Jlg 450AJ Service Manual User Manual

Service and Maintenance ManualModel450A450AJ3120869February 16, 2000

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31208691.5 TORQUE REQUIREMENTS* Check swing bearing bolts for security after first 50hours of operation and

SECTION 3 - TROUBLESHOOTING3-18 – JLG Lift – 3120869.Table 3-6.Electrical System - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYPLATFORM CONTROLS.No po

SECTION 3 - TROUBLESHOOTING3120869 – JLG Lift – 3-19INSTRUMENTS AND INDICATORS.Travel warning horn inoperative.Circuit breaker open. Determine and cor

SECTION 3 - TROUBLESHOOTING3-20 – JLG Lift – 3120869Figure 3-1. Electrical Components Installation - Sheet 1

SECTION 3 - TROUBLESHOOTING3120869 – JLG Lift – 3-21Figure 3-2. Electrical Components Installation - Sheet 2

SECTION 3 - TROUBLESHOOTING3-22 – JLG Lift – 3120869Figure 3-3. Electrical Schematic - Boom, Turntable, Chassis - Deutz - Sheet 1

SECTION 3 - TROUBLESHOOTING3120869 – JLG Lift – 3-231870085CFigure 3-4. Electrical Schematic - Boom, Turntable, Chassis - Deutz - Sheet 2

SECTION 3 - TROUBLESHOOTING3-24 – JLG Lift – 3120869Figure 3-5. Electrical Schematic - Platform -Deutz - Sheet 1

SECTION 3 - TROUBLESHOOTING3120869 – JLG Lift – 3-25Figure 3-6. Electrical Schematic - Platform -Deutz - Sheet 21870085C

SECTION 3 - TROUBLESHOOTING3-26 – JLG Lift – 3120869Figure 3-7. Hydraulic Schematic - Proportional Controls (Sheet 1 of 6)

SECTION 3 - TROUBLESHOOTING3120869 – JLG Lift – 3-27Figure 3-14. Hydraulic Shematic - Proportional Controls (Sheet 2 of 6)2792372D

SECTION 1 - SPECIFICATIONS3120869 – JLG Lift – 1-31.7 PRESSURE SETTINGS - PSI (BAR)Main ReliefMain Relief - 3000 (207)Lift Up - 3000 (207) - Governed

SECTION 3 - TROUBLESHOOTING3-28 – JLG Lift – 3120869Figure 3-14. Hydraulic Shematic - Proportional Controls (Sheet 3 of 6)

SECTION 3 - TROUBLESHOOTING3120869 – JLG Lift – 3-292792372DFigure 3-14. Hydraulic Shematic - Proportional Controls (Sheet 4 of 6)

SECTION 3 - TROUBLESHOOTING3-30 – JLG Lift – 3120869Figure 3-14. Hydraulic Shematic - Proportional Controls (Sheet 5 of 6)

SECTION 3 - TROUBLESHOOTING3120869 – JLG Lift – 3-312792372DFigure 3-14. Hydraulic Shematic - Proportional Controls (Sheet 6 of 6)

SECTION 3 - TROUBLESHOOTING3-32 – JLG Lift – 3120869This page left blank intentionally.

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Customer Support Toll Free:

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3120869Figure 1-1. Lubrication DiagramUpdated 11-1-99

SECTION 1 - SPECIFICATIONS3120869 – JLG Lift – 1-5Table 1-8. Lubrication ChartComponentsNumber/TypeLube PointsCapacity LubeInterval HoursComments3 Mon

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 312086918Air Filter - DeutzReplaceableElementN/A N/A X Or as indicated by condition indicator19Air Filter -

SECTION 1 - SPECIFICATIONS3120869 – JLG Lift – 1-71.11 FUNCTION SPEEDS (IN SECONDS)450AMain Boom Lift Up - 22-38Main Boom Lift Down - 12-24Tele In - 1

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 3120869SIZE412126677891212121416181820202424202432324010111213141618283236404861-1/21-1/23.81003.49254.0132

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-1SECTION 2. PROCEDURES2.1 GENERALThis section provides information necessary to performmaintenance on th

SECTION 2 - PROCEDURES2-2 – JLG Lift – 3120869Bearings1. When a bearing is removed, cover it to keep out dirtand abrasives. Clean bearings in nonflamm

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-33. Cloudy oils indicate a high moisture content whichpermits organic growth, resulting in oxidation or c

