JLG 450A 450AJ Illustrated Parts Manual 3120870 – PDF DOWNLOAD

Illustrated Parts Manual

Models 450A 450AJ P/N - 3120870 June 20, 2007

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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 Revision 26)

3120870

A

REVISION LOG

This page left blank intentionally.

B

3120870

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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 AXLE AND STEERING INSTALLATION - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18 DRIVE HUB ASSEMBLY (PRIOR TO S/N 39594). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20 DRIVE HUB ASSEMBLY (S/N 39594 TO PRESENT). . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22 DRIVE MOTOR ASSEMBLY - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26 DRIVE MOTOR ASSEMBLY - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28 DRIVE VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30 TOW BAR INSTALLATION - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34 SEMI-TRACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38

SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11

CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 MAIN CONTROL VALVE ASSEMBLY - PROPORTIONAL . . . . . . . . . . . . . . . . . . . . . . . .2-4 TURNTABLE AND SWING DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 DEUTZ ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) . . . . . . . . . . . . . . . . .2-16 PISTON PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24 GROUND CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) . . . . . . . . . . . . . . .2-30 HOODS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 3-1 3-2 3-3 3-4 3-5

TOWER/MID BOOMS AND CYLINDERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .3-2 MAIN BOOM AND CYLINDERS INSTALLATION - 450A . . . . . . . . . . . . . . . . . . . . . . . . .3-6 MAIN BOOM AND CYLINDERS INSTALLATION - 450AJ . . . . . . . . . . . . . . . . . . . . . . . .3-10 MAIN BOOM ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 BOOM COVERS, CABLES AND CLAMPS INSTALLATION . . . . . . . . . . . . . . . . . . . . . .3-18

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8

PLATFORM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 CONTROLLER ASSEMBLY (LIFT & SWING) (PRIOR TO S/N39857) . . . . . . . . . . . . . .4-12 CONTROLLER ASSEMBLY (LIFT & SWING) (S/N39857 TO PRESENT) . . . . . . . . . . . .4-14 CONTROLLER ASSEMBLY (DRIVE & STEER) (PRIOR TO S/N39857) . . . . . . . . . . . . .4-18 CONTROLLER ASSEMBLY (DRIVE & STEER) (S/N39857 TO PRESENT). . . . . . . . . . .4-22 CONTROLLER ASSEMBLY (SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 SOFT TOUCH SYSTEM INSTALLATION (S/N 49601 TO PRESENT) . . . . . . . . . . . . . . .4-28

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 5-1 5-2 5-3 5-4

3120870

AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 PLATFORM LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 LIFT CYLINDER ASSEMBLY - JIB (450AJ ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 LIFT CYLINDER ASSEMBLY - MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

i

TABLE OF CONTENTS

FIGURE NO. 5-5 5-6 5-7 5-8 5-9

TITLE

PAGE NO.

LIFT CYLINDER ASSEMBLY - MID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 LIFT CYLINDER ASSEMBLY - TOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 ROTATOR CYLINDER ASSEMBLY - PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1 6-2 6-3 6-4 6-5 6-6 6-7

AXLE LOCKOUT HYDRAULIC DIAGRAM - 2WD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 TOW BAR HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 AXLE LOCKOUT HYDRAULIC DIAGRAM - 4WD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 DRIVE HYDRAULIC DIAGRAM - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 DRIVE HYDRAULIC DIAGRAM - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 STANDARD HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-1 7-2 7-3

ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 ELECTRICAL SCHEMATIC - DEUTZ ENGINE MACHINES . . . . . . . . . . . . . . . . . . . . . . 7-4 HARNESS COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-1

DECALS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . 9-1 SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

ii

3120870

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

PAGE

AXLE AND STEERING INSTALLATION - 2WD WITH OUT TOW BAR . . . . . . . . . . . . . . . . . . . 1-2 AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR (S/N 49971 TO PRESENT) . 1-6 AXLE AND STEERING INSTALLATION - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 DRIVE HUB ASSEMBLY (PRIOR TO S/N 39594) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 DRIVE HUB ASSEMBLY (S/N 39594 to PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 DRIVE MOTOR ASSEMBLY - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 DRIVE MOTOR ASSEMBLY - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 DRIVE VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 TOW BAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 SEMI-TRACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

S E C T I O N 1 F R A M E

1-1

SECTION 1 FRAME S E C T I O N

FIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW BAR

1 F R A M E

1-2

3120870

SECTION 1 FRAME .

FIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW BAR FIG & ITEM #

PART NUMBER 0258026

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 18A

0100011 0362763 0362764 0641606 0641626 0642012 0961950 Use 3422592 3422592 3570901 3841258 4060951 4070972 4070973 4070974 4740158 4751600 Not Used 4845643 0561300 0258024

101 102 103 104 105 106 107 108 109

110 111 112

113 114

3120870

0100011 0641414 0641606 0641812 0642012 0682248 0961950 1100107

1683575 1684139 3272201 3322201 Use 3422592 3422592 3841258 3841367 7020180

DESCRIPTION FIXED AXLE INSTALLATION

QTY.

REV.

Ref.

C

Loctite #242 (Not Shown) Bar, Stop Bar, Stop Bolt 3/8”-16NC x 3/4” Bolt 3/8”-16NC x 3 1/4” Bolt 5/8”-11NC x 1 1/2” Bushing, Garmax Pin, Axle Pivot Options: Prior to S/N 56275 (Was p/n 3422431) S/N 56275 to Present Plate, Stop Keeper, Pin Shield, Frame Shim 3/16” Shim 1/8” Shim 1/16” Thrustwasher Flatwasher 3/8”

2 1 1 A/R A/R A/R 1 8

Axle Weldment Steer Cylinder Mounting Block Assembly

1 2

OSCILLATING AXLE INSTALLATION Loctite #242 (Not Shown) Bolt 1/4”-20NC x 1 3/4” Bolt 3/8”-16NC x 3/4” Bolt 1/2”-13NC x 1 1/2” Bolt 5/8”-11NC x 1 1/2” Bolt 3/4”-10NC x 6” Bushing, Garmax Cam, Lockout Lockout Cylinder Assembly Options (See Section 5 for Breakdown): Prior to S/N 63921 S/N 63921 to Present Nut 3/4”-10NC Nut 3/4”-16NF Pin, Axle Pivot Options: Prior to S/N 56275 (Was p/n 3422431) S/N 56275 to Present Keeper, Pin Rod-End with Grease Fitting Grease Fitting

A/R 4 2 6 2 1 2 1

Ref.

S E C T I O N 1 F R A M E

G

A/R 4 6 2 1 2 2 1 2

2 2 1

1 2 1

1-3

SECTION 1 FRAME S E C T I O N

FIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW BAR (CONTINUED) FIG & ITEM #

PART NUMBER

115

116 117 118

1

119 120 121 122 123 123A 124 125 126 127 128

F R A M E

3900109 3422936 4060951 4567462 4640871 7012693 7002840 4711400 4740158 4751800 4751600 4845643 0561300 4892200 Not Used 0100019 0641607 3841520 0258022

201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218

1-4

0100011 0440162 0641606 0681828 1683614 2780230 3312008 3322201 3323003 3422692 3450812 3841367 7020180 3841377 3900109 4060950 4713000 4751800 4740086

DESCRIPTION

QTY.

Hardware Options: Screw, Shoulder (Prior to S/N 63921) Pin (S/N 63921 to Present) Shield, Frame Tube, Mounting Lockout Valve Assembly Seal Kit - 4640871 Valve Anit-Rotation Pin Removal Tool Flatwasher 1/4” Narrow Thrustwasher Flatwasher 1/2” Flatwasher 3/8” Axle Weldment Steer Cylinder Mounting Block Assembly Flatwasher 3/4”

1 2 1 1 1 4 1 4 6 1 2 4

Loctite #271 (Not Shown) Bolt 3/8”-16NC x 7/8” (S/N 63921 to Present) Keeper 3/8” (S/N 63921 to Present)

A/R 2 2

STEERING INSTALLATION Loctite #242 (Not Shown) Thrustwasher Bolt 3/8”-16NC x 3/4” Bolt 1/2”-13NC x 3 1/2” Steer Cylinder Assembly (See Section 5 for Breakdown) Hub/Spindle Assembly (See 301 to 313 for Breakdown) Nut 5/8”-11NC Nut 3/4”-16NF Nut 1 1/4”-12NF Kingpin Pin, Cotter 1/4” x 3” Rod-End with Grease Fitting Grease Fitting Tie-Rod Screw, Shoulder Shield, Frame Flatwasher 1 1/4” Flatwasher 1/2” Washer, Thrust

REV.

