3121291 450A Series II/450AJ Series II 3
4 450A Series II/450AJ Series II 3121291
3121291 450A Series II/450AJ Series II 5
TABLE OF CONTENTS
3121291 450A Series II/450AJ Series II 7
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 (NON-FOLDING) INSTALLATION (OPTIONAL) ................................................................................... 42
FIGURE 1-11. TOW BAR (FOLDING) INSTALLATION (OPTIONAL) ............................................................................................ 44
SECTION 2 - TURNTABLE ................................................................................................................................................................ 47
FIGURE 2-1. MAIN CONTROL VALVE AND ALARM INSTALLATIONS ....................................................................................... 48
FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY ...................................................................................................................... 50
FIGURE 2-3. TURNTABLE AND SWING DRIVE INSTALLATIONS .............................................................................................. 52
FIGURE 2-4. SWING MOTOR ASSEMBLY ................................................................................................................................... 54
FIGURE 2-5. SWING BEARING AND ROTATION BOX ASSEMBLY (ORIGINAL EQUIPMENT) ................................................. 56
FIGURE 2-6. SWING BEARING AND ROTATION BOX ASSEMBLY (SERVICE REPLACEMENT) ............................................. 58
FIGURE 2-7. CATERPILLAR ENGINE INSTALLATION (USA BUILT MACHINES) ....................................................................... 60
FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (ROMANIAN BUILT MACHINES) ........................................................... 68
FIGURE 2-9. DEUTZ D2011 ENGINE INSTALLATION (USA BUILT MACHINES) ........................................................................ 76
FIGURE 2-10. DEUTZ D2011 ENGINE INSTALLATION (ROMANIAN BUILT MACHINES) .......................................................... 84
FIGURE 2-11. DEUTZ TD2.9L4 ENGINE INSTALLATION (USA BUILT MACHINES) ................................................................... 90
FIGURE 2-12. GM ENGINE INSTALLATION ............................................................................................................................... 100
FIGURE 2-13. PISTON PUMP ASSEMBLY ................................................................................................................................. 106
FIGURE 2-14. GEAR PUMP ASSEMBLY .................................................................................................................................... 110
FIGURE 2-15. AUXILIARY PUMP ASSEMBLY ............................................................................................................................ 112
FIGURE 2-16. TANK INSTALLATIONS ........................................................................................................................................ 114
FIGURE 2-17. LP TANK INSTALLATION (GM ENGINE MACHINES ONLY) .............................................................................. 118
FIGURE 2-18. GROUND CONTROL BOX ASSEMBLY (FIBERGLASS BOX) ............................................................................ 120
FIGURE 2-19. GROUND CONTROL BOX ASSEMBLY (STEEL BOX) ........................................................................................ 124
FIGURE 2-20. LIGHT INSTALLATIONS ....................................................................................................................................... 130
FIGURE 2-21. HOODS INSTALLATION ...................................................................................................................................... 134
FIGURE 2-22. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) ............................................ 140
FIGURE 2-23. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) ........................................................ 144
FIGURE 2-24. 2500W GENERATOR INSTALLATION - DEUTZ TD2.9L4 MACHINES (ANSI, CSA AND JAPANESE SPECS)
(OPTIONAL) ................................................................................................................................................................................. 148
FIGURE 2-25. 2500W GENERATOR INSTALLATION - GM MACHINES (ANSI, ANSI EXPORT AND CSA SPECS) (OPTIONAL)
...................................................................................................................................................................................................... 152
FIGURE 2-26. 4000W GENERATOR INSTALLATION - DEUTZ D2011 ENGINES ..................................................................... 156
FIGURE 2-27. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES ........................................................ 160
FIGURE 2-28. 4000W/60HZ GENERATOR INSTALLATION - GM ENGINES ............................................................................. 164
FIGURE 2-29. 7500W/60HZ GENERATOR INSTALLATION - CATERPILLAR ENGINE MACHINES (USA BUILT MACHINES) 168
FIGURE 2-30. 7500W GENERATOR INSTALLATION - CATERPILLAR ENGINE MACHINES (ROMANIAN BUILT MACHINES)
...................................................................................................................................................................................................... 172
FIGURE 2-31. 7500W GENERATOR INSTALLATION - DEUTZ D2011 ENGINES (USA BUILT MACHINES) ........................... 178
FIGURE 2-32. 7500W GENERATOR INSTALLATION - DEUTZ D2011 ENGINES (ROMANIAN BUILT MACHINES) ............... 184
FIGURE 2-33. 7500W GENERATOR INSTALLATION - DEUTZ D2.9L4 ENGINE ...................................................................... 190
FIGURE 2-34. 7500W GENERATOR INSTALLATION - GM ENGINE MACHINES ..................................................................... 194
