JLG 450AJ II Series Manuals

Manuals and User Guides for JLG 450AJ II Series. We have 3 JLG 450AJ II Series manuals available for free PDF download: Service And Maintenance Manual, Operation And Safety Manual

JLG 450AJ II Series Service And Maintenance Manual (396 pages)

Brand: JLG | Category: Lifting Systems | Size: 36.27 MB

A General
3
Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Specifications

17
General

33
- Machine Preparation, Inspection, and Maintenance
  33
- Service and Guidelines
  34
  - General
    34
  - Safety and Workmanship
    34
  - Cleanliness
    34
  - Components Removal and Installation
    34
  - Component Disassembly and Reassembly
    35
  - Pressure-Fit Parts
    35
  - Bearings
    35
  - Gaskets
    35
  - Battery
    35
  - Bolt Usage and Torque Application
    35
  - Hydraulic Lines and Electrical Wiring
    35
  - Hydraulic System
    35
  - Lubrication
    35
- Lubrication and Information
  36
  - Hydraulic System
    36
  - Hydraulic Oil
    36
  - Changing Hydraulic Oil
    36
  - Lubrication Specifications
    36
- Cylinder Drift Test
  36
  - Platform Drift
    36
  - Cylinder Drift
    36
- Pins and Composite Bearing Repair Guidelines
  37
- Welding on JLG Equipment
  37
Chassis & Turntable

41
- 3.1 Tires and Wheels
  41
  - Tire Inflation
    41
  - Tire Damage
    41
  - Tire Replacement
    41
  - Wheel Replacement
    41
  - Wheel Installation
    42
- 3.2 Torque Hub
  43
  - Oil Information
    43
  - Roll and Leak Testing
    43
  - Tightening and Torquing Bolts
    43
- Drive Hub and Brake Assembly (2WD and 4WD)
  44
- Drive Hub and Brake Assembly (2WD and 4WD) Parts List
  45
- Drive Hub (4WD Front Only)
  46
- Drive Hub (4WD Front Only) Parts List
  47
- MAIN DISASSEMBLY for "B" Drives
  48
  - Hub-Spindle Disassembly
    48
  - Cover Disassembly
    49
  - Carrier Disassembly
    49
  - Assemble Carrier
    49
  - Cover Sub-Assembly
    51
  - Hub-Spindle Sub-Assembly
    52
  - Main Assembly
    54
- Cluster Gear Punch Marks
  56
  - Tool List
    59
  - 3.3 Re-Align Torque Hub Input Coupling
    60
    
    Equipment Required
    60
    
    Procedure
    60
  - 3.4 Drive Motor
    60
    
    Description
    60
    
    Shaft Seal Replacement
    61
    
    Loop Flushing Valve
    61
    
    Troubleshooting
    62
    
    Disassembly
    63
- End Cap
  64
- Cylinder Kit
  65
  - Swash Plate & Servo Piston
    66
  - Inspection
    67
  - Assembly
    69
- Swash Plate and Journal Bearing
  70
- Cylinder Kit Installation
  71
- End Cap
  72
  - Initial Start-Up Procedures
    73
- Chassis Torque Values
  74
- Swing Bearing Installation
  77
  - Disassembly
    78
- Swing Bearing Drive
  79
  - Assembly
    80
  - Installation
    80
- Swing Bearing (Dohi) Torque Sequence
  81
  - Turntable Bearing Mounting Bolt Checks
    82
  - Check Frame to Bearing Bolts
    82
  - Check Turntable to Bearing Bolts
    82
  - Wear Tolerance
    82
  - 3.8 Swing Motor
    83
    
    Preparation before Disassembly
    83
    
    Removal
    84
    
    Preparation before Disassembly
    84
- Swing Motor Removal and Installation
  85
  - Disassembly and Inspection
    86
- Swing Motor - Exploded View
  92
  - Assembly
    93
  - One Piece Stator Assembly
    99
  - Two Piece Stator Assembly
    100
  - Final Checks
    100
  - Installation
    100
- Auxiliary Pump
  101
  - 3.9 Generator
    102
    
    Every 250 Hours
    102
    
    Every 500 Hours
    102
    
    Overload Protection
    102
    
    Brushes and Slip Rings
    102
- Generator Brushes and Slip Rings
  103
  - 3.10 Deutz Engine
    104
    
