Parts Manual Owner manual

ManualsBrandsJLG ManualsSpecial machinery450AJ

Table Of Contents

Illustrated Parts Manual

Models

450A

450AJ

P/N

3120870

January 28, 2011

Summary of content (212 pages)

PAGE 1
Illustrated Parts Manual Models 450A 450AJ P/N 3120870 January 28, 2011
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REVISION LOG May 1998 - Original Issue Of Manual November 18, 1998 - Revised (Edited to Top B/M Revision 7) February 5, 1999 - Revised (Edited to Top B/M Revision 9) August 15, 1999 - Revised (Edited to Top B/M Revision 14) February 16, 2000 - Revised (Edited to Top B/M Revision 18) February 7, 2001 - Revised (Edited to Top B/M Revision 23) February 14, 2003 - Revised (Edited to Top B/M Revision 25) December 16, 2004 - Revised (Edited to Top B/M Revision 25) June 20, 2007 - Revised (Edited to Top B/M Revisi
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REVISION LOG This page left blank intentionally.
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TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW BAR . . . . . . . . . . . . . . .1-2 AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR (S/N 49971 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS FIGURE NO. 5-4 5-5 5-6 5-7 5-8 5-9 TITLE PAGE NO. LIFT CYLINDER ASSEMBLY - MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 LIFT CYLINDER ASSEMBLY - MID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 LIFT CYLINDER ASSEMBLY - TOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 ROTATOR CYLINDER ASSEMBLY - PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 FRAME TABLE OF CONTENTS FIGURE 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 3120870 DESCRIPTION AXLE AND STEERING INSTALLATION - 2WD WITH OUT TOW BAR . . . . . . . . . . . . . . . . . . . AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR (S/N 49971 TO PRESENT) . AXLE AND STEERING INSTALLATION - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 FRAME S E C T I O N FIGURE 1-1.
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SECTION 1 FRAME . FIGURE 1-1.
PAGE 10
SECTION 1 FRAME S E C T I O N FIGURE 1-1.
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SECTION 1 FRAME FIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW BAR (CONTINUED) FIG & ITEM # PART NUMBER 2780230 301 7020033 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 7020034 0961951 0962140 7020035 7020036 7020038 7020037 7020039 7020040 7020041 Not Used 7020042 7020054 3450608 7020055 401 2360460 2360536 3120870 DESCRIPTION HUB ASSEMBLY QTY. REV. Ref.
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SECTION 1 FRAME S E C T I O N FIGURE 1-2.
PAGE 13
SECTION 1 FRAME . FIGURE 1-2.
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SECTION 1 FRAME S E C T I O N FIGURE 1-2.
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SECTION 1 FRAME FIGURE 1-2. AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR (S/N 49971 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER 301 2360460 2360536 DESCRIPTION QTY. FRAME WELDMENT OPTIONS Frame Weldment - Standard Frame Weldment - With Semi Track Ref. 1 1 REV.
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SECTION 1 FRAME S E C T I O N FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD.
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SECTION 1 FRAME FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD.
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SECTION 1 FRAME S E C T I O N FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD.
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SECTION 1 FRAME FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD. (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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SECTION 1 FRAME S E C T I O N FIGURE 1-4.
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SECTION 1 FRAME . FIGURE 1-4.
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SECTION 1 FRAME S E C T I O N 1 F R A M E FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER 111 112 113 114 115 to 116 117 118 119 120 121 122 to 123 124 125 126 127 to 128 129 Not Used 3311801 4300120 0641836 Not Used 4711800 Not Used 4751600 4891800 4892000 Not Used 0641606 Not Used 4060970 Not Used 3960526 0258030 0259643 0258031 0259129 0258009 0258010 0259638 0259636 0258011 0258012 0259128 201 202 QTY.
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SECTION 1 FRAME FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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SECTION 1 FRAME S E C T I O N FIGURE 1-5. DRIVE BRAKE ASSEMBLY.
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SECTION 1 FRAME . FIGURE 1-5. DRIVE BRAKE ASSEMBLY. FIG & ITEM # PART NUMBER 0920112 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 7003451 7003452 7003094 7003049 7003453 7003050 7003454 7000798 7000782 7003455 7003456 7003457 Not Used 7003459 7003460 7000722 7000723 7000724 7000725 Not Used 7003461 7000728 7003462 7003463 7000731 Not Available 0920117 101 3120870 7000731 7018612 7018613 DESCRIPTION DRIVE BRAKE ASSEMBLY (PRIOR TO S/N 56958) QTY. REV. Ref.
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SECTION 1 FRAME S E C T I O N FIGURE 1-6. DRIVE HUB ASSEMBLY (PRIOR TO S/N 39594).
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SECTION 1 FRAME . FIGURE 1-6. DRIVE HUB ASSEMBLY (PRIOR TO S/N 39594).
PAGE 28
SECTION 1 FRAME S E C T I O N FIGURE 1-7.
