JLG 450A 450AJ PVC 2001 2007 Parts Manual (31215023) –  PDF DOWNLOAD (english)

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JLG 450A 450AJ PVC 2001 2007 Parts Manual (31215023) –  PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 450A 450AJ PVC 2001 2007 Parts Manual (31215023) –  PDF DOWNLOAD

SECTION 1 - FRAME............................................................................................................................... 13
	FIGURE 1-1. AXLE INSTALLATION............................................................................................................... 14
	FIGURE 1-2. STEER INSTALLATION WITHOUT TOW PACKAGE.......................................................................................... 16
	FIGURE 1-3. STEER INSTALLATION WITH TOW PACKAGE............................................................................................. 18
	FIGURE 1-4. WHEEL DRIVE INSTALLATION (2WD).................................................................................................. 20
	FIGURE 1-5. WHEEL DRIVE INSTALLATION (4WD).................................................................................................. 22
	FIGURE 1-6. HUB - SPINDLE ASSEMBLY.......................................................................................................... 24
	FIGURE 1-7. DRIVE HUB AND BRAKE ASSEMBLY - REAR............................................................................................. 26
	FIGURE 1-8. DRIVE HUB ASSEMBLY - FRONT...................................................................................................... 30
	FIGURE 1-9. DRIVE MOTOR ASSEMBLY (2WD)...................................................................................................... 32
	FIGURE 1-10. DRIVE MOTOR ASSEMBLY (4WD)..................................................................................................... 34
	FIGURE 1-11. FRAME SHIELD INSTALLATION...................................................................................................... 36
	FIGURE 1-12. TIRE AND WHEEL INSTALLATION - 12 X 16.5 FOAM FILLED (AVAILABLE ON ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)................... 38
	FIGURE 1-13. TIRE AND WHEEL INSTALLATION - 12 X 16.5 FOAM FILLED NON MARKING (AVAILABLE ON ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)....... 40
	FIGURE 1-14. TIRE AND WHEEL INSTALLATION - 33 X 12-20 SOLID NON-MARKING (AVAILABLE ON AUSTRALIAN AND CE SPECS).............................. 42
	FIGURE 1-15. TIRE AND WHEEL INSTALLATION - 33/1550 X 16.5 FOAM-FILLED (AVAILABLE ON ALL SPECS).............................................. 44
	FIGURE 1-16. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED (AVAILABLE ON AUSTRALIAN, CE AND CHINA SPECS)............................. 46
	FIGURE 1-17. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED NON-MARKING (AVAILABLE ON AUSTRALIAN, CE AND CHINA SPECS)................. 48
	FIGURE 1-18. 2WD VALVES INSTALLATION - 450A FRAME MOUNTED................................................................................... 50
	FIGURE 1-19. 2WD VALVES INSTALLATION - 450AJ FRAME MOUNTED.................................................................................. 52
	FIGURE 1-20. 4WD VALVES INSTALLATION - 450A FRAME MOUNTED................................................................................... 54
	FIGURE 1-21. 4WD VALVES INSTALLATION - 450AJ FRAME MOUNTED.................................................................................. 56
	FIGURE 1-22. TRACTION VALVE ASSEMBLY - 2WD.................................................................................................. 58
	FIGURE 1-23. TRACTION VALVE ASSEMBLY - 4WD.................................................................................................. 60
	FIGURE 1-24. TOW PACKAGE INSTALLATION (OPTIONAL)............................................................................................ 62
	FIGURE 1-25. TOW BAR ASSEMBLY............................................................................................................... 64
SECTION 2 - TURNTABLE........................................................................................................................... 67
	FIGURE 2-1. 2WD VALVES INSTALLATION - 450A TURNTABLE MOUNTED................................................................................ 68
	FIGURE 2-2. 2WD VALVES INSTALLATION - 450AJ TURNTABLE MOUNTED............................................................................... 70
	FIGURE 2-3. 4WD VALVES INSTALLATION - 450A TURNTABLE MOUNTED................................................................................ 72
	FIGURE 2-4. 4WD VALVES INSTALLATION - 450AJ TURNTABLE MOUNTED............................................................................... 74
	FIGURE 2-5. MAIN VALVE ASSEMBLY............................................................................................................. 76
	FIGURE 2-6. AUXILIARY PUMP ASSEMBLY......................................................................................................... 78
	FIGURE 2-7. SWING DRIVE AND TURNTABLE BEARING INSTALLATION.................................................................................. 80
	FIGURE 2-8. SWING MOTOR ASSEMBLY............................................................................................................ 82
	FIGURE 2-9. TURNTABLE BEARING ASSEMBLY...................................................................................................... 84