    Check Oil Level
    104
    
    Change Engine Oil
    104
    
    Change Oil Filter
    104
    
    Replace Fuel Filter
    105
    
    Clean Fuel Strainer (D2011 L03 Only)
    105
  - Deutz EMR 2
    106
- EMR 2 Engine Plug Pin Identification
  111
- EMR 2 Vehicle Plug Pin Identification
  112
  - 3.12 Bio Fuel in Deutz Engines
    118
    
    General
    118
    
    Bio Fuel
    118
    
    Biological Contamination in Fuels
    119
  - 3.13 Gm Engine General Maintenance
    120
    
    Drive Belt Maintenance
    120
    
    Engine Electrical System Maintenance
    120
    
    Checking/Filling Engine Oil Level
    120
    
    Change Engine Oil
    121
    
    Coolant Fill Procedure - Dual Fuel Engine
    121
  - 3.14 Gm Engine Dual Fuel System
    122
    
    Fuel Filter
    122
- GM 3.0 Dual Fuel System Components
  123
  - Direct Electronic Pressure Regulator (DEPR)
    124
  - Air Fuel Mixer
    124
  - Electronic Throttle Control (ETC)
    125
  - Electric Lock off
    125
  - Engine Control Module (ECM)
    125
  - Heated Exhaust Gas Oxygen Sensor
    126
  - Gasoline Multi Point Fuel Injection System (MPFI)
    126
  - Gasoline Fuel Pump
    126
  - Gasoline Pressure and Temperature Sensor Manifold
    126
  - Fuel Filter
    127
  - Fuel Injector Rail
    127
  - Fuel Injector
    127
  - 3.15 Gm Engine Fuel System Repair
    127
    
    Propane Fuel System Pressure Relief
    127
    
    Propane Fuel System Leak Test
    127
    
    Propane Fuel Filter Replacement
    128
    
    Direct Electronic Pressure Regulator (DEPR) Maintenance and Inspection
    128
    
    Check/Drain Oil Build-Up in 2-Stage Vaporizer
    129
    
    Air Fuel Mixer/Throttle Control Device Maintenance and Inspection
    129
    
    Exhaust System and Catalytic Converter Inspection and Maintenance
    130
    
    Temperature Manifold Absolute Pressure (TMAP) Sensor
    130
    
    Throttle Body (ETC) Replacement
    130
    
    Mixer Replacement
    130
    
    Electronic Pressure Regulator (EPR) Replacement
    131
    
    Regulator Replacement
    131
    
    Coolant Hose Replacement
    131
    
    Vapor Hose Replacement
    131
    
    Engine Control Module Replacement
    132
    
    Heated Exhaust Gas Oxygen Sensor Replacement
    132
  - 3.16 Gm Engine Lpg Fuel System Diagnosis
    133
    
    Fuel System Description
    133
    
    Diagnostic Aids
    133
- LPF Fuel System Diagnosis
  134
- Symptom Diagnosis
  136
- DTC to SPN/FMI Cross Reference Chart
  144
- GM 3.0L Engine - Sheet 1 of 2
  146
- GM 3.0L Engine - Sheet 2 of 2
  147
  - DGC Diagnostic Support and Trouble Code Definitions
    148
    
    Section Layout
    148
    
    Fault Code Broadcast
    150
    
    Diagnostic Trouble Codes
    150
    
    Can
    150
    
    MIL Output
    150
    
    Diagnostic Calibration Configuration and Corrective Actions
    150
    
    Fault/Diagnostic Trouble Code Interaction
    151
- Faults Page with Active Fault Message
  152
- Faults Page with Historic Fault Message
  153
  - DBW Diagnostic Test
    154
- Historic Fault Information Interface
  155
- Snapshot Data Interface
  156
- Exhaust Venturi Adjustment
  211
- Counterweight Installation
  212
Boom & Platform

213
- 4.1 Boom Maintenance
  213
  - Remove Boom Assembly
    213
  - Main Boom Disassembly
    214
  - Inspection
    214
  - Main Boom Assembly
    215
  - Install Boom Assembly
    215
- Boom Assembly
  216
- Boom Limit Switches
  217
- Main Boom
  218
  - 4.2 Rotary Actuator
    219
    