PAGE 29
SECTION 1 FRAME . FIGURE 1-7.
PAGE 30
SECTION 1 FRAME S E C T I O N FIGURE 1-7.
PAGE 31
SECTION 1 FRAME FIGURE 1-7. DRIVE HUB ASSEMBLY (S/N 39594 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 32
SECTION 1 FRAME S E C T I O N FIGURE 1-8.
PAGE 33
SECTION 1 FRAME . FIGURE 1-8.
PAGE 34
SECTION 1 FRAME S E C T I O N FIGURE 1-9.
PAGE 35
SECTION 1 FRAME S E C T I O N .
PAGE 36
SECTION 1 FRAME S E C T I O N 1 F R A M E FIGURE 1-9. DRIVE MOTOR ASSEMBLY - FRONT FIG & ITEM # PART NUMBER DESCRIPTION Note: Drive Motor p/n 3160227 is no longer available. Replace complete drive motor with Service Replacement Drive Motor p/n 1001096417 Note: Visually identify the drive motor by Eaton part number before ordering replacement parts.
PAGE 37
SECTION 1 FRAME FIGURE 1-9.
PAGE 38
SECTION 1 FRAME S E C T I O N 1 F R A M E FIGURE 1-9. DRIVE MOTOR ASSEMBLY - FRONT (CONTINUED) FIG & ITEM # PART NUMBER 131 131A 131B 132 to 134 135 136 137 138 139 140 70002541 Use Item 43 Use Item 43 Not Used 7004929 Not Used 7004928 Use Item 43 7004938 7020347 1-32 DESCRIPTION QTY. Piston Control O-Ring Ring, Slipper 1 1 1 Pin, Connector 2 Plate, Connector Ring, Retaining Bolt Seal Kit - Complete (Includes items 103B,103C,106,118,119, 120,125,130A,131A,131B & 138) 2 2 4 1 REV.
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SECTION 1 FRAME FIGURE 1-9. DRIVE MOTOR ASSEMBLY - FRONT (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 40
SECTION 1 FRAME S E C T I O N FIGURE 1-10.
PAGE 41
SECTION 1 FRAME . FIGURE 1-10.
PAGE 42
SECTION 1 FRAME S E C T I O N 1 F R A M E FIGURE 1-10.
PAGE 43
SECTION 1 FRAME FIGURE 1-10. DRIVE VALVES INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 44
SECTION 1 FRAME S E C T I O N FIGURE 1-11.
PAGE 45
SECTION 1 FRAME . FIGURE 1-11.
PAGE 46
SECTION 1 FRAME S E C T I O N FIGURE 1-11. TOW BAR INSTALLATION - 2WD (CONTINUED) FIG & ITEM # PART NUMBER 203 1704456 1704576 204 205 206 1 3252692 3252693 3820001 4420051 DESCRIPTION Decal - Warning Options: Spanish Spec Spanish/English Spec Nameplate - Steer/Tow Select Valve Options: Spanish Spec Spanish/English Spec Rivet Tape QTY. REV. 1 1 4 43in/ 109.
PAGE 47
SECTION 1 FRAME FIGURE 1-11. TOW BAR INSTALLATION - 2WD (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 48
SECTION 1 FRAME S E C T I O N FIGURE 1-12.
PAGE 49
SECTION 1 FRAME . FIGURE 1-12. SEMI-TRACK INSTALLATION FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. Ref. 1 1 8 8 4 8 2 Ref. Ref. Ref.
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SECTION 1 FRAME S E C T I O N FIGURE 1-12. SEMI-TRACK INSTALLATION (CONTINUED) FIG & ITEM # 201 202 203 204 1 F R A M E 301 302 303 304 305 306 307 PART NUMBER REV. Ref. Ref. 1 1 B A 4860218 4860215 2780221 7012519 7012520 7012521 7012522 7012523 7012524 7016360 HUB ASSEMBLY Cup, Inner Bearing Cone, Inner Bearing Cup, Outer Bearing Cone, Outer Bearing Seal Cap, Dust Stud, Wheel 1/2”-20NF Ref. 1 1 1 1 1 1 Ref. Ref. Ref.
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SECTION 2 TURNTABLE TABLE OF CONTENTS FIGURE 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 3120870 DESCRIPTION CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN CONTROL VALVE ASSEMBLY - PROPORTIONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURNTABLE AND SWING DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 52
SECTION 2 TURNTABLE FIGURE 2-1.
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SECTION 2 TURNTABLE . FIGURE 2-1. CONTROL VALVES INSTALLATIONS FIG & ITEM # PART NUMBER 0258388 0258389 1 2 3 4 5 6 7 8 9 10 11 12 13 0100011 0140001 0641405 0641406 0641408 0641416 0641607 0651406 Not Used 2120163 2120150 7020020 7023206 7023207 2120165 2120158 7020021 3311405 4921927 14 4641056 4641057 15 15A 15B 15C 16 17 18 19 20 3120870 4641059 7017466 2900708 7012959 7012981 7012998 7012944 7017467 7012967 4711400 4711600 4791400 0902459 4640907 7012944 7012941 7012907 QTY. REV.
