JLG 450AJ Service & Maintenance Manual (3121659) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 450AJ Service & Maintenance Manual (3121659) – PDF DOWNLOAD
3121659_E_450AJ_JLG_Service_English...................................................................................... 0
Section A. Introduction - Maintenance Safety Precautions............................................................. 0
A General........................................................................................................ 0
B Hydraulic System Safety........................................................................................ 0
C Maintenance.................................................................................................... 0
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................................................................................................ 26
1.7 Maintenance and Lubrication.................................................................................. 32
Section 2. General................................................................................................... 45
2.1 Machine Preparation, Inspection, and Maintenance............................................................. 45
General...................................................................................................... 45
Preparation, Inspection, and Maintenance..................................................................... 45
Pre-Start Inspection......................................................................................... 45
Pre-Delivery Inspection and Frequent Inspection.............................................................. 45
Annual Machine Inspection.................................................................................... 45
Preventive Maintenance....................................................................................... 45
2.2 Service and Guidelines....................................................................................... 46
General...................................................................................................... 46
Safety and Workmanship....................................................................................... 46
Cleanliness.................................................................................................. 46
Components Removal and Installation.......................................................................... 46
Component Disassembly and Reassembly......................................................................... 47
Pressure-Fit Parts........................................................................................... 47
Bearings..................................................................................................... 47
Gaskets...................................................................................................... 47
Bolt Usage and Torque Application............................................................................ 47
Hydraulic System............................................................................................. 47
Lubrication.................................................................................................. 47
Battery...................................................................................................... 47
Lubrication and Servicing.................................................................................... 47
2.3 Lubrication and Information.................................................................................. 48
Hydraulic System............................................................................................. 48
Hydraulic Oil................................................................................................ 48
Changing Hydraulic Oil....................................................................................... 48
Lubrication Specifications................................................................................... 48
2.4 Cylinder Drift Test.......................................................................................... 49
Theory....................................................................................................... 49
Cylinder Leakage Test........................................................................................ 49
Cylinder Thermal Drift....................................................................................... 49
2.5 Pins and Composite Bearing Repair Guidelines................................................................. 50
2.6 Welding on JLG Equipment..................................................................................... 50
Do the Following When Welding on JLG Equipment............................................................... 50
Do NOT Do the Following When Welding on JLG Equipment........................................................ 50
Section 3. Chassis & Turntable....................................................................................... 59
3.1 Tires and Wheels............................................................................................. 59
Tire Damage.................................................................................................. 59
Tire Replacement............................................................................................. 59
Wheel Replacement............................................................................................ 59
Wheel Installation........................................................................................... 59
3.2 Oscillating Axle System...................................................................................... 60
3.3 Lockout Cylinder Bleeding.................................................................................... 60
3.4 Chassis Tilt Indicator System................................................................................ 60
3.5 Oscillating Axle Lockout Test................................................................................ 64
3.6 Drive Orientation System..................................................................................... 64
3.7 Drive System................................................................................................. 65
3.8 Wheel Drive Assembly......................................................................................... 66
Removal...................................................................................................... 66
Installation................................................................................................. 66
3.9 Torque Hub................................................................................................... 67
Roll and Leak Testing........................................................................................ 67
Tightening and Torquing Bolts................................................................................ 67
Main Disassembly for “B” Drives.............................................................................. 68
Hub-Spindle Disassembly...................................................................................... 68
Cover Disassembly............................................................................................ 74
Carrier Disassembly.......................................................................................... 74
Assemble Carrier............................................................................................. 74
Cover Sub-Assembly........................................................................................... 76
Hub-Spindle Sub-Assembly..................................................................................... 77
Main Assembly................................................................................................ 79
Tool List.................................................................................................... 84
3.10 Re-Align Torque Hub Input Coupling.......................................................................... 85
Equipment Required........................................................................................... 85
Procedure.................................................................................................... 85
3.11 Drive Motor................................................................................................. 85
Description.................................................................................................. 85
Shaft Seal Replacement....................................................................................... 86
Loop Flushing Valve.......................................................................................... 86
Troubleshooting.............................................................................................. 87
Disassembly.................................................................................................. 88
Inspection................................................................................................... 92
Assembly..................................................................................................... 94
Initial Start-Up Procedures.................................................................................. 98
3.12 Drive Brake................................................................................................. 99
Disassembly.................................................................................................. 99
