JLG 450A & 450AJ Series II Parts Manual (3121243) – PDF DOLWNLOAD Eng

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JLG 450A & 450AJ Series II Parts Manual (3121243) – PDF DOLWNLOAD

TABLE OF CONTENTS:

JLG 450A & 450AJ Series II Parts Manual (3121243) – PDF DOLWNLOAD

SECTION 1 - FRAME........................................................................................................................................................................ 11
	FIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW BAR..................................................................................................................... 12
	FIGURE 1-2. AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR........................................................................................................................ 16
	FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD..................................................................................................................................... 20
	FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS....................................................................................................................................... 28
	FIGURE 1-5. FRAME SHIELDS INSTALLATION (SN 0300069841 through 0300123999, SN 13000000001 through 1300006000)......................................................................... 34
	FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY (REAR).......................................................................................................................................... 36
	FIGURE 1-7. DRIVE HUB/BRAKE ASSEMBLY................................................................................................................................................. 40
	FIGURE 1-8. DRIVE HUB ASSEMBLY (FRONT) (4WD ONLY).................................................................................................................................... 44
	FIGURE 1-9. DRIVE HUB ASSEMBLY (FRONT) (4WD ONLY).................................................................................................................................... 48
	FIGURE 1-10. DRIVE MOTOR ASSEMBLY (2WD).............................................................................................................................................. 52
	FIGURE 1-11. DRIVE MOTOR ASSEMBLY (2WD).............................................................................................................................................. 54
	FIGURE 1-12. DRIVE MOTOR ASSEMBLY (2WD).............................................................................................................................................. 58
	FIGURE 1-13. DRIVE MOTOR ASSEMBLY (4WD).............................................................................................................................................. 62
	FIGURE 1-14. DRIVE MOTOR ASSEMBLY (4WD).............................................................................................................................................. 66
	FIGURE 1-15. DRIVE VALVES INSTALLATIONS.............................................................................................................................................. 70
	FIGURE 1-16. TOW BAR INSTALLATION (OPTIONAL)......................................................................................................................................... 74
	FIGURE 1-17. SEMI-TRACK INSTALLATION................................................................................................................................................. 78
SECTION 2 - TURNTABLE.................................................................................................................................................................... 81
	FIGURE 2-1. CONTROL VALVE INSTALLATION............................................................................................................................................... 82
	FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY.............................................................................................................................................. 84
	FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONS.................................................................................................................................. 86
	FIGURE 2-4. SWING MOTOR ASSEMBLY (ORIGINAL EQUIPMENT)................................................................................................................................ 90
	FIGURE 2-5. SWING MOTOR ASSEMBLY (SERVICE REPLACEMENT)............................................................................................................................... 94
	FIGURE 2-6. SWING BEARING AND ROTATION BOX ASSEMBLY (ORIGINAL EQUIPMENT)............................................................................................................. 96
	FIGURE 2-7. SWING BEARING AND ROTATION BOX ASSEMBLY (SERVICE REPLACEMENT FOR 0440203) (SN 0300065080 through 0300069336).............................................................100
	FIGURE 2-8. SWING BEARING AND ROTATION BOX ASSEMBLY (SERVICE REPLACEMENT FOR 0440203 & 0440339) (SN 0300065080 through 0300069336)...................................................102
	FIGURE 2-9. SWING BEARING AND ROTATION BOX ASSEMBLY (SERVICE REPLACEMENT FOR 0440255 & 0440272) (SN 0300069337 through 0300123999, SN 1300000001 through 1300006000).................104
	FIGURE 2-10. SWING BEARING AND ROTATION BOX ASSEMBLY (SERVICE REPLACEMENT FOR 0440255, 0440272 & 1001153016) (SN 0300069337 through 0300123999, SN 1300000001 through 1300006000)....106