SECTION 2 - PROCEDURES2-4 – JLG Lift – 31208692.5 VALVES - THEORY OF OPERATION Solenoid Control ValveControl valves used are four-way three-position s

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-52. Remove the boom from the turntable as follows: a. Disconnect wiring harness from ground controlharnes

SECTION 2 - PROCEDURES2-6 – JLG Lift – 31208696. Using a suitable lifting device, remove telescope cyl-inder from boom sections.7. Using a piece of ta

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-713. Install wear pads at end of base boom section.Using shims, adjust the adjustable wear pads tozero cl

SECTION 2 - PROCEDURES2-8 – JLG Lift – 31208698. Position LIFT control switch to DOWN and hold untilboom reaches horizontal; check boom lengthagainst

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-9Cylinders With Dual Counterbalance Valves - Slave Level, Lift, and TelescopeOPERATE ALL FUNCTIONS FROM G

SECTION 2 - PROCEDURES2-10 – JLG Lift – 3120869Figure 2-4. Boom Prop Configuration

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-114. Place the cylinder barrel into a suitable holding fix-ture.5. Mark cylinder head and barrel with a c

SECTION 2 - PROCEDURES2-12 – JLG Lift – 312086912. Remove the bushing from the piston.13. Screw the piston CCW, by hand, and remove thepiston from cyl

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-1315. If applicable, inspect port block fittings and holdingvalve. Replace as necessary.16. Inspect the o

INTRODUCTION3120869 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 2 - PROCEDURES2-14 – JLG Lift – 31208697. If applicable, correctly place new seals and guidelock rings in the outer piston diameter groove. (A

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-15b. Tap each space once; this means the taperedbushing is tapped 3 times as there are 3 spacesbetween th

SECTION 2 - PROCEDURES2-16 – JLG Lift – 3120869IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ONTHE MACHINE, EXTREME CARE SHOULD BE USED TO INS

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-172. Remove port plugs and drain oil from pump.3. Use a permanent marker pen to mark a line acrossthe mou

SECTION 2 - PROCEDURES2-18 – JLG Lift – 312086911. Remove idler shaft from bearing block.12. Remove drive shaft from mounting flange. There isno need

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-19Inspect Parts For Wear1. Clean and dry all parts thoroughly prior to inspec-tion. It is not necessary t

SECTION 2 - PROCEDURES2-20 – JLG Lift – 3120869General InformationIt is important that the relationship of the mounting flange,bearing blocks and gear

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-215. Place mounting flange, with shaft seal side down, ona clean flat surface.6. Apply a light coating of

SECTION 2 - PROCEDURES2-22 – JLG Lift – 312086914. The surface of the rear bearing block should beslightly below the face of the gear housing. If theb

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-23Placing Pump Back Into Service1. If shop test stand is available, the following proce-dure for testing

INTRODUCTIONA-2 – JLG Lift – 3120869REVISON LOGMay, 1998 - Original IssueAugust 5, 1999 - Revised2-54 thru 2-57 - Updated 10-12-992-59 - Updated 10-12

SECTION 2 - PROCEDURES2-24 – JLG Lift – 3120869TOREMOTEFigure 2-18. Swing Bearing Installation

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-25Wear Tolerance1. With the boom positioned over the side of themachine, the Upper Boom horizontal with t

SECTION 2 - PROCEDURES2-26 – JLG Lift – 31208693. Apply Mobiltac 375NC Open Gear Compound tobearing and worm gear teeth.4. Grease bearing with Mobilit

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-272.13 WORM GEARChecking Worm Gear End PlayNOTE: JLG Industries requires that a annual inspection beperfo

SECTION 2 - PROCEDURES2-28 – JLG Lift – 31208692.15 EXTEND-A-REACHRemoval1. Place the Extend-A-Reach in a horizontal positionand support the complete

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-292. The ideal adjustment is 9.5 mm (3/8"). Do not pushthe plunger in more that 9.5 mm (3/8").