	FIGURE 2-10. TURNTABLE COVERS INSTALLATION.................................................................................................. 86
	FIGURE 2-11. TURNTABLE LOCK INSTALLATION.................................................................................................... 88
	FIGURE 2-12. TANKS INSTALLATION - DIESEL MACHINES........................................................................................... 90
	FIGURE 2-13. TANKS INSTALLATION - GAS MACHINES.............................................................................................. 92
	FIGURE 2-14. DRIVE ORIENTATION INSTALLATION................................................................................................. 94
	FIGURE 2-15. GROUND CONTROL ASSEMBLY - 450A WITH DEUTZ ENGINES (ANSI SPECS)................................................................. 96
	FIGURE 2-16. GROUND CONTROL ASSEMBLY - 450AJ WITH DEUTZ ENGINES (ALL SPECS EXCEPT CE AND CHINA SPECS)....................................... 98
	FIGURE 2-17. GROUND CONTROL ASSEMBLY - 450AJ WITH DEUTZ ENGINE (CHINA SPECS)................................................................100
	FIGURE 2-18. GROUND CONTROL ASSEMBLY - 450AJ WITH DEUTZ D2.9L4 ENGINE (STAGE V) (CE SPECS)..................................................102
	FIGURE 2-19. GROUND CONTROL ASSEMBLY - 450A WITH KUBOTA ENGINE (ANSI AND CSA SPECS).........................................................104
	FIGURE 2-20. GROUND CONTROL ASSEMBLY - 450AJ WITH KUBOTA ENGINE (ANSI SPECS)................................................................106
	FIGURE 2-21. LIGHT PANEL INSTALLATION – GROUND CONTROL (USA & CHINA BUILT MACHINES).........................................................108
	FIGURE 2-22. LIGHT PANEL INSTALLATION – GROUND CONTROL (ROMANIAN BUILT MACHINES)............................................................110
	FIGURE 2-23. ELECTRICAL SYSTEM INSTALLATION.................................................................................................112
	FIGURE 2-24. WHITE NOISE ALARM INSTALLATION.................................................................................................116
	FIGURE 2-25. BEACON LIGHT INSTALLATION - AMBER..............................................................................................118
	FIGURE 2-26. BEACON LIGHT INSTALLATION - BLUE...............................................................................................120
	FIGURE 2-27. BEACON LIGHT INSTALLATION - RED................................................................................................122
	FIGURE 2-28. BATTERY AND CABLE INSTALLATION - USA AND CHINA BUILT MACHINES (PVC 2001).......................................................124
	FIGURE 2-29. BATTERY AND CABLE INSTALLATION - USA AND CHINA BUILT MACHINES (PVC 2007).......................................................126
	FIGURE 2-30. BATTERY AND CABLE INSTALLATION - ROMANIAN BUILT MACHINES (PVC 2001)............................................................128
	FIGURE 2-31. BATTERY AND CABLE INSTALLATION - ROMANIAN BUILT MACHINES (PVC 2007)............................................................130
	FIGURE 2-32. HOODS INSTALLATION - 450A WITH DEUTZ ENGINES...................................................................................132
	FIGURE 2-33. HOODS INSTALLATION - 450A WITH KUBOTA ENGINE...................................................................................136
	FIGURE 2-34. HOODS INSTALLATION - 450AJ WITH DEUTZ ENGINES (USA & CHINA BUILT MACHINES).....................................................140
	FIGURE 2-35. HOODS INSTALLATION - 450AJ WITH DEUTZ ENGINE (ROMANIAN BUILT MACHINES).........................................................144
	FIGURE 2-36. HOODS INSTALLATION - 450AJ WITH KUBOTA ENGINE..................................................................................148
	FIGURE 2-37. HOOD ASSEMBLY - TANK SIDE (USA & CHINA BUILT MACHINES).........................................................................152
	FIGURE 2-38. HOOD ASSEMBLY - TANK SIDE (ROMANIAN BUILT MACHINES)............................................................................154
	FIGURE 2-39. HOOD ASSEMBLY - ENGINE SIDE (USA & CHINA BUILT MACHINES).......................................................................156
	FIGURE 2-40. HOOD ASSEMBLY - ENGINE SIDE (ROMANIAN BUILT MACHINES)..........................................................................158
SECTION 3 - ENGINE..............................................................................................................................161
	FIGURE 3-1. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)..................162
	FIGURE 3-2. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)................166
	FIGURE 3-3. ENGINE ASSEMBLY - DEUTZ D2.9L4 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS) (PVC 2001)...........168
	FIGURE 3-4. ENGINE ASSEMBLY - DEUTZ D2.9L4 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS) (PVC 2007)...........174
	FIGURE 3-5. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (WITH ARCTIC PACKAGE) (ANSI AND CSA SPECS)............................................180
	FIGURE 3-6. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 (WITH ARCTIC PACKAGE) (ANSI AND CSA SPECS)..........................................186