    Theory of Operation
    219
    
    Required Tools
    219
- Rotary Actuator - Exploded View
  220
  - Disassembly
    221
  - Inspection
    224
  - Assembly
    225
  - Installing Counterbalance Valve
    230
- Platform Support Torque Values
  231
  - 4.3 Powertrack Maintenance
    232
    
    Remove Link
    232
    
    Install New Link
    235
    
    Replace Fixed End Brackets
    238
    
    Replace Moving End Brackets
    239
Hydraulics

241
- O-Ring Lubrication
  241
  - Cup and Brush
    241
  - Dip
    242
  - Spray
    242
  - Brush-On
    242
- Hydraulic Cylinders
  243
  - Tower Lift Cylinder
    244
    
    Tower Lift Cylinder
    245
    
    Tapered Bushing Removal
    246
- Rod Seal Installation
  247
  - Tapered Bushing Installation
    248
  - Main Lift Cylinder
    249
  - Main Lift Cylinder
    250
- Composite Bushing Installation
  251
- Rod Seal Installation
  252
  - Master Cylinder (450 A/AJ) Without Arctic Package
    253
- Master Cylinder (450A)
  254
- Master Cylinder (450AJ W/O Arctic Package)
  255
- Composite Bushing Installation
  256
- Installation of Head Seal Kit
  257
  - Master Cylinder (450 A/AJ) with Arctic Package
    258
- Master Cylinder (450AJ W/Arctic Package)
  259
- Tapered Bushing Removal
  260
- Rod Seal Installation
  261
- Tapered Bushing Installation
  262
  - Telescope Cylinder
    263
  - Telescope Cylinder 450A/AJ
    264
- Composite Bushing Installation
  265
- Rod Seal Installation
  266
  - Slave (Platform Level) Cylinder Without Arctic Pkg
    267
- Platform Level Slave Cylinder Assembly (450A)
  268
- Platform Level Slave Cylinder Assembly (450AJ W/O Arctic Package)
  269
- Composite Bushing Installation
  270
- Installation of Head Seal Kit
  271
  - Platform Level (Slave) Cylinder with Arctic Package
    272
- Platform Level Slave Cylinder Assembly (450AJ W/Arctic Package)
  273
- Tapered Bushing Removal
  274
- Rod Seal Installation
  275
- Tapered Bushing Installation
  276
  - Jib Lift Cylinder (AJ Only) Without Arctic Package
    277
- Jib Lift Cylinder (450AJ W/O Arctic Package)
  278
- Composite Bushing Installation
  279
- Rod Seal Installation
  280
- Cylinder Head Installation
  281
  - Jib Lift Cylinder (AJ Only) with Arctic Package
    282
- Jib Lift Cylinder (450AJ W/Arctic Package)
  283
  - Tapered Bushing Removal
    284
  - Rod Seal Installation
    285
  - Tapered Bushing Installation
    286
  - Steer Cylinder
    287
  - Steer Cylinder Assembly
    288
- Piston Seal and Wear Ring
  289
- Cylinder Head Assembly
  290
  - Axle Lockout Cylinder
    291
  - Axle Lockout Cylinder
    292
  - Hydraulic Pump (Gear)
    293
    
    Disassembly
    293
    
    Inspect Parts for Wear
    295
    
    General Information
    296
    
    Reverse Shaft Rotation of Pump
    296
    
    Assembly
    296
- Hydraulic Pump Bolt Torque Chart
  298
  - Placing Pump Back into Service
    299
  - Variable Pump
    299
    
    Ports and Pressure Gauges
    299
    
    NFPE Control
    299
    
    Remove and Install FNR and NFPE Modules
    300
    
    Remove and Install FNR and NFPE Control Orifices
    300
    
    Charge Relief Valve
    300
- Gauge Port Locations
  301
  - Plugs/Fittings Size & Torque
    302
  - Shaft Seal and Shaft Replacement
    303
- Shaft Components
  304
  - Charge Pump
    305
  - Hydraulic Component Start-Up
    306
  - Main Valve Block Pressure Setting Procedures
    307
    
    Telescope
    307
    
    Main Relief
    307
    
    Steer
    307
    
    Lift down
    307
    
    Swing
    307
  - Platform Valve Block Pressure Setting Procedures
    307
    
    Platform Level Extend
    307
    
    Platform Level Retract
    307
    
    Articulating Jib (AJ Only)
    307
- Main Control Valve
  308
- Platform Control Valves
  309
Jlg Control System