	FIGURE 2-11. USA BUILT MACHINES/CATERPILLAR ENGINE INSTALLATION......................................................................................................................108
	FIGURE 2-12. USA BUILT MACHINES/DEUTZ ENGINE INSTALLATION (SN 0300065080 through 0300077682).........................................................................................118
	FIGURE 2-13. USA BUILT MACHINES/DEUTZ ENGINE INSTALLATION (SN 0300077683 through 0300123999).........................................................................................124
	FIGURE 2-14. USA BUILT MACHINES/FORD ENGINE INSTALLATION (SN 0300065080 through 0300078472)..........................................................................................134
	FIGURE 2-15. USA BUILT MACHINES/FORD ENGINE INSTALLATION (SN 0300078473 through 0300123999)..........................................................................................142
	FIGURE 2-16. USA BUILT MACHINES/DUAL FUEL INSTALLATIONS (GAS MACHINES ONLY)..........................................................................................................150
	FIGURE 2-17. USA BUILT MACHINES/GM ENGINE INSTALLATION...............................................................................................................................154
	FIGURE 2-18. USA BUILT MACHINES/PERKINS ENGINE INSTALLATION..........................................................................................................................160
	FIGURE 2-19. BELGIUM BUILT MACHINES/DEUTZ ENGINE INSTALLATION (Prior to SN 1300000979)...............................................................................................168
	FIGURE 2-20. BELGIUM BUILT MACHINES/DEUTZ ENGINE INSTALLATION (SN 1300000979 through 1300006000).....................................................................................174
	FIGURE 2-21. BELGIUM BUILT MACHINES/PERKINS ENGINE INSTALLATION......................................................................................................................182
	FIGURE 2-22. PISTON PUMP ASSEMBLY (SERIES M46 PUMP)..................................................................................................................................190
	FIGURE 2-23. PISTON PUMP ASSEMBLY (SERIES 42 PUMP)...................................................................................................................................194
	FIGURE 2-24. GEAR PUMP ASSEMBLY......................................................................................................................................................200
	FIGURE 2-25. AUXILIARY PUMP ASSEMBLY.................................................................................................................................................202
	FIGURE 2-26. TANK INSTALLATIONS......................................................................................................................................................206
	FIGURE 2-27. GROUND CONTROL BOX ASSEMBLY.............................................................................................................................................210
	FIGURE 2-28. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED).....................................................................................................................218
	FIGURE 2-29. HOODS INSTALLATION......................................................................................................................................................222
	FIGURE 2-30. 2500W GENERATOR INSTALLATION - CATERPILLAR ENGINES (USA BUILT MACHINES) (OPTIONAL)......................................................................................226
	FIGURE 2-31. 2500W GENERATOR INSTALLATION - DEUTZ ENGINES (USA AND BELGIUM BUILT MACHINES) (OPTIONAL)................................................................................230
	FIGURE 2-32. 2500W GENERATOR INSTALLATION - FORD ENGINES (USA BUILT MACHINES) (OPTIONAL) (SN 0300065080 through 0300078472)..........................................................236
	FIGURE 2-33. 2500W GENERATOR INSTALLATION - FORD ENGINES (USA BUILT MACHINES) (OPTIONAL) (SN 0300078473 through 0300123999)..........................................................240
	FIGURE 2-34. 2500W GENERATOR INSTALLATION - GM ENGINES (USA BUILT MACHINES) (OPTIONAL)...............................................................................................244
	FIGURE 2-35. 2500W GENERATOR INSTALLATION - PERKINS ENGINES (USA AND BELGIUM BUILT MACHINES) (OPTIONAL)..............................................................................248
	FIGURE 2-36. 7500W GENERATOR INSTALLATION - CATERPILLAR ENGINE MACHINES (USA BUILT MACHINES).........................................................................................252
	FIGURE 2-37. 7500W GENERATOR INSTALLATION - DEUTZ ENGINE MACHINES (USA BUILT MACHINES)...............................................................................................256
	FIGURE 2-38. 7500W GENERATOR INSTALLATION - DEUTZ ENGINE MACHINES (BELGIUM BUILT MACHINES)...........................................................................................262
	FIGURE 2-39. 7500W GENERATOR INSTALLATION - FORD ENGINE MACHINES (USA BUILT MACHINES)................................................................................................268
	FIGURE 2-40. 7500W GENERATOR INSTALLATION - GM ENGINE MACHINES (USA BUILT MSCHINES)..................................................................................................272
	FIGURE 2-41. 7500W GENERATOR INSTALLATION - PERKINS ENGINE MACHINES (USA BUILT MACHINES).............................................................................................278
