JLG Boom Lift 450A 450AJ Parts Catalog 3122318600

Hyundai · Jun 21, 2026

JLG Boom Lift 450A 450AJ Parts Catalog 3122318600
Size: 84.26 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Catalog
Model: JLG 450A, 450AJ Boom Lift
Part Number: 3122318600
Publication Date: 2025
Number of Pages: 1006 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. AXLE INSTALLATION (MACHINES WITH SN STARTING WITH 03)

FIGURE 1-2. AXLE INSTALLATION (MACHINES WITH SN STARTING WITH B3)

FIGURE 1-3. STEER INSTALLATION WITHOUT TOW PACKAGE

FIGURE 1-4. STEER INSTALLATION WITH TOW PACKAGE

FIGURE 1-5. WHEEL DRIVE INSTALLATION (2WD)

FIGURE 1-6. WHEEL DRIVE INSTALLATION (4WD) (DANFOSS MOTOR)

FIGURE 1-7. WHEEL DRIVE INSTALLATION (4WD) (HENGLI MOTOR)

FIGURE 1-8. HUB - SPINDLE ASSEMBLY

FIGURE 1-9. DRIVE HUB AND BRAKE ASSEMBLY - REAR

FIGURE 1-10. DRIVE HUB ASSEMBLY - FRONT

FIGURE 1-11. DRIVE MOTOR ASSEMBLY (2WD)

FIGURE 1-12. DRIVE MOTOR ASSEMBLY (4WD) (DANFOSS MOTOR)

FIGURE 1-13. DRIVE MOTOR ASSEMBLY (4WD) (HENGLI MOTOR)

FIGURE 1-14. FRAME SHIELD INSTALLATION

FIGURE 1-15. TIRE AND WHEEL INSTALLATION - 12 X 16.5 FOAM FILLED (AVAILABLE ON ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)

FIGURE 1-16. TIRE AND WHEEL INSTALLATION - 12 X 16.5 FOAM FILLED NON MARKING (AVAILABLE ON ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)

FIGURE 1-17. TIRE AND WHEEL INSTALLATION - 33 X 12-20 SOLID NON-MARKING (AVAILABLE ON ANSI EXPORT, AUSTRALIAN, CE AND RUSSIA SPECS)

FIGURE 1-18. TIRE AND WHEEL INSTALLATION - 33 X 16L500 TURF AND SAND FOAM-FILLED (AVAILABLE ON ANSI, ANSI EXPORT & CSA SPECS)

FIGURE 1-19. TIRE AND WHEEL INSTALLATION - 33/1550 X 16.5 FOAM-FILLED (AVAILABLE ON ALL SPECS)

FIGURE 1-20. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED (AVAILABLE ON ANSI EXPORT, AUSTRALIAN, CE, CHINA AND RUSSIA SPECS)

FIGURE 1-21. TIRE AND WHEEL INSTALLATION - 315/55 D20 FOAM FILLED NON-MARKING (AVAILABLE ON ANSI EXPORT, AUSTRALIAN, CE, CHINA AND RUSSIA SPECS)

FIGURE 1-22. TIRE AND WHEEL INSTALLATION - 33 X 12 FOAM FILLED (ALL SPECS)

FIGURE 1-23. 2WD VALVES INSTALLATION - FRAME MOUNTED (450A)

FIGURE 1-24. 2WD VALVES INSTALLATION - FRAME MOUNTED (450AJ)

FIGURE 1-25. 4WD VALVES INSTALLATION - FRAME MOUNTED (450A)

FIGURE 1-26. 4WD VALVES INSTALLATION - FRAME MOUNTED (MACHINES WITH SN STARTING WITH 03) (450AJ)

FIGURE 1-27. 4WD VALVES INSTALLATION - FRAME MOUNTED (MACHINES WITH SN STARTING WITH B3) (450AJ)

FIGURE 1-28. TRACTION VALVE ASSEMBLY - 2WD

FIGURE 1-29. TRACTION VALVE ASSEMBLY - 4WD

FIGURE 1-30. TOW PACKAGE INSTALLATION (OPTIONAL)

FIGURE 1-31. TOW BAR ASSEMBLY

SECTION 2 - TURNTABLE

FIGURE 2-1. 2WD VALVES INSTALLATION - TURNTABLE MOUNTED (450A)

FIGURE 2-2. 2WD VALVES INSTALLATION - TURNTABLE MOUNTED (450AJ)

FIGURE 2-3. 4WD VALVES INSTALLATION - TURNTABLE MOUNTED (450A)

FIGURE 2-4. 4WD VALVES INSTALLATION - TURNTABLE MOUNTED (MACHINES WITH SN STARTING WITH 03) (450AJ)

FIGURE 2-5. 4WD VALVES INSTALLATION - TURNTABLE MOUNTED (MACHINES WITH SN STARTING WITH B3) (450AJ)

FIGURE 2-6. MAIN VALVE ASSEMBLY

FIGURE 2-7. AUXILIARY PUMP ASSEMBLY (MACHINES WITH SN STARTING WITH 03)

FIGURE 2-8. AUXILIARY PUMP ASSEMBLY (MACHINES WITH SN STARTING WITH B3)

FIGURE 2-9. SWING DRIVE AND TURNTABLE BEARING INSTALLATION (MACHINES WITH SN STARTING WITH 03)

FIGURE 2-10. SWING DRIVE AND TURNTABLE BEARING INSTALLATION (MACHINES WITH SN STARTING WITH B3)