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SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES INSTALLATIONS (CONTINUED) S E C T I O N FIG & ITEM # PART NUMBER 101 102 103 0254604 4360372 0641406 3311405 DESCRIPTION TILT INDICATOR INSTALLATION Sensor, Level Bolt 1/4”-20NC x 3/4” Locknut 1/4”-20NC QTY. REV. Ref.
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SECTION 2 TURNTABLE FIGURE 2-1. CONTROL VALVES INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 56
SECTION 2 TURNTABLE FIGURE 2-2.
PAGE 57
SECTION 2 TURNTABLE . FIGURE 2-2.
PAGE 58
SECTION 2 TURNTABLE FIGURE 2-3.
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SECTION 2 TURNTABLE . FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONS FIG & ITEM # PART NUMBER Ref. 0258032 SWING DRIVE INSTALLATION Ref. 0100019 0440203 3 4 5 6 7 8 9 0681814 0682038 3020029 3020036 3160182 4891800 4892000 0258400 3120870 QTY.
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SECTION 2 TURNTABLE FIGURE 2-4.
PAGE 61
SECTION 2 TURNTABLE . FIGURE 2-4.
PAGE 62
SECTION 2 TURNTABLE FIGURE 2-5.
PAGE 63
SECTION 2 TURNTABLE . FIGURE 2-5. SWING BEARING ASSEMBLY FIG & ITEM # PART NUMBER DESCRIPTION Note: Visually identify the brand before ordering replacement parts.
PAGE 64
SECTION 2 TURNTABLE FIGURE 2-5. SWING BEARING ASSEMBLY (CONTINUED) S E C T I O N FIG & ITEM # PART NUMBER 115 116 117 7012596 2160003 Not Available Not Available DESCRIPTION Bearing, Turntable Fitting, Grease - 45° Capscrew, Socket Head 5/16”-18NC Washer 5/16” (Not Shown) QTY. REV.
PAGE 65
SECTION 2 TURNTABLE FIGURE 2-5. SWING BEARING ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 66
SECTION 2 TURNTABLE FIGURE 2-6.
PAGE 67
SECTION 2 TURNTABLE . FIGURE 2-6.
PAGE 68
SECTION 2 TURNTABLE FIGURE 2-6.
PAGE 69
SECTION 2 TURNTABLE FIGURE 2-6.
PAGE 70
SECTION 2 TURNTABLE FIGURE 2-6.
PAGE 71
SECTION 2 TURNTABLE FIGURE 2-6. DEUTZ ENGINE INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 72
SECTION 2 TURNTABLE FIGURE 2-7.
PAGE 73
SECTION 2 TURNTABLE . FIGURE 2-7.
PAGE 74
SECTION 2 TURNTABLE FIGURE 2-7.
PAGE 75
SECTION 2 TURNTABLE FIGURE 2-7. GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 76
SECTION 2 TURNTABLE FIGURE 2-8.
PAGE 77
SECTION 2 TURNTABLE . FIGURE 2-8.
PAGE 78
SECTION 2 TURNTABLE FIGURE 2-8.
PAGE 79
SECTION 2 TURNTABLE FIGURE 2-8. PISTON PUMP ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER 86 87 7007475 88 89 7007477 7021226 7007476 7010120 101 2900752 102 103 104 7007412 2900826 2900827 DESCRIPTION Plug, Orifice/Screen (.156) Plug, Orifice Options:(.37) .037 (3600260 Pump .
PAGE 80
SECTION 2 TURNTABLE FIGURE 2-9.
PAGE 81
SECTION 2 TURNTABLE . FIGURE 2-9.
PAGE 82
SECTION 2 TURNTABLE FIGURE 2-10.
PAGE 83
SECTION 2 TURNTABLE . FIGURE 2-10.
PAGE 84
SECTION 2 TURNTABLE FIGURE 2-10. GROUND CONTROL BOX ASSEMBLY (CONTINUED) S E C T I O N FIG & ITEM # PART NUMBER DESCRIPTION QTY.
PAGE 85
SECTION 2 TURNTABLE FIGURE 2-10. GROUND CONTROL BOX ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. Ref. 4922432 3740118 3911024 4751000 4761000 3311001 GENERATOR TIMER RELAY INSTALLATION (NOT SHOWN) Note: Required S/N 56107 to Present Only.
PAGE 86
SECTION 2 TURNTABLE FIGURE 2-11.
PAGE 87
SECTION 2 TURNTABLE . FIGURE 2-11. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. 0258307 STROBE LIGHT INSTALLATIONS (AMBER) (OPTIONAL) Ref.