	FIGURE 2-42. 7500W GENERATOR INSTALLATION - PERKINS ENGINE MACHINES (BELGIUM BUILT MACHINES).........................................................................................284
SECTION 3 - BOOM.........................................................................................................................................................................289
	FIGURE 3-1. TOWER/MID BOOMS AND CYLINDERS INSTALLATION (USA BUILT MACHINES) (SN 0300065080 through 0300123999).......................................................................290
	FIGURE 3-2. TOWER/MID BOOMS AND CYLINDERS INSTALLATION (BELGIUM BUILT MACHINES) - 450AJ SERIES II....................................................................................296
	FIGURE 3-3. MAIN BOOM INSTALLATION - 450A SERIES II..................................................................................................................................300
	FIGURE 3-4. MAIN BOOM INSTALLATION - 450AJ SERIES II (USA BUILT MACHINES)............................................................................................................304
	FIGURE 3-5. MAIN BOOM INSTALLATION - 450AJ SERIES II (BELGIUM BUILT MACHINES)........................................................................................................308
	FIGURE 3-6. MAIN BOOM ASSEMBLIES.....................................................................................................................................................312
	FIGURE 3-7. ROTATOR ASSEMBLIES.......................................................................................................................................................316
	FIGURE 3-8. PLATFORM SUPPORT AND CONTROL VALVES INSTALLATIONS (FRONT ENTRY PLATFORM).................................................................................................320
	FIGURE 3-9. PLATFORM SUPPORT AND CONTROL VALVES INSTALLATIONS (SIDE ENTRY PLATFORM)..................................................................................................324
	FIGURE 3-10. PLATFORM SUPPORT INSTALLATION - WITH LSS................................................................................................................................328
SECTION 4 - PLATFORM.....................................................................................................................................................................331
	FIGURE 4-1. PLATFORM INSTALLATION (USA BUILT MACHINES) (SN 0300065080 through 0300069154)............................................................................................332
	FIGURE 4-2. PLATFORM INSTALLATION (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (SN 0300069155 through 0300123999).................................................................336
	FIGURE 4-3. FALL ARREST PLATFORM COMPONENTS INSTALLATION (OPTIONAL)..................................................................................................................340
	FIGURE 4-4. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL)................................................................................................................................342
	FIGURE 4-5. PLATFORM CONSOLE ASSEMBLY................................................................................................................................................344
	FIGURE 4-6. CONTROLLER ASSEMBLY (SWING AND LIFT) (ORIGINAL EQUIPMENT)................................................................................................................350
	FIGURE 4-7. CONTROLLER ASSEMBLY (LIFT AND SWING) (SERVICE REPLACEMENT)...............................................................................................................352
	FIGURE 4-8. CONTROLLER ASSEMBLY (LIFT AND SWING) (SERVICE REPLACEMENT)...............................................................................................................354
	FIGURE 4-9. CONTROLLER ASSEMBLY (DRIVE AND STEER) (ORIGINAL EQUIPMENT)...............................................................................................................358
	FIGURE 4-10. CONTROLLER ASSEMBLY (DRVIE AND STEER) (SERVICE REPLACEMENT).............................................................................................................360
	FIGURE 4-11. CONTROLLER ASSEMBLY (DRIVE AND STEER) (SERVICE REPLACEMENT).............................................................................................................362
	FIGURE 4-12. SKYGLAZIER INSTALLATION - WITHOUT LSS (ANSI, CSA AND AUSTRALIAN SPECS)..................................................................................................364
	FIGURE 4-13. SKYGLAZIER INSTALLATION - WITH LSS (AUSTRALIAN SPECS)...................................................................................................................366
	FIGURE 4-14. SKYWELDER INSTALLATION (50HZ)...........................................................................................................................................368
	FIGURE 4-15. SKYWELDER INSTALLATION (60HZ)...........................................................................................................................................370
	FIGURE 4-16. WELDER ASSEMBLY.........................................................................................................................................................372
	FIGURE 4-17. SKYCUTTER INSTALLATION (SN 0300035080 through 0300119210)...............................................................................................................374
	FIGURE 4-18. SKYCUTTER INSTALLATION (SN 0300119211 through 0300123999)...............................................................................................................376
