JLG 450A Series II, 450AJ Series II Boom Lift Service Manual
396 pages · Publication 3121290
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- Models
- 450A Series II, 450AJ Series II
- Serial coverage
- 0300160835-0300201990, E300001114-E300002832, Exclude Serial Number Range: 0300199221-0300199224, 0300200428, 0300201105-0300201109, 0300201481, 0300201482, 0300201528, 0300201529, 0300201575-0300201577, 0300201623, 0300201624, 0300201668, 0300201811-0300201814, 0300201858-0300201862, 0300201906-0300201910, 0300201954-0300201958
- Manual type
- Service Manual
- Pages
- 396
- Publication
- 3121290
- Condition
- Brand new
What's inside
From the manual's own table of contents: 454 sections, 506 entries. See sample pages (PDF, 650 KB)
General
Hydraulic System Safety
Maintenance12 topics
- Operating specifications and Performance Data
- Reach Specifications
- Dimensional Data
- Chassis
- Capacities
- Tires
- Engine
- Major Component Weights
- Hydraulic Oil
- Serial Number Location
- Operator Maintenance
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance1 topic
- Service and Guidelines
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Battery
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication1 topic
- Lubrication and Information
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift Test
Platform Drift
Show all 454 sections
Cylinder Drift2 topics
- Pins and Composite Bearing Repair Guidelines
- Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment1 topic
- Tires And Wheels
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation1 topic
- Torque Hub
Oil Information
Roll and Leak Testing
Tightening and Torquing Bolts
MAIN DISASSEMBLY for “B” Drives
Hub-Spindle Disassembly
Cover Disassembly
Carrier Disassembly
Assemble Carrier
Cover Sub-Assembly
Hub-Spindle Sub-Assembly
Main Assembly
Tool List1 topic
- Re-Align Torque Hub Input Coupling
Equipment Required
Procedure1 topic
- Drive Motor
Description
Shaft Seal Replacement
Loop Flushing Valve
Troubleshooting
Disassembly
Inspection
Assembly
Initial Start-Up Procedures2 topics
- Adjustment Procedure For Lockout Valve
- Oscillating Axle Bleeding Procedure and Lockout Test
Lockout Cylinder Bleeding (Ram Cylinders)
Oscillating Axle Lockout Test1 topic
- Swing Bearing
Removal
Installation
Turntable Bearing Mounting Bolt Checks
Check Frame To Bearing Bolts
Check Turntable To Bearing Bolts
Wear Tolerance1 topic
- Swing Motor
Preparation Before Disassembly
Disassembly and Inspection
One Piece Stator Assembly
Two Piece Stator Assembly
Final Checks1 topic
- Generator
Every 250 hours
Every 500 hours
Overload Protection
Brushes and Slip Rings1 topic
- Deutz Engine
Check Oil Level
Change Engine Oil
Change Oil Filter
Replace Fuel Filter
Clean Fuel Strainer (D2011 L03 Only)2 topics
- Deutz EMR 2
- Bio Fuel in Deutz Engines
Bio Fuel
Biological Contamination In Fuels1 topic
- GM Engine General Maintenance
Drive Belt Maintenance
Engine Electrical System Maintenance
Checking/Filling Engine Oil Level
Coolant Fill Procedure - Dual Fuel Engine1 topic
- GM Engine Dual Fuel System
Fuel Filter
Direct Electronic Pressure Regulator (DEPR)
Air Fuel Mixer
Electronic Throttle Control (ETC)
Electric Lock Off
Engine Control Module (ECM)
Heated Exhaust Gas Oxygen Sensor
Gasoline Multi Point Fuel Injection System (MPFI)
Gasoline Fuel Pump
Gasoline Pressure And Temperature Sensor Manifold
Fuel Injector Rail
Fuel Injector1 topic
- GM Engine Fuel System Repair
Propane Fuel System Pressure Relief
Propane Fuel System Leak Test