	FIGURE 3-7. ENGINE ASSEMBLY - DEUTZ D2.9L4 ENGINE (WITH ARCTIC PACKAGE) (ANSI AND CSA SPECS) (PVC 2001).....................................188
	FIGURE 3-8. ENGINE ASSEMBLY - DEUTZ D2.9L4 ENGINE (WITH ARCTIC PACKAGE) (ANSI AND CSA SPECS) (PVC 2007).....................................194
	FIGURE 3-9. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (STAGE V) (CE SPECS)..................................................................200
	FIGURE 3-10. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ENGINE (STAGE V) (CE SPECS)........................................................206
	FIGURE 3-11. ENGINE ASSEMBLY – DEUTZ D2.9L4 ENGINE (STAGE V) (CE SPECS).....................................................................208
	FIGURE 3-12. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 ENGINE)..................................................................214
	FIGURE 3-13. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 ENGINE) (STAGE V)........................................................216
	FIGURE 3-14. BREATHER HEATER INSTALLATION - DEUTZ D2.9L4 ENGINE WITH ARCTIC PACKAGE.........................................................218
	FIGURE 3-15. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC) AND CHINA SPECS)..........220
	FIGURE 3-16. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN AND CHINA SPECS)..................224
	FIGURE 3-17. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN AND CHINA SPECS)........................226
	FIGURE 3-18. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITH ARCTIC PACKAGE) (ANSI EXPORT AND CHINA SPECS)...................................230
	FIGURE 3-19. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (WITH ARCTIC PACKAGE) (ANSI EXPORT AND CHINA SPECS).................................234
	FIGURE 3-20. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (WITH ARCTIC PACKAGE) (ANSI EXPORT AND CHINA SPECS).......................................236
	FIGURE 3-21. ENGINE COMPONENTS - DEUTZ D2011................................................................................................240
	FIGURE 3-22. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS) (PVC 2001)..............................244
	FIGURE 3-23. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS) (PVC 2001)............................248
	FIGURE 3-24. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS) (PVC 2001)..................................250
	FIGURE 3-25. PUMP COUPLING KIT – DEUTZ ENGINES..............................................................................................254
	FIGURE 3-26. ENGINE INSTALLATION - KUBOTA ENGINE (WITHOUT ARCTIC PACKAGE)...................................................................256
	FIGURE 3-27. ENGINE AND PUMP SUB-ASSEMBLY - KUBOTA ENGINE (WITHOUT ARCTIC PACKAGE)..........................................................262
	FIGURE 3-28. ENGINE ASSEMBLY - KUBOTA ENGINE (WITHOUT ARCTIC PACKAGE).......................................................................264
	FIGURE 3-29. ENGINE INSTALLATION - KUBOTA ENGINE (WITH ARCTIC PACKAGE)......................................................................270
	FIGURE 3-30. ENGINE AND PUMP SUB-ASSEMBLY - KUBOTA ENGINE (WITH ARCTIC PACKAGE).............................................................276
	FIGURE 3-31. ENGINE ASSEMBLY - KUBOTA ENGINE (WITH ARCTIC PACKAGE)..........................................................................278
	FIGURE 3-32. ENGINE COMPONENTS - KUBOTA.....................................................................................................284
	FIGURE 3-33. PUMP COUPLING KIT - KUBOTA ENGINE..............................................................................................288
	FIGURE 3-34. PISTON PUMP ASSEMBLY...........................................................................................................290
	FIGURE 3-35. SPARK ARRESTOR INSTALLATION - DEUTZ D2011 ENGINE...............................................................................294
	FIGURE 3-36. ENGINE BAFFLE INSTALLATION - WITH DEUTZ ENGINES................................................................................296
	FIGURE 3-37. ENGINE BAFFLE INSTALLATION – WITH KUBOTA ENGINE................................................................................298
	FIGURE 3-38. GENERATOR INSTALLATION - 2500W/50HZ (DEUTZ D2011 ENGINE).......................................................................300
	FIGURE 3-39. GENERATOR INSTALLATION - 2500W/60HZ (DEUTZ D2011 ENGINE).......................................................................304
	FIGURE 3-40. GENERATOR INSTALLATION - 2500W/60HZ (DEUTZ D2.9L4 ENGINE)......................................................................308
	FIGURE 3-41. GENERATOR INSTALLATION - 2500W/60HZ (KUBOTA ENGINE)............................................................................312
	FIGURE 3-42. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ D2011 ENGINE).......................................................................316
	FIGURE 3-43. GENERATOR INSTALLATION - 4000W/60HZ (DEUTZ D2011 ENGINE).......................................................................320
	FIGURE 3-44. GENERATOR INSTALLATION - 4000W/60HZ (DEUTZ D2.9L4 ENGINE)......................................................................324
	FIGURE 3-45. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ ENGINE) (STAGE V)...................................................................328