FIGURE 2-11. SWING MOTOR ASSEMBLY (MACHINES WITH SN STARTING WITH 03)

FIGURE 2-12. SWING MOTOR ASSEMBLY (MACHINES WITH SN STARTING WITH B3)

FIGURE 2-13. TURNTABLE BEARING ASSEMBLY (MACHINES WITH SN STARTING WITH 03)

FIGURE 2-14. TURNTABLE BEARING ASSEMBLY (MACHINES WITH SN STARTING WITH B3)

FIGURE 2-15. TURNTABLE COVERS INSTALLATION

FIGURE 2-16. TURNTABLE LOCK INSTALLATION

FIGURE 2-17. TANKS INSTALLATION - DIESEL MACHINES (17 GAL HYDRAULIC TANK WITH 4 INCH BREATHER)

FIGURE 2-18. TANKS INSTALLATION - DIESEL MACHINES (17 GAL HYDRAULIC TANK WITH 6 INCH BREATHER)

FIGURE 2-19. TANKS INSTALLATION - GAS MACHINES

FIGURE 2-20. HYDRAULIC TANK ASSEMBLY - 17 GAL WITH 4 INCH BREATHER (DIESEL MACHINES)

FIGURE 2-21. DRIVE ORIENTATION INSTALLATION

FIGURE 2-22. GROUND CONTROL ASSEMBLY - (ANSI SPECS) (450A)

FIGURE 2-23. GROUND CONTROL ASSEMBLY - (ALL SPECS EXCEPT CE, RUSSIAN & UK CA SPECS) (450AJ)

FIGURE 2-24. GROUND CONTROL ASSEMBLY - (CE, RUSSIA & UK CA SPECS) (450AJ)

FIGURE 2-25. GROUND CONTROL ASSEMBLY - (DEUTZ STAGE V) (CE & UK CA SPECS) (450AJ)

FIGURE 2-26. LIGHT PANEL INSTALLATION – GROUND CONTROLS

FIGURE 2-27. ELECTRICAL SYSTEM INSTALLATION

FIGURE 2-28. WHITE NOISE ALARM AMBIENT INSTALLATION

FIGURE 2-29. WHITE NOISE ALARM INSTALLATION

FIGURE 2-30. BEACON LIGHT INSTALLATION - AMBER (WITHOUT CLEARSKY BEACON)

FIGURE 2-31. BEACON LIGHT INSTALLATION - ORANGE (WITHOUT CLEARSKY BEACON)

FIGURE 2-32. BATTERY AND CABLE INSTALLATION

FIGURE 2-33. HOODS INSTALLATION (ABS) - WITH DEUTZ ENGINES (450A)

FIGURE 2-34. HOODS INSTALLATION (ABS) - WITH KUBOTA ENGINE (450A)

FIGURE 2-35. HOODS INSTALLATION (ABS) - WITH DEUTZ ENGINES (ALL MACHINES WITH SN STARTING WITH 03) (MACHINES WITH SN STARTING WITH B3, JAPANESE & RUSSIA SPECS) (450AJ)

FIGURE 2-36. HOODS INSTALLATION (ABS) - WITH DEUTZ ENGINE (MACHINES WITH SN STARTING WITH B3, ALL SPECS EXCEPT JAPANESE & RUSSIA SPECS) (450AJ)

FIGURE 2-37. HOODS INSTALLATION (STEEL) - WITH DEUTZ ENGINES (MACHINES WITH SN STARTING WITH B3) (450AJ)

FIGURE 2-38. HOODS INSTALLATION (ABS) - WITH KUBOTA ENGINE (450AJ)

FIGURE 2-39. HOOD ASSEMBLY (ABS) - TANK SIDE (MACHINES WITH SN STARTING WITH 03)

FIGURE 2-40. HOOD ASSEMBLY (ABS) - TANK SIDE (MACHINES WITH SN STARTING WITH B3)

FIGURE 2-41. HOOD ASSEMBLY (STEEL) - ENGINE SIDE (MACHINES WITH SN STARTING WITH B3)

FIGURE 2-42. HOOD ASSEMBLY (ABS) - ENGINE SIDE (MACHINES WITH SN STARTING WITH 03)

FIGURE 2-43. HOOD ASSEMBLY (ABS) - ENGINE SIDE (MACHINES WITH SN STARTING WITH B3)

FIGURE 2-44. HOOD ASSEMBLY (STEEL) - TANK SIDE (MACHINES WITH SN STARTING WITH B3)

SECTION 3 - ENGINE

FIGURE 3-1. ENGINE INSTALLATION - DEUTZ D2.9L4 ERM5 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)

FIGURE 3-2. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ERM5 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT AND CSA SPECS)

FIGURE 3-3. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (WITHOUT ARCTIC PACKAGE) (WITH PMP PUMP)

FIGURE 3-4. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ENGINE (WITHOUT ARCTIC PACKAGE) (WITH PMP PUMP)

FIGURE 3-5. ENGINE ASSEMBLY - DEUTZ D2.9L4 ERM4 ENGINE (WITHOUT ARCTIC PACKAGE)

FIGURE 3-6. ENGINE ASSEMBLY - DEUTZ D2.9L4 ERM5 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT AND CSA SPECS) (Prior to SN 0300321377, Prior to SN B300027330)