PAGE 88
SECTION 2 TURNTABLE FIGURE 2-11. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) (CONTINUED) S E C T I O N FIG & ITEM # PART NUMBER 0258308 44 45 46 47 0257887 0641406 4711400 0100048 DESCRIPTION ALARMS INSTALLATIONS Alarm/Harness Assembly Bolt 1/4”-20NC x 3/4” Flatwasher 1/4” Sealant, Silicone (Not Shown) QTY. REV. Ref.
PAGE 89
SECTION 2 TURNTABLE FIGURE 2-11. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 90
SECTION 2 TURNTABLE FIGURE 2-12.
PAGE 91
SECTION 2 TURNTABLE . FIGURE 2-12.
PAGE 92
SECTION 2 TURNTABLE FIGURE 2-12. HOODS INSTALLATION (CONTINUED) S E C T I O N FIG & ITEM # 101 102 103 104 105 106 107 108 2 T U R N T A B L E PART NUMBER DESCRIPTION QTY. REV. 2680438 HOOD ASSEMBLY (ENGINE SIDE) Note: Replacement Decals Must Be Ordered Separately See Section 8. Ref.
PAGE 93
SECTION 3 BOOM TABLE OF CONTENTS FIGURE 3-1 3-2 3-3 3-4 3-5 DESCRIPTION TOWER/MID BOOMS AND CYLINDERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN BOOM AND CYLINDERS INSTALLATION - 450A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN BOOM AND CYLINDERS INSTALLATION - 450AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN BOOM ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 94
SECTION 3 BOOM FIGURE 3-1.
PAGE 95
SECTION 3 BOOM . FIGURE 3-1.
PAGE 96
SECTION 3 BOOM FIGURE 3-1. TOWER/MID BOOMS AND CYLINDERS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 0258300 S E C T I O N 101 102 103 104 105 106 107 108 109 4360321 4460428 3311005 Not Used 3900246 3900104 1060341 1670832 1670833 1670898 DESCRIPTION VALVES AND SWITCHES INSTALLATION QTY. REV. Ref.
PAGE 97
SECTION 3 BOOM FIGURE 3-1. TOWER/MID BOOMS AND CYLINDERS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 98
SECTION 3 BOOM FIGURE 3-2.
PAGE 99
SECTION 3 BOOM . FIGURE 3-2.
PAGE 100
SECTION 3 BOOM FIGURE 3-2.
PAGE 101
SECTION 3 BOOM FIGURE 3-2. MAIN BOOM AND CYLINDERS INSTALLATION - 450A (CONTINUED) FIG & ITEM # PART NUMBER 0259523 0271483 301 302 303 303A 303B 304 305 306 0641408 0701010 2901811 7023331 7023333 3990109 7023332 3311405 4751400 4812000 DESCRIPTION LOAD SENSOR INSTALLATION BPE Load Sensor BPE Load Sensing Device (Lift Down) Bolt 1/4”-20NC x 1” Bolt, Metric M10 x 20mm Load Sensor Kit Fuse Fuseholder Cell, Load Control. PC Board Locknut 1/4”-20NC Flatwasher 1/4” Flatwasher Metric 10mm QTY. REV. Ref.
PAGE 102
SECTION 3 BOOM FIGURE 3-3.
PAGE 103
SECTION 3 BOOM . FIGURE 3-3.
PAGE 104
SECTION 3 BOOM FIGURE 3-3.
PAGE 105
SECTION 3 BOOM FIGURE 3-3.
PAGE 106
SECTION 3 BOOM FIGURE 3-4.
PAGE 107
SECTION 3 BOOM . FIGURE 3-4. MAIN BOOM ASSEMBLIES FIG & ITEM # PART NUMBER 0801131 0801148 1 2 3 4 5 6 7 0100011 0560923 0641404 0641606 0641607 0641608 0801129 0801146 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Use 0801170 0801170 0801147 0961950 Not Used 3311401 3311605 3340756 3340836 3340837 3422705 3422706 3422745 3570869 3760115 3760133 4070559 4070898 4751400 4751600 4761400 4761600 4845767 4845696 1180227 7006152 7006151 7006139 7006156 3120870 DESCRIPTION QTY. REV.
PAGE 108
SECTION 3 BOOM FIGURE 3-4. MAIN BOOM ASSEMBLIES (CONTINUED) FIG & ITEM # PART NUMBER 29 S E C T I O N 30 Use 1683716 1683716 Use 1683718 1683718 4070897 DESCRIPTION Telescope Cylinder Assembly Options: 450A Prior to S/N 38481(was p/n 1683582) 450A S/N 38481 to Present 450AJ Prior to S/N 38481(was p/n 1683653) 450AJ S/N 38481 to Present Shim (S/N 47619 to Present) QTY. REV.
PAGE 109
SECTION 3 BOOM FIGURE 3-4. MAIN BOOM ASSEMBLIES (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 110
SECTION 3 BOOM FIGURE 3-5.
PAGE 111
SECTION 3 BOOM FIGURE 3-5.
