JLG 450A II Series Operation And Safety Manual
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JLG 450A II Series Operation And Safety Manual

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See also: Service Maintenance Manual
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
450A Series II
450AJ Series II
S/N 0300160835-
S/N E300001114
to Present
3121289
ANSI
®
January 5, 2015

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  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Boom Lift Models 450A Series II 450AJ Series II S/N 0300160835- S/N E300001114 to Present 3121289 ANSI ® January 5, 2015...
  • Page 2 NOTE: This manual also applies to machines with the following Serial Numbers: 0300159794, 0300159795, 0300160088, 0300160456, and E300001067.
  • Page 3 The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.
  • Page 4 INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD RESULT IN INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI- SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACKGROUND. RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY. – JLG Lift – 3121289...
  • Page 5 • Questions Regarding Prod- • Questions Regarding uct Modifications Product Safety JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE CURRENT OWNER Contact: RECORDS ARE UPDATED AND ACCURATE.

  • Page 6: Revision Log

    FOREWORD REVISION LOG Original Issue - June 19, 2012 Revised - June 29, 2012 Revised - April 1, 2013 Revised - October 1, 2014 Revised - January 5, 2015 – JLG Lift – 3121289...

  • Page 7: Table Of Contents

    Function Check........2-5 Platform Level Adjustment......4-9 3121289 – JLG Lift –...
  • Page 8 Hydraulic Oil ........6-7 Serial Number Location......6-11 – JLG Lift – 3121289...
  • Page 9 PROPANE FUEL SYSTEM PRESSURE RELIEF ... 6-38 SUPPLEMENTAL INFORMATION ..... 6-39 SECTION - 7 - INSPECTION AND REPAIR LOG 3121289 – JLG Lift –...
  • Page 10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This Page Left Blank Intentionally. – JLG Lift – 3121289...
  • Page 11 4-11. Decal Installation - Sheet 6 of 6 ..... . 4-22 6-1. Serial Number Locations ......6-11 3121289 – JLG Lift –...
  • Page 12 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE This Page Left Blank Intentionally. – JLG Lift – 3121289...
  • Page 13 Wheel Torque Chart....... . .6-36 Inspection and Repair Log......7-1 3121289 – JLG Lift –...
  • Page 14 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE This Page Left Blank Intentionally. viii – JLG Lift – 3121289...

  • Page 15: Section 1 - Safety Precautions

    JLG Industries, Inc. completed under the supervision of an experienced and quali- fied operator.

  • Page 16: Workplace Inspection

    JLG. unit. • Before operation, check work area for overhead hazards such •...

  • Page 17: Machine Inspection

    • Check the machine for modifications to original components. opposite direction. Always return switch to neutral and stop Ensure that any modifications have been approved by JLG. before moving the switch to the next function. Operate con- trols with slow and even pressure.

  • Page 18: Trip And Fall Hazards

    Face the machine when entering or not operate this machine. leaving the platform. Always maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit. – JLG Lift – 3121298...

  • Page 19: Electrocution Hazards

    • Keep both feet firmly positioned on the platform floor at all times. Never position ladders, boxes, steps, planks, or similar items on unit to provide additional reach for any purpose. • Keep oil, mud, and slippery substances cleaned from footwear and the platform floor. 3121298 – JLG Lift –...
  • Page 20 • Allow for machine movement and electrical line swaying. ment from any electrical line or apparatus carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less. – JLG Lift – 3121298...

  • Page 21: Tipping Hazards

    • Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces. 3121298 – JLG Lift –...
  • Page 22 Keep all loads within the confines of the platform, mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Refer- unless authorized by JLG. ence Only). • Keep the chassis of the machine a minimum of 2 ft. (0.6m) •...
  • Page 23 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind. 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road. 47-54 20.8-24.4 Strong Gale Light structure damage. 3121298 – JLG Lift –...