FIGURE 3-7. ENGINE ASSEMBLY - DEUTZ D2.9L4 ERM5 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT AND CSA SPECS) (SN 0300321378 to Present, SN B300027331 to Present, SN 0300295214 through 0300295216, Including 0300311793, B300027237 and B300027239)

FIGURE 3-8. ENGINE ASSEMBLY - DEUTZ D2.9L4 ERM5 ENGINE (WITH ARCTIC PACKAGE) (ANSI AND CSA SPECS) (Prior to SN 0300321377, Prior to SN B300027330)

FIGURE 3-9. ENGINE ASSEMBLY - DEUTZ D2.9L4 ERM5 ENGINE (WITH ARCTIC PACKAGE) (ANSI AND CSA SPECS) (SN 0300321378 to Present, SN B300027331 to Present, SN 0300295214 through 0300295216, Including 0300311793, B300027237 and B300027239)

FIGURE 3-10. ENGINE INSTALLATION - DEUTZ D2.9L4 ERM5 ENGINE (WITH ARCTIC PACKAGE) (ANSI AND CSA SPECS)

FIGURE 3-11. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (WITH ARCTIC PACKAGE) (WITH PMP PUMP)

FIGURE 3-12. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ENGINE (WITH ARCTIC PACKAGE) (WITH PMP PUMP)

FIGURE 3-13. ENGINE ASSEMBLY - DEUTZ D2.9L4 ERM4 ENGINE (WITH ARCTIC PACKAGE)

FIGURE 3-14. DEUTZ D2.9L4 - EMR4 (49HP) ENGINE COMPONENTS

FIGURE 3-15. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ERM5 ENGINE (WITH ARCTIC PACKAGE) (ANSI AND CSA SPECS)

FIGURE 3-16. ENGINE COMPONENTS - DEUTZ D2.9L4 ERM5 ENGINE (ANSI, ANSI EXPORT AND CSA SPECS)

FIGURE 3-17. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)

FIGURE 3-18. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)

FIGURE 3-19. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (STAGE V) (WITH PMP PUMP)

FIGURE 3-20. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 ENGINE (STAGE V)

FIGURE 3-21. ENGINE ASSEMBLY - DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS) (Prior to SN 0300321377, Prior to SN B300027330)

FIGURE 3-22. ENGINE ASSEMBLY - DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS) (SN 0300321378 to Present, SN B300027331 to Present, SN 0300295214 through 0300295216, Including 0300311793, B300027237 and B300027239)

FIGURE 3-23. ENGINE COMPONENTS - DEUTZ D2.9L4 ENGINE (STAGE V) (CE & UK CA SPECS)

FIGURE 3-24. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 ENGINE)

FIGURE 3-25. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 ENGINE) (STAGE V)

FIGURE 3-26. BREATHER HEATER INSTALLATION - DEUTZ D2.9L4 ENGINE WITH ARCTIC PACKAGE

FIGURE 3-27. ENGINE MOUNT INSTALLATION - DEUTZ D2.9L4 WITHOUT GENERATOR

FIGURE 3-28. ENGINE MOUNT INSTALLATION - DEUTZ D2.9L4 WITH GENERATOR

FIGURE 3-29. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (CHINA IV)

FIGURE 3-30. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ENGINE (CHINA IV)

FIGURE 3-31. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (CHINA IV) (WITH PMP PUMP)

FIGURE 3-32. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ENGINE (CHINA IV)

FIGURE 3-33. ENGINE ASSEMBLY - DEUTZ D2.9L4 ENGINE (CHINA IV) (Prior to SN 0300321377, Prior to SN B300027330)

FIGURE 3-34. ENGINE ASSEMBLY - DEUTZ D2.9L4 ENGINE (CHINA IV) (SN 0300321378 to Present, SN B300027331 to Present, SN 0300295214 through 0300295216, Including 0300311793, B300027237 and B300027239)

FIGURE 3-35. ENGINE COMPONENTS - DEUTZ D2.9L4 (CHINA IV)

FIGURE 3-36. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 CHINA IV ENGINE)

FIGURE 3-37. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CHINA, RUSSIA & UK CA SPECS)

FIGURE 3-38. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CHINA, RUSSIA & UK CA SPECS)

FIGURE 3-39. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI EXPORT, AUSTRALIAN, CE (LRC), CHINA, RUSSIA & UK CA SPECS)

FIGURE 3-40. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (WITH PMP PUMP)

FIGURE 3-41. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (WITH PMP PUMP)

FIGURE 3-42. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITH 17GAL HYDRAULIC TANK & ARCTIC PACKAGE) (ANSI EXPORT, CHINA & RUSSIA SPECS)

FIGURE 3-43. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITH 36GAL HYDRAULIC TANK & ARCTIC PACKAGE) (ANSI EXPORT & RUSSIA SPECS)

FIGURE 3-44. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (WITH ARCTIC PACKAGE) (ANSI EXPORT, CHINA, RUSSIA & UK CA SPECS)

FIGURE 3-45. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITH ARCTIC PACKAGE) (WITH PMP PUMP)

FIGURE 3-46. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 ENGINE (WITH ARCTIC PACKAGE) (WITH PMP PUMP)

FIGURE 3-47. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (WITH ARCTIC PACKAGE) (ANSI EXPORT, CHINA, RUSSIA & UK CA SPECS)

FIGURE 3-48. ENGINE COMPONENTS - DEUTZ D2011

FIGURE 3-49. PUMP COUPLING KIT - DEUTZ ENGINES

FIGURE 3-50. ENGINE INSTALLATION - KUBOTA ENGINE (WITHOUT ARCTIC PACKAGE)

