JLG Lift 450A/AJ Series II Articulating Boom Lift Service and Maintenance Manual (Global)

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This service manual PDF download for the 450A/AJ Series II JLG Articulating Boom Lift has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JLG Lift 450A/AJ Series II
Prior To S/N 0300160835

TABLE OF CONTENTS :

Section 1. Specifications
1.1 Capacities
1.2 Tires
1.3 Engine
1.4 Specifications and Performance Data
1.5 Function Speeds
1.6 Torque Requirements
1.7 Lubrication
1.8 Major Component Weights
1.9 Pressure Settings – PSI (BAR)
1.10 Serial Number Location
1.11 Operator Maintenance
1.12 Draining Propane Regulator Oil Build Up (Prior to S/N 0300137808)
1.13 Propane Fuel Filter Replacement
1.14 Propane System Pressure Relief

Section 2. General
2.1 General
2.2 Service and Guidelines
2.3 Lubrication and Information
2.4 Cylinder Drift Test
2.5 Pins and Composite Bearing Repair Guidelines
2.6 Welding on JLG Equipment

Section 3. Chassis & Turntable
3.1 Tires & Wheels
3.2 Torque Hub (Machines Built Before S/N 0300071527)
3.3 Torque Hub (Machines built after S/N 0300071527)
3.4 Re-Aligning Torque Hub Input Coupling
3.5 Drive Motor
3.6 Drive Motor
3.7 Adjustment Procedure For Lockout Valve
3.8 Oscillating Axle Bleeding Procedure and Lockout Test
3.9 Swing Bearing
3.10 Swing Motor
3.11 Semi-Track
3.12 Generator
3.13 Ford EFI Engine
3.14 Circuit Testing Tools
3.15 Deutz Engine
3.16 Deutz EMR 2 (S/N 85332 to Present)
3.17 GM Engine General Maintenance
3.18 GM Engine Dual Fuel System
3.19 GM Engine Fuel System Repair
3.20 GM Engine LPG Fuel System Diagnosis
3.21 Perkins Engine General Maintenance
3.22 Engine Radiator Fill Procedure – Perkins & Caterpillar
3.23 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS
3.24 Diagnostic Trouble Code Fault Descriptions

Section 4. Boom & Platform
4.1 Boom Maintenance
4.2 Rotator
4.3 Rotary Actuator (S/N 0300130812 and 1300006433 to Present)

Section 5. Hydraulics
5.1 Cylinder Repair -USA Manufactured Only
5.2 Hydraulic Pump (Gear)
5.3 Variable Pump
5.4 Hydraulic Component Start-Up Procedures and Recommendations
5.5 Pressure Setting Procedure

Section 6. JLG Control System
6.1 Introduction
6.2 Connect JLG Control System Analyzer
6.3 Using Analyzer
6.4 Changing Hand Held Analyzer Access Level
6.5 Adjusting Parameters Using the Hand Held Analyzer
6.6 Machine Setup
6.7 Machine Personality Settings
6.8 System Test

Section 7. Basic Electrical Information & Schematics
7.1 General
7.1 Multimeter Basics
7.2 Applying Silicone Dielectric Compound to Electrical Connections
7.3 AMP Connector
7.4 Deutsch Connectors

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 3121180
Total Pages : 472

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Section A. Introduction – Maintenance Safety Precautions
A. General
B. Hydraulic System Safety
C. Maintenance

Section 1. Specifications
1.1 Capacities
1.2 Tires
1.3 Engine
1.4 Specifications and Performance Data
Reach Specifications
Dimensional Data
Chassis
1.5 Function Speeds
Machine Orientation When Doing Speed Tests
Test Notes
1.6 Torque Requirements
1.7 Lubrication
Hydraulic Oil
1.8 Major Component Weights
1.9 Pressure Settings – PSI (BAR)
1.10 Serial Number Location
1.11 Operator Maintenance
1.12 Draining Propane Regulator Oil Build Up (Prior to S/N 0300137808)
1.13 Propane Fuel Filter Replacement
Removal
Installation
1.14 Propane System Pressure Relief

Section 2. General
General
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance
2.2 Service and Guidelines
General
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Lubrication and Servicing
2.3 Lubrication and Information
Hydraulic System
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications
2.4 Cylinder Drift Test
Platform Drift
Cylinder Drift
2.5 Pins and Composite Bearing Repair Guidelines
2.6 Welding on JLG Equipment
DO the Following When Welding on JLG Equipment
DO NOT Do the Following When Welding on JLG Equipment