Propane Fuel Filter Replacement
Direct Electronic Pressure Regulator (DEPR) Maintenance And Inspection
Check/Drain Oil Build-Up In 2-Stage Vaporizer
Air Fuel Mixer/Throttle Control Device Maintenance And Inspection
Exhaust System And Catalytic Converter Inspection And Maintenance
Temperature Manifold Absolute Pressure (TMAP) Sensor
Throttle Body (ETC) Replacement
Mixer Replacement
Electronic Pressure Regulator (EPR) Replacement
Regulator Replacement
Coolant Hose Replacement
Vapor Hose Replacement
Engine Control Module Replacement
Heated Exhaust Gas Oxygen Sensor Replacement1 topic
- GM Engine LPG Fuel System Diagnosis
Fuel System Description
Diagnostic Aids1 topic
- DGC Diagnostic Support And Trouble Code Definitions
Section Layout
Fault Code Broadcast
Diagnostic Trouble Codes
MIL Output
Diagnostic Calibration Configuration and Corrective Actions
Fault/Diagnostic Trouble Code Interaction
DBW Diagnostic Test1 topic
- 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 Table1 topic
- Boom Maintenance
Remove Boom Assembly
Main Boom Disassembly
Main Boom Assembly
Install Boom Assembly1 topic
- Rotary Actuator
Theory of Operation
Required Tools
Installing Counterbalance Valve1 topic
- Powertrack Maintenance
Remove Link
Install New Link
Replace Fixed End Brackets
Replace Moving End Brackets1 topic
- O-Ring Lubrication
Cup and Brush
Spray
Brush-On1 topic
- Hydraulic Cylinders
Tower Lift Cylinder
Main Lift Cylinder
Master Cylinder (450 A/AJ) Without Arctic Package
Master Cylinder (450 A/AJ) With Arctic Package
Telescope Cylinder
Slave (Platform Level) Cylinder Without Arctic Pkg
Platform Level (Slave) Cylinder With Arctic Package
Jib Lift Cylinder (AJ Only) Without Arctic Package
Jib Lift Cylinder (AJ Only) With Arctic Package
Steer Cylinder
Axle Lockout Cylinder1 topic
- Hydraulic Pump (Gear)
Inspect Parts For Wear
General Information
Reverse Shaft Rotation of Pump
Placing Pump Back Into Service1 topic
- Variable Pump
Ports and Pressure Gauges
NFPE Control
Remove and Install FNR and NFPE Modules
Remove and Install FNR and NFPE Control Orifices
Charge Relief Valve
Shaft Seal and Shaft Replacement
Charge Pump2 topics
- Hydraulic Component Start-Up
- Main Valve Block Pressure Setting Procedures
Telescope
Main Relief
Steer
Lift Down
Swing1 topic
- Platform Valve Block Pressure Setting Procedures
Platform Level Extend
Platform Level Retract
Articulating Jib (AJ Only)1 topic
- introduction
Connect JLG Control System Analyzer
Using Analyzer
Changing Access Level
Adjust Parameters
Machine Setup
Level Vehicle Description1 topic
- System Test
Test from Platform
Test From Ground Station2 topics
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement1 topic
- Applying Silicone Dielectric Compound to Electrical Connections
Dielectric Grease Application
Deutsch HD, DT, DTM, DRC Series
AMP Seal
AMP Mate-N-Lok
DIN Connectors
Exclusions1 topic
- AMP Connector
Contact Assembly
Connector Assembly
Wedge Lock
Service - Voltage Reading1 topic
- Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
Serial Number Locations
Operator Maintenance and Lubrication Diagram
Deutz Engine Dipstick Markings
Torque Chart (SAE Fasteners - Sheet 1 of 7)
Torque Chart (SAE Fasteners - Sheet 2 of 7)
Torque Chart (SAE Fasteners - Sheet 3 of 7)
Torque Chart (SAE Fasteners - Sheet 4 of 7)
Torque Chart (METRIC Fasteners - Sheet 5 of 7)
Torque Chart (METRIC Fasteners - Sheet 6 of 7)
Torque Chart (METRIC Fasteners - Sheet 7 of 7)
Wheel Lug Nut Tightening Sequence
Bolt Tightening Sequence