FIGURE 3-51. ENGINE AND PUMP SUB-ASSEMBLY - KUBOTA ENGINE (WITHOUT ARCTIC PACKAGE)

FIGURE 3-52. ENGINE ASSEMBLY - KUBOTA ENGINE (WITHOUT ARCTIC PACKAGE)

FIGURE 3-53. ENGINE INSTALLATION - KUBOTA ENGINE (WITH ARCTIC PACKAGE)

FIGURE 3-54. ENGINE AND PUMP SUB-ASSEMBLY - KUBOTA ENGINE (WITH ARCTIC PACKAGE)

FIGURE 3-55. ENGINE ASSEMBLY - KUBOTA ENGINE (WITH ARCTIC PACKAGE)

FIGURE 3-56. ENGINE COMPONENTS - KUBOTA

FIGURE 3-57. PUMP COUPLING KIT - KUBOTA ENGINE

FIGURE 3-58. PISTON PUMP ASSEMBLY

FIGURE 3-59. CLOSED PUMP LOOP ASSEMEBLY

FIGURE 3-60. SPARK ARRESTOR INSTALLATION - DEUTZ D2011 ENGINE

FIGURE 3-61. ENGINE BAFFLE INSTALLATION - WITH DEUTZ ENGINES

FIGURE 3-62. ENGINE BAFFLE INSTALLATION - WITH KUBOTA ENGINE

FIGURE 3-63. FUEL/WATER SEPARATOR ASSEMBLY (DEUTZ D2.9L4 CHINA IV ENGINE)

FIGURE 3-64. GENERATOR INSTALLATION - 2500W/50HZ (DEUTZ D2011 ENGINE)

FIGURE 3-65. GENERATOR INSTALLATION - 2500W/60HZ (DEUTZ D2011 ENGINE)

FIGURE 3-66. GENERATOR INSTALLATION - 2500W/60HZ (DEUTZ D2.9L4 ENGINE)

FIGURE 3-67. GENERATOR INSTALLATION - 2500W/60HZ (KUBOTA ENGINE)

FIGURE 3-68. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ D2011 ENGINE)

FIGURE 3-69. GENERATOR INSTALLATION - 4000W/60HZ (DEUTZ D2011 ENGINE)

FIGURE 3-70. GENERATOR INSTALLATION - 4000W/60HZ (DEUTZ D2.9L4 ENGINE)

FIGURE 3-71. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ ENGINE) (STAGE V)

FIGURE 3-72. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ D2011 ENGINE)

FIGURE 3-73. GENERATOR INSTALLATION - 7500W/60HZ (DEUTZ D2011 ENGINE)

FIGURE 3-74. GENERATOR INSTALLATION - 7500W/60HZ (DEUTZ D2.9L4 ENGINE)

FIGURE 3-75. GENERATOR INSTALLATION - 7500W/60HZ (KUBOTA ENGINE)

FIGURE 3-76. QUICKFIT OIL DRAIN INSTALLATION (DEUTZ ENGINES)

FIGURE 3-77. QUICKFIT OIL DRAIN INSTALLATION (KUBOTA ENGINES)

SECTION 4 - BOOM

FIGURE 4-1. CYLINDERS INSTALLATION (450A)

FIGURE 4-2. CYLINDERS INSTALLATION – (MACHINES WITH SN STARTING WITH 03) (450AJ)

FIGURE 4-3. CYLINDERS INSTALLATION – (MACHINES WITH SN STARTING WITH B3) (450AJ)

FIGURE 4-4. BOOM INSTALLATION (450A) (Prior to SN 0300319976)

FIGURE 4-5. BOOM INSTALLATION (450A) (SN 0300319977 to Present, SN 0300295214 through 0300295216, Including 0300311793)

FIGURE 4-6. BOOM INSTALLATION (WITH AIRLINE) (450A) (Prior to SN 0300319976)

FIGURE 4-7. BOOM INSTALLATION (WITH AIRLINE) (450A) (SN 0300319977 to Present, SN 0300295214 through 0300295216, Including 0300311793)

FIGURE 4-8. BOOM INSTALLATION (WITH SKYPOWER AND AIRLINE) (450A) (Prior to SN 0300319976)

FIGURE 4-9. BOOM INSTALLATION (WITH SKYPOWER AND AIRLINE) (450A) (SN 0300319977 to Present, SN 0300295214 through 0300295216, Including 0300311793)

FIGURE 4-10. BOOM INSTALLATION (WITH SKYPOWER) (450A) (Prior to SN 0300319976)

FIGURE 4-11. BOOM INSTALLATION (WITH SKYPOWER) (450A) (SN 0300319977 to Present, SN 0300295214 through 0300295216, Including 0300311793)

FIGURE 4-12. BOOM INSTALLATION KIT (450A)

FIGURE 4-13. BOOM INSTALLATION (450AJ)

FIGURE 4-14. BOOM INSTALLATION - (MACHINES WITH SN STARTING WITH B3)

FIGURE 4-15. BOOM INSTALLATION - (MACHINES WITH SN STARTING WITH B3) (CHINEESE SPEC)

FIGURE 4-16. JIB INSTALLATION - (MACHINES WITH SN STARTING WITH 03) (Prior to SN 0300319976)