  • Page 24: Crushing And Collision Hazards

    • Use the boom functions, not the drive function, to position the boom or platform. Position barricades on floor if necessary. platform close to obstacles. • Always post a lookout when driving in areas where vision is obstructed. 1-10 – JLG Lift – 3121298...

  • Page 25: Towing, Lifting, And Hauling

    • DO NOT attempt to repair or tighten any hydraulic hoses or fit- tings while the machine is powered on or when the hydraulic system is under pressure. • Always relieve hydraulic pressure from all hydraulic circuits before loosening or removing hydraulic components. 3121298 – JLG Lift – 1-11...
  • Page 26 • Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. Ensure adequate support is provided when raising components of the machine. 1-12 – JLG Lift – 3121298...

  • Page 27: Battery Hazards

    • Avoid overfilling the battery fluid level. Add distilled water to terminals. batteries only after the batteries are fully charged. • Always wear hand, eye, and face protection when servicing batteries. Ensure that battery acid does not come in contact with skin or clothing. 3121298 – JLG Lift – 1-13...
  • Page 28 SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-14 – JLG Lift – 3121298...

  • Page 29: Section - 2 - User Responsibilities, Machine Preparation

    4. Use of approved fall protection device. site. 5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunc- tion. 3121289 – JLG Lift –...

  • Page 30: Preparation, Inspection, And Maintenance

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION PREPARATION, INSPECTION, AND MAINTENANCE JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A PER- The following table covers the periodic machine inspections and SON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE maintenance required by JLG Industries, Inc.
  • Page 31 At intervals as specified in the Service and Maintenance Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual Manual. NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. 3121289 – JLG Lift –...

  • Page 32: Pre-Start Inspection

    Safety Manual of each attachment for accessory installed ity. Make sure none of the decals and placards are missing. upon the machine for specific inspection, operation, and Make sure all illegible decals and placards are cleaned or maintenance instructions. replaced. – JLG Lift – 3121289...

  • Page 33: Function Check

    Check auxiliary power (or manual descent); d. Ensure that all machine functions are disabled when the Emergency Stop Button is activated. e. Ensure all boom functions stop when the function enable switch is released. 3121289 – JLG Lift –...

  • Page 34: Skyguard Function Test

    If SkyGuard remains activated after function reversal or cutout, depress and hold the SkyGuard Override Switch to allow normal use of machine functions until the SkyGuard sensor is disen- gaged. – JLG Lift – 3121289...
  • Page 35 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-1. Basic Nomenclature - Sheet 1 of 2 3121289 – JLG Lift –...
  • Page 36 11. Platform Console 12. Jib 13. Fly Boom Section 14. Base Boom Section 15. Master Cylinder 16. Tower Boom 17. Turntable 18. Frame 19. SkyGuard (If Equipped) Figure 2-2. Basic Nomenclature - Sheet 2 of 2 – JLG Lift – 3121289...
  • Page 37 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-3. Daily Walk-Around Inspection - Sheet 1 of 3 3121289 – JLG Lift –...

  • Page 38: General

    1. Platform Assembly and Gate - Footswitch works properly, not modified, disabled or blocked. Gate latch, stop, and hinges in working condition. Figure 2-4. Daily Walk-Around Inspection - Sheet 2 of 3 2-10 – JLG Lift – 3121289...
  • Page 39 11. Swing Motor and Worm Gear - Evidence of proper lubri- 16. Hydraulic Reservoir - See Inspection Note. cation; No evidence of damage. 17. SkyGuard - See Inspection Note. Figure 2-5. Daily Walk-Around Inspection - Sheet 3 of 3 3121289 – JLG Lift – 2-11...

  • Page 40: Oscillating Axle Lockout Test (If Equipped)

    6. Have an assistant check to see that left front or right rear wheel remains elevated in position off of ground. 7. Carefully activate Swing control lever and return boom to stowed position (centered between drive wheels). When 2-12 – JLG Lift – 3121289...