311
- 6.1 Introduction
  311
- Controller Block Diagram
  312
  - Connect JLG Control System Analyzer
    313
  - Using Analyzer
    313
  - Changing Access Level
    314
  - Adjust Parameters
    315
  - Machine Setup
    316
  - Level Vehicle Description
    316
  - Revision
    317
- Analyzer Software Version 6.8 - Sheet 1 of 6
  319
- Analyzer Software Version 6.8 - Sheet 2 of 6
  320
- Analyzer Software Version 6.8 - Sheet 3 of 6
  321
- Analyzer Software Version 6.8 - Sheet 4 of 6
  322
- Analyzer Software Version 6.8 - Sheet 5 of 6
  323
- Analyzer Software Version 6.8 - Sheet 6 of 6
  324
- Personality Ranges/Defaults
  325
- Machine Configuration Programming Information Software Version P6.1 to Present
  328
  - System Test
    336
    
    Test from Platform
    336
    
    Test from Ground Station
    338
    
    System Test Messages
    340
- Fault Codes
  343
- Control Module and Fault Code Light Locations
  350
- Help Fault Codes, Displayed Faults, and Descriptions
  351
Basic Electrical Information & Schematics

371
- General
  371
- 7.2 Multimeter Basics
  371
  - Grounding
    371
  - Backprobing
    371
  - Min/Max
    371
  - Polarity
    371
  - Scale
    371
  - Voltage Measurement
    371
  - Resistance Measurement
    372
  - Continuity Measurement
    372
  - Current Measurement
    373
- Applying Silicone Dielectric Compound to Electrical Connections
  373
  - Dielectric Grease Application
    374
  - Deutsch HD, DT, DTM, DRC Series
    374
  - AMP Seal
    374
  - AMP Mate-N-Lok
    375
  - DIN Connectors
    375
  - Exclusions
    375
- 7.4 Amp Connector
  376
  - Contact Assembly
    376
  - Connector Assembly
    376
  - Disassembly
    377
  - Wedge Lock
    377
  - Service - Voltage Reading
    377
- 7.5 Deutsch Connectors
  378
  - DT/DTP Series Assembly
    378
  - DT/DTP Series Disassembly
    378
  - HD30/HDP20 Series Assembly
    379
  - HD30/HDP20 Series Disassembly
    379
- Electrical Components 1 of 2
  380
- Electrical Components 2 of 2
  381
- Chassis/Platform Electrical Schematic - Sheet 1 of 2
  382
- Chassis/Platform Electrical Schematic -Sheet 2 of 2
  383
- Deutz Engine Electrical Schematic
  384
- GM 3.0L Engine/Chassis Electrical Schematic
  385
- ECM Electrical Schematic - Sheet 1 of 2
  386
- ECM Electrical Schematic - Sheet 2 of 2
  387
- Main Hydraulic Schematic - 1 of 2
  388
- Main Hydraulic Schematic - 2 of 2
  389
- Two Wheel Drive Hydraulic Schematic - 1 of 2
  390
- Two Wheel Drive Hydraulic Schematic - 2 of 2
  391
- Four Wheel Drive Hydraulic Schematic - 1 of 2
  392
- Four Wheel Drive Hydraulic Schematic - 2 of 2
  393

JLG 450AJ II Series Operation And Safety Manual (112 pages)

Brand: JLG | Category: Boom Lifts | Size: 3.63 MB

Table of Contents
7
Section - Paragraph, Subject

12
Section - Paragraph, Subject Page

13
Section 1. Safety Precautions

13
- General
  13
- Pre-Operation
  13
  - Operator Training and Knowledge
    13
  - Workplace Inspection
    14
  - Machine Inspection
    14
- Operation
  15
  - General
    15
  - Trip and Fall Hazards
    15
  - Electrocution Hazards
    16
- Minimum Approach Distances (M.A.D.)
  17
  - Tipping Hazards
    18
  - Crushing and Collision Hazards
    19
  - Towing, Lifting, and Hauling
    20
  - Additional Hazards / Safety
    21
Section 2. User Responsibilities, Machine Preparation, and Inspection