	FIGURE 3-46. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ D2011 ENGINE) (PVC 2001)............................................................332
	FIGURE 3-47. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ D2011 ENGINE) (PVC 2007)............................................................336
	FIGURE 3-48. GENERATOR INSTALLATION - 7500W/60HZ (DEUTZ D2011 ENGINE).......................................................................340
	FIGURE 3-49. GENERATOR INSTALLATION - 7500W/60HZ (DEUTZ D2.9L4 ENGINE)......................................................................344
	FIGURE 3-50. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ ENGINE) (STAGE V)...................................................................348
	FIGURE 3-51. GENERATOR INSTALLATION - 7500W/60HZ (KUBOTA ENGINE)............................................................................352
SECTION 4 - BOOM................................................................................................................................357
	FIGURE 4-1. CYLINDERS INSTALLATION - 450A...................................................................................................358
	FIGURE 4-2. CYLINDERS INSTALLATION - 450AJ (USA AND CHINA BUILT MACHINES)...................................................................360
	FIGURE 4-3. CYLINDERS INSTALLATION - 450AJ (ROMANIAN BUILT MACHINES)........................................................................362
	FIGURE 4-4. BOOM INSTALLATION - 450A........................................................................................................364
	FIGURE 4-5. BOOM INSTALLATION WITH AIRLINE - 450A...........................................................................................366
	FIGURE 4-6. BOOM INSTALLATION WITH SKYPOWER AND AIRLINE - 450A..............................................................................368
	FIGURE 4-7. BOOM INSTALLATION WITH SKYPOWER - 450A..........................................................................................370
	FIGURE 4-8. BOOM INSTALLATION KIT - 450A....................................................................................................372
	FIGURE 4-9. BOOM INSTALLATION - 450AJ USA AND CHINA BUILT MACHINES..........................................................................374
	FIGURE 4-10. BOOM INSTALLATION - 450AJ ROMANIAN BUILT MACHINES..............................................................................376
	FIGURE 4-11. JIB INSTALLATION - USA AND CHINA BUILT MACHINES................................................................................378
	FIGURE 4-12. JIB INSTALLATION - ROMANIAN BUILT MACHINES.....................................................................................380
	FIGURE 4-13. MAIN BOOM ASSEMBLY - 450A......................................................................................................382
	FIGURE 4-14. MAIN BOOM ASSEMBLY - 450AJ.....................................................................................................384
	FIGURE 4-15. TOWER BOOM ASSEMBLY - 450A.....................................................................................................386
	FIGURE 4-16. TOWER BOOM ASSEMBLY - 450AJ USA AND CHINA BUILT MACHINES.......................................................................388
	FIGURE 4-17. TOWER BOOM ASSEMBLY - 450AJ ROMANIAN BUILT MACHINES............................................................................390
	FIGURE 4-18. ROTATOR ASSEMBLY...............................................................................................................392
	FIGURE 4-19. PLATFORM SUPPORT INSTALLATION..................................................................................................394
	FIGURE 4-20. 2WD VALVES INSTALLATION - 450A BOOM MOUNTED....................................................................................396
	FIGURE 4-21. 2WD VALVES INSTALLATION - 450AJ BOOM MOUNTED...................................................................................398
	FIGURE 4-22. 4WD VALVES INSTALLATION - 450A BOOM MOUNTED....................................................................................400
	FIGURE 4-23. 4WD VALVES INSTALLATION - 450AJ BOOM MOUNTED...................................................................................402
	FIGURE 4-24. UPRIGHT VALVE ASSEMBLY.........................................................................................................404
	FIGURE 4-25. BOOM VALVE ASSEMBLY - 450A.....................................................................................................406
	FIGURE 4-26. BOOM VALVE ASSEMBLY - 450AJ....................................................................................................408
SECTION 5 - PLATFORM............................................................................................................................411
	FIGURE 5-1. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - SIDE GATE ENTRY (USA BUILT MACHINES)............................................412
	FIGURE 5-2. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - SIDE GATE ENTRY (USA AND CHINA BUILT MACHINES)..................................414
	FIGURE 5-3. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - SIDE GATE ENTRY (USA AND CHINA BUILT MACHINES)..................................416
	FIGURE 5-4. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - SIDE GATE ENTRY (ROMANIAN BUILT MACHINES).......................................418
