................307
	5.7 Platform Valve Block Pressure Setting Procedures..........................307
		Platform Level Extend.....................................................307
		Platform Level Retract....................................................307
		Articulating Jib (AJ Only)................................................307
Section 6. JLG Control System.....................................................311
	6.1 introduction..............................................................311
		Connect JLG Control System Analyzer.......................................313
		Using Analyzer............................................................313
		Changing Access Level.....................................................314
		Adjust Parameters.........................................................315
		Machine Setup.............................................................316
		Level Vehicle Description.................................................316
	6.8 System Test...............................................................336
		Test from Platform........................................................336
		Test From Ground Station..................................................338
Section 7. Basic Electrical Information & Schematics..............................371
	7.1 General...................................................................371
	7.2 Multimeter Basics.........................................................371
		Grounding.................................................................371
		Backprobing...............................................................371
		Min/Max...................................................................371
		Polarity..................................................................371
		Scale.....................................................................371
		Voltage Measurement.......................................................371
		Resistance Measurement....................................................372
		Continuity Measurement....................................................372
		Current Measurement.......................................................373
	7.3 Applying Silicone Dielectric Compound to Electrical Connections...........373
		Dielectric Grease Application.............................................374
		Deutsch HD, DT, DTM, DRC Series...........................................374
		AMP Seal..................................................................374
		AMP Mate-N-Lok............................................................375
		DIN Connectors............................................................375
		Exclusions................................................................375
	7.4 AMP Connector.............................................................376
		Contact Assembly..........................................................376
		Connector Assembly........................................................376
		Disassembly...............................................................377
		Wedge Lock................................................................377
		Service - Voltage Reading.................................................377
	7.5 Deutsch Connectors........................................................378
		DT/DTP Series Assembly....................................................378
		DT/DTP Series Disassembly.................................................378
		HD30/HDP20 Series Assembly................................................379
		HD30/HDP20 Series Disassembly.............................................379

IMAGES PREVIEW OF THE MANUAL:

 PLEASE NOTE:

• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
• No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
• Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
• So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com