JLG 450A & 450AJ Series II Parts Manual (3121244) – PDF DOWNLOAD En

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JLG 450A & 450AJ Series II Parts Manual (3121244) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 450A & 450AJ Series II Parts Manual (3121244) – PDF DOWNLOAD

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 INSTALLATION......................................................................... 24
	FIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (REAR)........................................................................... 28
	FIGURE 1-6. DRIVE HUB ASSEMBLY (FRONT) (4WD ONLY)..................................................................... 32
	FIGURE 1-7. DRIVE MOTOR ASSEMBLY (2WD)................................................................................ 34
	FIGURE 1-8. DRIVE MOTOR ASSEMBLY (4WD)................................................................................ 36
	FIGURE 1-9. DRIVE VALVES AND FRAME SHIELDS INSTALLATION............................................................... 38
	FIGURE 1-10. TOW BAR INSTALLATION (OPTIONAL).......................................................................... 42
	FIGURE 1-11. SEMI-TRACK INSTALLATION.................................................................................. 46
SECTION 2 - TURNTABLE..................................................................................................... 49
	FIGURE 2-1. CONTROL VALVE INSTALLATION................................................................................ 50
	FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY............................................................................... 52
	FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONS................................................................... 54
	FIGURE 2-4. SWING MOTOR ASSEMBLY...................................................................................... 58
	FIGURE 2-5. SWING MOTOR ASSEMBLY...................................................................................... 60
	FIGURE 2-6. SWING BEARING AND ROTATION BOX ASSEMBLY (ORIGINAL EQUIPMENT).............................................. 62
	FIGURE 2-7. SWING BEARING AND ROTATION BOX ASSEMBLY (SERVICE REPLACEMENT))............................................ 64
	FIGURE 2-8. USA BUILT MACHINES/CATERPILLAR ENGINE INSTALLATION (WITH ELECTRICAL DRIVEN COOLING FAN) (WITHOUT UGM)..... 66
	FIGURE 2-9. USA BUILT MACHINES/CATERPILLAR ENGINE INSTALLATION (WITH ENGINE DRIVEN COOLING FAN) (WITHOUT UGM)......... 74
	FIGURE 2-10. USA BUILT MACHINES/CATERPILLAR ENGINE INSTALLATION (WITH UGM)............................................ 82
	FIGURE 2-11. USA BUILT MACHINES/DEUTZ ENGINE INSTALLATION............................................................. 90
	FIGURE 2-12. USA BUILT MACHINES/GM ENGINE INSTALLATION (WITHOUT UGM).................................................. 98
	FIGURE 2-13. USA BUILT MACHINES/GM ENGINE INSTALLATION (WITH UGM).....................................................104
	FIGURE 2-14. USA BUILT MACHINES/PERKINS ENGINE INSTALLATION (WITH ELECTRICAL DRIVEN COOLING FAN) (WITHOUT UGM)........110
	FIGURE 2-15. USA BUILT MACHINES/PERKINS ENGINE INSTALLATION (WITH ENGINE DRIVEN COOLING FAN (WITHOUT UGM).............120
	FIGURE 2-16. USA BUILT MACHINES/PERKINS ENGINE INSTALLATION (WITH UGM)................................................130
	FIGURE 2-17. BELGIUM AND ROMANIAN BUILT MACHINES/CATERPILLAR ENGINE INSTALLATION......................................138
	FIGURE 2-18. BELGIUM AND ROMANIAN BUILT MACHINES/DEUTZ ENGINE INSTALLATION............................................146
	FIGURE 2-19. BELGIUM BUILT MACHINES/PERKINS ENGINE INSTALLATION (WITH ELECTRICAL DRIVEN COOLING FAN) (WITHOUT UGM)....152
	FIGURE 2-20. BELGIUM BUILT MACHINES/PERKINS ENGINE INSTALLATION (WITH ENGINE DRIVEN COOLING FAN) (WITHOUT UGM)........160
	FIGURE 2-21. BELGIUM BUILT MACHINES/PERKINS ENGINE INSTALLATION (WITH UGM)............................................168
	FIGURE 2-22. PISTON PUMP ASSEMBLY.....................................................................................176
	FIGURE 2-23. GEAR PUMP ASSEMBLY.......................................................................................180
	FIGURE 2-24. AUXILIARY PUMP ASSEMBLY..................................................................................182
	FIGURE 2-25. TANK INSTALLATIONS.......................................................................................184
	FIGURE 2-26. LP TANK INSTALLATION (GM ENGINE MACHINES ONLY)...........................................................188
	FIGURE 2-27. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM)................................................................190
	FIGURE 2-28. GROUND CONTROL BOX ASSEMBLY (WITH UGM)...................................................................194
	FIGURE 2-29. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED)......................................................198
	FIGURE 2-30. HOODS INSTALLATION.......................................................................................202