  • Page 41: Section 3 - Machine Controls And Indicators

    3121289 – JLG Lift –...

  • Page 42: Ground Control Station

    This switch provides raising and lowering EXCEPT IN AN EMERGENCY. of the jib. PERFORM AS MANY PRE-OPERATIONAL CHECK AND INSPECTIONS FROM GROUND CON- TROLS AS POSSIBLE. 1. Platform Rotate A three position switch controls rotation of the platform. – JLG Lift – 3121289...
  • Page 43 4. Engine Start/Auxiliary Power/Function Enable 5. Power/Emergency Stop 6. Platform/Ground Select 7. Hourmeter 8. Swing 9. Tower Boom Lift 10. Main Boom Lift 11. Telescope 12. Indicator Panel QUARTZ HOURS Figure 3-1. Ground Control Station - A Models 3121289 – JLG Lift –...
  • Page 44 9. Tower Boom Lift 10. Main Boom Lift 11. Telescope 12. Indicator Panel 13. Machine Safety System Override (MSSO) Figure 3-1. Ground Control Station - A Models with Machine Safety System Override (MSSO) (CE Only) – JLG Lift – 3121289...
  • Page 45 4. Engine Start/Auxiliary Power/Function Enable 5. Power/Emergency Stop 6. Platform/Ground Select 7. Hourmeter 8. Swing 9. Tower Boom Lift 10. Main Boom Lift 11. Telescope 12. Indicator Panel QUARTZ HOURS Figure 3-2. Ground Control Station - AJ Models 3121289 – JLG Lift –...

  • Page 46: Jib Lift

    9. Tower Boom Lift 10. Main Boom Lift 11. Telescope 12. Indicator Panel 13. Machine Safety System Override (MSSO) Figure 3-3. Ground Control Station - AJ Models with Machine Safety System Override (MSSO) (CE Only) – JLG Lift – 3121289...

  • Page 47: Power/Emergency Stop

    (on). When pushed in 8. Swing Control (off ), power is shut off to the Platform/Ground Select switch. The Swing control switch provides 360 degrees non-continuous turntable rota- tion when positioned to the right or left. 3121289 – JLG Lift –...

  • Page 48: Ground Control Indicator Panel

    Indicates that the temperature of the engine (CE Only) oil, which also serves as engine coolant, is abnormally high and service is required. Provides emergency override of function controls that are locked out in the event of Load Sense System activation. – JLG Lift – 3121289...
  • Page 49 2. Low Engine Oil Pressure 7. Glow Plug Wait to Start 3. High Engine Coolant Temp. Platform Overload 9. Drive and Steer Disable 4. Engine Oil Temp. 5. System Distress Figure 3-4. Ground Control Indicator Panel 3121289 – JLG Lift –...
  • Page 50 SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. System Distress Indicator 7. Glow Plug Wait to Start Indicator The light indicates that the JLG Control System Indicates the glow plugs are on. The glow has detected an abnormal condition and a...

  • Page 51: Platform Control Station

    (on). When pushed in (off ), power is placement. shut off to the platform functions. (2WD Machines) - The forward position selects maximum speed by operating at high engine rpm. The backward posi- tion selects mid engine rpm. 3121289 – JLG Lift – 3-11...
  • Page 52 15. Platform Rotate 3. Horn 8. Drive/Steer 12. Soft Touch/SkyGuard Override 16. Function Speed 4. Power/Emergency Stop 9. Telescope 13. Soft Touch/SkyGuard Indicator 17. Main Lift/Swing Controller 5. Start/Auxiliary Power Figure 3-5. Platform Control Console 3-12 – JLG Lift – 3121289...
  • Page 53 6. Fuel Select (Dual Fuel Engine Only) (If Steering is accomplished via a Equipped) thumb-activated rocker switch on the end of the steer handle. Moving the switch to the appropriate position selects gasoline or liquid propane fuel. 3121289 – JLG Lift – 3-13...
  • Page 54 15. Platform Rotate caused the shutdown situation. Provides rotation of the platform when posi- tioned to the right or left. 3-14 – JLG Lift – 3121289...

