JLG 450A 450AJ Service & Maintenance Manual (3120749) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 450A 450AJ Service & Maintenance Manual (3120749) – PDF DOWNLOAD
SUBJECT – SECTION, PARAGRAPH PAGE NO
SECTION A – INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS
A General A-1
B Hydraulic System Safety A-1
C Maintenance A-1
SECTION 1 – SPECIFICATIONS
1 1 Capacities 1-1
1 2 Component Data 1-1
1 3 Tires 1-1
1 4 Specifications and Performance Data 1-1
1 5 Torque Requirements 1-2
1 6 Lubrication 1-2
1 7 Pressure Settings – PSI (Bar) 1-3
1 8 Major Component Weights 1-3
1 9 Critical Stability Weights 1-7
1 10 Cylinder Specifications 1-7
1 11 Function Speeds (in Seconds) 1-7
1 12 Serial Number Location 1-8
SECTION 2 – PROCEDURES
2 1 General 2-1
2 2 Service and Guidelines 2-1
2 3 Lubrication and Information 2-2
2 4 Cylinders – Theory of Operation 2-3
2 5 Valves – Theory of Operation 2-4
2 6 Boom Maintenance 2-4
2 7 Cylinder Checking Procedure 2-7
2 8 Cylinder Repair 2-8
2 9 Mid and Lower Lift Cylinder Bleeding Procedure 2-15
2 10 Hydraulic Pump (Gear) 2-15
2 11 Swing Bearing 2-22
2 12 Worm Gear 2-26
2 13 Boom Synchronizing Procedure 2-26
2 14 Jib 2-27
2 15 Bleeding Oscillation Cylinders 2-27
2 16 Oscillating Axle Lockout Test 2-27
2 17 Adjustment Procedure For Lockout Valve 2-29
2 18 Torque Hub (Prior to S/N 39594) 2-29
2 19 Torque Hub (S/N 39594 to Present) 2-34
2 20 Drive Brake (Ausco) 2-45
2 21 Boom Limit Switches 2-48
2 22 Lift Up and Platform Level Down Disable Switch 2-48
2 23 Electric Governor Installation and Adjustments – Ford Engine (Prior to S/N 46089) 2-48
2 24 Ford EFI Engine (machines after S/N 46089) 2-55
2 25 Drive and Steer Controller 2-66
2 26 Lift and Swing Controller 2-68
2 27 Function Control 2-68
2 28 Throttle Checks and Adjustments – Deutz Engine 2-70
2 29 Automatic Choke Adjustment – Ford Engine 2-72
2 30 Cold Weather Starting Difficulty 2-72
2 31 Checking the Fuel 2-74
2 32 Tilt Alarm Switch 2-74
ii – JLG Lift – 3120749
TABLE OF CONTENTS
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
2 33 Pressure Setting Procedures 2-74
2 34 Hydraulic Component Start-Up Procedures and Recommendations 2-79
2 35 Semi-Track 2-80
2 36 Preventive Maintenance and Inspection Schedule 2-87
SECTION 3 – TROUBLESHOOTING
3 1 General 3-1
3 2 Troubleshooting 3-1
3 3 Hydraulic Circuit Checks 3-1
LIST OF FIGURES
FIGURE NO TITLE PAGE NO
1-1 Lubrication Diagram 1-4
1-2 Serial Number Locations 1-8
1-3 Torque Chart 1-9
2-1 Location of Components – Boom Removal 2-4
2-2 Location of Components – Removal of Telescope Cylinder 2-5
2-3 Location of Components – Front Wear Pads 2-6
2-4 Boom Prop Configuration 2-9
2-5 Cylinder Barrel Support 2-10
2-6 Capscrew Removal 2-10
2-7 Cylinder Rod Support 2-10
2-8 Tapered Bushing Removal 2-11
2-9 Gar-Max Bearing Installation 2-11
2-10 Rod Seal Installation 2-12
2-11 Wiper Seal Installation 2-12
2-12 Installation of Head Seal Kit 2-12
2-13 Piston Seal Kit Installation 2-13
2-14 Tapered Bushing Installation 2-13
2-15 Seating the Tapered Bearing 2-14
2-16 Poly-Pak Piston Seal Installation 2-14
2-17 Rod Assembly Installation 2-14
2-19 Swing Bearing Feeler Gauge Check 2-22
2-18 Swing Bearing Installation 2-23
2-20 Swing Bearing Tolerance Measuring Point 2-24
2-21 Swing Bearing Torque Sequence 2-25
2-22 Synchronizing Valve 2-26