Inspection................................................................................................... 99
Assembly..................................................................................................... 99
3.13 Swing Bearing...............................................................................................102
Removal......................................................................................................102
Installation.................................................................................................102
Turntable Bearing Mounting Bolt Condition Check..............................................................104
Wear Tolerance...............................................................................................104
3.14 Swing Motor.................................................................................................108
Removal......................................................................................................110
Preparation Before Disassembly...............................................................................112
Disassembly and Inspection...................................................................................112
Assembly.....................................................................................................119
One Piece Stator Construction................................................................................125
Two Piece Stator Construction................................................................................126
Final Checks.................................................................................................127
Installation.................................................................................................127
3.15 Generator...................................................................................................127
Maintenance Schedule.........................................................................................127
Overload Protection..........................................................................................128
Inspecting Brushes, Replacing Brushes and Cleaning Slip Rings................................................128
Generator Disassembly and Assembly...........................................................................130
Lead Connection List for Generator...........................................................................138
3.16 Deutz Engine................................................................................................139
3.17 GM Engine...................................................................................................143
3.18 Kubota Engine...............................................................................................145
3.19 Deutz Engine - D2.9L4.......................................................................................147
Check Oil Level..............................................................................................147
Replacing Engine Oil.........................................................................................147
Replacing the Oil Filter.....................................................................................147
Replacing the Fuel Filters...................................................................................148
3.20 Deutz Engine - D2011........................................................................................149
Check Oil Level..............................................................................................149
Replacing Engine Oil.........................................................................................150
Replacing the Oil Filter.....................................................................................150
Replacing the Fuel Filter....................................................................................151
3.21 Deutz EMR 2.................................................................................................152
3.22 GM Engine General Maintenance...............................................................................189
Maintenance of the Drive Belt................................................................................189
Engine Electrical System Maintenance.........................................................................189
Checking/Filling Engine Oil Level............................................................................189
Changing the Engine Oil......................................................................................190
Coolant Fill Procedure - Dual Fuel Engine....................................................................190
3.23 GM Engine Dual Fuel System..................................................................................191
Fuel Filter..................................................................................................191
Electric Lock Off............................................................................................192
EPR Assembly.................................................................................................192
Low Pressure Regulator (LPR).................................................................................192
Air Fuel Mixer...............................................................................................193
Electronic Throttle Control (ETC)............................................................................193
Engine Control Module........................................................................................194
Heated Exhaust Gas Oxygen Sensor.............................................................................194
Gasoline Multi Point Fuel Injection System (MPFI)............................................................194
Gasoline Fuel Pump...........................................................................................195
Gasoline Pressure And Temperature Sensor Manifold............................................................195
Fuel Filter..................................................................................................195
Fuel Injector Rail...........................................................................................195
Fuel Injector................................................................................................195
3.24 GM Engine Fuel System Repair................................................................................196
Propane Fuel System Pressure Relief..........................................................................196
Propane Fuel System Leak Test................................................................................196
Propane Fuel Filter Replacement..............................................................................197
Electronic Pressure Regulator (EPR) Assembly Replacement.....................................................198
Electronic Throttle Control Replacement......................................................................199
Mixer Replacement............................................................................................201
Coolant Hose Replacement.....................................................................................201
Vapor Hose Replacement.......................................................................................201
Engine Control Module Replacement............................................................................202
Heated Exhaust Gas Oxygen Sensor Replacement.................................................................202
3.25 GM Engine LPG Fuel System Diagnosis.........................................................................203
Fuel System Description......................................................................................203
Diagnostic Aids..............................................................................................203
3.26 Kubota Engine General Maintenance...........................................................................214
Checking Oil Level...........................................................................................214
Replacing Engine Oil.........................................................................................214
Replacing the Oil Filter.....................................................................................215
Maintenance of the Drive Belt................................................................................215
REPLACING OIL SEPARATOR......................................................................................216
3.27 Counterweight...............................................................................................220
Section 4. Boom & Platform...........................................................................................221
4.1 Boom Systems.................................................................................................221
Platform Control Enable System...............................................................................221
Transport Position Sensing System............................................................................221
Platform Load Sensing System (LSS) (if Equipped).............................................................221
Beyond Transport Position - Drive Speed Cutback System.......................................................221
Drive/Steer –Boom Function Interlock System..................................................................221