SECTION 2 - PROCEDURES2-30 – JLG Lift – 31208695. Repeat steps 2 thru 4 for the remaining two planetgears.6. Remove the bearing needles (13) and the t

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-31Figure 2-27. Torque Hub (Prior to S/N 39594) - Exploded View

SECTION 2 - PROCEDURES2-32 – JLG Lift – 3120869Figure 2-28. Torque Hub (Prior to S/N 39594) - Cutaway View

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-336. Place the assembled planet gear (11), large endtowards the roll pin onto the planet shaft (10).7. Pu

3120869 – JLG Lift – i TABLE OF CONTENTSTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION A - INTRODUCTION - MAINTENANCE SA

SECTION 2 - PROCEDURES2-34 – JLG Lift – 312086910. Install carrier sub-assembly with sun gear (28) ontoinput shaft (29) and into internal gear (31). R

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-35Figure 2-29. Torque Hub (S/N 39594 to Present) - Cutaway View

SECTION 2 - PROCEDURES2-36 – JLG Lift – 31208693. Set hub (1G), small end/spindle facing down, up onsomething that will support the hub’s flange while

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-372. Place one spacer (3D) inside cluster gear (3F) sothat it rests on top of the needle rollers. 3. Line

SECTION 2 - PROCEDURES2-38 – JLG Lift – 31208698. Use an alignment punch or similar tool to align theroll pin holes in carrier housing (3A) and planet

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-395. Place two of the cover cap bolts (6C) into any twobolt hoes that are 180° apart on the cover cap (6B

SECTION 2 - PROCEDURES2-40 – JLG Lift – 3120869Hub-Spindle Sub-AssemblyNOTE: Make sure the cup sits square with the counterborebefore pressing.1. Set

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-417. Oil spindle, then lower hub (1G), small end down,onto spindle (1A).8. Press bearing cone (1F) onto s

SECTION 2 - PROCEDURES2-42 – JLG Lift – 31208692. Oil all exposed surfaces inside hub (1G). 3. Place internal gear (2) into hub (1G) so that its inter

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-438. Using retaining ring pliers, insert retaining ring (7B)into the groove on input shaft (7A) by compre

ii – JLG Lift – 3120869TABLE OF CONTENTS TABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION 3 - TR

SECTION 2 - PROCEDURES2-44 – JLG Lift – 312086912. With "X" marked side facing up, place the ring gear(4) around cluster gears (3F).NOTE: Th

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-4517. Place cover sub-assembly (6) onto ring gear (4),aligning the pipe plug holes according to the align

SECTION 2 - PROCEDURES2-46 – JLG Lift – 312086916171819222111121214141524232512525634789101. Housing2. Gasket3. Torque Pin4. Ball Bearing5. Retaining

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-47AssemblyTHERE MAY BE MORE PARTS IN A SERVICE KIT THAN YOURBRAKE REQUIRES. CHECK THE PARTS LIST CAREFULL

SECTION 2 - PROCEDURES2-48 – JLG Lift – 31208692.20 BOOM LIMIT SWITCHESThere are no adjustments to be made to the two boomlimit switches which bolt in

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-492.22 THROTTLE CHECKS AND ADJUSTMENTS - DEUTZ ENGINEGeneralThe throttle control system on the Deutz engi

SECTION 2 - PROCEDURES2-50 – JLG Lift – 3120869Clutch engaged actuator retractingController fault - clutch disengaged and no actuator movementFailure

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-51Only green light on and no actuator movementAction:1. Adjust trim potentiometers.2. If problem continue

SECTION 2 - PROCEDURES2-52 – JLG Lift – 3120869R.T.O. (Ramp Thru Off)This controller is configured with an enhanced ramp fea-ture that allows the hand

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-532.24 LIFT AND SWING CONTROLLERAdjustmentNOTE: The following procedures are for a preliminaryadjustment.

3120869 – JLG Lift – iii TABLE OF CONTENTSLIST OF FIGURES (continued)FIGURE NO. TITLE PAGE NO.3-1. Electrical Components Installation

SECTION 2 - PROCEDURES2-54 – JLG Lift – 3120869Current Regulated OutputThis Rotary Selector Controller output is also current regu-lated. This Rotary

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-552.26 TILT ALARM SWITCHPERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINI-MUM OF EVERY SIX MONTHS TO EN

SECTION 2 - PROCEDURES2-56 – JLG Lift – 3120869Figure 2-39. Main Valve (Proportional Controls) - Sheet 1Updated 10-12-99

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-57Figure 2-40. Main Valve (Proportional Controls) - Sheet 2Updated 10-12-99

SECTION 2 - PROCEDURES2-58 – JLG Lift – 3120869FRONTFRONT FLOW DIVIDERBYPASS VALVETWO WHEEL/FOUR WHEEL VALVEREAR FLOW DIVIDERHIGH SPEEDVALVEFigure 2-4

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-59Swing1. Remove the hoses at ports S1 and S2 on the MainValve and plug both hoses.2. Install pressure ga

SECTION 2 - PROCEDURES2-60 – JLG Lift – 3120869Fill the reservoir with recommended hydraulic fluid. Thisfluid should be passed through a 10 micron (no

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-612.29 SEMI-TRACKThe semi-track option is available in either soft or hardtrack configurations. The semi-

SECTION 2 - PROCEDURES2-62 – JLG Lift – 3120869AdjustmentIMPROPER SLACK ADJUSTMENT COULD CAUSE TRACK PARTSTO BREAK.Place a straight edge long enough t

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-632.30 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULEThe preventive maintenance and inspection checks are

iv – JLG Lift – 3120869TABLE OF CONTENTS This Page Left Blank Intentionally.