  • Page 55: Platform Control Indicator Panel

    Provides main lift and swing. Push forward to lift up, pull backward to boom down. Move right to swing right, move left to swing left. Moving the joystick activates switches to provide the functions selected. 3121289 – JLG Lift – 3-15...
  • Page 56 1. AC Generator 4. Glow Plug/Wait to Start 7. Creep Speed 2. Platform Overload 5. Enable/Footswitch 8. System Distress 3. Tilt Alarm Warning 6. Fuel Level 9. Drive Orientation Figure 3-6. Platform Control Indicator Panel 3-16 – JLG Lift – 3121289...
  • Page 57 IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL. 3121289 – JLG Lift – 3-17...
  • Page 58 TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS. FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY OPER- ATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM. 3-18 – JLG Lift – 3121289...
  • Page 59 SECTION 3 - MACHINE CONTROLS AND INDICATORS 8. System Distress Indicator 9. Drive Orientation Indicator The light indicates that the JLG Control System When the boom is swung beyond the rear has detected an abnormal condition and a drive tires or further in either direction, the...
  • Page 60 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTES: 3-20 – JLG Lift – 3121289...

  • Page 61: Section 4 - Machine Operation

    4. Proper tire pressure. operate Boom Lift and Swing, and are to be used in an emer- 5. Machine is as originally equipped from JLG. gency to lower the platform to the ground should the operator in the platform be unable to do so. The Ground Control is also to be used in Pre-Start Inspection.

  • Page 62: Stability

    1. Turn key of SELECT switch to GROUND. Position POWER/ EMERGENCY STOP switch to ON, then push the ENGINE START switch until engine starts. ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD. – JLG Lift – 3121289...

  • Page 63: Shutdown Procedure

    3-5 minutes; this allows further reduction of internal tion, DO NOT OPERATE MACHINE. engine temperature. 2. Push POWER/EMERGENCY STOP switch in. 3. Turn Platform/Ground Select switch to Off. Refer to Engine Manufacturer’s manual for detailed information. 3121289 – JLG Lift –...

  • Page 64: Fuel Reserve / Shut-Off System

    Reference the Service and Maintenance Manual along with a After the 2 minute run time is complete or if the engine is qualified JLG Mechanic to verify your machine setup. shut down by the operator prior to the completion of the 2...

  • Page 65: Telescope

    SECTION 4 - MACHINE OPERATION MAIN BOOM TELESCOPE HORIZONTAL FULLY EXTENDED TOWER BOOM STOWED POSITION MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT-OF-LEVEL SURFACE Figure 4-1. Position of Least Forward Stability 3121289 – JLG Lift –...

  • Page 66: Traveling (Driving)

    1. Gradeability, which is the percent of grade of the incline the machine can climb. 2. Sideslope, which is the angle of the slope the machine can be driven across. Figure 4-2. Position of Least Backward Stability – JLG Lift – 3121289...

  • Page 67: Traveling Forward And Reverse

    The indicator light will flash during the 3 second interval BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWS ON BOTH THE CHAS- until the drive function is selected. SIS AND THE PLATFORM CONTROLS. MOVE THE DRIVE CONTROLS IN A DIRECTION MATCH- ING THE DIRECTIONAL ARROWS. 3121289 – JLG Lift –...
  • Page 68 SECTION 4 - MACHINE OPERATION LEVEL Figure 4-3. Grade and Side Slopes – JLG Lift – 3121289...

  • Page 69: Steering

    SLOPES SPECIFIED IN THE OPERATING SPECIFICATIONS SECTION OF THIS MANUAL. Platform Rotation To rotate the platform to the left or right, use the Platform Rotate control switch to select the direction and hold until desired posi- tion is reached. 3121289 – JLG Lift –...