2

Ref.

B

A/R 2 4 4 1 2 4 2 2 2 2 2 1 2 4 1 2 4 2

3120870

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.

A

Cap, Dust (1 per Assembly) ——————————— Spindle Assembly (1 per Assembly) Bushing, Garmax (2 per Assembly) Bearing, Garmax (1 per Assembly) Hub (1 per Assembly) (Includes 306 & 307) Cup, Bearing - Inner(1 per Assembly) Cup, Bearing - Outer (1 per Assembly) Cone, Bearing - Inner (1 per Assembly) Cone, Bearing - Outer (1 per Assembly) Seal (1 per Assembly) Stud, Wheel (9 per Assembly)

2 2 4 2 2 2 2 2 2 2 18

Lugnut (9 per Assembly) Nut, Castle (1 Per Assembly) Pin, Cotter (1 Per Assembly) Washer, Spindle (1 Per Assembly)

18 2 2 2

FRAME WELDMENT OPTIONS Frame Weldment - Standard Frame Weldment - With Semi Track

Ref. 1 1

S E C T I O N 1 F R A M E

1-5

SECTION 1 FRAME S E C T I O N

FIGURE 1-2. AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR (S/N 49971 TO PRESENT)

1 F R A M E

1-6

3120870

SECTION 1 FRAME .

FIGURE 1-2. AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR (S/N 49971 TO PRESENT) FIG & ITEM #

PART NUMBER 0259967

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15

0100011 0641414 0641606 0641812 0642012 0682248 0961950 1100107

1683575 1684139 Not Used 3272201 3322201 3422592 3841258 3841367 7020180

16

17 18 19

20 21 22 23 24 24A 25 26 27

101 102 103 104 105 106

3120870

3900109 3422936 4060951 4567462 4640871 7012693 7002840 4711400 4740158 4751600 4751800 4846167 0561300 4892200 0641607 3841520

DESCRIPTION

QTY.

REV.

OSCILLATING AXLE INSTALLATION

Ref.

C

Loctite #242 (Not Shown) Bolt 1/4”-20NC x 1 3/4” Bolt 3/8”-16NC x 3/4” Bolt 1/2”-13NC x 1 1/2” Bolt 5/8”-11NC x 1 1/2” Bolt 3/4”-10NC x 6” Bushing, Garmax Cam, Lockout Lockout Cylinder Assembly Options (See Section 5 for Breakdown): Prior to S/N 63921 S/N 63921 to Present

A/R 4 10 2 1 2 2 1 2

Nut 3/4”-10NC Nut 3/4”-16NF Pin, Axle Pivot Keeper, Pin Rod-End with Grease Fitting Grease Fitting Hardware Options: Screw, Shoulder (Prior to S/N 63921) Pin (S/N 63921 to Present) Shield, Frame Tube, Mounting Lockout Valve Assembly Seal Kit - 4640871 Valve Anit-Rotation Pin Removal Tool Flatwasher 1/4” Narrow Thrustwasher Flatwasher 3/8” Flatwasher 1/2” Axle Weldment Steer Cylinder Mounting Block Assembly Flatwasher 3/4” Bolt 3/8”-16NC x 7/8” (S/N 63921 to Present) Keeper 3/8” (S/N 63921 to Present)

2 2 1 1 2 1 2

1 F R A M E

1 2 1 1 1 4 1 6 4 1 2 4 2 2

0259966

STEERING INSTALLATION

Ref.

0100011 0440162 0630544 0641508 0641606 0681828

Loctite #242 (Not Shown) Thrustwasher Bolt 1”-8NC x 6” Bolt 5/16”-18NC x 1” Bolt 3/8”-16NC x 3/4” Bolt 1/2”-13NC x 3 1/2”

A/R 2 1 1 4 4

S E C T I O N

B

1-7

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• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

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