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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