  • Page 70: Swinging The Boom

    Drive and all boom functions are placed LEFT direction. in creep speed. Raising and Lowering the Tower Boom To raise or lower the Tower Boom, use Tower Boom Lift switch to select UP or DOWN movement. 4-10 – JLG Lift – 3121289...

  • Page 71: Machine Safety System Override (Msso)

    I = Input is Ignored Note: When Soft Touch is enabled with SkyGuard all functions are cut out only. * Reversal only applies to Main Tele Out. Main Tele In would be cut out 3121289 – JLG Lift – 4-11...

  • Page 72: Auxiliary Pump

    Determine the reason for pri- mary power failure and have the problem corrected by a certified JLG service technician. Operate as follows: 1. Position Platform/Ground switch to Platform. 2. Position Power/Emergency Stop switch to the on position.

  • Page 73: Shut Down And Park

    1. Drive machine to a reasonably well protected area. 1. Refer to the Serial Number Tag, call JLG Industries, or weigh the individual unit to find out the Gross Vehicle Weight. 2. Ensure boom is lowered over rear drive axle.
  • Page 74 SERIES II 64.3 in 62.8 in 63.7 in (1634 mm) (1595 mm) (1618 mm) 47.2 in 47.1 in 48.1 in (1196 mm) (1222 mm) (1199 mm) 1001143110 A Figure 4-4. Lifting and Tie Down Chart 4-14 – JLG Lift – 3121289...

  • Page 75: Towing

    1. Retract, lower and position boom over rear drive wheels in line with direction of travel. Figure 4-5. Drive Disconnect Hub 2. Disconnect drive hubs by inverting disconnect cap. (See Fig- ure 4-5.) After towing the machine, complete the following: 3121289 – JLG Lift – 4-15...

  • Page 76: Dual Fuel System (Gas Engine Only)

    2. Open hand valve on LP gas supply tank by turning counter- clockwise. 3. While engine is operating on GASOLINE under a no-load condition, place FUEL SELECT switch at Platform Control to LP position. 4-16 – JLG Lift – 3121289...
  • Page 77 SECTION 4 - MACHINE OPERATION Figure 4-6. Decal Installation - Sheet 1 of 6 3121289 – JLG Lift – 4-17...
  • Page 78 SECTION 4 - MACHINE OPERATION Figure 4-7. Decal Installation - Sheet 2 of 6 4-18 – JLG Lift – 3121289...
  • Page 79 SECTION 4 - MACHINE OPERATION 20 22 21 Figure 4-8. Decal Installation - Sheet 3 of 6 3121289 – JLG Lift – 4-19...
  • Page 80 SECTION 4 - MACHINE OPERATION Figure 4-9. Decal Installation - Sheet 4 of 6 4-20 – JLG Lift – 3121289...
  • Page 81 SECTION 4 - MACHINE OPERATION Figure 4-10. Decal Installation - Sheet 5 of 6 3121289 – JLG Lift – 4-21...
  • Page 82 SECTION 4 - MACHINE OPERATION Figure 4-11. Decal Installation - Sheet 6 of 6 4-22 – JLG Lift – 3121289...
  • Page 83 1001108493 1001108493 1001108493 1706941 1706941 1706941 1702868 1704000 1704002 1704001 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1001121801 1001121808 1001121918 1001121803 1001121810 1001121920 1001121805 1001121814 1001121821 1001121821 1001121816 1001121823 1001121923 1001121818 1705084 3121289 – JLG Lift – 4-23...
  • Page 84 1702300 1702300 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 3251243 3251242 3251243 3251243 3251243 3252347 3252347 1703980 1703981 1703984 1703982 1703985 1705828 1703983 4-24 – JLG Lift – 3121289...
  • Page 85 1001143101-D 1001143102-D 1001143103-D 1001143104-D 1001143106-D 1001143105-D 1001143107-D 1705514 1001143110 1001143110 1001143110 1001143110 1001143110 1001143110 1001143110 1001143110 1001143110 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1705351 1705426 1705427 1705429 1705430 1705905 1705910 1001112551 3121289 – JLG Lift – 4-25...
  • Page 86 SECTION 4 - MACHINE OPERATION NOTES: 4-26 – JLG Lift – 3121289...

