JLG 450A & 450AJ Series II Parts Manual (3121291) – PDF DOWNLOAD English

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JLG 450A & 450AJ Series II Parts Manual (3121291) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 450A & 450AJ Series II Parts Manual (3121291) – 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 (NON-FOLDING) INSTALLATION (OPTIONAL)...................................................... 42
	FIGURE 1-11. TOW BAR (FOLDING) INSTALLATION (OPTIONAL).......................................................... 44
SECTION 2 - TURNTABLE............................................................................................... 47
	FIGURE 2-1. MAIN CONTROL VALVE AND ALARM INSTALLATIONS.......................................................... 48
	FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY......................................................................... 50
	FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONS............................................................. 52
	FIGURE 2-4. SWING MOTOR ASSEMBLY................................................................................ 54
	FIGURE 2-5. SWING BEARING AND ROTATION BOX ASSEMBLY (ORIGINAL EQUIPMENT)........................................ 56
	FIGURE 2-6. SWING BEARING AND ROTATION BOX ASSEMBLY (SERVICE REPLACEMENT)....................................... 58
	FIGURE 2-7. CATERPILLAR ENGINE INSTALLATION (USA BUILT MACHINES)................................................ 60
	FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (ROMANIAN BUILT MACHINES)........................................... 68
	FIGURE 2-9. DEUTZ D2011 ENGINE INSTALLATION (USA BUILT MACHINES)................................................ 76
	FIGURE 2-10. DEUTZ D2011 ENGINE INSTALLATION (ROMANIAN BUILT MACHINES).......................................... 84
	FIGURE 2-11. DEUTZ TD2.9L4 ENGINE INSTALLATION (USA BUILT MACHINES)............................................. 90
	FIGURE 2-12. GM ENGINE INSTALLATION.............................................................................100
	FIGURE 2-13. PISTON PUMP ASSEMBLY...............................................................................106
	FIGURE 2-14. GEAR PUMP ASSEMBLY.................................................................................110
	FIGURE 2-15. AUXILIARY PUMP ASSEMBLY............................................................................112
	FIGURE 2-16. TANK INSTALLATIONS.................................................................................114
	FIGURE 2-17. LP TANK INSTALLATION (GM ENGINE MACHINES ONLY).....................................................118
	FIGURE 2-18. GROUND CONTROL BOX ASSEMBLY (FIBERGLASS BOX).......................................................120
	FIGURE 2-19. GROUND CONTROL BOX ASSEMBLY (STEEL BOX)............................................................124
	FIGURE 2-20. LIGHT INSTALLATIONS................................................................................130
	FIGURE 2-21. HOODS INSTALLATION.................................................................................134
	FIGURE 2-22. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL).....................................140
	FIGURE 2-23. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)...........................................144
	FIGURE 2-24. 2500W GENERATOR INSTALLATION - DEUTZ TD2.9L4 MACHINES (ANSI, CSA AND JAPANESE SPECS) (OPTIONAL)....148
	FIGURE 2-25. 2500W GENERATOR INSTALLATION - GM MACHINES (ANSI, ANSI EXPORT AND CSA SPECS) (OPTIONAL)............152
	FIGURE 2-26. 4000W GENERATOR INSTALLATION - DEUTZ D2011 ENGINES.................................................156
	FIGURE 2-27. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES..........................................160
	FIGURE 2-28. 4000W/60HZ GENERATOR INSTALLATION - GM ENGINES.....................................................164
	FIGURE 2-29. 7500W/60HZ GENERATOR INSTALLATION - CATERPILLAR ENGINE MACHINES (USA BUILT MACHINES)...............168
	FIGURE 2-30. 7500W GENERATOR INSTALLATION - CATERPILLAR ENGINE MACHINES (ROMANIAN BUILT MACHINES)...............172
	FIGURE 2-31. 7500W GENERATOR INSTALLATION - DEUTZ D2011 ENGINES (USA BUILT MACHINES)............................178
	FIGURE 2-32. 7500W GENERATOR INSTALLATION - DEUTZ D2011 ENGINES (ROMANIAN BUILT MACHINES).......................184