	FIGURE 4-19. PLASMA CUTTER ASSEMBLY..................................................................................................................................................378
	FIGURE 4-20. PLASMA CUTTER ASSEMBLY..................................................................................................................................................380
SECTION 5 - CYLINDER.....................................................................................................................................................................383
	FIGURE 5-1. USA BUILT MACHINES/AXLE LOCKOUT CYLINDER (SN 0300065080 through 0300107511)..............................................................................................384
	FIGURE 5-2. USA BUILT MACHINES/AXLE LOCKOUT CYLINDER (SN 0300107512 through 0300123999)..............................................................................................386
	FIGURE 5-3. USA BUILT MACHINES/LEVEL (PLATFORM SLAVE) CYLINDER (450A SERIES II) (ORIGINAL EQUIPMENT) (SN 0300065080 through 0300123999)..............................................388
	FIGURE 5-4. USA BUILT MACHINES/LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY (450A SERIES II) (SERVICE REPLACEMENT) (SN 0300065080 through 0300123999)....................................390
	FIGURE 5-5. USA BUILT MACHINES/LEVEL (PLATFORM) CYLINDER (450AJ SERIES II) (ORIGINAL EQUIPMENT) (SN 0300065080 through 0300123999)...................................................392
	FIGURE 5-6. USA BUILT MACHINES/LEVEL (PLATFORM) CYLINDER (450AJ SERIES II) (SERVICE REPLACEMENT) (SN 0300065080 through 0300123999)..................................................394
	FIGURE 5-7. USA BUILT MACHINES/LIFT (JIB) CYLINDER (450AJ SERIES II ONLY) (ORIGINAL EQUIPMENT) (SN 0300065080 through 0300123999)....................................................396
	FIGURE 5-8. USA BUILT MACHINES/LIFT (JIB) CYLINDER (450AJ SERIES II ONLY) (SERVICE REPLACEMENT) (SN 0300065080 through 0300123999)...................................................398
	FIGURE 5-9. USA BUILT MACHINES/LIFT (MAIN BOOM) CYLINDER (SN 0300065080 through 0300123999)..........................................................................................400
	FIGURE 5-10. USA BUILT MACHINES/LIFT (TOWER BOOM) CYLINDER (SN 0300065080 through 0300123999)........................................................................................402
	FIGURE 5-11. USA BUILT MACHINES/MASTER CYLINDER (450A SERIES II) (ORIGINAL EQUIPMENT) (SN 0300065080 through 0300123999).............................................................404
	FIGURE 5-12. USA BUILT MACHINES/MASTER CYLINDER (450A SERIES II) (SERVICE REPLACEMENT) (SN 0300065080 through 0300123999)............................................................406
	FIGURE 5-13. USA BUILT MACHINES/MASTER CYLINDER (450AJ SERIES II) (ORIGINAL EQUIPMENT) (SN 0300065080 through 0300123999)............................................................408
	FIGURE 5-14. USA BUILT MACHINES/MASTER CYLINDER (450AJ SERIES II) (SERVICE REPLACEMENT) (SN 0300065080 through 0300123999)...........................................................410
	FIGURE 5-15. USA BUILT MACHINES/STEER CYLINDER (SN 0300065080 through 0300087392)....................................................................................................412
	FIGURE 5-16. USA BUILT MACHINES/STEER CYLINDER (SN 0300087393 through 0300123999)....................................................................................................414
	FIGURE 5-17. USA BUILT MACHINES/TELESCOPE CYLINDER (SN 0300065080 through 0300123999)................................................................................................416
	FIGURE 5-18. BELGIUM BUILT MACHINES/AXLE LOCKOUT CYLINDER (Prior to SN 1300003222)...................................................................................................418
	FIGURE 5-19. BELGIUM BUILT MACHINES/AXLE LOCKOUT CYLINDER (SN 1300003222 through 1300006000).........................................................................................420
	FIGURE 5-20. BELGIUM BUILT MACHINES/LEVEL (PLATFORM) CYLINDER (450AJ SERIES II)......................................................................................................422
	FIGURE 5-21. BELGIUM BUILT MACHINES/LIFT (JIB) CYLINDER (450AJ SERIES II ONLY).......................................................................................................424
	FIGURE 5-22. BELGIUM BUILT MACHINES/LIFT (MAIN BOOM) CYLINDER........................................................................................................................426
	FIGURE 5-23. BELGIUM BUILT MACHINES/LIFT (TOWER BOOM) CYLINDER.......................................................................................................................428
	FIGURE 5-24. BELGIUM BUILT MACHINES/MASTER CYLINDER (450AJ SERIES II)................................................................................................................430
	FIGURE 5-25. BELGIUM BUILT MACHINES/STEER CYLINDER...................................................................................................................................432
	FIGURE 5-26. BELGIUM BUILT MACHINES/TELESCOPE CYLINDER...............................................................................................................................434
SECTION 6 - HYDRAULIC....................................................................................................................................................................437
	FIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM - 2WD (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (SN 0300065080 through 0300077284, Prior to SN 1300000353)..........................438