Jib Lift End of Stroke Dampening (if equipped)...............................................................221
Main Boom Lift End of Stroke Dampening.......................................................................221
Emergency Decent System......................................................................................221
4.2 Platform.....................................................................................................222
Platform/Support Removal.....................................................................................222
Platform/Support Installation................................................................................223
4.3 Rotator......................................................................................................226
Removal......................................................................................................226
Installation.................................................................................................226
4.4 Jib..........................................................................................................227
Removal......................................................................................................227
Disassembly..................................................................................................227
Inspection...................................................................................................227
Assembly.....................................................................................................228
Installation.................................................................................................228
4.5 Platform Level Cylinder......................................................................................229
Removal......................................................................................................229
Installation.................................................................................................229
4.6 Main Boom Powertrack.........................................................................................230
Removal......................................................................................................230
Installation.................................................................................................230
4.7 Powertrack Maintenance.......................................................................................231
Remove Link..................................................................................................231
Install New Link.............................................................................................234
Replace Fixed End Brackets...................................................................................237
Replace Moving End Brackets..................................................................................238
4.8 Boom Cleanliness Guidelines..................................................................................245
4.9 Boom Shimming Procedure......................................................................................246
4.10 Boom Assembly...............................................................................................255
Upper Boom Removal...........................................................................................255
Mid Boom Removal.............................................................................................256
Lower Boom Removal...........................................................................................258
Upper Boom Disassembly.......................................................................................258
Inspection...................................................................................................260
Upper Boom Assembly..........................................................................................260
Lower Boom Installation......................................................................................261
Mid Boom Installation........................................................................................262
Upper Boom Installation......................................................................................263
4.11 Rotator Assembly............................................................................................265
Theory of Operation..........................................................................................265
Required Tools...............................................................................................266
Making a Seal Tool...........................................................................................266
Before Disassembly...........................................................................................266
Disassembly..................................................................................................269
Inspection...................................................................................................273
Assembly.....................................................................................................273
Installing Counterbalance Valve..............................................................................279
Greasing Thrust Washers......................................................................................280
Testing the Actuator.........................................................................................280
Installation and Bleeding....................................................................................281
4.12 Foot Switch Adjustment......................................................................................281
Troubleshooting..............................................................................................282
4.13 Skyguard....................................................................................................283
Operation....................................................................................................283
Function Test................................................................................................283
Diagnostics & Troubleshooting................................................................................284
Section 5. Basic Hydraulics Information & Schematics.................................................................285
5.1 Lubricating O-rings In The Hydraulic System..................................................................285
Cup and Brush................................................................................................285
Dip Method...................................................................................................286
Spray Method.................................................................................................286
Brush-on Method..............................................................................................286
5.2 Hydraulic Connection Assembly And Torque Specification.......................................................287
Tapered Thread Types.........................................................................................287
Straight Thread Types, Tube and Hose Connections.............................................................287
Straight Thread Types, Port Connections......................................................................288
Flange Connection Types......................................................................................288
Tightening Methods...........................................................................................288
Assembly And Torque Specifications...........................................................................289
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections...........................290
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections............................291
Assembly Instructions for 37° (JIC) Flare Fittings...........................................................292
Assembly Instructions for 45° SAE Flare Fittings.............................................................295
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings...................................................297
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)...................................299
Assembly Instructions for Bulkhead (BH) Fittings.............................................................301
Assembly Instructions for O-Ring Boss (ORB) Fittings.........................................................304
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings..........................................311
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends......................................318
Assembly instructions for Adjustable Port End (BSPP) Fittings................................................321
Assembly Instructions for Flange Connections: (FL61 and FL62)................................................328
Double Wrench Method.........................................................................................331
FFWR and TFFT Methods........................................................................................332
Adjustable Stud End Assembly.................................................................................332
O-ring Installation (Replacement)............................................................................333