PAGE 112
SECTION 3 BOOM FIG & ITEM # PART NUMBER 49 3340859 DESCRIPTION Pad, Rubber QTY. REV.
PAGE 113
SECTION 4 PLATFORM TABLE OF CONTENTS FIGURE 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 DESCRIPTION PLATFORM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROLLER ASSEMBLY (LIFT AND SWING) (PRIOR TO S/N 39857) . . . . . . . . . . . . . . . . CONTROLLER ASSEMBLY (LIFT AND SWING) (S/N 39857 TO PRESENT). . . . . . . . . . . . . .
PAGE 114
SECTION 4 PLATFORM FIGURE 4-1.
PAGE 115
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM INSTALLATION FIG & ITEM # PART NUMBER 3510632 3510631 3510680 3510628 3510681 3510630 3510679 3510627 3510682 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0681610 2080040 7016652 2600219 2940074 3311001 3311605 Not Available 3520072 3539685 3911008 4060803 4220165 4711600 4751000 4761000 3120870 PLATFORM ASSEMBLIES: 48in x 30in (1.22m x .76m) (Australian Spec) 60in x 30in (1.52m x .76m) (Australian Spec) 60in x 30in (1.52m x .
PAGE 116
SECTION 4 PLATFORM FIGURE 4-1.
PAGE 117
SECTION 4 PLATFORM FIGURE 4-1. PLATFORM INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 118
SECTION 4 PLATFORM FIGURE 4-2.
PAGE 119
SECTION 4 PLATFORM FIGURE 4-2. PLATFORM CONSOLE ASSEMBLY FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 120
SECTION 4 PLATFORM FIGURE 4-2.
PAGE 121
SECTION 4 PLATFORM FIGURE 4-2.
PAGE 122
SECTION 4 PLATFORM FIGURE 4-2. PLATFORM CONSOLE ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER 0259523 0271483 S E C T I O N 301 to 309 310 311 4120012 4120013 312 4 401 P L A T F O R M 4-10 LOAD SENSOR COMPONENTS INSTALLATIONS BPE Load Sensor BPE Load Sensing Device (Lift Down) QTY. REV. Ref. Ref. Ref.
PAGE 123
SECTION 4 PLATFORM FIGURE 4-2. PLATFORM CONSOLE ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 124
SECTION 4 PLATFORM FIGURE 4-3.
PAGE 125
SECTION 4 PLATFORM FIGURE 4-3. CONTROLLER ASSEMBLY (LIFT & SWING) (PRIOR TO S/N39857) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. Ref.
PAGE 126
SECTION 4 PLATFORM FIGURE 4-4.
PAGE 127
SECTION 4 PLATFORM FIGURE 4-4.
PAGE 128
SECTION 4 PLATFORM FIGURE 4-4.
PAGE 129
SECTION 4 PLATFORM FIGURE 4-4. CONTROLLER ASSEMBLY (LIFT & SWING) (S/N39857 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 130
SECTION 4 PLATFORM FIGURE 4-5.
PAGE 131
SECTION 4 PLATFORM FIGURE 4-5. CONTROLLER ASSEMBLY (DRIVE & STEER) (PRIOR TO S/N39857) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. Ref.
PAGE 132
SECTION 4 PLATFORM FIGURE 4-5. CONTROLLER ASSEMBLY (DRIVE & STEER) (PRIOR TO S/N39857) (CONTINUED) FIG & ITEM # PART NUMBER 37 38 39 40 41 42 43 44 45 46 7019113 7019114 7019115 7019124 7019112 7019111 7019110 7019116 Not Used 7003994 Not Serviced Not Serviced 7019117 Not Serviced 4460265 4460268 4460266 4460267 7019153 7003985 S E C T I O N 47 48 49 4 P L A T F O R M 50 51 4-20 DESCRIPTION QTY.
PAGE 133
SECTION 4 PLATFORM FIGURE 4-5. CONTROLLER ASSEMBLY (DRIVE & STEER) (PRIOR TO S/N39857) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 134
SECTION 4 PLATFORM FIGURE 4-6.
PAGE 135
SECTION 4 PLATFORM FIGURE 4-6.
PAGE 136
SECTION 4 PLATFORM FIGURE 4-6. CONTROLLER ASSEMBLY (DRIVE & STEER) (S/N39857 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION HANDLE ASSEMBLY 201 202 203 204 205 206 S E C T I O N 7019160 7019155 7019111 7019110 7019112 7003946 Cast Housing Assembly Shaft 8mm Bearing Spacer, Head Gear Washer Spring, Return QTY. REV. Ref.
PAGE 137
SECTION 4 PLATFORM FIGURE 4-6. CONTROLLER ASSEMBLY (DRIVE & STEER) (S/N39857 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 138
SECTION 4 PLATFORM FIGURE 4-7.
PAGE 139
SECTION 4 PLATFORM FIGURE 4-7.
PAGE 140
SECTION 4 PLATFORM FIGURE 4-8.