	FIGURE 5-5. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - SIDE GATE ENTRY (ROMANIAN BUILT MACHINES).......................................420
	FIGURE 5-6. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - SIDE GATE ENTRY (ROMANIAN BUILT MACHINES).......................................422
	FIGURE 5-7. PLATFORM ASSEMBLY - 30IN X 3FT (76CM X .91M) - DROP BAR ENTRY (USA AND ROMANIAN BUILT MACHINES).................................424
	FIGURE 5-8. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - WITH DROP BAR (USA BUILT MACHINES)..............................................426
	FIGURE 5-9. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - WITH DROP BAR (USA AND CHINA BUILT MACHINES)....................................428
	FIGURE 5-10. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - WITH DROP BAR (USA AND CHINA BUILT MACHINES)...................................430
	FIGURE 5-11. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - WITH DROP BAR (ROMANIAN BUILT MACHINES)........................................432
	FIGURE 5-12. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - WITH DROP BAR (ROMANIAN BUILT MACHINES)........................................434
	FIGURE 5-13. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - WITH DROP BAR (ROMANIAN BUILT MACHINES)........................................436
	FIGURE 5-14. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M - FALL ARREST (ANSI, ANSI EXPORT AND CSA SPECS)...................................438
	FIGURE 5-15. CONSOLE BOX INSTALLATION - 450A................................................................................................440
	FIGURE 5-16. CONSOLE BOX INSTALLATION - 450AJ...............................................................................................442
	FIGURE 5-17. PLATFORM CONSOLE BOX ASSEMBLY - 450A...........................................................................................444
	FIGURE 5-18. PLATFORM CONSOLE BOX ASSEMBLY - 450AJ..........................................................................................448
	FIGURE 5-19. LIGHT PANEL INSTALLATION – PLATFORM CONSOLE (USA & CHINA BUILT MACHINES).......................................................452
	FIGURE 5-20. LIGHT PANEL INSTALLATION – PLATFORM CONSOLE (ROMANIAN BUILT MACHINES)..........................................................454
	FIGURE 5-21. CONTROLLER ASSEMBLY - DRIVE AND STEER..........................................................................................456
	FIGURE 5-22. CONTROLLER ASSEMBLY - LIFT AND SWING...........................................................................................458
	FIGURE 5-23. FOOTSWITCH ASSEMBLY............................................................................................................462
	FIGURE 5-24. TRAY ASSEMBLY..................................................................................................................464
	FIGURE 5-25. SOFT TOUCH INSTALLATION - 6FT/1.8M PLATFORM (ANSI, ANSI EXPORT, CHINA, CSA AND JAPANESE SPECS) (PVC 2001)......................466
	FIGURE 5-26. SOFT TOUCH INSTALLATION - 5FT/1.52M PLATFORM WITH FALL ARREST (ANSI, ANSI EXPORT, CHINA, CSA AND JAPANESE SPECS) (PVC 2001)....468
	FIGURE 5-27. SKYEYE INSTALLATION............................................................................................................470
	FIGURE 5-28. SKYGUARD BAR INSTALLATION......................................................................................................472
	FIGURE 5-29. SKYLINE INSTALLATION...........................................................................................................474
	FIGURE 5-30. SKYGLAZIER INSTALLATION........................................................................................................476
	FIGURE 5-31. SKYWELDER INSTALLATION (50HZ)..................................................................................................478
	FIGURE 5-32. SKYWELDER INSTALLATION (60HZ)..................................................................................................480
	FIGURE 5-33. SKYWELDER PREP PACKAGE INSTALLATION............................................................................................482
	FIGURE 5-34. WELDER ASSEMBLY................................................................................................................484
	FIGURE 5-35. PIPE RACK INSTALLATION (ALL SPECS EXCEPT AUSTRALIAN SPECS).....................................................................486
	FIGURE 5-36. PIPE RACK INSTALLATION (AUSTRALIAN SPEC).......................................................................................488
	FIGURE 5-37. FALL ARREST INSTALLATION (BOLT-ON) (4FT/1.22M PLATFORM)........................................................................490
	FIGURE 5-38. FALL ARREST INSTALLATION (BOLT-ON) (5FT/1.52M PLATFORM)........................................................................492
	FIGURE 5-39. FALL ARREST INSTALLATION (BOLT-ON) (6FT/1.83M PLATFORM)........................................................................494
SECTION 6 - CYLINDER............................................................................................................................497
	FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY..................................................................................................498
