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JLG 450A Service Manual

JLG 450A
148 pages
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Service and Maintenance Manual
Models
450A
450AJ
PVC 2001
31215022
December 19, 2019 - Rev A
AS/NZS
Go to Discount-Equipment.com to order your parts

Table of Contents

Other manuals for JLG 450A

Questions and Answers:

JLG 450A Specifications

General IconGeneral
Platform Height45 ft
Horizontal Outreach25 ft
Platform Capacity500 lbs
Power SourceDiesel
Drive Speed3 mph

Summary

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A GENERAL

General safety precautions for mobile elevating work platforms.

B HYDRAULIC SYSTEM SAFETY

Safety precautions for high-pressure hydraulic systems.

C MAINTENANCE

Safety rules and precautions for maintenance procedures.

REVISON LOG

SECTION 1 - SPECIFICATIONS

1.1 Operating Specifications

Machine operational capabilities, limits, and environmental factors.

1.2 Dimensional Data

Physical dimensions of the machine, including turning radius, height, and length.

1.3 Capacities

Fluid capacities for hydraulic system, drive hub, engine coolant, and drive brake.

1.4 Tires

Specifications for tire sizes, types, pressures, and weights.

1.5 Engine Data

Technical data for different engine models, including displacement, oil capacity, and RPM.

1.6 Hydraulic Oil

Recommendations for hydraulic oil types, viscosity grades, and operating temperatures.

1.7 Major Component Weight

Approximate weights of key components like counterweight, tires, and platform.

1.8 Maintenance and Lubrication

Schedules and specifications for lubrication and maintenance of machine components.

1.9 Threadlocking Compound

JLG part numbers and equivalents for threadlocking compounds.

1.10 Torque Charts

Tables providing torque values for SAE and metric fasteners for safe assembly.

SECTION 3 - CHASSIS & TURNTABLE

3.1 Tires and Wheels

Guidelines for inspecting, replacing, and installing tires and wheels for machine stability.

3.2 Oscillating Axle System

Function and operation of the oscillating front axle and its lockout cylinders.

3.3 Lockout Cylinder Bleeding

Procedure for bleeding air from lockout cylinders for proper axle function.

3.4 Chassis Tilt Indicator System

How the tilt indicator warns operators of unstable positions and affects drive.

3.5 Oscillating Axle Lockout Test

Quarterly test procedure to ensure correct operation of the oscillating axle lockout system.

3.6 Drive Orientation System

Explanation of the DOS system indicating chassis direction and enabling override.

3.7 Drive System

Description of four-wheel and two-wheel drive systems and variable drive speed.

3.8 Wheel Drive Assembly

Procedures for removing and installing the wheel drive assembly, including torque specs.

3.9 Torque Hub

Procedures for roll/leak testing and tightening/torquing bolts for the torque hub.

3.10 Re-Align Torque Hub Input Coupling

Procedure to re-align torque hub input coupling using hydraulic pressure.

3.11 Drive Motor

Description, controls, and disassembly/assembly procedures for drive motors.

3.12 Drive Brake

Procedures for disassembling, inspecting, and assembling the drive brake.

3.13 Swing Bearing

Steps for removing, installing, and checking the condition of the swing bearing.

3.14 Swing Motor

Procedures for preparing, disassembling, inspecting, and assembling the swing motor.

3.15 Generator

Maintenance schedule, overload protection, and generator disassembly/assembly.

3.16 Deutz Engine

Identification of Deutz engine components and related systems.

3.17 Kubota Engine

Identification of Kubota engine components and related systems.

3.18 Deutz Engine - D2.9L4

Instructions for checking oil level and replacing engine oil/filters for Deutz D2.9L4.

3.19 Deutz Engine - D2011

Instructions for checking oil level and replacing engine oil/filters for Deutz D2011.

3.20 Deutz EMR 2

Information related to the Deutz EMR 2 system.

3.21 Kubota Engine General Maintenance

Procedures for checking oil, replacing oil, and maintaining the drive belt for Kubota engines.

3.22 Counterweight

Information regarding the counterweight component.

Tool List

Specialized tools required for assembly of the torque hub unit.

Initial Start-Up Procedures

Procedure for starting up a new or reinstalled motor unit.

Turntable Bearing Mounting Bolt Condition Check

Procedure for checking the condition and torque of turntable bearing mounting bolts.

Lead Connection List for Generator

Physical lead connections for the generator, used with circuit diagrams.

SECTION 4 - BOOM & PLATFORM

4.1 Boom Systems

Overview of boom control and safety systems like LSS and dampening.

4.2 Platform

Procedures for removing and installing the platform and its support structure.

4.3 Rotator

Steps for removing and installing the rotator assembly.

4.4 Jib

Procedures for removing, disassembling, inspecting, assembling, and installing the jib.

SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS

5.1 Lubricating O-rings In The Hydraulic System

Methods for lubricating O-rings in hydraulic systems.

5.2 Hydraulic Connection Assembly And Torque Specification

Guidelines for hydraulic connection assembly and torque specs for fittings.

5.3 Hydraulic Cylinders

Details on various hydraulic cylinders, components, and maintenance.

5.4 Pressure Setting Procedure

Procedures for setting system relief pressures for main, steer, and swing functions.

5.5 Drive Pump Pre-Fill Procedure

Steps for pre-filling the drive pump for proper operation.

5.6 Hydraulic Schematics

Reference to hydraulic schematic diagrams for system understanding.

SECTION 6 - JLG CONTROL SYSTEM

6.1 JLG Control System Analyzer Kit Instructions

Instructions for connecting and using the JLG Control System Analyzer kit.

6.2 LSS System

Information on the Load Sensing System (LSS), including diagnostics, calibration, and troubleshooting.

6.3 Resetting The MSSO System

Procedure for resetting the MSSO system.

6.4 Machine Model Adjustment

Guidelines for adjusting machine parameters and orientation for testing.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.1 General

General information related to basic electrical systems.

7.2 Multimeter Basics

Fundamental principles and techniques for using a multimeter in electrical diagnostics.

7.3 Applying Silicone Dielectric Compound to Electrical Connections

Proper application of dielectric compound to electrical connections for reliability.

7.4 AMP Connector

Procedures for assembly, disassembly, and service of AMP connectors.

7.5 Deutsch Connectors

Information on the assembly and disassembly of Deutsch connectors.

7.6 Telematics Gateway

Details about the Telematics Gateway and its plug.

7.7 Wiring Harness Connector Labels

Identification of wiring harness connector labels for electrical tracing.

7.8 Wiring Harness

Information pertaining to the wiring harness.

7.9 Electrical Schematics

Reference to electrical schematic diagrams for system troubleshooting.

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

Essential information for placing machines in operation and maintaining safe condition.

2.2 SERVICE AND GUIDELINES

General information to assist with servicing and maintenance procedures.

2.3 LUBRICATION AND INFORMATION

Hydraulic system care, oil recommendations, and lubrication specifications.

2.4 CYLINDER DRIFT TEST

Theory and testing procedures for cylinder drift, including acceptable leakage.

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

Guidelines for inspecting, replacing, and repairing pins and bearings.

2.6 WELDING ON JLG EQUIPMENT

Safety instructions and precautions for welding on JLG equipment.

Troubleshooting

Troubleshooting guides for common issues like noise, vibration, overheating, and shifting problems.

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