JLG 450AJ Service & Maintenance Manual (3121659) – PDF DOWNLOAD

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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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