	FIGURE 2-33. 7500W GENERATOR INSTALLATION - DEUTZ D2.9L4 ENGINE.................................................190
	FIGURE 2-34. 7500W GENERATOR INSTALLATION - GM ENGINE MACHINES..................................................194
SECTION 3 - BOOM....................................................................................................199
	FIGURE 3-1. TOWER/MID BOOMS AND CYLINDERS INSTALLATION (USA BUILT MACHINES).....................................200
	FIGURE 3-2. TOWER/MID BOOMS AND CYLINDERS INSTALLATION (ROMANIAN BUILT MACHINES)................................204
	FIGURE 3-3. MAIN BOOM INSTALLATION - 450A SERIES II.............................................................208
	FIGURE 3-4. MAIN BOOM INSTALLATION - 450AJ SERIES II (USA BUILT MACHINES).......................................212
	FIGURE 3-5. MAIN BOOM INSTALLATION - 450AJ SERIES II (ROMANIAN BUILT MACHINES)..................................216
	FIGURE 3-6. MAIN BOOM ASSEMBLIES................................................................................220
	FIGURE 3-7. ROTATOR ASSEMBLIES..................................................................................224
	FIGURE 3-8. PLATFORM SUPPORT AND CONTROL VALVES INSTALLATIONS...................................................228
	FIGURE 3-9. PLATFORM SUPPORT INSTALLATION - WITH LSS............................................................232
SECTION 4 - PLATFORM................................................................................................235
	FIGURE 4-1. PLATFORM INSTALLATION...............................................................................236
	FIGURE 4-2. FALL ARREST PLATFORM COMPONENTS INSTALLATION (OPTIONAL).............................................240
	FIGURE 4-3. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL)...........................................................242
	FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY...........................................................................244
	FIGURE 4-5. CONTROLLER ASSEMBLY (LIFT AND SWING) (ORIGINAL EQUIPMENT)...........................................250
	FIGURE 4-6. CONTROLLER ASSEMBLY (LIFT AND SWING) (SERVICE REPLACEMENT)..........................................252
	FIGURE 4-7. CONTROLLER ASSEMBLY (DRIVE AND STEER) (ORIGINAL EQUIPMENT)..........................................256
	FIGURE 4-8. CONTROLLER ASSEMBLY (DRIVE AND STEER) (SERVICE REPLACEMENT).........................................258
	FIGURE 4-9. SKYGUARD SYSTEM INSTALLATION........................................................................260
	FIGURE 4-10. CROSS RAIL INSTALLATION............................................................................262
	FIGURE 4-11. SKYGLAZIER INSTALLATION - WITHOUT LSS (ANSI, CSA AND AUSTRALIAN SPECS).............................264
	FIGURE 4-12. SKYGLAZIER INSTALLATION - WITH LSS (AUSTRALIAN SPECS)..............................................266
	FIGURE 4-13. SKYWELDER INSTALLATION (50HZ)......................................................................268
	FIGURE 4-14. SKYWELDER INSTALLATION (60HZ)......................................................................270
	FIGURE 4-15. WELDER ASSEMBLY....................................................................................272
	FIGURE 4-16. SKYCUTTER INSTALLATION.............................................................................274
	FIGURE 4-17. PLASMA CUTTER ASSEMBLY.............................................................................276
SECTION 5 - CYLINDER................................................................................................279
	FIGURE 5-1. USA BUILT MACHINES/AXLE LOCKOUT CYLINDER............................................................280
	FIGURE 5-2. USA BUILT MACHINES/LEVEL (PLATFORM SLAVE) CYLINDER (450A SERIES II).................................282
	FIGURE 5-3. USA BUILT MACHINES/LEVEL (PLATFORM SLAVE) CYLINDER (450AJ SERIES II WITHOUT ARCTIC PACKAGE).........284
	FIGURE 5-4. USA BUILT MACHINES/ LEVEL (PLATFORM SLAVE) CYLINDER (450AJ SERIES II WITH ARCTIC PACKAGE)...........286
	FIGURE 5-5. USA BUILT MACHINES/LIFT (JIB) CYLINDER (450AJ SERIES II WITHOUT ARCTIC PACKAGE).....................288
	FIGURE 5-6. USA BUILT MACHINES/LIFT (JIB) CYLINDER (450AJ SERIES II WITH ARCTIC PACKAGE)........................290