2-23 Jib 2-27
2-24 Front Axle 2-28
2-25 Ring Gear/Cover 2-29
2-26 Carrier 2-29
2-27 Torque Hub (Prior to S/N 39594) – Exploded View 2-31
2-28 Torque Hub (Prior to S/N 39594) – Cutaway View 2-32
2-29 Torque Hub (S/N 39594 to Present) – Cutaway View 2-35
2-30 Cluster Gear Punch Marks 2-43
2-31 Drive Brake (Ausco) 2-46
2-32 Switch Adjustment 2-48
2-33 Functional Check 2-48
2-34 Malfunction Indicator Light and Test Button 2-55
2-35 EFI Component Location 2-59
2-36 Typical Fuel System 2-63
2-37 Drive and Steer Adjustment 2-67
2-38 Lift and Swing Adjustment 2-68
3120749 – JLG Lift – iii
TABLE OF CONTENTS
LIST OF FIGURES (continued)
FIGURE NO TITLE PAGE NO
2-39 Function Control Card Adjustment 2-69
2-40 Addco Adjustments – Deutz 2-70
2-41 Tilt Switch Adjustment 2-74
2-42 Main Valve (Proportional Controls) – Sheet 1 2-75
2-43 Main Valve (Proportional Controls) – Sheet 2 2-76
2-44 Valve Location – Chassis 2-77
2-45 Cable Installation and Routing – Sheet 1 of 5 2-82
2-46 Cable Installation and Routing – Sheet 2 of 5 2-83
2-47 Cable Installation and Routing – Sheet 3 of 5 2-84
2-48 Cable Installation and Routing – Sheet 4 of 5 2-85
2-49 Cable Installation and Routing – Sheet 5 of 5 2-86
3-1 Electrical Components Installation – Sheet 1 3-20
3-2 Electrical Components Installation – Sheet 2 3-21
3-3 Electrical Schematic – Boom, Turntable, Chassis -Ford (Prior to S/N 46089) – Sheet 1 3-22
3-4 Electrical Schematic – Boom, Turntable, Chassis -Ford (Prior to S/N 46089) – Sheet 2 3-23
3-5 Electrical Schematic – Platform -Ford (Prior to S/N 46089) – Sheet 1 3-24
3-6 Electrical Schematic – Platform -Ford (Prior to S/N 46089) – Sheet 2 3-25
3-7 Electrical Schematic – Ford EFI (After S/N 46089) Sheet 1 3-26
3-8 Electrical Schematic – Ford EFI (After S/N 46089) – Sheet 2 3-27
3-9 Electrical Schematic – Boom, Turntable, Chassis – Deutz – Sheet 1 3-28
3-10 Electrical Schematic – Boom, Turntable, Chassis – Deutz – Sheet 2 3-29
3-11 Electrical Schematic – Platform -Deutz – Sheet 1 3-30
3-12 Electrical Schematic – Platform -Deutz – Sheet 2 3-31
3-13 Electrical Schematic – Boom, Turntable, Chassis – Isuzu – Sheet 1 3-32
3-14 Electrical Schematic – Boom, Turntable, Chassis – Isuzu – Sheet 2 3-33
3-15 Electrical Schematic – Platform – Isuzu – Sheet 1 3-34
3-16 Electrical Schematic – Platform – Isuzu – Sheet 2 3-35
3-17 Hydraulic Schematic – Proportional Controls 3-36
LIST OF TABLES
TABLE NO TITLE PAGE NO
1-1 Torque Requirements 1-2
1-2 Hydraulic Oil 1-2
1-3 Lubrication Specifications 1-2
1-4 Mobil EAL Envirosyn H 46 Specs 1-3
1-5 Major Component Weights 1-3
1-6 Lubrication Chart 1-5
1-7 Critical Stability Weights 1-7
1-8 Cylinder Specifications 1-7
2-1 Cylinder Head and Tapered Bushing Torque Specifications 2-15
2-2 Holding Valve Torque Specification 2-15
2-3 Hydraulic Pump Bolt Torque Chart 2-21
2-4 ECM Diagnostic Trouble Codes 2-57
2-5 Position Controller Truth Table 2-70
2-6 Adjustment Chart 2-81
2-7 Preventive Maintenance and Inspection Schedule 2-88
3-1 Platform Assembly – Troubleshooting 3-2
3-2 Boom Assembly – Troubleshooting 3-3
3-3 Turntable Assembly – Troubleshooting 3-8
3-4 Chassis Assembly – Troubleshooting 3-9
3-5 Hydraulic System – Troubleshooting 3-15
3-6 Electrical System – Troubleshooting 3-18
iv –
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