SECTION 2 - PROCEDURES2-64 – JLG Lift – 3120869Table 2-6.Preventive Maintenance and Inspection ScheduleAREADAILY WEEKLYINTERVALMONTHLY 3 MONTH 6 MONTH

SECTION 2 - PROCEDURES3120869 – JLG Lift – 2-65TURNTABLE1.Engine Oil (see mfg. manual)352.Battery353.Radiator354.Air Cleaner1145.Exhaust System11,56.S

SECTION 2 - PROCEDURES2-66 – JLG Lift – 3120869 CHASSIS1.Wheel and Tire Assembly18,9,152.Drive Motors1,5,63.Drive Torque Hubs**1,5,6 34.Drive Brakes1,

SECTION 3 - TROUBLESHOOTING3120869 – JLG Lift – 3-1SECTION 3. TROUBLESHOOTING3.1 GENERALThis section contains troubleshooting information to beused f

SECTION 3 - TROUBLESHOOTING3-2 – JLG Lift – 3120869.Table 3-1.Platform Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYAutomatic leveling inope

SECTION 3 - TROUBLESHOOTING3120869 – JLG Lift – 3-3.Table 3-2.Boom Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYCONTROL VALVESValve spool st

SECTION 3 - TROUBLESHOOTING3-4 – JLG Lift – 3120869Control valve not functioning properly. Repair or replace valve.Lift cylinder not functioning prope

SECTION 3 - TROUBLESHOOTING3120869 – JLG Lift – 3-5Function Speed, Drive Speed and High Engine does not operate below horizontal.Damaged wiring on lev

SECTION 3 - TROUBLESHOOTING3-6 – JLG Lift – 3120869Boom extends and retracts erratically.Hydraulic system oil low. Replenish oil as necessary.Wear pad

SECTION 3 - TROUBLESHOOTING3120869 – JLG Lift – 3-7Boom swings erratically in either direction.Hydraulic system oil low. Replenish oil as necessary.La

SECTION 1 - SPECIFICATIONS3120869 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESFuel Tank - 62.5 litersHydraulic Oil Tank - 106 litersTorque

SECTION 3 - TROUBLESHOOTING3-8 – JLG Lift – 3120869.Table 3-3.Turntable Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYCONTROL VALVE.Valve Spo

SECTION 3 - TROUBLESHOOTING3120869 – JLG Lift – 3-9.Table 3-4.Chassis Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYPOWER PLANT.Engine will n

SECTION 3 - TROUBLESHOOTING3-10 – JLG Lift – 3120869Engine worn badly. Rebuild engine.Engine improperly timed. Time engine.Engine overheating. Determi

SECTION 3 - TROUBLESHOOTING3120869 – JLG Lift – 3-11Drive wheel tire treads worn smooth. Replace tires as necessary and inflate to speci-fied pressure

SECTION 3 - TROUBLESHOOTING3-12 – JLG Lift – 3120869Motor turns slowly in the direction of the last com-mand.Valve not returning to neutral. Check neu

SECTION 3 - TROUBLESHOOTING3120869 – JLG Lift – 3-13If equipped, swivel coupling leaking internally. (Seals defective.)Repair or replace coupling.Stee

SECTION 3 - TROUBLESHOOTING3-14 – JLG Lift – 3120869Machine wanders; steering not firm.Crossover relief valve set too low or not function-ing properly

SECTION 3 - TROUBLESHOOTING3120869 – JLG Lift – 3-15.Table 3-5.Hydraulic System - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYHYDRAULIC SYSTEMS - GENE

SECTION 3 - TROUBLESHOOTING3-16 – JLG Lift – 3120869Pump not delivering oil.Restricted suction line. Clean, repair, or replace line.Air entering syste

SECTION 3 - TROUBLESHOOTING3120869 – JLG Lift – 3-17Damaged wiring on control switch or auxiliary pump.See proper wiring diagram.Control switch not fu