  • Page 87: Section 5 - Emergency Procedures

    TIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CONTROLS. DO involving a JLG product. Even if no injury or property damage is NOT LIFT ABOVE 10 FT. (3 M) UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN evident, the factory should be contacted by telephone and pro- REPAIRED, IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING CORRECTLY.

  • Page 88: Emergency Operation

    If the MSSO functionality is used, the fault indicator will flash DO NOT FUNCTION PROPERLY. and a fault code is set in the JLG Control System which must be reset by a qualified JLG Service Technician. 3. Cranes, forklift trucks or other equipment can be used to sta- bilize motion of the machine.

  • Page 89: Section 6 - General Specifications And Operator Maintenance

    Boom retracted and approximately horizon- tal. Tower Boom fully lowered (if equipped) - ANSI Markets. Maximum Travel Grade (Sideslope) with 4° Boom retracted and approximately horizon- tal. Tower Boom fully lowered (if equipped) - CE & Australia Markets. 3121289 – JLG Lift –...

  • Page 90: Reach Specifications

    Up & Over Height-450A SII 25 ft-9.5 in (7.56 m) Electrical System Voltage 12 volts Up & Over Height-450AJ SII 25 ft-10 in (7.57 m) Main Boom Up Angle 75° Main Boom Down Angle -24° – JLG Lift – 3121289...

  • Page 91: Dimensional Data

    Gross Machine Weight - 450A SII Pneumatic Tires 12,750 lb (5783 kg) Foam-Filled Tires 13,660 lb (6196 kg) Gross Machine Weight - 450AJ SII Pneumatic Tires 13,250 lb (6010 kg) Foam-Filled Tires 14,160 lb (6423 kg) 3121289 – JLG Lift –...

  • Page 92: Major Component Weights

    328 lb (149 kg) Counterweight 2297 1042 33/1550x16.5 Pneumatic 90 psi (6 bar) 135 lb (61 kg) 33/1550x16.5 Foam-Filled 395 lb (179 kg) 14x17.5 Pneumatic 90psi (6 bar) 170 lb (77.2 kg) 14x17.5 Foam-Filled 440 lb (200 kg) – JLG Lift – 3121289...

  • Page 93: Engine

    1.2 gph (4.1 Lph) Oil Capacity 3.8 qt (3.6 L) crankcase only Min. Low Engine RPM 1200 Compression Ratio 19:1 Mid Engine RPM 1800 Firing Order 1-3-4-2 Max. High Engine RPM 2500 Max. RPM 2800 3121289 – JLG Lift –...
  • Page 94 6 psi (0.4 bar) @ 1000 rpm Tower Lift, Upper Lift, Tele 18 psi (1.2 bar) @ 2000 rpm Swing, Basket Level, Basket 1800 Compression Ratio 9.2:1 Rotate, Jib Lift 1500 Firing Order 1-3-4-2 High RPM 2800 Max. RPM 2800 – JLG Lift – 3121289...

