JLG 450A_AJ Series II Service Manual User Manual
Service and maintenance manual, Models 450a/aj series ii
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Table of contents
Document Outline
- 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
- 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
- General
- Preparation, Inspection, and Maintenance
- Pre-Start Inspection
- Pre-Delivery Inspection and Frequent Inspection
- Annual Machine Inspection
- Preventative Maintenance
- 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)
- 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)
- 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
- 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
- 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
- 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
- Section 5. Hydraulics
- Section 6. JLG Control System
- Section 7. Basic Electrical Information & Schematics