Section 3. Chassis & Turntable
3.1 Tires & Wheels
Tire Inflation
Tire Damage
Pneumatic Tires
Polyurethane Foam Filled Tires
Solid Flex Tires
Tire Replacement
Wheel Replacement
Wheel Installation
3.2 Torque Hub (Machines Built Before S/N 0300071527)
Roll, Leak, and Brake Testing
Tightening and Torquing Bolts
Main Disassembly
Input Carrier Disassembly
Output Carrier Disassembly
Housing-Spindle Disassembly
Spindle-Brake Disassembly
Input Carrier Sub-Assembly
Output Carrier Sub-Assembly
Spindle-Brake Sub-Assembly
Housing-Spindle Sub-Assembly
DW2B INTEGRAL BRAKE CHECK
Main Assembly
3.3 Torque Hub (Machines built after S/N 0300071527)
Roll and Leak Testing
Tightening and Torquing Bolts
Oil Information
MAIN DISASSEMBLY for “B” Drives
Hub-Spindle Disassembly
Cover Disassembly
Carrier Disassembly
Assemble Carrier
Cover Sub-Assembly
Hub-Spindle Sub-Assembly
Main Assembly
Tool List
3.4 Re-Aligning Torque Hub Input Coupling
Equipment Required
Procedure
3.5 Drive Motor
Disassembly
Inspection
Assembly
Drive Motor Troubleshooting
3.6 Drive Motor
Description
Shaft Seal Replacement
Loop Flushing Valve
Troubleshooting
Disassembly
Inspection
Assembly
Initial Start-up Procedures
3.7 Adjustment Procedure For Lockout Valve
3.8 Oscillating Axle Bleeding Procedure and Lockout Test
Lockout Cylinder Bleeding (Early Cylinders)
Lockout Cylinder Bleeding (Ram Cylinders)
Oscillating Axle Lockout Test
3.9 Swing Bearing
Description
Removal
Disassembly
Assembly
Installation
Turntable Bearing Mounting Bolt Condition Check
Check Frame To Bearing Bolts
Wear Tolerance
3.10 Swing Motor
Preparation Before Disassembly
Removal
Preparation Before Disassembly
Disassembly and Inspection
Assembly
One Piece Stator Assembly
Two Piece Stator Assembly
Final Checks
Installation
3.11 Semi-Track
Testing
Removing
Normal Wear
Adjustment
3.12 Generator
Every 250 hours
Every 500 hours
Overload Protection
Brushes and Slip Rings
3.13 Ford EFI Engine
Performing Diagnostics
EFI Diagnostics
ECM and Sensors
Intake Air Temperature (IAT) Sensor
Manifold Absolute Pressure (MAP) Sensor
Engine Control Module (ECM)
ECM Inputs/Outputs
Throttle Position (TP) Sensor
3.14 Circuit Testing Tools
Electrostatic Discharge Damage
Fuel System
3.15 Deutz Engine
Checking Oil Level
Changing Engine Oil
Changing Oil Filter
Replacing Fuel Filter
Cleaning Fuel Strainer
3.16 Deutz EMR 2 (S/N 85332 to Present)
3.17 GM Engine General Maintenance
Drive Belt Maintenance
Engine Electrical System Maintenance
Checking/Filling Engine Oil Level
Changing Engine Oil
Coolant Fill Procedure – Dual Fuel Engine
3.18 GM Engine Dual Fuel System
Fuel Filter
Electric Lock Off
EPR Assembly
Low Pressure Regulator (LPR)
Air Fuel Mixer
Electronic Throttle Control (ETC)
Engine Control Module
Heated Exhaust Gas Oxygen Sensor
Gasoline Multi Point Fuel Injection System (MPFI)
Gasoline Fuel Pump
Gasoline Pressure And Temperature Sensor Manifold
Fuel Filter
Fuel Injector Rail
Fuel Injector
3.19 GM Engine Fuel System Repair
Propane Fuel System Pressure Relief
Propane Fuel System Leak Test
Propane Fuel Filter Replacement
Removal
Installation
Electronic Pressure Regulator (EPR) Assembly Replacement
Temperature Manifold Absolute Pressure (TMAP) Sensor
Electronic Throttle Control Replacement
MIXER REPLACEMENT
Coolant Hose Replacement
Vapor Hose Replacement
Engine Control Module Replacement
Heated Exhaust Gas Oxygen Sensor Replacement
3.20 GM Engine LPG Fuel System Diagnosis
Fuel System Description
Diagnostic Aids
3.21 Perkins Engine General Maintenance
Replacing the Engine Crankcase Breather
Engine Oil Level – Check
Engine Oil and Filter – Change
Fuel Filter/Water Separator
Setting Actuator