  • Page 95: Hydraulic Oil

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Hydraulic Oil Aside from JLG recommendations, it is not advisable to mix oils of differ- ent brands or types, as they may not contain the same required addi- tives or be of comparable viscosities. If use of hydraulic oil other than Table 6-12.
  • Page 96 46 cSt (215SUS) at 100° C 6.6 cSt at 65° C (150° F) 22 cSt (106SUS) at 100° F 169 SUS Viscosity Index at 210° F 48 SUS cp at -20° F 6,200 Viscosity Index – JLG Lift – 3121289...
  • Page 97 0 to 180°F (-17 to 162°C) Viscosity Index 7.64 lb/gal NOTE: Mobil/Exxon recommends that this oil be checked on a Weight (0.9 kg/L) yearly basis for viscosity. Viscosity at 40° C 45 cSt at 100° C 8.0 cSt Viscosity Index 3121289 – JLG Lift –...
  • Page 98 Fire Point 325°C (617°F) Autoignition Temperature 450°C (842°F) Viscosity at 0° C (32°F) 360 cSt at 20° C (68°F) 102 cSt at 40° C (104°F) 46 cSt at 100° C (212°F) 10 cSt Viscosity Index 6-10 – JLG Lift – 3121289...

  • Page 99: Serial Number Location

    SERIAL NUMBER SERIAL NUMBER STAMPED PLATE ON FRAME Figure 6-1. Serial Number Locations 3121289 – JLG Lift – 6-11...
  • Page 100 0°F(-18°C) ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10°F(-23°C) WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20°F(-29°C) PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND -30° F(-34 C) °...
  • Page 101 (HYD. OIL TANK TEMP.) IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC AMBIENT AIR OIL COOLER (CONSULT JLG SERVICE TEMPERATURE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS AMBIENT AIR TEMPERATURES 110°...

  • Page 102: Specifications

    ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10°F(-23°C) GRADE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY FUEL AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20°F(-29°C) WITH PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR KEROSENE -30F°(-34°C)
  • Page 103 IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS AMBIENT AIR THE ADDITION OF A HYDRAULIC TEMPERATURE OIL COOLER (CONSULT JLG SERVICE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS N O T E : AMBIENT AIR TEMPERATURES 110°...
  • Page 104 -10 F(-23 C) ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C) (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
  • Page 105 IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC AMBIENT AIR TEMPERATURE OIL COOLER (CONSULT JLG SERVICE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS AMBIENT AIR TEMPERATURES 110° F (43° C) AMBIENT TEMPERATURE OF 100°...
  • Page 106 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Figure 6-8. Operator Maintenance and Lubrication Diagram - Deutz D2.9 6-18 – JLG Lift – 3121289...
  • Page 107 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 8,10 14,15 Figure 6-9. Operator Maintenance and Lubrication Diagram - Deutz D2011 and CAT C2.2 3121289 – JLG Lift – 6-19...
  • Page 108 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 20,21 Figure 6-10. Operator Maintenance and Lubrication Diagram - GM Dual-Fuel 6-20 – JLG Lift – 3121289...