23
Section 3. Machine Controls and Indicators

35
Section 4. Machine Operation

49
- Description
  49
- Operating Characteristics and Limitations
  49
  - Capacities
    49
  - Stability
    50
- Engine Operation
  50
  - Starting Procedure
    50
  - Shutdown Procedure
    51
- Position of Least Forward Stability
  52
  - Traveling (Driving)
    53
- Position of Least Backward Stability
  53
- Grade and Side Slopes
  54
  - Traveling Forward and Reverse
    55
  - Steering
    55
  - Platform
    55
  - Platform Level Adjustment
    55
  - Platform Rotation
    55
- Boom
  55
- Function Speed Control
  56
- Auxiliary Pump
  56
- Oscillating Axle Lockout Test (if Equipped)
  57
- 4.11 Shut down and Park
  57
- 4.12 Lifting and Tie down
  58
  - Lifting
    58
  - Tie down
    58
- Lifting and Tie down Chart
  59
- 4.13 Towing
  60
  - Prior to Towing
    60
- Drive Disconnect Hub
  60
- Dual Fuel System (Gas Engine Only)
  61
  - Changing from Gasoline to LP Gas
    61
  - Changing from LP Gas to Gasoline
    61
- Decal Installation - Sheet 1 of 6
  62
- Decal Installation - Sheet 2 of 6
  63
- Decal Installation - Sheet 3 of 6
  64
- Decal Installation - Sheet 4 of 6
  65
- Decal Installation - Sheet 5 of 6
  66
- Decal Installation - Sheet 6 of 6
  67
Section 5. Emergency Procedures

71
- General
  71
- Incident Notification
  71
- Emergency Operation
  72
  - Operator Unable to Control Machine
    72
  - Platform or Boom Caught Overhead
    72
- Emergency Towing Procedures
  72
Section 6. General Specifications & Operator Maintenance

73
- Introduction
  73
- Operating Specifications and Performance Data
  73
- Operating Specifications - 450A/450AJ
  73
  - Reach Specifications
    74
- Operating Specifications - 510AJ
  74
  - Dimensional Data
    75
  - Chassis
    75
  - Capacities
    76
  - Tires
    76
  - Engine
    77
- Deutz F3M1011F
  77
- Deutz F3M2011F
  78
  - Major Component Weights
    79
- Gm 3.0L
  79
  - Hydraulic Oil
    80
- Mobil DTE 13M Specs
  81
- Mobil EAL H 46 Specs
  82
  - Serial Number Location
    83
- Serial Number Locations
  83
- Engine Operating Temperature Specifications
  84
- Engine Operating Temperature Specifications
  85
- Engine Operating Temperature Specifications
  86
- Engine Operating Temperature Specifications
  87
- Engine Operating Temperature Specifications
  88
- Engine Operating Temperature Specifications
  89
- Engine Operating Temperature Specifications
  90
- Engine Operating Temperature Specifications
  91
- Operator Maintenance and Lubrication Diagram
  92
- Operator Maintenance
  93
- Tires & Wheels
  102
  - Tire Inflation
    102
  - Tire Damage
    102
  - Tire Replacement
    102
  - Wheel Replacement
    103
  - Wheel Installation
    103
- Wheel Torque Chart
  104
Section - Paragraph, Subject Page

105
- Draining Oil Build up from the Propane Regulator
  105
- Propane Fuel Filter Replacement
  106
  - Removal
    107
  - Installation
    107
- Propane Fuel System Pressure Relief
  108
Section 7 - Inspection and Repair Log

109
- Inspection and Repair Log
  110

JLG 450AJ II Series Operation And Safety Manual (134 pages)

Brand: JLG | Category: Boom Lifts | Size: 4.03 MB

Revision Log
6
Table of Contents
7
Section 1 - Safety Precautions

15
- General
  15
- Pre-Operation
  15
  - Operator Training and Knowledge
    15
  - Workplace Inspection
    16
  - Machine Inspection
    17
- Operation
  17
  - General
    17
  - Trip and Fall Hazards
    18
  - Electrocution Hazards
    19
  - Tipping Hazards
    21
  - Crushing and Collision Hazards
    24
- Towing, Lifting, and Hauling
  25
- Maintenance
  25
  - Maintenance Hazards
    25
  - Battery Hazards
    27
Section - 2 - User Responsibilities, Machine Preparation

