JLG Boom Lifts 450A 450AJ ANSI Illustrated Master Parts List Manual ! (P/N 3120750)
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Illustrated Parts Manual
Models
450A
450AJ
P/N
3120870
January 28, 2011
REVISION LOG
3120870 A
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)
January 28, 2011 - Revised Manual
REVISION LOG
B 3120870
This page left blank intentionally.
3120870 i
FIGURE NO. TITLE PAGE NO.
TABLE OF CONTENTS
SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-1 AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW BAR . . . . . . . . . . . . . . . 1-2
1-2 AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR
(S/N 49971 TO PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-3 AXLE AND STEERING INSTALLATION - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-4 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1-5 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1-6 DRIVE HUB ASSEMBLY (PRIOR TO S/N 39594). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1-7 DRIVE HUB ASSEMBLY (S/N 39594 TO PRESENT). . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1-8 DRIVE MOTOR ASSEMBLY - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1-9 DRIVE MOTOR ASSEMBLY - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
1-10 DRIVE VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
1-11 TOW BAR INSTALLATION - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
1-12 SEMI-TRACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2-1 CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 MAIN CONTROL VALVE ASSEMBLY - PROPORTIONAL . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3 TURNTABLE AND SWING DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-4 SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-5 SWING BEARING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-6 DEUTZ ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-7 GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) . . . . . . . . . . . . . . . . . 2-22
2-8 PISTON PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2-9 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2-10 GROUND CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2-11 ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) . . . . . . . . . . . . . . . 2-36
2-12 HOODS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3-1 TOWER/MID BOOMS AND CYLINDERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 MAIN BOOM AND CYLINDERS INSTALLATION - 450A . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-3 MAIN BOOM AND CYLINDERS INSTALLATION - 450AJ . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-4 MAIN BOOM ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-5 BOOM COVERS, CABLES AND CLAMPS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 3-18
SECTION 4 - PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4-1 PLATFORM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-3 CONTROLLER ASSEMBLY (LIFT & SWING) (PRIOR TO S/N39857) . . . . . . . . . . . . . . 4-12
4-4 CONTROLLER ASSEMBLY (LIFT & SWING) (S/N39857 TO PRESENT) . . . . . . . . . . . . 4-14
4-5 CONTROLLER ASSEMBLY (DRIVE & STEER) (PRIOR TO S/N39857) . . . . . . . . . . . . . 4-18
4-6 CONTROLLER ASSEMBLY (DRIVE & STEER) (S/N39857 TO PRESENT) . . . . . . . . . . . 4-22
4-7 CONTROLLER ASSEMBLY (SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4-8 SOFT TOUCH SYSTEM INSTALLATION (S/N 49601 TO PRESENT) . . . . . . . . . . . . . . . 4-28
SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5-1 AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 PLATFORM LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-3 LIFT CYLINDER ASSEMBLY - JIB (450AJ ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
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TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
5-4 LIFT CYLINDER ASSEMBLY - MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-5 LIFT CYLINDER ASSEMBLY - MID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-6 LIFT CYLINDER ASSEMBLY - TOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-7 ROTATOR CYLINDER ASSEMBLY - PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-8 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5-9 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-1 AXLE LOCKOUT HYDRAULIC DIAGRAM - 2WD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-2 TOW BAR HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-3 AXLE LOCKOUT HYDRAULIC DIAGRAM - 4WD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-4 DRIVE HYDRAULIC DIAGRAM - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-5 DRIVE HYDRAULIC DIAGRAM - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6-6 STANDARD HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-7 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-2 ELECTRICAL SCHEMATIC - DEUTZ ENGINE MACHINES . . . . . . . . . . . . . . . . . . . . . . 7-4
7-3 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
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SECTION 1 FRAME
TABLE OF CONTENTS
FIGURE DESCRIPTION PAGE
1-1 AXLE AND STEERING INSTALLATION - 2WD WITH OUT TOW BAR . . . . . . . . . . . . . . . . . . . 1-2
1-2 AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR (S/N 49971 TO PRESENT) . 1-6
1-3 AXLE AND STEERING INSTALLATION - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-4 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1-5 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1-6 DRIVE HUB ASSEMBLY (PRIOR TO S/N 39594) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1-7 DRIVE HUB ASSEMBLY (S/N 39594 to PRESENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1-8 DRIVE MOTOR ASSEMBLY - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1-9 DRIVE MOTOR ASSEMBLY - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
1-10 DRIVE VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
1-11 TOW BAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
1-12 SEMI-TRACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
1-2 3120870
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FIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW BAR
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SECTION 1 FRAME
.
FIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW BAR
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
0258026 FIXED AXLE INSTALLATION Ref. C
1 0100011 Loctite #242 (Not Shown) A/R
2 0362763 Bar, Stop 4
3 0362764 Bar, Stop 2
4 0641606 Bolt 3/8”-16NC x 3/4” 6
5 0641626 Bolt 3/8”-16NC x 3 1/4” 2
6 0642012 Bolt 5/8”-11NC x 1 1/2” 1
7 0961950 Bushing, Garmax 2
8 Pin, Axle Pivot Options: 1
Use 3422592 Prior to S/N 56275 (Was p/n 3422431)
3422592 S/N 56275 to Present
9 3570901 Plate, Stop 2
10 3841258 Keeper, Pin 1
11 4060951 Shield, Frame 1
12 4070972 Shim 3/16” A/R
13 4070973 Shim 1/8” A/R
14 4070974 Shim 1/16” A/R
15 4740158 Thrustwasher 1
16 4751600 Flatwasher 3/8” 8
17 Not Used
18 4845643 Axle Weldment 1
18A 0561300 Steer Cylinder Mounting Block Assembly 2
0258024 OSCILLATING AXLE INSTALLATION Ref. G
101 0100011 Loctite #242 (Not Shown) A/R
102 0641414 Bolt 1/4”-20NC x 1 3/4” 4
103 0641606 Bolt 3/8”-16NC x 3/4” 6
104 0641812 Bolt 1/2”-13NC x 1 1/2” 2
105 0642012 Bolt 5/8”-11NC x 1 1/2” 1
106 0682248 Bolt 3/4”-10NC x 6” 2
107 0961950 Bushing, Garmax 2
108 1100107 Cam, Lockout 1
109 Lockout Cylinder Assembly Options (See Section 5 for Break-
down):
2
1683575 Prior to S/N 63921
1684139 S/N 63921 to Present
110 3272201 Nut 3/4”-10NC 2
111 3322201 Nut 3/4”-16NF 2
112 Pin, Axle Pivot Options: 1
Use 3422592 Prior to S/N 56275 (Was p/n 3422431)
3422592 S/N 56275 to Present
113 3841258 Keeper, Pin 1
114 3841367 Rod-End with Grease Fitting 2
7020180 Grease Fitting 1
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115 Hardware Options: 2
3900109 Screw, Shoulder (Prior to S/N 63921)
3422936 Pin (S/N 63921 to Present)
116 4060951 Shield, Frame 1
117 4567462 Tube, Mounting 2
118 4640871 Lockout Valve Assembly 1
7012693 Seal Kit - 4640871 Valve 1
7002840 Anit-Rotation Pin Removal Tool 1
119 4711400 Flatwasher 1/4” Narrow 4
120 4740158 Thrustwasher 1
121 4751800 Flatwasher 1/2” 4
122 4751600 Flatwasher 3/8” 6
123 4845643 Axle Weldment 1
123A 0561300 Steer Cylinder Mounting Block Assembly 2
124 4892200 Flatwasher 3/4” 4
125 Not Used
126 0100019 Loctite #271 (Not Shown) A/R
127 0641607 Bolt 3/8”-16NC x 7/8” (S/N 63921 to Present) 2
128 3841520 Keeper 3/8” (S/N 63921 to Present) 2
0258022 STEERING INSTALLATION Ref. B
201 0100011 Loctite #242 (Not Shown) A/R
202 0440162 Thrustwasher 2
203 0641606 Bolt 3/8”-16NC x 3/4” 4
204 0681828 Bolt 1/2”-13NC x 3 1/2” 4
205 1683614 Steer Cylinder Assembly (See Section 5 for Breakdown) 1
206 2780230 Hub/Spindle Assembly (See 301 to 313 for Breakdown) 2
207 3312008 Nut 5/8”-11NC 4
208 3322201 Nut 3/4”-16NF 2
209 3323003 Nut 1 1/4”-12NF 2
210 3422692 Kingpin 2
211 3450812 Pin, Cotter 1/4” x 3” 2
212 3841367 Rod-End with Grease Fitting 2
7020180 Grease Fitting 1
213 3841377 Tie-Rod 2
214 3900109 Screw, Shoulder 4
215 4060950 Shield, Frame 1
216 4713000 Flatwasher 1 1/4” 2
217 4751800 Flatwasher 1/2” 4
218 4740086 Washer, Thrust 2
FIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW BAR (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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This parts manual is a comprehensive guide for the JLG Boom Lifts 450A 450AJ ANSI. It provides step-by-step instructions and detailed exploded diagrams for easy and efficient completion of repair and maintenance tasks. The manual covers all parts and is suitable for use by both professional mechanics and DIY enthusiasts.
- SECTION 1: FRAME
- SECTION 2: TURNTABLE
- SECTION 3: BOOM
- SECTION 4: PLATFORMS
- SECTION 5: CYLINDER
- SECTION 6: HYDRAULICS
- SECTION 7: ELECTRICAL
- SECTION 8: DECALS
- SECTION 9: RECOMMENDED SERVICE PARTS STOCK
- SECTION 10: SPECIAL OPTIONS
Instant delivery eliminates shipping costs and waiting time for a physical manual. The manual is compatible with all versions of Windows and Mac, and is available in English. It requires Adobe Reader and Win for viewing and printing.