SECTION 3 - BOOM ........................................................................................................................................................................ 199
FIGURE 3-1. TOWER/MID BOOMS AND CYLINDERS INSTALLATION (USA BUILT MACHINES) ........................................... 200
FIGURE 3-2. TOWER/MID BOOMS AND CYLINDERS INSTALLATION (ROMANIAN BUILT MACHINES) ............................... 204
FIGURE 3-3. MAIN BOOM INSTALLATION - 450A SERIES II .................................................................................................... 208
FIGURE 3-4. MAIN BOOM INSTALLATION - 450AJ SERIES II (USA BUILT MACHINES) ......................................................... 212
FIGURE 3-5. MAIN BOOM INSTALLATION - 450AJ SERIES II (ROMANIAN BUILT MACHINES) ............................................. 216
FIGURE 3-6. MAIN BOOM ASSEMBLIES ................................................................................................................................... 220
FIGURE 3-7. ROTATOR ASSEMBLIES ....................................................................................................................................... 224
FIGURE 3-8. PLATFORM SUPPORT AND CONTROL VALVES INSTALLATIONS.................................................................... 228
FIGURE 3-9. PLATFORM SUPPORT INSTALLATION - WITH LSS ............................................................................................ 232
TABLE OF CONTENTS
8 450A Series II/450AJ Series II 3121291
SECTION 4 - PLATFORM ................................................................................................................................................................ 235
FIGURE 4-1. PLATFORM INSTALLATION ................................................................................................................................... 236
FIGURE 4-2. FALL ARREST PLATFORM COMPONENTS INSTALLATION (OPTIONAL) .......................................................... 240
FIGURE 4-3. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) .......................................................................................... 242
FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY ...................................................................................................................... 244
FIGURE 4-5. CONTROLLER ASSEMBLY (LIFT AND SWING) (ORIGINAL EQUIPMENT) ......................................................... 250
FIGURE 4-6. CONTROLLER ASSEMBLY (LIFT AND SWING) (SERVICE REPLACEMENT) ..................................................... 252
FIGURE 4-7. CONTROLLER ASSEMBLY (DRIVE AND STEER) (ORIGINAL EQUIPMENT) ..................................................... 256
FIGURE 4-8. CONTROLLER ASSEMBLY (DRIVE AND STEER) (SERVICE REPLACEMENT) ................................................. 258
FIGURE 4-9. SKYGUARD SYSTEM INSTALLATION .................................................................................................................. 260
FIGURE 4-10. CROSS RAIL INSTALLATION .............................................................................................................................. 262
FIGURE 4-11. SKYGLAZIER INSTALLATION - WITHOUT LSS (ANSI, CSA AND AUSTRALIAN SPECS) ................................ 264
FIGURE 4-12. SKYGLAZIER INSTALLATION - WITH LSS (AUSTRALIAN SPECS) ................................................................... 266
FIGURE 4-13. SKYWELDER INSTALLATION (50HZ).................................................................................................................. 268
FIGURE 4-14. SKYWELDER INSTALLATION (60HZ).................................................................................................................. 270
FIGURE 4-15. WELDER ASSEMBLY ........................................................................................................................................... 272
FIGURE 4-16. SKYCUTTER INSTALLATION .............................................................................................................................. 274
FIGURE 4-17. PLASMA CUTTER ASSEMBLY ............................................................................................................................ 276
SECTION 5 - CYLINDER.................................................................................................................................................................. 279
FIGURE 5-1. USA BUILT MACHINES/AXLE LOCKOUT CYLINDER ........................................................................................... 280
FIGURE 5-2. USA BUILT MACHINES/LEVEL (PLATFORM SLAVE) CYLINDER (450A SERIES II) ........................................... 282
FIGURE 5-3. USA BUILT MACHINES/LEVEL (PLATFORM SLAVE) CYLINDER (450AJ SERIES II WITHOUT ARCTIC
PACKAGE) .................................................................................................................................................................................... 284
FIGURE 5-4. USA BUILT MACHINES/ LEVEL (PLATFORM SLAVE) CYLINDER (450AJ SERIES II WITH ARCTIC PACKAGE)
...................................................................................................................................................................................................... 286
FIGURE 5-5. USA BUILT MACHINES/LIFT (JIB) CYLINDER (450AJ SERIES II WITHOUT ARCTIC PACKAGE) ..................... 288
FIGURE 5-6. USA BUILT MACHINES/LIFT (JIB) CYLINDER (450AJ SERIES II WITH ARCTIC PACKAGE) ............................. 290
FIGURE 5-7. USA BUILT MACHINES/LIFT (MAIN BOOM) CYLINDER....................................................................................... 292
FIGURE 5-8. USA BUILT MACHINES/LIFT (TOWER BOOM) CYLINDER .................................................................................. 294
FIGURE 5-9. USA BUILT MACHINES/MASTER CYLINDER (450A SERIES II) .......................................................................... 296
FIGURE 5-10. USA BUILT MACHINES/MASTER CYLINDER (450AJ SERIES II WITHOUT ARCTIC PACKAGE) .................... 298