FIGURE 4-17. JIB INSTALLATION - (MACHINES WITH SN STARTING WITH 03) (SN 0300319977 to Present, SN 0300295214 through 0300295216, Including 0300311793)

FIGURE 4-18. JIB INSTALLATION - (MACHINES WITH SN STARTING WITH B3)

FIGURE 4-19. MAIN BOOM ASSEMBLY (450A)

FIGURE 4-20. MAIN BOOM ASSEMBLY (450AJ)

FIGURE 4-21. MAIN BOOM ASSEMBLY - (MACHINES WITH SN STARTING WITH B3) (CHINEESE SPEC)

FIGURE 4-22. TOWER BOOM ASSEMBLY (450A)

FIGURE 4-23. TOWER BOOM ASSEMBLY (450AJ)

FIGURE 4-24. ROTATOR ASSEMBLY (Prior to SN 0300319976)

FIGURE 4-25. ROTATOR ASSEMBLY (SN 0300319977 to Present, SN 0300295214 through 0300295216, Including 0300311793)

FIGURE 4-26. PLATFORM ROTATE ACTUATOR - (MACHINES WITH SN STARTING WITH B3) (CHINEESE SPEC)

FIGURE 4-27. PLATFORM SUPPORT INSTALLATION

FIGURE 4-28. 2WD VALVES INSTALLATION - BOOM MOUNTED (450A)

FIGURE 4-29. 2WD VALVES INSTALLATION - BOOM MOUNTED (450AJ)

FIGURE 4-30. 4WD VALVES INSTALLATION - BOOM MOUNTED (450A)

FIGURE 4-31. 4WD VALVES INSTALLATION - BOOM MOUNTED (MACHINES WITH SN STARTING WITH 03) (450AJ)

FIGURE 4-32. 4WD VALVES INSTALLATION - BOOM MOUNTED (MACHINES WITH SN STARTING WITH B3) (450AJ)

FIGURE 4-33. UPRIGHT VALVE ASSEMBLY

FIGURE 4-34. BOOM VALVE ASSEMBLY (450A)

FIGURE 4-35. BOOM VALVE ASSEMBLY (450AJ)

SECTION 5 - PLATFORM

FIGURE 5-1. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - SIDE GATE ENTRY

FIGURE 5-2. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - SIDE GATE ENTRY

FIGURE 5-3. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - SIDE GATE ENTRY

FIGURE 5-4. PLATFORM ASSEMBLY - 30IN X 3FT (76CM X .91M) - DROP BAR ENTRY

FIGURE 5-5. PLATFORM ASSEMBLY - 30IN X 4FT (76CM X 1.22M) - WITH DROP BAR

FIGURE 5-6. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) - WITH DROP BAR

FIGURE 5-7. PLATFORM ASSEMBLY - 30IN X 6FT (76CM X 1.83M) - WITH DROP BAR

FIGURE 5-8. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M - FALL ARREST (ANSI, ANSI EXPORT AND CSA SPECS)

FIGURE 5-9. CONSOLE BOX INSTALLATION (450A)

FIGURE 5-10. CONSOLE BOX INSTALLATION (450AJ)

FIGURE 5-11. PLATFORM CONSOLE BOX ASSEMBLY (450A)

FIGURE 5-12. PLATFORM CONSOLE BOX ASSEMBLY (450AJ)

FIGURE 5-13. LIGHT PANEL INSTALLATION – PLATFORM CONSOLE

FIGURE 5-14. FOOTSWITCH ASSEMBLY

FIGURE 5-15. TRAY ASSEMBLY

FIGURE 5-16. SKYEYE INSTALLATION

FIGURE 5-17. SKYGUARD BAR INSTALLATION

FIGURE 5-18. SKYLINE INSTALLATION

FIGURE 5-19. USB CHARGER INSTALLATION

FIGURE 5-20. SKYGLAZIER INSTALLATION

FIGURE 5-21. SKYWELDER INSTALLATION (50HZ)

FIGURE 5-22. SKYWELDER INSTALLATION (60HZ)

FIGURE 5-23. SKYWELDER PREP PACKAGE INSTALLATION

FIGURE 5-24. WELDER ASSEMBLY

FIGURE 5-25. FALL ARREST INSTALLATION (BOLT-ON) (4FT/1.22M PLATFORM)

FIGURE 5-26. FALL ARREST INSTALLATION (BOLT-ON) (5FT/1.52M PLATFORM)

FIGURE 5-27. SOFT-TOUCH INSTALLATION (30X60)

FIGURE 5-28. SOFT-TOUCH INSTALLATION (30X72)

SECTION 6 - CYLINDER

FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH 03)

FIGURE 6-2. AXLE LOCKOUT CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH B3)

FIGURE 6-3. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH 03)

FIGURE 6-4. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH B3) (450AJ)

FIGURE 6-5. LIFT CYLINDER ASSEMBLY - JIB (MACHINES WITH SN STARTING WITH 03) (450AJ)

FIGURE 6-6. LIFT CYLINDER ASSEMBLY - JIB (MACHINES WITH SN STARTING WITH B3) (450AJ)

FIGURE 6-7. LIFT CYLINDER ASSEMBLY - MAIN BOOM (450A)

FIGURE 6-8. LIFT CYLINDER ASSEMBLY - MAIN BOOM (450AJ)

FIGURE 6-9. LIFT CYLINDER ASSEMBLY - TOWER BOOM

FIGURE 6-10. MASTER CYLINDER ASSEMBLY (MACHINES WITH SN STARTING WITH 03)