PAGE 141
SECTION 4 PLATFORM FIGURE 4-8.
PAGE 142
SECTION 4 PLATFORM FIGURE 4-8. SOFT TOUCH SYSTEM INSTALLATION (S/N 49601 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 143
SECTION 5 CYLINDER TABLE OF CONTENTS FIGURE 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 DESCRIPTION AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATFORM LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDER ASSEMBLY - JIB (450AJ ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDER ASSEMBLY - MAIN . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 144
SECTION 5 CYLINDER FIGURE 5-1.
PAGE 145
SECTION 5 CYLINDER FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY FIG & ITEM # PART NUMBER 1683575 1684139 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1683572 Not Used Use Item 51 Use Item 51 Use Item 51 Use Item 51 Use Item 51 Use Item 51 Use Item 51 1683574 1684138 1683076 3760367 3931516 Use 4641162 4641162 2900770 15 16 4640858 17 18 19 20 Use 0962474 0962474 0100011 0100038 2220885 0962140 51 2901548 3120870 DESCRIPTION AXLE LOCKOUT CYLINDER ASSEMBLIES PRIOR TO S/N 63921 S/N 63921 TO PRESENT QTY. REV.
PAGE 146
SECTION 5 CYLINDER FIGURE 5-2.
PAGE 147
SECTION 5 CYLINDER FIGURE 5-2.
PAGE 148
SECTION 5 CYLINDER FIGURE 5-2. PLATFORM LEVEL CYLINDER ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER 23 S E C T I O N 24 4567761 4567978 4567760 4567979 0630534 51 2901543 DESCRIPTION Tube, Spacer Options (S/N 38944 to Present Only): 450A S/N 38944 to S/N 45397 450A S/N 45397 to Present 450AJ S/N 38944 to Present 450AJ S/N 45397 to Present Capscrew #10-24NC x 1” —————————— Seal Kit (Includes Items 7-15) QTY. REV.
PAGE 149
SECTION 5 CYLINDER FIGURE 5-2. PLATFORM LEVEL CYLINDER ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 150
SECTION 5 CYLINDER FIGURE 5-3.
PAGE 151
SECTION 5 CYLINDER FIGURE 5-3.
PAGE 152
SECTION 5 CYLINDER FIGURE 5-4.
PAGE 153
SECTION 5 CYLINDER FIGURE 5-4.
PAGE 154
SECTION 5 CYLINDER FIGURE 5-4. LIFT CYLINDER ASSEMBLY - MAIN (CONTINUED) FIG & ITEM # PART NUMBER 23 0630535 51 2901554 2901284 DESCRIPTION Capscrew 1/4”-20NC x 1 1/8” —————————— Seal Kit Options (Includes Items 13-21): 1683637 & 1683729 Cylinders 1683588 & 1683728 Cylinders QTY. REV.
PAGE 155
SECTION 5 CYLINDER FIGURE 5-4. LIFT CYLINDER ASSEMBLY - MAIN (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 156
SECTION 5 CYLINDER FIGURE 5-5.
PAGE 157
SECTION 5 CYLINDER FIGURE 5-5.
PAGE 158
SECTION 5 CYLINDER FIGURE 5-6.
PAGE 159
SECTION 5 CYLINDER FIGURE 5-6.
PAGE 160
SECTION 5 CYLINDER FIGURE 5-7.
PAGE 161
SECTION 5 CYLINDER FIGURE 5-7.
PAGE 162
SECTION 5 CYLINDER FIGURE 5-8.
PAGE 163
SECTION 5 CYLINDER FIGURE 5-8. STEER CYLINDER ASSEMBLY FIG & ITEM # PART NUMBER 1683614 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1683615 1683658 1683076 3760367 3931516 Not Used Use Item 51 Use Item 51 Use Item 51 Use Item 51 Use Item 51 Use Item 51 Use Item 51 0100011 0100038 51 2901547 DESCRIPTION STEER CYLINDER ASSEMBLY QTY. REV.
PAGE 164
SECTION 5 CYLINDER FIGURE 5-9.
PAGE 165
SECTION 5 CYLINDER FIGURE 5-9.
PAGE 166
SECTION 5 FIG & ITEM # PART NUMBER CYLINDER DESCRIPTION QTY. REV.
PAGE 167
SECTION 6 HYDRAULIC TABLE OF CONTENTS FIGURE 6-1 6-2 6-3 6-4 6-5 6-6 6-7 DESCRIPTION AXLE LOCKOUT HYDRAULIC DIAGRAM - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOW BAR HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE LOCKOUT HYDRAULIC DIAGRAM - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE HYDRAULIC DIAGRAM - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 168
SECTION 6 HYDRAULIC FIGURE 6-1.
PAGE 169
SECTION 6 HYDRAULIC FIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM - 2WD FIG & ITEM # PART NUMBER 2792356 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 2220502 2220415 2220603 2220579 2220635 2220582 Not Used 2220371 2750895 2751026 2750888 2753070 2752648 2220619 2220861 DESCRIPTION AXLE LOCKOUT HYDRAULIC DIAGRAMS 2WD QTY. REV. Ref.