Drive Hub and Brake Assembly (2WD and 4WD)
Drive Hub (4WD Front Only)
Cluster Gear Punch Marks
Drive Motor Cross Section
Removing Shaft Seal
Loop Flushing Spool
Plugs, Fittings, and Speed Sensor
End Cap
Valve Plate & Rear Shaft Bearing
Cylinder Kit
Shaft Seal
Shaft & Front Bearing
Swash Plate & Servo Piston
Cylinder Kit Disassembly
Servo Piston
Cylinder Kit Assembly
Swash Plate and Journal Bearing
Shaft and Front Bearing
Cylinder Kit Installation
Servo Spring and Minimum Angle Stop
Valve Plate and Rear Bearing
Plugs and Fittings Installation
Chassis Torque Values
Valve Adjustment
Swing Bearing Installation
Swing Bearing Drive
Swing Bearing Lubrication Points
Swing Bearing (Dohi) Torque Sequence
Swing Bearing (Jing Wei) Torque Sequence
Swing Bearing Alignment
Swing Bearing Feeler Gauge Check
Swing Bearing Tolerance Measuring Point
Swing Motor - Cutaway
Swing Motor Removal and Installation
Swing Motor - Exploded View
Auxiliary Pump
Generator Brushes and Slip Rings
Deutz Dipstick Markings
Engine Oil Viscosity
EMR 2 Engine Side Equipment
Deutz EMR 2 Troubleshooting Flow Chart
Deutz EMR 2 Vehicle Side Connection Diagram
Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
EMR 2 Engine Plug Pin Identification
EMR 2 Vehicle Plug Pin Identification
EMR2 Fault Codes - Sheet 1 of 5
EMR2 Fault Codes - Sheet 2 of 5
EMR2 Fault Codes - Sheet 3 of 5
EMR2 Fault Codes - Sheet 4 of 5
EMR2 Fault Codes - Sheet 5 of 5
GM Engine Oil Dip Stick
GM 3.0 Dual Fuel System Components
Direct Electronic Pressure Regulator
ELectronic Throttle Control Device
Electric Lock Off Assembly
ECM Assembly
ECM Input-Output Diagram
Heated Exhaust Gas Oxygen Sensor (HEGO)
Gasoline Fuel Pressure and Temperature Manifold Assembly
Filter Lock Assembly
DEPR
GM 3.0L Engine - Sheet 1 of 2
GM 3.0L Engine - Sheet 2 of 2
Faults Page with Active Fault Message
Faults Page with Historic Fault Message
Custom Fault Variable Interface
Historic Fault Information Interface
Snapshot Data Interface
Flight Data Recorder Interface
Clear Faults Prompt
Exhaust Venturi Adjustment
Counterweight Installation
Location of Components - Boom Removal
Boom Assembly
Boom Limit Switches
Main Boom
Rotary Actuator - Exploded View
Rotator Counterbalance Valve
Platform Support Torque Values
Hydraulic Cylinder Locations
Cylinder Barrel Support
Cylinder Head Removal
Cylinder Rod Support
Tapered Bushing Removal
Composite Bushing Installation
Rod Seal Installation
Poly-Pak Piston Seal Installation
Wiper Seal Installation
Head Seal Installation
Piston Seal Installation
Tapered Bushing Installation
Rod Assembly Installation
Head Seals
Piston Seal Kit Installation
Master Cylinder (450A)
Master Cylinder (450AJ W/O Arctic Package)
Installation of Head Seal Kit
Cylinder Head Installation
Master Cylinder (450AJ W/Arctic Package)
Cylinder Head Seal Installation
Telescope Cylinder 450A/AJ
Platform Level Slave Cylinder Assembly (450A)
Platform Level Slave Cylinder Assembly (450AJ W/O Arctic Package)
Marking Cylinder for Alignment
Platform Level Slave Cylinder Assembly (450AJ W/Arctic Package)
Jib Lift Cylinder (450AJ W/O Arctic Package)
Cylinder Head Seals
Jib Lift Cylinder (450AJ W/Arctic Package)
Removing Cylinder Head
Steer Cylinder Assembly
Piston Seal and Wear Ring
Cylinder Head Disassembly
Cylinder Head Assembly
Steering Cylinder Assembly
Cylinder Head Torque
Shim Adjustable Charge Relief Valve Components
Gauge Port Locations
Plugs/Fittings Size & Torque
Screw Adjustable Charge Relief Valve Components
Shaft Seal Removal
Installation of Shaft Seal