  • Page 109: Operator Maintenance

    Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424. Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C. Open Gear Lubricant - Mobiltac 375 or equivalent. 3121289 – JLG Lift – 6-21...
  • Page 110 Interval - A/R DO NOT OVERGREASE BEARINGS. OVERGREASING BEARINGS WILL RESULT IN DAMAGE TO OUTER SEAL IN HOUSING. *If necessary install grease fitting into worm gear housing and grease. Replace fitting with pipe plug when complete. 6-22 – JLG Lift – 3121289...
  • Page 111 Lube Point(s) - Level/Fill Plug Capacity - 17 oz (0.5 L) - 1/2 Full Lube - EPGL Interval - Check level every 3 months or 150 hours of operation; change every 2 years or 1200 hours of operation. 3121289 – JLG Lift – 6-23...
  • Page 112 Capacity - 27 gal (102 L); 23.6 gal (89 L) to mid point of upper sight window (cold) Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation. 6-24 – JLG Lift – 3121289...
  • Page 113 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 8. Oil Change w/Filter - Caterpillar 9. Oil Change w/Filter - Deutz 2.9 L4 Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N Lube Point(s) - Fill Cap/Spin-on Element 7026855) Capacity - 2.4 gal (8.9 L) Capacity - 10 qt (9.4 L)
  • Page 114 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 10. Oil Change w/Filter - Deutz D2011 Fill Cap/Spin-on Element (JLG P/N 7016641) Capacity - 11 qt (10.5 L) Crankcase; 5 qt (4.7 L) Cooler Lube - EO Interval - Every Year or 1200 hours of operation Comments - Check level daily/Change in accordance with engine manual.
  • Page 115 MAXIMUM OIL OIL COLD LEVEL MAXIMUM LEVEL, OIL COLD NOTE: Hot oil checks should be made a period of 5 minutes after the engine has been shut down. Figure 6-11. Deutz D2011 Engine Dipsticks 3121289 – JLG Lift – 6-27...
  • Page 116 Interval - Every Year or 600 hours of operation (JLG P/N 7027965) Capacity - 4.5 qt (4.25 L) w/filter Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual. 6-28 – JLG Lift – 3121289...
  • Page 117 14. Fuel Filter - Deutz D2.9 Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Drain water daily; Every year or 600 hours of Interval - Every year or 600 hours of operation operation 3121289 – JLG Lift – 6-29...
  • Page 118 16. Fuel Filter - Deutz D2011 Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation Interval - Every Year or 600 hours of operation 6-30 – JLG Lift – 3121289...
  • Page 119 Interval - Every 6 months or 300 hours of operation Lube Point(s) - Fill Cap Capacity - 3.2 gal (12.1 L) Lube - Anti-Freeze Interval - Check level daily; change every 1000 hours or 2 years, whichever comes first. 3121289 – JLG Lift – 6-31...
  • Page 120 19. Air Filter DEUTZ D2011, GM Deutz 2.9 Filter Indicator Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator (19A) CAT, DEUTZ D2.9 6-32 – JLG Lift – 3121289...
  • Page 121 Interval - 3 Months or 150 hours of operation Comments - Replace filter. Refer to Section 6.5, Propane Fuel Comments - Drain oil build up. Refer to Section 6.5, Propane Filter Replacement. Fuel Filter Replacement. 3121289 – JLG Lift – 6-33...

  • Page 122: Tires & Wheels

    The air pressure for pneumatic tires must be equal to the air pres- sure that is stenciled on the side of the JLG product or rim decal Tire Replacement for safe and proper operational characteristics.

  • Page 123: Wheel And Tire Replacement

    The proper procedure for attaching wheels is as follows: 1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts. 3121289 – JLG Lift – 6-35...
  • Page 124 (55 Nm) (130 Nm) (255 Nm) 4. Wheel nuts should be torqued after first 50 hours of opera- tion and after each wheel removal. Check torque every 3 months or 150 hours of operation. 6-36 – JLG Lift – 3121289...

  • Page 125: Propane Fuel Filter Replacement

    7. O-ring 9. Remove and discard mounting plate to lock off O-ring seal. 3. Filter Magnet 8. Filter 4. Filter Housing 9. Fuel Inlet 5. Electrical Connector 10. Ring Figure 6-12. Filter Lock Assembly 3121289 – JLG Lift – 6-37...

  • Page 126: Installation

    AREA IS WELL VENTILATED BEFORE DISCONNECTING ANY FUEL LINE. 9. Open manual shut-off valve. Start the vehicle and leak check the propane fuel system at each serviced fitting. Refer to Propane Fuel System Leak Test. 6-38 – JLG Lift – 3121289...

  • Page 127: Supplemental Information

    The vibration total value to which the hand-arm system is sub- jected does not exceed 2,5 m/s . The highest root mean square value of weighted acceleration to which the whole body is sub- jected does not exceed 0,5 m/s 3121289 – JLG Lift – 6-39...
  • Page 128 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE NOTES: 6-40 – JLG Lift – 3121289...
  • Page 129 SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 7-1. Inspection and Repair Log Date Comments 3121289 – JLG Lift –...
  • Page 130 SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log Date Comments – JLG Lift – 3121289...
  • Page 134 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 3121289 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu...

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