	FIGURE 6-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY........................................................................................500
	FIGURE 6-3. LIFT CYLINDER ASSEMBLY - JIB....................................................................................................502
	FIGURE 6-4. LIFT CYLINDER ASSEMBLY - 450A MAIN BOOM.........................................................................................504
	FIGURE 6-5. LIFT CYLINDER ASSEMBLY - 450AJ MAIN BOOM........................................................................................506
	FIGURE 6-6. LIFT CYLINDER ASSEMBLY - TOWER BOOM.............................................................................................508
	FIGURE 6-7. MASTER CYLINDER ASSEMBLY........................................................................................................510
	FIGURE 6-8. STEER CYLINDER ASSEMBLY.........................................................................................................512
	FIGURE 6-9. TELESCOPE CYLINDER ASSEMBLY - 450A..............................................................................................514
	FIGURE 6-10. TELESCOPE CYLINDER ASSEMBLY - 450AJ............................................................................................516
SECTION 7 - HYDRAULIC...........................................................................................................................519
	FIGURE 7-1. 2WD HYDRAULIC SYSTEM INSTALLATION - 450A........................................................................................520
	FIGURE 7-2. 2WD HYDRAULIC SYSTEM INSTALLATION - 450AJ.......................................................................................526
	FIGURE 7-3. 4WD HYDRAULIC SYSTEM INSTALLATION - 450A........................................................................................532
	FIGURE 7-4. 4WD HYDRAULIC SYSTEM INSTALLATION - 450AJ.......................................................................................538
SECTION 8 - ELECTRICAL..........................................................................................................................545
	FIGURE 8-1. AC BOX AT PLATFORM INSTALLATION - 110V - ANSI, ANSI EXPORT, CHINA, CSA AND JAPANESE SPECS.......................................546
	FIGURE 8-2. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE SPECS WITH 4000W/50HZ GENERATOR)..........................................548
	FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - 110V IEC 60309 YELLOW WITHOUT 2500W GENERATOR (CE SPECS)......................................550
	FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE SPECS WITH 4000W/50HZ GENERATOR)............................................552
	FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 220V IEC 60309 BLUE WITHOUT 2500W GENERATOR (CE SPECS)........................................554
	FIGURE 8-6. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE SPECS)............................556
	FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE SPECS)............................558
	FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2IN X 4IN POST GROUND (CE SPECS WITH 4000W/50HZ GENERATOR)..........................560
	FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2IN X 4IN SIDE GROUND (CE SPECS WITH 4000W/50HZ GENERATOR)..........................562
	FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT107 (CE SPECS WITH 4000W/50HZ GENERATOR)..........................................564
	FIGURE 8-11. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE SPECS)....................566
	FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 220V CUSTOMER SUPPLIED COMPONENTS (ANSI EXPORT, CE AND CHINA SPECS)..........................568
	FIGURE 8-13. AC BOX AT PLATFORM INSTALLATION - 240V (WITH 4000W GENERATOR) (ALL SPECS EXCEPT AUSTRALIAN & CE SPECS).........................570
	FIGURE 8-14. AC BOX AT PLATFORM INSTALLATION - 240V (WITH 7500W SKYPOWER GENERATOR) (ALL SPECS EXCEPT AUSTRALIAN & CE SPECS)................572
	FIGURE 8-15. AC CABLE INSTALLATION - WITH TWO BREAKERS (CE SPECS)...........................................................................574
	FIGURE 8-16. AC CABLE INSTALLATION - WITH THREE BREAKERS (CE SPECS).........................................................................576
	FIGURE 8-17. BATTERY DISCONNECT SWITCH......................................................................................................578
	FIGURE 8-18. BEACON LIGHT HARNESS (BLUE AND RED BEACON LIGHT)...............................................................................580
	FIGURE 8-19. BOOM CABLES AND CLAMPS INSTALLATION - 450A (WITHOUT ARCTIC PACKAGE)............................................................582
	FIGURE 8-20. BOOM CABLES AND CLAMPS INSTALLATION - 450AJ (WITHOUT ARCTIC PACKAGE)...........................................................586
	FIGURE 8-21. BOOM CABLES AND CLAMPS INSTALLATION - 450A (WITH ARCTIC PACKAGE)...............................................................590
	FIGURE 8-22. BOOM CABLES AND CLAMPS INSTALLATION - 450AJ (WITH ARCTIC PACKAGE)..............................................................594
	FIGURE 8-23. BOOM CABLES AND CLAMPS INSTALLATION - 450AJ (MACHINES WITH 50HZ 4000W GENERATORS)..............................................598
	FIGURE 8-24. BOOM CABLES AND CLAMPS INSTALLATION - 450AJ (MACHINES WITH 60HZ 4000W GENERATORS)..............................................602