Shaft Components
Charge Pump Components
Main Control Valve
Platform Control Valves
Hand-Held Analyzer (WANALYZER Controls and Display Similar)
Controller Block Diagram
Analyzer Platform Connector
Analyzer Ground Control Box Connector
Analyzer Software Version 6.8 - Sheet 1 of 6
Analyzer Software Version 6.8 - Sheet 2 of 6
Analyzer Software Version 6.8 - Sheet 3 of 6
Analyzer Software Version 6.8 - Sheet 4 of 6
Analyzer Software Version 6.8 - Sheet 5 of 6
Analyzer Software Version 6.8 - Sheet 6 of 6
System Test Flow Chart - Platform Tests
System Test Flow Chart - Ground Station Tests
Control Module And Fault Code Light Locations
Voltage Measurement (DC)
Current Measurement (DC)
Applying Dielectric Grease
Deutsch Connector
Dielectric Grease On Female Contacts
Seal Plugs
AMP Mate-N-Lok Connector
DIN Connector
Brad Harrison/Phoenix Connectors
AMP Junior Timer
AMP Connector
AMP Contact Assembly
AMP Connector Assembly
AMP Contact Installation
Close Wedge Lock
Seating Wedge Lock
AMP Connector Disassembly
DT/DTP Contact Installation
DT/DTP Contact Removal
HD/HDP Contact Installation
HD/HDP Locking Contacts Into Position
HD/HDP Contact Removal
HD/HDP Unlocking Contacts
Electrical Components 1 of 2
Electrical Components 2 of 2
Chassis/Platform Electrical Schematic - Sheet 1 of 2
Chassis/Platform Electrical Schematic -Sheet 2 of 2
Deutz Engine Electrical Schematic
GM 3.0L Engine/Chassis Electrical Schematic
ECM Electrical Schematic - Sheet 1 of 2
ECM Electrical Schematic - Sheet 2 of 2
Main Hydraulic Schematic - 1 of 2
Main Hydraulic Schematic - 2 of 2
Two Wheel Drive Hydraulic Schematic - 1 of 2
Two Wheel Drive Hydraulic Schematic - 2 of 2
Four Wheel Drive Hydraulic Schematic - 1 of 2
Four Wheel Drive Hydraulic Schematic - 2 of 2
Operating Specifications
Reach Specifications
Dimensional Data
Chassis Specifications
Capacities
Tires
Component Weights - 450
Mobilfluid 424 Specs
Mobil DTE 13M Specs
UCon Hydrolube HP-5046
Mobil EAL H 46 Specs
Exxon Univis HVI 26 Specs
Quintolubric 888-46
Inspection and Maintenance
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Drive Hub and Brake Assembly (2WD and 4WD) Parts List
Drive Hub (4WD Front Only) Parts List
Excessive Noise and/or Vibration
System Operating Hot
Won’t Shift or Slow to Start
Displacement Identifiers
Slipper Foot Thickness & End Play
Cylinder Block Measurements
Swing Motor Troubleshooting
LPF Fuel System Diagnosis
Symptom Diagnosis
DTC to SPN/FMI Cross Reference Chart
J1939 Diagnostic Lamp Configuration
Diagnostic Corrective Actions
Historic Fault Information Interface Functions
Hydraulic Pump Bolt Torque Chart
Recommended Gauge Size
Analyzer Abbreviations
Personality Ranges/Defaults
Machine Configuration Programming Information Software Version P6.1 to Present
System Test Messages
Fault Codes
Help Fault Codes, Displayed Faults, and Descriptions
Inside this manual
Real pages from this service manual (396 pages). Open the sample pages (PDF, 647 KB)
- Specifications, page 18: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 150: Fault Code Broadcast
- Diagram, page 384: SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
- Color page, page 236: SECTION 4 - BOOM & PLATFORM
- Color page, page 375: SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 450A Series II, 450AJ Series II are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 396 pages
Quantity one is the manual described above.
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Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).