	FIGURE 5-7. USA BUILT MACHINES/LIFT (MAIN BOOM) CYLINDER........................................................292
	FIGURE 5-8. USA BUILT MACHINES/LIFT (TOWER BOOM) CYLINDER.......................................................294
	FIGURE 5-9. USA BUILT MACHINES/MASTER CYLINDER (450A SERIES II).................................................296
	FIGURE 5-10. USA BUILT MACHINES/MASTER CYLINDER (450AJ SERIES II WITHOUT ARCTIC PACKAGE)........................298
	FIGURE 5-11. USA BUILT MACHINES/MASTER CYLINDER (450AJ SERIES II WITH ARCTIC PACKAGE)...........................300
	FIGURE 5-12. USA BUILT MACHINES/STEER CYLINDER..................................................................302
	FIGURE 5-13. USA BUILT MACHINES/TELESCOPE CYLINDER (SN 0300160835 through 0300175028)...........................304
	FIGURE 5-14. USA BUILT MACHINES/TELESCOPE CYLINDER (SN 0300175029 through 0300201990)...........................306
	FIGURE 5-15. ROMANIAN BUILT MACHINES/AXLE LOCKOUT CYLINDER......................................................308
	FIGURE 5-16. ROMANIAN BUILT MACHINES/LEVEL (PLATFORM SLAVE) CYLINDER............................................310
	FIGURE 5-17. ROMANIAN BUILT MACHINES/LIFT (JIB) CYLINDER........................................................312
	FIGURE 5-18. ROMANIAN BUILT MACHINES/LIFT (MAIN BOOM) CYLINDER..................................................314
	FIGURE 5-19. ROMANIAN BUILT MACHINES/LIFT (TOWER BOOM) CYLINDER.................................................316
	FIGURE 5-20. ROMANIAN BUILT MACHINES/MASTER CYLINDER............................................................318
	FIGURE 5-21. ROMANIAN BUILT MACHINES/STEER CYLINDER.............................................................320
	FIGURE 5-22. ROMANIAN BUILT MACHINES/TELESCOPE CYLINDER.........................................................322
SECTION 6 - HYDRAULIC...............................................................................................325
	FIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM - 2WD................................................................326
	FIGURE 6-2. AXLE LOCKOUT HYDRAULIC DIAGRAM - 4WD................................................................328
	FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 2WD.......................................................................330
	FIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD.......................................................................332
	FIGURE 6-5. STANDARD HYDRAULIC DIAGRAM..........................................................................336
	FIGURE 6-6. HYDRAULIC DIAGRAM LIST..............................................................................340
SECTION 7 - ELECTRICAL..............................................................................................343
	FIGURE 7-1. ELECTRICAL DIAGRAM LIST.............................................................................344
	FIGURE 7-2. HARNESS COMPONENTS INSTALLATION.....................................................................346
SECTION 8 - DECALS..................................................................................................367
	FIGURE 8-1. DECAL INSTALLATION - ANSI SPEC......................................................................368
	FIGURE 8-2. DECAL INSTALLATION - ANSI EXPORT SPECS..............................................................372
	FIGURE 8-3. DECALS INSTALLATION - AUSTRALIAN AND CE SPECS.......................................................376
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK.........................................................................379
	FIGURE 9-1. MODEL 450A / 450AJ SERIES II STANDARD PARTS.........................................................380
	FIGURE 9-2. MODEL 450A / 450AJ SERIES II VARIABLE PARTS.........................................................382
SECTION 10 - SPECIAL OPTIONS........................................................................................383
	FIGURE 10-1. SPECIAL OPTIONS....................................................................................384
PART NUMBER INDEX...................................................................................................391

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