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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