Speed Sensor Installation
3.22 Engine Radiator Fill Procedure – Perkins & Caterpillar
3.23 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS
Section Layout
Fault Code Broadcast
Diagnostic Trouble Codes
CAN
MIL Output
Diagnostic Calibration Configuration and Corrective Actions
Fault/Diagnostic Trouble Code Interaction
DBW Diagnostic Test
3.24 Diagnostic Trouble Code Fault Descriptions
DTC 116- ECT Higher Than Expected Stage 1
DTC 117- ECT/CHT Low Voltage
DTC 118- ECT/CHT High Voltage
DTC 122- TPS1 Signal Voltage Low
DTC 123- TPS1 Signal Voltage High
DTC 217- ECT Higher Than Expected 2
DTC 219- RPM Higher Than Max Allowed Governed Speed
DTC 336- Crank Signal Input Noise
DTC 337- Loss of Crank Input Signal
DTC 521- Oil Pressure Sender/Switch High Pressure
DTC 524- Oil Pressure Low
DTC 562- Battery Voltage (VBat) Low
DTC 563- Battery Voltage (VBat) High
DTC 601- Microprocessor Failure – FLASH
DTC 604- Microprocessor Failure – RAM
DTC 606- Microprocessor Failure – COP
DTC 642- 5 Volt External Low Voltage
DTC 643- 5 Volt External High Voltage
DTC 1612- Microprocessor Failure – RTI 1
DTC 1613- Microprocessor Failure – RTI 2
DTC 1614- Microprocessor Failure – RTI 3
DTC 1615- Microprocessor Failure – A/D
DTC 1616- Microprocessor Failure – interrupt
DTC 1625- CAN J1939 Shutdown Request
DTC 1626- CAN J1939 Transmit (Tx) Fault
DTC 1627- CAN J1939 Receive (Rx) Fault
DTC 1628- CAN Address Conflict Failure
DTC 1629- J1939 TSC1 Message Receipt Loss
DTC 1652- TPS1 Loss of Communications
DTC 2111- Unable to Reach Lower TPS
DTC 2112- Unable to Reach Higher TPS
DTC 9999- Throttle Actuator Failsafe Spring Failure
DTC to SPN/FMI Table
Section 4. Boom & Platform
4.1 Boom Maintenance
Removal of Boom Assembly
Disassembly of Main Boom
Inspection
Assembly of Main Boom
Installation of Boom Assembly
4.2 Rotator
Theory of Operation
Disassembly and Inspection
Assembly and Testing
4.3 Rotary Actuator (S/N 0300130812 and 1300006433 to Present)
Theory of Operation
Required Tools
Disassembly
Inspection
Assembly
Installing Counterbalance Valve
Section 5. Hydraulics
5.1 Cylinder Repair -USA Manufactured Only
Disassembly
Cleaning and Inspection
Assembly
5.2 Hydraulic Pump (Gear)
Disassembly
Inspect Parts For Wear
General Information
Reverse Shaft Rotation of Pump
Assembly
Placing Pump Back Into Service
5.3 Variable Pump
Ports and Pressure Gauges
NFPE Control
Removal and Installation of FNR and NFPE Modules
Removal and Installation of FNR and NFPE Control Orifices
Charge Relief Valve
Shaft Seal and Shaft Replacement
Charge Pump
5.4 Hydraulic Component Start-Up Procedures and Recommendations
5.5 Pressure Setting Procedure
Bang-Bang Main Relief
Steer
Platform Level Up
Platform Level Down
Articulating Jib
Proportional Main Relief
Lift Down
Swing
Section 6. JLG Control System
6.1 Introduction
6.2 Connect JLG Control System Analyzer
6.3 Using Analyzer
6.4 Changing Hand Held Analyzer Access Level
6.5 Adjusting Parameters Using the Hand Held Analyzer
6.6 Machine Setup
6.7 Machine Personality Settings
6.8 System Test
Test from Platform
Test from the Ground Station
Section 7. Basic Electrical Information & Schematics
7.1 General
7.1 Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement
7.2 Applying Silicone Dielectric Compound to Electrical Connections
7.3 AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
Assembly
Disassembly
Wedge Lock
7.4 Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly

 

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JLG Lift 450A/AJ Series II Articulating Boom Lift Service and Maintenance Manual (Global).pdf

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