	FIGURE 2-31. HOODS INSTALLATION.......................................................................................206
	FIGURE 2-32. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL)...........................................210
	FIGURE 2-33. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL).................................................214
	FIGURE 2-34. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL)....................................................218
	FIGURE 2-35. 2500W GENERATOR INSTALLATION - PERKINS MACHINES (OPTIONAL)...............................................222
	FIGURE 2-36. 7500W GENERATOR INSTALLATION - CATERPILLAR ENGINE MACHINES (USA BUILT MACHINES)..........................226
	FIGURE 2-37. 7500W GENERATOR INSTALLATION - DEUTZ ENGINE MACHINES (USA BUILT MACHINES)................................232
	FIGURE 2-38. 7500W GENERATOR INSTALLATION - DEUTZ ENGINE MACHINES (BELGIUM AND ROMANIAN BUILT MACHINES)...............238
	FIGURE 2-39. 7500W GENERATOR INSTALLATION - GM ENGINE MACHINES (USA BUILT MSCHINES)...................................244
	FIGURE 2-40. 7500W GENERATOR INSTALLATION - PERKINS ENGINE MACHINES (BELGIUM AND ROMANAIN BUILT MACHINES).............250
SECTION 3 - BOOM..........................................................................................................255
	FIGURE 3-1. TOWER/MID BOOMS AND CYLINDERS INSTALLATION (USA BUILT MACHINES)...........................................256
	FIGURE 3-2. TOWER/MID BOOMS AND CYLINDERS INSTALLATION (BELGIUM AND ROMANIAN BUILT MACHINES)..........................260
	FIGURE 3-3. MAIN BOOM INSTALLATION - 450A SERIES II...................................................................264
	FIGURE 3-4. MAIN BOOM INSTALLATION - 450AJ SERIES II (USA BUILT MACHINES).............................................268
	FIGURE 3-5. MAIN BOOM INSTALLATION - 450AJ SERIES II (BELGIUM AND ROMANIAN BUILT MACHINES)............................272
	FIGURE 3-6. MAIN BOOM ASSEMBLIES......................................................................................276
	FIGURE 3-7. ROTATOR ASSEMBLIES........................................................................................280
	FIGURE 3-8. PLATFORM SUPPORT AND CONTROL VALVES INSTALLATIONS.........................................................284
	FIGURE 3-9. PLATFORM SUPPORT INSTALLATION - WITH LSS..................................................................288
SECTION 4 - PLATFORM......................................................................................................291
	FIGURE 4-1. PLATFORM INSTALLATION.....................................................................................292
	FIGURE 4-2. FALL ARREST PLATFORM COMPONENTS INSTALLATION (OPTIONAL)...................................................296
	FIGURE 4-3. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL).................................................................298
	FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY.................................................................................300
	FIGURE 4-5. CONTROLLER ASSEMBLY (SWING AND LIFT) (ADE SYSTEM) (ORIGINAL EQUIPMENT)....................................306
	FIGURE 4-6. CONTROLLER ASSEMBLY (LIFT AND SWING) (SERVICE REPLACEMENT)................................................308
	FIGURE 4-7. CONTROLLER ASSEMBLY (LIFT AND SWING) (SERVICE REPLACEMENT)................................................310
	FIGURE 4-8. CONTROLLER ASSEMBLY (DRIVE AND STEER) (ADE SYSTEM) (ORIGINAL EQUIPMENT)...................................314
	FIGURE 4-9. CONTROLLER ASSEMBLY (DRVIE AND STEER) (SERVICE REPLACEMENT)...............................................316
	FIGURE 4-10. CONTROLLER ASSEMBLY (DRIVE AND STEER) (SERVICE REPLACEMENT)..............................................318
	FIGURE 4-11. SKYGLAZIER INSTALLATION - WITHOUT LSS (ANSI, CSA AND AUSTRALIAN SPECS)...................................320
	FIGURE 4-12. SKYGLAZIER INSTALLATION - WITH LSS (AUSTRALIAN SPECS)....................................................322
	FIGURE 4-13. SKYWELDER INSTALLATION (50HZ)............................................................................324
	FIGURE 4-14. SKYWELDER INSTALLATION (60HZ)............................................................................326
	FIGURE 4-15. WELDER ASSEMBLY..........................................................................................328
	FIGURE 4-16. SKYCUTTER INSTALLATION (USA BUILT MACHINES)..............................................................330
	FIGURE 4-17. PLASMA CUTTER ASSEMBLY...................................................................................332
SECTION 5 - CYLINDER......................................................................................................335
	FIGURE 5-1. USA BUILT MACHINES/AXLE LOCKOUT CYLINDER..................................................................336
	FIGURE 5-2. USA BUILT MACHINES/LEVEL (PLATFORM SLAVE) CYLINDER (450A SERIES II) (ORIGINAL EQUIPMENT)..................338
