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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