PAGE 170
SECTION 6 HYDRAULIC FIGURE 6-2.
PAGE 171
SECTION 6 HYDRAULIC FIGURE 6-2. TOW BAR HYDRAULIC DIAGRAM FIG & ITEM # PART NUMBER 2792414 1 2 3 4 5 6 7 2220628 2752589 2220468 2220605 2751426 2220609 2752590 DESCRIPTION TOW BAR HYDRAULIC DIAGRAM Fitting, 90° Hose Fitting, Straight Fitting, Tee Hose Fitting, Reducer Hose QTY. REV. Ref.
PAGE 172
SECTION 6 HYDRAULIC FIGURE 6-3.
PAGE 173
SECTION 6 HYDRAULIC FIGURE 6-3. AXLE LOCKOUT HYDRAULIC DIAGRAM - 4WD FIG & ITEM # PART NUMBER 2792361 1 2 3 4 5 6 7 8 9 10 11 12 2220502 2220415 2220603 2220579 2220635 2220582 2220861 2220371 2750888 2753070 2752469 2751026 DESCRIPTION AXLE LOCKOUT HYDRAULIC DIAGRAMS 4WD Fitting Fitting Fitting Fitting Fitting Fitting Fitting, Tee Fitting Hose Hose Hose Hose QTY. REV. Ref.
PAGE 174
6-8 23 38 28 CASE 22 38 21 A M1 RIGHT REAR DRIVE MOTOR PORT 5 1 6 B M3 M2 M4 35 50 21 50 19 26 27 36 FLOW DIVIDER /COMBINER 20 20 23 DRAIN 39 48 REAR AXLE 34 24 51 FREE FLOW 25 34 24 49 33 49 LEFT REAR DRIVE MOTOR 22 35 13 35 12 2 1 3 11 9 54 43 54 8 REFERENCE LOCKOUT HYDRAULIC INLET SIDE CHARGE FILTER 12 30 29 REFERENCE LOCKOUT HYDRAULIC 28 H Y D R A U L I C 30 6 BRAKE VALVE 2 SUCTION 3 5 1 RETURN FILTER DRIVE PUMP UPPER CASE PORT 37 45
PAGE 175
SECTION 6 HYDRAULIC FIGURE 6-4.
PAGE 176
SECTION 6 HYDRAULIC FIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 2WD (CONTINUED) FIG & ITEM # PART NUMBER 46 47 48 49 50 51 52 53 2220642 2220710 2220273 2220415 2220240 4641076 2752357 2221032 7023480 2752325 2752362 54 55 S E C T I O N DESCRIPTION Fitting, Tee Fitting, Reducer Fitting, Straight Fitting, Straight Fitting, Plug Valve, Restrictor Hose Fitting, Swivel Kit, Repair Hose Hose QTY. REV.
PAGE 177
SECTION 6 HYDRAULIC FIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 2WD (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 178
SECTION 6 HYDRAULIC FIGURE 6-5.
PAGE 179
SECTION 6 HYDRAULIC FIGURE 6-5.
PAGE 180
SECTION 6 HYDRAULIC FIGURE 6-5.
PAGE 181
SECTION 6 HYDRAULIC FIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 4WD (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 182
18 24 14 P 6-16 15 49 53 55 79 21 LR 16 30 LC S1 STEER LU 1 TC 40 R1 22 TR 14 15 26 27 28 29 B1 77 J2 15 32 ST2 16 36 77 15 33 16 30 22 J1 CB2 13 74 1 P2 41 79 80 64 LR T1 ST1 78 FREEFLOW 54 MD C A 15 61 60 V2 63 T1 SWING MOTOR 52 56 75 V1 PLATFORM LEVEL G2 51 P V 20 19 3 58 15 R2 15 16 V V1 P LOWER LIFT 22 P1 V2 17 MID LIFT 14 24 23 H Y D R A U L I C 59 6 15 32 16 27 28 29 37 39 15 33 25 35 34 35 68 34 76 B TELESCOPE
PAGE 183
SECTION 6 HYDRAULIC FIGURE 6-6.
PAGE 184
SECTION 6 HYDRAULIC FIGURE 6-6.
PAGE 185
SECTION 6 HYDRAULIC FIGURE 6-6. STANDARD HYDRAULIC DIAGRAM (CONTINUED) FIG & ITEM # PART NUMBER 76 77 78 79 80 81 Not Required 2220473 2220819 4640757 2220372 2752463 1704395 DESCRIPTION Fitting Options 450A 450AJ Fitting, 90° Valve, Colorflow Fitting, Straight Hose Hose Tag Kit (Not Shown) QTY. REV.