5.3 Hydraulic Cylinders..........................................................................................334
Axle Lockout Cylinder........................................................................................334
Platform Level Cylinder......................................................................................336
Jib Lift Cylinder............................................................................................341
Main Lift Cylinder (USA Built Machines, SN 0300201991 through 0300226834)....................................346
Main Lift Cylinder (USA Built Machines, SN 0300226835 through 0300234431)....................................352
Main Lift Cylinder (SN E300002833 through E300004190, SN 0300234432 to Present, SN E300004191 to Present)....358
Tower Boom Lift Cylinder.....................................................................................364
Master Cylinder..............................................................................................369
Steer Cylinder...............................................................................................374
Telescope Cylinder (SN 0300201991 through 0300234431)........................................................377
Telescope Cylinder (SN 0300234432 to Present, SN E300002833 to Present)......................................383
5.4 Pressure Setting Procedure...................................................................................416
Main System Relief...........................................................................................416
Steer Left Relief............................................................................................416
Steer Right Relief...........................................................................................416
Swing Relief.................................................................................................417
Jib Lift Down Relief.........................................................................................417
Platform Level Up Relief.....................................................................................417
Platform Level Down Relief...................................................................................418
5.5 Drive Pump Pre-Fill Procedure................................................................................418
5.6 Hydraulic Schematics.........................................................................................426
Section 6. JLG Control System........................................................................................431
6.1 JLG Control System Analyzer Kit Instructions.................................................................431
Introduction.................................................................................................431
To Connect the JLG Control System Analyzer...................................................................432
Using the Analyzer...........................................................................................432
Changing the Access Level of the Hand Held Analyzer..........................................................433
Adjusting Parameters Using the Hand Held Analyzer............................................................434
Machine Setup................................................................................................435
Tilt Sensor Calibration......................................................................................436
Ground Control Console Display Gauge.........................................................................439
6.2 LSS System...................................................................................................466
Diagnostic Menu..............................................................................................467
Calibration Procedure........................................................................................468
Testing & Evaluation.........................................................................................472
Troubleshooting..............................................................................................473
6.3 Resetting The MSSO System....................................................................................474
6.4 Machine Model Adjustment.....................................................................................476
Adjustment Notes.............................................................................................476
Machine Orientation When Performing Test.....................................................................476
Section 7. Basic Electrical Information & Schematics.................................................................509
7.1 General......................................................................................................509
7.2 Multimeter Basics............................................................................................509
Grounding....................................................................................................509
Backprobing..................................................................................................509
Min/Max......................................................................................................509
Polarity.....................................................................................................509
Scale........................................................................................................509
Voltage Measurement..........................................................................................509
Resistance Measurement.......................................................................................510
Continuity Measurement.......................................................................................510
Current Measurement..........................................................................................511
7.3 Applying Silicone Dielectric Compound to Electrical Connections..............................................511
Installation of Dielectric Grease............................................................................512
Deutsch HD, DT, DTM, DRC Series..............................................................................512
AMP Seal.....................................................................................................512
AMP Mate-N-Lok...............................................................................................513
DIN Connectors...............................................................................................513
Exclusions...................................................................................................514
7.4 AMP Connector................................................................................................516
Applying Silicone Dielectric Compound to AMP Connectors......................................................516
Assembly.....................................................................................................516
Disassembly..................................................................................................518
Wedge Lock...................................................................................................518
Service - Voltage Reading....................................................................................518
7.5 Deutsch Connectors...........................................................................................520
DT/DTP Series Assembly.......................................................................................520
DT/DTP Series Disassembly....................................................................................520
HD30/HDP20 Series Assembly...................................................................................521
HD30/HDP20 Series Disassembly................................................................................521
7.6 Telematics Gateway...........................................................................................522
Telematics-Ready (TCU) Plug..................................................................................522
7.7 Wiring Harness Connector Labels..............................................................................526
Connector Labels.............................................................................................526
Component Labels.............................................................................................526
7.8 Wiring Harness...............................................................................................538
7.9 Electrical Schematics........................................................................................629
1659.1.pdf............................................................................................................... 0
Section A. Introduction - Maintenance Safety Precautions............................................................. 3
A General........................................................................................................ 3
B Hydraulic System Safety........................................................................................ 3
C Maintenance.................................................................................................... 3
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JLG 450AJ Service & Maintenance Manual (3121659) – PDF DOWNLOADJLG 450AJ Service & Maintenance Manual (3121659) – PDF DOWNLOAD
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