FIGURE 5-11. USA BUILT MACHINES/MASTER CYLINDER (450AJ SERIES II WITH ARCTIC PACKAGE) ............................ 300
FIGURE 5-12. USA BUILT MACHINES/STEER CYLINDER ........................................................................................................ 302
FIGURE 5-13. USA BUILT MACHINES/TELESCOPE CYLINDER (SN 0300160835 through 0300175028)................................ 304
FIGURE 5-14. USA BUILT MACHINES/TELESCOPE CYLINDER (SN 0300175029 through 0300201990)................................ 306
FIGURE 5-15. ROMANIAN BUILT MACHINES/AXLE LOCKOUT CYLINDER ............................................................................. 308
FIGURE 5-16. ROMANIAN BUILT MACHINES/LEVEL (PLATFORM SLAVE) CYLINDER .......................................................... 310
FIGURE 5-17. ROMANIAN BUILT MACHINES/LIFT (JIB) CYLINDER ........................................................................................ 312
FIGURE 5-18. ROMANIAN BUILT MACHINES/LIFT (MAIN BOOM) CYLINDER ......................................................................... 314
FIGURE 5-19. ROMANIAN BUILT MACHINES/LIFT (TOWER BOOM) CYLINDER .................................................................... 316
FIGURE 5-20. ROMANIAN BUILT MACHINES/MASTER CYLINDER ......................................................................................... 318
FIGURE 5-21. ROMANIAN BUILT MACHINES/STEER CYLINDER ............................................................................................ 320
FIGURE 5-22. ROMANIAN BUILT MACHINES/TELESCOPE CYLINDER ................................................................................... 322
SECTION 6 - HYDRAULIC ............................................................................................................................................................... 325
FIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM - 2WD................................................................................................... 326
FIGURE 6-2. AXLE LOCKOUT HYDRAULIC DIAGRAM - 4WD................................................................................................... 328
FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 2WD ................................................................................................................... 330
FIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD ................................................................................................................... 332
FIGURE 6-5. STANDARD HYDRAULIC DIAGRAM...................................................................................................................... 336
FIGURE 6-6. HYDRAULIC DIAGRAM LIST.................................................................................................................................. 340
SECTION 7 - ELECTRICAL.............................................................................................................................................................. 343
FIGURE 7-1. ELECTRICAL DIAGRAM LIST ................................................................................................................................ 344
FIGURE 7-2. HARNESS COMPONENTS INSTALLATION .......................................................................................................... 346
SECTION 8 - DECALS ..................................................................................................................................................................... 367
FIGURE 8-1. DECAL INSTALLATION - ANSI SPEC .................................................................................................................... 368
FIGURE 8-2. DECAL INSTALLATION - ANSI EXPORT SPECS .................................................................................................. 372
FIGURE 8-3. DECALS INSTALLATION - AUSTRALIAN AND CE SPECS................................................................................... 376
TABLE OF CONTENTS
3121291 450A Series II/450AJ Series II 9
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK ........................................................................................................... 379
FIGURE 9-1. MODEL 450A / 450AJ SERIES II STANDARD PARTS .......................................................................................... 380
FIGURE 9-2. MODEL 450A / 450AJ SERIES II VARIABLE PARTS ............................................................................................ 382
SECTION 10 - SPECIAL OPTIONS ................................................................................................................................................. 383
FIGURE 10-1. SPECIAL OPTIONS .............................................................................................................................................. 384
PART NUMBER INDEX ................................................................................................................................................................... 391
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JLG Boom Lifts 450A & 450AJ Series II Global Illustrated Master Parts List Manual ! (USA BUILT MACHINES S/N 0300
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This is a comprehensive parts manual for the JLG Boom Lifts 450A & 450AJ Series II Global. It provides easy access to detailed instructions, exploded diagrams, and images, making it suitable for both professional mechanics and DIY enthusiasts.
The manual covers the following sections:
- FRAME
- TURNTABLE
- BOOM
- PLATFORMS
- CYLINDER
- HYDRAULICS
- ELECTRICAL
- DECALS
- RECOMMENDED SERVICE PARTS STOCK
- SPECIAL OPTIONS
- PART NUMBER INDEX
Instant delivery eliminates shipping costs and waiting time. The manual is compatible with all Windows and Mac operating systems and can be viewed on a PC or laptop. It is available in English and requires Adobe Reader and Win to access. Upon payment completion, you will receive the manual instantly, and all pages are printable for convenience.