PAGE 186
SECTION 6 HYDRAULIC FIGURE 6-7.HYDRAULIC DIAGRAM LIST Note: Diagrams with asterick (*) are shown in the preceding pages. Diagrams not shown are available from JLG service department. S E C T I O N 2792356* 2792361* Axle Lockout Hydraulic Diagrams: 2WD Machines 4WD Machines Ref. Ref. Ref. 2792414* Tow Bar Hydraulic Diagrams: Ref. 2792358* 2792359* Drive Hydraulic Diagrams: 2WD Machines 4WD Machines Ref. Ref. Ref. 2792352* 2792353* Standard Hydraulic Diagrams: 450A 450AJ Ref. Ref. Ref.
PAGE 187
SECTION 7 ELECTRICAL TABLE OF CONTENTS FIGURE 7-1 7-2 7-3 DESCRIPTION PAGE ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 ELECTRICAL SCHEMATIC - DEUTZ ENGINE MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 HARNESS COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 188
SECTION 7 ELECTRICAL FIGURE 7-1.ELECTRICAL DIAGRAM LIST FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. ALARM ELECTRICAL DIAGRAMS Motion Alarm Travel Alarm Ref. Ref. 1/A 1/A ETHER START ELECTICAL DIAGRAM Ref. 2/C GENERATOR ELECTRICAL DIAGRAMS 220Volt Prior to S/N 56107 220Volt S/N 56107 to Present Ref. Ref.
PAGE 189
SECTION 7 ELECTRICAL FIGURE 7-1.ELECTRICAL DIAGRAM LIST FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. 0258770 PROXIMITY SWITCH ELECTRICAL DIAGRAM Ref. 1/A 4933133 SOFT TOUCH ELECTRICAL DIAGRAM Ref. 1/A 4933053 STANDARD ELECTRICAL DIAGRAM Ref. 4/G 1870085* STANDARD ELECTRICAL SCHEMATIC Ref. C 0258431 2WD/4WD ELECTRICAL DIAGRAM Ref.
PAGE 190
SECTION 7 ELECTRICAL FIGURE 7-2.
PAGE 191
SECTION 7 ELECTRICAL S E C T I O N 7 E L E C T R I C A L 3120870 7-5
PAGE 192
SECTION 7 ELECTRICAL FIGURE 7-2.
PAGE 193
SECTION 7 ELECTRICAL S E C T I O N 7 E L E C T R I C A L 3120870 7-7
PAGE 194
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 195
SECTION 7 ELECTRICAL S E C T I O N 7 E L E C T R I C A L 3120870 7-9
PAGE 196
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 197
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 198
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION FIG & ITEM # PART NUMBER 241 Cable, Electrical - 12/3 (Upper) 40ft/12.2m 1060461 1060709 1060461 Prior to S/N 41790 (Was p/n 1060461) S/N 41790 to S/N 43309 S/N 43309 to Present 45ft/13.
PAGE 199
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 200
SECTION 7 ELECTRICAL FIGURE 7-3. HARNESS COMPONENTS INSTALLATION FIG & ITEM # PART NUMBER DESCRIPTION QTY.
PAGE 201
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 202
SECTION 7 ELECTRICAL FIGURE 7-3.
PAGE 203
SECTION 8 DECALS TABLE OF CONTENTS FIGURE 8-1 DESCRIPTION PAGE DECALS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 204
SECTION 8 DECALS FIGURE 8-1.
PAGE 205
SECTION 8 DECALS FIGURE 8-1.
PAGE 206
SECTION 8 DECALS FIGURE 8-1.
PAGE 207
SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODELS 450A/450AJ WITH PROPORTIONAL CONTROLS The following list will service fleets of machines (built to current production per date on the front cover) with emergency repair parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep service parts stock supplied. For further infomation, contact your JLG dealer or the JLG Industries Parts Department.
PAGE 208
S E C T I O N 9 R E C O M M E N D E D S E R V I C E P A R T S S T O C K SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODELS 450A/450AJ WITH PROPORTIONAL CONTROLS The following list will service fleets of machines (built to current production per date on the front cover) with emergency repair parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep service parts stock supplied.
PAGE 209
SECTION 10 SPECIAL OPTIONS Note: This list is to accomodate machines ordered with special equipment. Options may not be applicable to all models. For more specific parts information contact JLG Parts Department. FIG & ITEM # PART NUMBER 10-1 MISCELLANEOUS SPECIAL OPTIONS QTY. Air Cleaner with Dust Evacuator Valve Ref. 0270723 Beacon Installation Mounted Under Platform Ref.
PAGE 210
SECTION 10 SPECIAL OPTIONS Note: This list is to accomodate machines ordered with special equipment. Options may not be applicable to all models. For more specific parts information contact JLG Parts Department. S E C T I O N FIG & ITEM # 1 0 S P E C I A L PART NUMBER DESCRIPTION QTY. 0258430 Ref.
PAGE 211
PAGE 212
3120870 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +61 2 65 811111 +61 2 65 810122 +55 19 3295 1025 JLG Deutschland GmbH Max-Planck-Str.