	FIGURE 8-25. BOOM CABLES AND CLAMPS INSTALLATION - 450A (MACHINES WITH 7500W GENERATOR AND WITHOUT ARCTIC PACKAGE)..........................606
	FIGURE 8-26. BOOM CABLES AND CLAMPS INSTALLATION - 450AJ (MACHINES WITH 7500W GENERATORS AND WITHOUT ARCTIC PACKAGE)........................610
	FIGURE 8-27. BOOM CABLES AND CLAMPS INSTALLATION - 450A (MACHINES WITH 7500W GENERATOR AND WITH ARCTIC PACKAGE).............................614
	FIGURE 8-28. BOOM CABLES AND CLAMPS INSTALLATION - 450AJ (MACHINES WITH 7500W GENERATORS AND WITH ARCTIC PACKAGE)...........................618
	FIGURE 8-29. BOOM HARNESS - 450A (MAIN BOOM) (WITHOUT ARCTIC PACKAGE).......................................................................622
	FIGURE 8-30. BOOM HARNESS - 450AJ (MAIN BOOM) (WITHOUT ARCTIC PACKAGE)......................................................................624
	FIGURE 8-31. BOOM HARNESS - 450A (MAIN BOOM) (WITH ARCTIC PACKAGE)..........................................................................626
	FIGURE 8-32. BOOM HARNESS - 450AJ (MAIN BOOM) (WITH ARCTIC PACKAGE).........................................................................628
	FIGURE 8-33. BOOM HARNESS - 450A (MAIN BOOM AC CABLE) (WITHOUT ARCTIC PACKAGE)..............................................................630
	FIGURE 8-34. BOOM HARNESS - 450AJ (MAIN BOOM AC CABLE) (WITHOUT ARCTIC PACKAGE).............................................................632
	FIGURE 8-35. BOOM HARNESS - 450A (MAIN BOOM AC CABLE) (WITH ARCTIC PACKAGE).................................................................634
	FIGURE 8-36. BOOM HARNESS - 450AJ (MAIN BOOM AC CABLE) (WITH ARCTIC PACKAGE)................................................................636
	FIGURE 8-37. BOOM HARNESS - TOWER BOOM (WITHOUT ARCTIC PACKAGE).............................................................................638
	FIGURE 8-38. BOOM HARNESS - TOWER BOOM (WITH ARCTIC PACKAGE)................................................................................640
	FIGURE 8-39. BOOM HARNESS - TOWER BOOM AC CABLE (WITHOUT ARCTIC PACKAGE)....................................................................642
	FIGURE 8-40. BOOM HARNESS - TOWER BOOM AC CABLE (WITH ARCTIC PACKAGE).......................................................................644
	FIGURE 8-41. BOOM VALVE HARNESS.............................................................................................................646
	FIGURE 8-42. BREAKER BOX KIT WITH SINGLE DOUBLE POLE BREAKER - CE SPEC......................................................................648
	FIGURE 8-43. BREAKER BOX KIT WITH THREE BREAKERS - CE SPEC..................................................................................650
	FIGURE 8-44. BREAKER BOX KIT - 30MA/16 AMP..................................................................................................652
	FIGURE 8-45. CHASSIS SOLENOID HARNESS.......................................................................................................654
	FIGURE 8-46. ENGINE HARNESS - DEUTZ D2011...................................................................................................656
	FIGURE 8-47. ENGINE HARNESS - DEUTZ D2.9L4 (PVC 2001).......................................................................................658
	FIGURE 8-48. ENGINE HARNESS - DEUTZ D2.9L4 (PVC 2007).......................................................................................662
	FIGURE 8-49. ENGINE HARNESS - DEUTZ D2.9L4 ENGINE (STAGE V).................................................................................666
	FIGURE 8-50. ENGINE HARNESS - KUBOTA........................................................................................................670
	FIGURE 8-51. FUEL HARNESS - DEUTZ D2.9L4 ENGINE.............................................................................................672
	FIGURE 8-52. FUEL HARNESS - DEUTZ D2.9L4 ENGINE (STAGE V)...................................................................................674
	FIGURE 8-53. GENERATOR HARNESS - 2500W GENERATOR (60HZ).....................................................................................676
	FIGURE 8-54. GENERATOR HARNESS - 2500W GENERATOR (50HZ).....................................................................................678
	FIGURE 8-55. GENERATOR HARNESS - 4000W GENERATOR............................................................................................680
	FIGURE 8-56. GROUND CONTROL PANEL HARNESS...................................................................................................682
	FIGURE 8-57. KUBOTA D/F POWER HARNESS.......................................................................................................684
	FIGURE 8-58. PLATFORM CONSOLE BOX HARNESS...................................................................................................686
	FIGURE 8-59. PLATFORM INTERFACE HARNESS (PVC 2001)..........................................................................................688
	FIGURE 8-60. PLATFORM INTERFACE HARNESS (PVC 2007)..........................................................................................690
	FIGURE 8-61. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE SPEC).................................................................................692
	FIGURE 8-62. RECEPTACLE BOX KIT - 220V IEC BLUE (CE SPEC)...................................................................................694
