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