	FIGURE 5-3. USA BUILT MACHINES/LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY (450A SERIES II) (SERVICE REPLACEMENT)........340
	FIGURE 5-4. USA BUILT MACHINES/LEVEL (PLATFORM) CYLINDER (450AJ SERIES II) (ORIGINAL EQUIPMENT).......................342
	FIGURE 5-5. USA BUILT MACHINES/LEVEL (PLATFORM) CYLINDER (450AJ SERIES II) (SERVICE REPLACEMENT)......................344
	FIGURE 5-6. USA BUILT MACHINES/LIFT (JIB) CYLINDER (450AJ SERIES II ONLY) (ORIGINAL EQUIPMENT)........................346
	FIGURE 5-7. USA BUILT MACHINES/LIFT (JIB) CYLINDER (450AJ SERIES II ONLY) (SERVICE REPLACEMENT).......................348
	FIGURE 5-8. USA BUILT MACHINES/LIFT (MAIN BOOM) CYLINDER..............................................................350
	FIGURE 5-9. USA BUILT MACHINES/LIFT (TOWER BOOM) CYLINDER.............................................................352
	FIGURE 5-10. USA BUILT MACHINES/MASTER CYLINDER (450A SERIES II) (ORIGINAL EQUIPMENT).................................354
	FIGURE 5-11. USA BUILT MACHINES/MASTER CYLINDER (450A SERIES II) (SERVICE REPLACEMENT)................................356
	FIGURE 5-12. USA BUILT MACHINES/MASTER CYLINDER (450AJ SERIES II) (ORIGINAL EQUIPMENT)................................358
	FIGURE 5-13. USA BUILT MACHINES/MASTER CYLINDER (450AJ SERIES II) (SERVICE REPLACEMENT)...............................360
	FIGURE 5-14. USA BUILT MACHINES/STEER CYLINDER........................................................................362
	FIGURE 5-15. USA BUILT MACHINES/TELESCOPE CYLINDER....................................................................364
	FIGURE 5-16. BELGIUM AND ROMANIAN BUILT MACHINES/AXLE LOCKOUT CYLINDER................................................366
	FIGURE 5-17. BELGIUM AND ROMANIAN BUILT MACHINES/LIFT (JIB) CYLINDER (450AJ SERIES II ONLY)...........................368
	FIGURE 5-18. BELGIUM AND ROMANIAN BUILT MACHINES/LIFT (MAIN BOOM) CYLINDER............................................370
	FIGURE 5-19. BELGIUM AND ROMANIAN BUILT MACHINES/LIFT (TOWER BOOM) CYLINDER...........................................372
	FIGURE 5-20. BELGIUM AND ROMANIAN BUILT MACHINES/STEER CYLINDER.......................................................374
	FIGURE 5-21. BELGIUM AND ROMANIAN BUILT MACHINES/TELESCOPE CYLINDER...................................................376
SECTION 6 - HYDRAULIC.....................................................................................................379
	FIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM - 2WD......................................................................380
	FIGURE 6-2. AXLE LOCKOUT HYDRAULIC DIAGRAM - 4WD......................................................................382
	FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 2WD.............................................................................384
	FIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD.............................................................................388
	FIGURE 6-5. STANDARD HYDRAULIC DIAGRAM................................................................................392
	FIGURE 6-6. TOW BAR HYDRAULIC DIAGRAM.................................................................................396
	FIGURE 6-7. HYDRAULIC DIAGRAM LIST....................................................................................398
SECTION 7 - ELECTRICAL....................................................................................................401
	FIGURE 7-1. ELECTRICAL DIAGRAM LIST...................................................................................402
	FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM).............................................................404
	FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITH UGM)................................................................422
SECTION 8 - DECALS........................................................................................................439
	FIGURE 8-1. DECAL INSTALLATION - ANSI SPEC............................................................................440
	FIGURE 8-2. DECAL INSTALLATION - ANSI EXPORT SPECS....................................................................444
	FIGURE 8-3. DECALS INSTALLATION - AUSTRALIAN AND CE SPECS.............................................................450
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK...............................................................................453
	FIGURE 9-1. MODEL 450A / 450AJ SERIES II STANDARD PARTS...............................................................454
	FIGURE 9-2. MODEL 450A / 450AJ SERIES II VARIABLE PARTS...............................................................456
SECTION 10 - SPECIAL OPTIONS..............................................................................................457
	FIGURE 10-1. SPECIAL OPTIONS..........................................................................................458
PART NUMBER INDEX.........................................................................................................463

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