FIGURE 6-11. MASTER CYLINDER ASSEMBLY - (MACHINES WITH SN STARTING WITH B3) (450AJ)

FIGURE 6-12. STEER CYLINDER ASSEMBLY

FIGURE 6-13. TELESCOPE CYLINDER ASSEMBLY (450A)

FIGURE 6-14. TELESCOPE CYLINDER ASSEMBLY (450AJ)

SECTION 7 - HYDRAULIC

FIGURE 7-1. 2WD HYDRAULIC SYSTEM INSTALLATION -(WITH 17GAL HYDRAULIC TANK) (450A) (Prior to SN 0300322914)

FIGURE 7-2. 2WD HYDRAULIC SYSTEM INSTALLATION - (WITH 17GAL HYDRAULIC TANK) (450A) (SN 0300322915 to Present, Including 0300311793)

FIGURE 7-3. 2WD HYDRAULIC SYSTEM INSTALLATION - (WITH 36GAL HYDRAULIC TANK) (450A) (Prior to SN 0300322914)

FIGURE 7-4. 2WD HYDRAULIC SYSTEM INSTALLATION - (WITH 36GAL HYDRAULIC TANK) (450A) (SN 0300322915 to Present, Including 0300311793)

FIGURE 7-5. 2WD HYDRAULIC SYSTEM INSTALLATION - (WITH 17GAL HYDRAULIC TANK) (450AJ) (Prior to SN 0300322914)

FIGURE 7-6. 2WD HYDRAULIC SYSTEM INSTALLATION - (WITH 17GAL HYDRAULIC TANK) (450AJ) (SN 0300322915 to Present, Including 0300311793)

FIGURE 7-7. 2WD HYDRAULIC SYSTEM INSTALLATION - (WITH PMP PUMP) (450AJ)

FIGURE 7-8. 2WD HYDRAULIC SYSTEM INSTALLATION - (WITH 36GAL HYDRAULIC TANK) (450AJ) (Prior to SN 0300322914)

FIGURE 7-9. 2WD HYDRAULIC SYSTEM INSTALLATION - (WITH 36GAL HYDRAULIC TANK) (450AJ) (SN 0300322915 to Present, Including 0300311793)

FIGURE 7-10. 4WD HYDRAULIC SYSTEM INSTALLATION - (WITH 17GAL HYDRAULIC TANK) (450A) (Prior to SN 0300322914)

FIGURE 7-11. 4WD HYDRAULIC SYSTEM INSTALLATION - (WITH 17GAL HYDRAULIC TANK) (450A) (SN 0300322915 to Present, Including 0300311793)

FIGURE 7-12. 4WD HYDRAULIC SYSTEM INSTALLATION - (WITH 36GAL HYDRAULIC TANK) (450A)

FIGURE 7-13. 4WD HYDRAULIC SYSTEM INSTALLATION - (WITH 17GAL HYDRAULIC TANK) (MACHINES WITH SN STARTING WITH 03) (450AJ) (Prior to SN 0300322914)

FIGURE 7-14. 4WD HYDRAULIC SYSTEM INSTALLATION - (WITH 17GAL HYDRAULIC TANK) (MACHINES WITH SN STARTING WITH 03) (450AJ) (SN 0300322915 to Present, Including 0300311793)

FIGURE 7-15. 4WD HYDRAULIC SYSTEM INSTALLATION - (WITH 36GAL HYDRAULIC TANK) (MACHINES WITH SN STARTING WITH 03) (450AJ) (Prior to SN 0300322914)

FIGURE 7-16. 4WD HYDRAULIC SYSTEM INSTALLATION - (WITH 36GAL HYDRAULIC TANK) (MACHINES WITH SN STARTING WITH 03) (450AJ) (SN 0300322915 to Present, Including 0300311793)

FIGURE 7-17. 4WD HYDRAULIC SYSTEM INSTALLATION - (WITH 17GAL HYDRAULIC TANK) (MACHINES WITH SN STARTING WITH B3) (450AJ) (Prior to SN 0300322914, Prior to SN B300027946)

FIGURE 7-18. 4WD HYDRAULIC SYSTEM INSTALLATION - (WITH 17GAL HYDRAULIC TANK) (MACHINES WITH SN STARTING WITH B3) (450AJ) (SN 0300322915 to Present, SN B300027947 through 0300311793, SN B300027549 through B300027574, Including B300027546, B300027803 an...

FIGURE 7-19. 4WD HYDRAULIC SYSTEM INSTALLATION - (WITH PMP PUMP) (450AJ)

SECTION 8 - ELECTRICAL

FIGURE 8-1. AC BOX AT PLATFORM INSTALLATION - 110V - ANSI, ANSI EXPORT, CHINA, CSA AND JAPANESE SPECS

FIGURE 8-2. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE, RUSSIA & UK CA SPECS WITH 4000W/50HZ GENERATOR)

FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - 110V IEC 60309 YELLOW WITHOUT 2500W GENERATOR (CE, RUSSIA & UK CA SPECS)

FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE, RUSSIA & UK CA WITH 4000W/50HZ GENERATOR)

FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 220V IEC 60309 BLUE WITHOUT 2500W GENERATOR (CE, RUSSIA & UK CA SPECS)

FIGURE 8-6. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE, RUSSIA & UK CA SPECS)

FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE, RUSSIA & UK CA SPECS)

FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2IN X 4IN POST GROUND (CE, RUSSIA & UK CA SPECS WITH 4000W/50HZ GENERATOR)

FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2IN X 4IN SIDE GROUND (CCE, RUSSIA & UK CA SPECS WITH 4000W/50HZ GENERATOR)

FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT107 (CE, RUSSIA & UK CA SPECS WITH 4000W/50HZ GENERATOR)

FIGURE 8-11. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 KEYED GROUND (2X4 BOX) WITHOUT 2500W GENERATOR (CE, RUSSIA & UK CA SPECS)

FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 220V CUSTOMER SUPPLIED COMPONENTS (AUSTRALIAN, CE & UK CA SPECS)

FIGURE 8-13. AC BOX AT PLATFORM INSTALLATION - 240V (WITH 4000W GENERATOR) (ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)

FIGURE 8-14. AC BOX AT PLATFORM INSTALLATION - 240V (WITH 7500W SKYPOWER GENERATOR) (ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)

FIGURE 8-15. AC CABLE INSTALLATION - WITH TWO BREAKERS (CE, RUSSIA & UK CA SPECS)

FIGURE 8-16. AC CABLE INSTALLATION - WITH TWO BREAKERS (MACHINES WITH SN STARTING WITH B3)

FIGURE 8-17. AC CABLE INSTALLATION - WITH THREE BREAKERS (CE, RUSSIA & UK CA SPECS)

FIGURE 8-18. AC CABLE AND PLUG INSTALLATION (MACHINES WITH SN STARTING WITH B3)

FIGURE 8-19. BATTERY DISCONNECT SWITCH

FIGURE 8-20. BEACON JUMPER HARNESS

FIGURE 8-21. BOOM CABLES AND CLAMPS INSTALLATION - (WITHOUT ARCTIC PACKAGE) (450A)

FIGURE 8-22. BOOM CABLES AND CLAMPS INSTALLATION - (WITHOUT ARCTIC PACKAGE) (450AJ)

FIGURE 8-23. BOOM CABLES AND CLAMPS INSTALLATION - (WITHOUT ARCTIC PACKAGE AND AC CABLES) (MACHINES WITH SN STARTING WITH B3) (450AJ)

FIGURE 8-24. BOOM CABLES AND CLAMPS INSTALLATION - (WITH ARCTIC PACKAGE) (450A)

FIGURE 8-25. BOOM CABLES AND CLAMPS INSTALLATION - (WITH ARCTIC PACKAGE) (450AJ)

FIGURE 8-26. BOOM CABLES AND CLAMPS INSTALLATION - (MACHINES WITH 50HZ 4000W GENERATORS) (450AJ)

FIGURE 8-27. BOOM CABLES AND CLAMPS INSTALLATION - (MACHINES WITH 60HZ 4000W GENERATORS) (450AJ)

FIGURE 8-28. BOOM CABLES AND CLAMPS INSTALLATION - (MACHINES WITH 7500W GENERATOR AND WITHOUT ARCTIC PACKAGE) (450A)

FIGURE 8-29. BOOM CABLES AND CLAMPS INSTALLATION - (MACHINES WITH 7500W GENERATORS AND WITHOUT ARCTIC PACKAGE) (450AJ)

FIGURE 8-30. BOOM CABLES AND CLAMPS INSTALLATION - (MACHINES WITH 7500W GENERATOR AND WITH ARCTIC PACKAGE) (450A)

FIGURE 8-31. BOOM CABLES AND CLAMPS INSTALLATION - (MACHINES WITH 7500W GENERATORS AND WITH ARCTIC PACKAGE) (450AJ)

FIGURE 8-32. BOOM HARNESS - (MAIN BOOM) (WITHOUT ARCTIC PACKAGE) (450A)

FIGURE 8-33. BOOM HARNESS - (MAIN BOOM) (WITHOUT ARCTIC PACKAGE) (450AJ)

FIGURE 8-34. BOOM HARNESS - (MAIN BOOM) (WITH ARCTIC PACKAGE) (450A)

FIGURE 8-35. BOOM HARNESS - (MAIN BOOM) (WITH ARCTIC PACKAGE) (450AJ)

FIGURE 8-36. BOOM HARNESS - (MAIN BOOM AC CABLE) (WITHOUT ARCTIC PACKAGE) (450A)

FIGURE 8-37. BOOM HARNESS - (MAIN BOOM AC CABLE) (WITHOUT ARCTIC PACKAGE) (450AJ)

FIGURE 8-38. BOOM HARNESS - (MAIN BOOM AC CABLE) (WITH ARCTIC PACKAGE) (450A)

FIGURE 8-39. BOOM HARNESS - (MAIN BOOM AC CABLE) (WITH ARCTIC PACKAGE) (450AJ)

FIGURE 8-40. BOOM HARNESS - TOWER BOOM (WITHOUT ARCTIC PACKAGE)

FIGURE 8-41. BOOM HARNESS - TOWER BOOM (WITH ARCTIC PACKAGE)

FIGURE 8-42. BOOM HARNESS - TOWER BOOM AC CABLE (WITHOUT ARCTIC PACKAGE)

FIGURE 8-43. BOOM HARNESS - TOWER BOOM AC CABLE (WITH ARCTIC PACKAGE)