	FIGURE 6-2. AXLE LOCKOUT HYDRAULIC DIAGRAM - 2WD (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (SN 0300077285 through 0300107511, SN 1300000353 through 1300003221)................440
	FIGURE 6-3. AXLE LOCKOUT HYDRAULIC DIAGRAM - 2WD (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (SN 0300107512 through 0300123999, SN 1300003222 through 1300006000)................442
	FIGURE 6-4. AXLE LOCKOUT HYDRAULIC DIAGRAM - 4WD (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (SN 0300065080 through 0300077284, Prior to SN 1300000353)..........................444
	FIGURE 6-5. AXLE LOCKOUT HYDRAULIC DIAGRAM - 4WD (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (SN 0300077285 through 0300107511, SN 1300000353 through 1300003221)................446
	FIGURE 6-6. AXLE LOCKOUT HYDRAULIC DIAGRAM - 4WD (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (SN 0300107512 through 0300123999, SN 1300003222 through 1300006000)................448
	FIGURE 6-7. DRIVE HYDRAULIC DIAGRAM - 2WD............................................................................................................................................450
	FIGURE 6-8. DRIVE HYDRAULIC DIAGRAM - 2WD............................................................................................................................................454
	FIGURE 6-9. DRIVE HYDRAULIC DIAGRAM - 2WD............................................................................................................................................458
	FIGURE 6-10. DRIVE HYDRAULIC DIAGRAM - 4WD...........................................................................................................................................462
	FIGURE 6-11. DRIVE HYDRAULIC DIAGRAM - 4WD...........................................................................................................................................466
	FIGURE 6-12. STANDARD HYDRAULIC DIAGRAM..............................................................................................................................................470
	FIGURE 6-13. TOW BAR HYDRAULIC DIAGRAM...............................................................................................................................................474
	FIGURE 6-14. HYDRAULIC DIAGRAM LIST..................................................................................................................................................476
SECTION 7 - ELECTRICAL...................................................................................................................................................................481
	FIGURE 7-1. ELECTRICAL DIAGRAM LIST..................................................................................................................................................482
	FIGURE 7-2. HARNESS COMPONENTS INSTALLATION..........................................................................................................................................484
SECTION 8 - DECALS.......................................................................................................................................................................507
	FIGURE 8-1. DECAL INSTALLATION - ANSI SPEC (USA BUILT MACHINES) (SN 0300065080 through 0300069154)...................................................................................508
	FIGURE 8-2. DECAL INSTALLATION - ANSI SPEC (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (SN 0300069155 through 0300123999, SN 1300000001 through 1300006000)......................512
	FIGURE 8-3. DECAL INSTALLATION - ANSI EXPORT SPECS (USA BUILT MACHINES) (SN 0300065080 through 0300069154)...........................................................................516
	FIGURE 8-4. DECAL INSTALLATION - ANSI EXPORT SPECS (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (SN 0300069155 through 0300123999, SN 1300000001 through 1300006000)..............520
	FIGURE 8-5. DECAL INSTALLATION - CE AND AUSTRALIAN SPECS (USA BUILT MACHINES) (SN 0300065080 through 0300069154).....................................................................526
	FIGURE 8-6. DECALS INSTALLATION - AUSTRALIAN AND CE SPECS (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (SN 0300069155 through 0300074818, SN 1300000001 through 1300000180).......530
	FIGURE 8-7. DECALS INSTALLATION - AUSTRALIAN AND CE SPECS (USA BUILT MACHINES AND BELGIUM BUILT MACHINES) (SN 0300074819 through 0300123999, SN 1300000180 through 1300006000).......534
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK..............................................................................................................................................537
	FIGURE 9-1. MODEL 450A / 450AJ SERIES II STANDARD PARTS..............................................................................................................................538
	FIGURE 9-2. MODEL 450A / 450AJ SERIES II VARIABLE PARTS..............................................................................................................................540
SECTION 10 - SPECIAL OPTIONS.............................................................................................................................................................541
	FIGURE 10-1. SPECIAL OPTIONS.........................................................................................................................................................542
PART NUMBER INDEX........................................................................................................................................................................547

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