	FIGURE 8-63. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2IN X 4IN BOX (CE SPEC).............................................................696
	FIGURE 8-64. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2IN X 4IN BOX (CE SPEC).............................................................698
	FIGURE 8-65. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE SPEC).................................................................................700
	FIGURE 8-66. SKYEYE INTERMEDIATE HARNESS....................................................................................................702
	FIGURE 8-67. SKYEYE RECEIVER HARNESS (PVC 2001).............................................................................................704
	FIGURE 8-68. SKYEYE RECEIVER HARNESS (PVC 2007).............................................................................................706
	FIGURE 8-69. SKYEYE EMITTER HARNESS (PVC 2001)..............................................................................................708
	FIGURE 8-70. SKYEYE EMITTER HARNESS (PVC 2007)..............................................................................................710
	FIGURE 8-71. SKYLINE HARNESS................................................................................................................712
	FIGURE 8-72. TURNTABLE HARNESS..............................................................................................................714
	FIGURE 8-73. VALVE HARNESS - MAIN VALVE.....................................................................................................718
	FIGURE 8-74. VALVE HARNESS - PLATFORM VALVE.................................................................................................720
SECTION 9 - DECALS..............................................................................................................................723
	FIGURE 9-1. DECAL INSTALLATION – ANSI AND ANSI EXPORT SPECS WITH DEUTZ ENGINES (ENGLISH)....................................................724
	FIGURE 9-2. DECAL INSTALLATION – ANSI AND ANSI EXPORT SPECS WITH KUBOTA ENGINES (ENGLISH)...................................................726
	FIGURE 9-3. DECAL INSTALLATION - AUSTRALIAN SPEC (ENGLISH...................................................................................728
	FIGURE 9-4. DECAL INSTALLATION - BRAZIL SPEC (ENGLISH)......................................................................................730
	FIGURE 9-5. DECAL INSTALLATION - CE SPEC (ENGLISH) (PVC 2001)...............................................................................732
	FIGURE 9-6. DECAL INSTALLATION - CE SPEC (ENGLISH) (PVC 2007)...............................................................................734
	FIGURE 9-7. DECAL INSTALLATION - CSA SPEC WITH DEUTZ ENGINES (FRENCH/ENGLISH)...............................................................736
	FIGURE 9-8. DECAL INSTALLATION - CSA SPEC WITH KUBOTA ENGINES (FRENCH/ENGLISH)..............................................................738
	FIGURE 9-9. DECAL INSTALLATION - CHINESE SPEC (CHINESE/ENGLISH).............................................................................740
	FIGURE 9-10. DECAL INSTALLATION - JAPANESE SPEC (JAPANESE/ENGLISH)..........................................................................742
	FIGURE 9-11. DECAL INSTALLATION - KOREAN SPEC (KOREAN/ENGLISH)..............................................................................744
	FIGURE 9-12. DECAL INSTALLATION - LATIN AMERICA SPEC (SPANISH/ENGLISH)......................................................................746
	FIGURE 9-13. DECAL INSTALLATION - OPTIONS...................................................................................................748
	FIGURE 9-14. TOW BAR DECAL INSTALLATION - ENGLISH LANGUAGE (ANSI, ANSI EXPORT, CE, CHINA AND JAPANESE SPECS)................................752
	FIGURE 9-15. TOW BAR DECAL INSTALLATION - ENGLISH/SPANISH LANGUAGE (ANSI EXPORT AND CE SPECS)...............................................754
	FIGURE 9-16. TOW BAR DECAL INSTALLATION - SPANISH LANGUAGE (ANSI EXPORT AND CE SPECS).......................................................756
	FIGURE 9-17. SKYWELDER DECAL INSTALLATION – 50HZ (ANSI EXPORT SPECS)........................................................................758
	FIGURE 9-18. SKYWELDER DECAL INSTALLATION – 60HZ (ANSI EXPORT SPECS) (PVC 2001).............................................................760
	FIGURE 9-19. SKYWELDER DECAL INSTALLATION - 60HZ (ANSI EXPORT SPECS) (PVC 2007).............................................................762
SECTION 10 - RECOMMENDED SERVICE PARTS STOCK....................................................................................................765
	FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK................................................................................................766
SECTION 11 - SPECIAL OPTIONS....................................................................................................................769
	FIGURE 11-1. SPECIAL OPTIONS................................................................................................................770
PART NUMBER INDEX...............................................................................................................................773

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