29
- Personnel Training
  29
  - Operator Training
    29
  - Training Supervision
    29
  - Operator Responsibility
    29
- Preparation, Inspection, and Maintenance
  30
  - Pre-Start Inspection
    32
  - Function Check
    33
  - Skyguard Function Test
    34
  - General
    38
- Oscillating Axle Lockout Test (if Equipped)
  40
Section 3 - Machine Controls and Indicators

41
- General
  41
- Controls and Indicators
  41
  - Ground Control Station
    42
  - Jib Lift
    46
  - Engine Start/Auxiliary Power/Function Enable
    46
  - Power/Emergency Stop
    47
  - Platform/Ground Select
    47
  - Hourmeter
    47
  - Ground Control Indicator Panel
    48
  - Tower Boom Lift
    48
  - Main Boom Lift
    48
  - Platform Control Station
    51
  - Platform Control Indicator Panel
    55
Section 4 - Machine Operation

61
- Description
  61
- Operating Characteristics and Limitations
  61
  - Capacities
    61
  - Stability
    62
  - Engine Operation
    62
  - Starting Procedure
    62
  - Shutdown Procedure
    63
  - Fuel Reserve / Shut-Off System
    64
  - Telescope
    65
- Traveling (Driving)
  66
  - Traveling Forward and Reverse
    67
- Steering
  69
- Platform
  69
  - Platform Level Adjustment
    69
- Platform Rotation
  69
- Boom
  69
- Function Speed Control
  70
- Machine Safety System Override (Msso)
  71
- Skyguard Operation
  71
- Auxiliary Pump
  72
- Oscillating Axle Lockout Test (if Equipped)
  72
- Shut down and Park
  73
- Lifting and Tie down
  73
  - Lifting
    73
  - Tie down
    73
- Towing
  75
  - Prior to Towing
    75
- Dual Fuel System (Gas Engine Only)
  76
  - Changing from Gasoline to LP Gas
    76
  - Changing from LP Gas to Gasoline
    76
Section 5 - Emergency Procedures

87
- General
  87
- Incident Notification
  87
- Emergency Operation
  88
  - Operator Unable to Control Machine
    88
  - Platform or Boom Caught Overhead
    88
- Emergency Towing Procedures
  88
Section 6 - General Specifications and Operator Maintenance

89
- Introduction
  89
- Operating Specifications and Performance
  89
  - Data
    89
  - Reach Specifications
    90
  - Dimensional Data
    91
  - Chassis
    91
  - Major Component Weights
    92
  - Capacities
    92
  - Tires
    92
  - Engine
    93
  - Hydraulic Oil
    95
  - Serial Number Location
    99
  - Specifications
    102
- Operator Maintenance
  109
- Tires & Wheels
  122
  - Tire Inflation
    122
  - Tire Damage
    122
  - Tire Replacement
    122
  - Wheel and Tire Replacement
    123
  - Wheel Installation
    123
- Propane Fuel Filter Replacement
  125
  - Removal
    125
  - Installation
    126
- Propane Fuel System Pressure Relief
  126
- Supplemental Information
  127

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JLG 450AJ II Series Manuals

JLG 450AJ II Series Service And Maintenance Manual (396 pages)

Table of Contents

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General

Chassis & Turntable

Boom & Platform

Hydraulics

Jlg Control System

Basic Electrical Information & Schematics

JLG 450AJ II Series Operation And Safety Manual (112 pages)

Table of Contents

Section - Paragraph, Subject

Section - Paragraph, Subject Page

Section 1. Safety Precautions

Section 2. User Responsibilities, Machine Preparation, and Inspection

Section 3. Machine Controls and Indicators

Section 4. Machine Operation

Section 5. Emergency Procedures

Section 6. General Specifications & Operator Maintenance

Section - Paragraph, Subject Page

Section 7 - Inspection and Repair Log

JLG 450AJ II Series Operation And Safety Manual (134 pages)

Table of Contents

Section 1 - Safety Precautions

Section - 2 - User Responsibilities, Machine Preparation

Section 3 - Machine Controls and Indicators

Section 4 - Machine Operation

Section 5 - Emergency Procedures

Section 6 - General Specifications and Operator Maintenance

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