FIGURE 8-44. BOOM VALVE HARNESS

FIGURE 8-45. BREAKER BOX KIT WITH SINGLE DOUBLE POLE BREAKER - CE, RUSSIA & UK CA SPECS

FIGURE 8-46. BREAKER BOX KIT

FIGURE 8-47. BREAKER BOX KIT WITH THREE BREAKERS - CE, RUSSIA & UK CA SPECS

FIGURE 8-48. BREAKER BOX KIT - 30MA/16 AMP

FIGURE 8-49. CHASSIS SOLENOID HARNESS

FIGURE 8-50. CLEARSKY CS550 BEACON INSTALLATION - WITH METAL HOOD

FIGURE 8-51. CLEARSKY CS550 BEACON INSTALLATION - WITH PLASTIC HOOD

FIGURE 8-52. ENGINE HARNESS - DEUTZ D2011

FIGURE 8-53. ENGINE HARNESS - DEUTZ D2.9L4

FIGURE 8-54. ENGINE HARNESS - DEUTZ D2.9L4 ENGINE (STAGE V)

FIGURE 8-55. ENGINE HARNESS - DEUTZ D2.9L4 ENGINE (CHINA IV)

FIGURE 8-56. ENGINE HARNESS - KUBOTA

FIGURE 8-57. FUEL HARNESS - DEUTZ D2.9L4 ENGINE

FIGURE 8-58. GENERATOR HARNESS - 2500W GENERATOR (60HZ)

FIGURE 8-59. GENERATOR HARNESS - 2500W GENERATOR (50HZ)

FIGURE 8-60. GENERATOR HARNESS - 4000W GENERATOR

FIGURE 8-61. GROUND CONTROL PANEL HARNESS

FIGURE 8-62. HOUR METER JUMPER HARNESS

FIGURE 8-63. KUBOTA D/F POWER HARNESS

FIGURE 8-64. PLATFORM CONSOLE BOX HARNESS

FIGURE 8-65. PLATFORM INTERFACE HARNESS

FIGURE 8-66. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE, RUSSIA & UK CA SPECS)

FIGURE 8-67. RECEPTACLE BOX KIT - 220V IEC BLUE (CE, RUSSIA & UK CA SPECS)

FIGURE 8-68. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2IN X 4IN BOX (CE, RUSSIA & UK CA SPECS)

FIGURE 8-69. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2IN X 4IN BOX (CE, RUSSIA & UK CA SPECS)

FIGURE 8-70. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE, RUSSIA & UK CA SPECS)

FIGURE 8-71. SKYEYE INTERMEDIATE HARNESS

FIGURE 8-72. SKYEYE RECEIVER HARNESS

FIGURE 8-73. SKYEYE EMITTER HARNESS

FIGURE 8-74. SKYLINE HARNESS

FIGURE 8-75. TURNTABLE HARNESS

FIGURE 8-76. VALVE HARNESS - MAIN VALVE

FIGURE 8-77. VALVE HARNESS - PLATFORM VALVE

SECTION 9 - DECALS

FIGURE 9-1. DECAL INSTALLATION – ANSI, ANSI EXPORT AND CSA SPECS WITH DEUTZ ENGINES (ENGLISH)

FIGURE 9-2. DECAL INSTALLATION – ANSI AND ANSI EXPORT SPECS WITH KUBOTA ENGINES (ENGLISH)

FIGURE 9-3. DECAL INSTALLATION - AUSTRALIAN SPEC (ENGLISH

FIGURE 9-4. DECAL INSTALLATION - BRAZIL SPEC (ENGLISH)

FIGURE 9-5. DECAL INSTALLATION - CE & UK CA SPEC (ENGLISH)

FIGURE 9-6. DECAL INSTALLATION - CSA SPEC WITH DEUTZ ENGINES (FRENCH/ENGLISH)

FIGURE 9-7. DECAL INSTALLATION - CSA SPEC WITH KUBOTA ENGINES (FRENCH/ENGLISH)

FIGURE 9-8. DECAL INSTALLATION - CHINESE SPEC (CHINESE/ENGLISH)

FIGURE 9-9. DECAL INSTALLATION - JAPANESE SPEC (JAPANESE/ENGLISH)

FIGURE 9-10. DECAL INSTALLATION - KOREAN SPEC (KOREAN/ENGLISH)

FIGURE 9-11. DECAL INSTALLATION - LATIN AMERICA SPEC (SPANISH/ENGLISH)

FIGURE 9-12. DECAL INSTALLATION - OPTIONS

FIGURE 9-13. TOW BAR DECAL INSTALLATION - ENGLISH LANGUAGE (ANSI, ANSI EXPORT, CE, CHINA, JAPANESE AND RUSSIA SPECS)

FIGURE 9-14. TOW BAR DECAL INSTALLATION - ENGLISH/SPANISH LANGUAGE (ANSI EXPORT SPECS)

FIGURE 9-15. TOW BAR DECAL INSTALLATION - SPANISH LANGUAGE (ANSI EXPORT, CE AND RUSSIA SPECS)

FIGURE 9-16. SKYWELDER DECAL INSTALLATION – 50HZ (ANSI EXPORT SPECS)

FIGURE 9-17. SKYWELDER DECAL INSTALLATION - 60HZ (ANSI EXPORT SPECS)

SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK

SECTION 11 - SPECIAL OPTIONS/ACCESSORIES/KITS

FIGURE 11-1. SPECIAL OPTIONS/ACCESSORIES/KITS

PART NUMBER INDEX

JLG Boom Lift 450A 450AJ Parts Catalog 3122318600

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