JLG 450A-AJ Parts Manual

Illustrated Parts Manual

Models

450A & 450AJ

Series II

PRIOR TO

S/N 0300124000

PRIOR TO

S/N 1300006000

3121243

November 27, 2013

REVISION LOG

NOTE: The 450A/AJ Series II may be manufactured by JLG Industries in the following countries: USA, Belgium or Romania. Refer to the Serial Number Tag to determine the country of manufacture. The country of manufacture may be determined by the Serial Number. Boom Lifts manufactured in the USA will have a serial number prefix of 03 (i.e. 03XXXXXXXX), Boom Lifts manufactured in Belgium will have a prefix of 13 (i.e. 13XXXXXXXX) and Boom Lifts manufactured in Romania will have a prefix of E3 (i.e. E3XXXXXXXX).

NOTE: Is the Parts Manual you are viewing correct for the machine that you are ordering parts for? See Below:

USA Built Machines Prior to S/N 0300124000 - Use Parts Manual p/n 3121243 USA Built Machines S/N 0300124000 to S/N 0300160835 - Use Parts Manual p/n 3121244 USA Built Machines S/N 0300160835 to Present - Use Parts Manual p/n 3121291 Belgium Built Machines Prior to S/N 1300006000 - Use Parts Manual p/n 3121243 Belgium Built Machines S/N 1300006000 to Present - Use Parts Manual p/n 3121244 Romanian Built Machines S/N E300000100 to S/N E300001114 - Use Parts Manual P/N 3121244 Romanian Built Machines S/N E300001114 to Present - Use Parts Manual P/N 3121291

December 15, 2007 - Original Issue (Edited to 0010578 Revision 121)

April 15, 2008 - Revised Manual (Edited to 0010578 Revision 121)

March 30, 2009 - Revised Manual

October 30, 2009 - Revised Manual

August 25, 2010 - Revised Manual

April 4, 2011 - Revised Manual

July 8, 2011 - Revised Manual

October 18, 2011 - Revised Manual

December 12, 2011 - Revised Manual

March 30, 2012 - Revised Manual

June 15, 2012 - Revised Manual

August 22, 2012 - Revised Manual

November 6, 2012 - Revised Manual

March 25, 2013 - Revised Manual

May 15, 2013 - Revised Manual

August 28, 2013 - Revised Manual

November 27, 2013 - Revised Manual

3121243 450A & 450AJ Series II A

REVISION LOG

B 450A & 450AJ Series II 3121243

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

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 . . . . . . . . . . . . . . . . . . 1-6

1-3 AXLE AND STEERING INSTALLATION - 4WD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-4 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

1-5 FRAME SHIELDS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

1-6 DRIVE HUB/BRAKE ASSEMBLY (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

1-7 DRIVE HUB/BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30

1-8 DRIVE HUB ASSEMBLY (FRONT) (4WD ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

1-9 DRIVE HUB ASSEMBLY (FRONT) (4WD ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

1-10 DRIVE MOTOR ASSEMBLY (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42

1-11 DRIVE MOTOR ASSEMBLY (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44

1-12 DRIVE MOTOR ASSEMBLY (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48

1-13 DRIVE MOTOR ASSEMBLY(4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

1-14 DRIVE MOTOR ASSEMBLY(4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56

1-15 DRIVE VALVES INSTALLATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60

1-16 TOW BAR INSTALLATION (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-64

1-17 SEMI-TRACK INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-68

SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 CONTROL VALVE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 MAIN CONTROL VALVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-3 TURNTABLE AND SWING DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-4 SWING MOTOR ASSEMBLY (ORIGINAL EQUIPMENT) . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-5 SWING MOTOR ASSEMBLY (SERVICE REPLACEMENT) . . . . . . . . . . . . . . . . . . . . . . 2-14

2-6 SWING BEARING & ROTATION BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-7 USA BUILT MACHINES/CATERPILLAR ENGINE INSTALLATION . . . . . . . . . . . . . . . . 2-20

2-8 USA BUILT MACHINES/DEUTZ ENGINE INSTALLATION (PRIOR TO

SN 0300077683). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2-9 USA BUILT MACHINES/DEUTZ ENGINE INSTALLATION (SN 0300077683 TO

SN 0300124000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

2-10 USA BUILT MACHINES/FORD ENGINE INSTALLATION (PRIOR TO SN 0300078473) 2-46 2-11 USA BUILT MACHINES/FORD ENGINE INSTALLATION (SN 0300078473 TO

SN 0300124000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

2-12 USA BUILT MACHINES/DUAL FUEL INSTALLATIONS (GAS MACHINES ONLY) . . . . 2-62

2-13 USA BUILT MACHINES/GM ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

2-14 USA BUILT MACHINES/PERKINS ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . 2-72

2-15 BELGIUM BUILT MACHINES/DEUTZ ENGINE INSTALLATION (PRIOR TO

SN 1300000979). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80

2-16 BELGIUM BUILT MACHINES/DEUTZ ENGINE INSTALLATION (SN 1300000979 TO

SN 1300006000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

2-17 BELGIUM BUILT MACHINES/PERKINS ENGINE INSTALLATION . . . . . . . . . . . . . . . . 2-94

2-18 2500W GENERATOR INSTALLATION - CATERPILLAR ENGINES (USA BUILT

MACHINES) (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102

2-19 2500W GENERATOR INSTALLATION - DEUTZ ENGINES (USA & BELGIUM BUILT

MACHINES) (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106

2-20 2500W GENERATOR INSTALLATION - FORD ENGINES (USA BUILT MACHINES

PRIOR TO SN 0300078473) (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112

2-21 2500W GENERATOR INSTALLATION - FORD ENGINES (USA BUILT MACHINES

SN 0300078473 TO SN 0300124000) (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116

3121243 450A & 450AJ Series II i

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2-22 2500W GENERATOR INSTALLATION - GM ENGINES (USA BUILT MACHINES)

(OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120

2-23 2500W GENERATOR INSTALLATION - PERKINS ENGINES (USA & BELGIUM

BUILT MACHINES) (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-124

2-24 PISTON PUMP ASSEMBLY (SERIES M46 PUMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-128

2-25 PISTON PUMP ASSEMBLY (SERIES 42 PUMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134

2-26 GEAR PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-140

2-27 AUXILIARY PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-142

2-28 TANK INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-146

2-29 GROUND CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-150

2-30 ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) . . . . . . . . . . . . . . . 2-158

2-31 HOODS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-162

SECTION 3 - BOOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1 TOWER/MID BOOMS AND CYLINDERS INSTALLATION (USA BUILT MACHINES) . . . 3-2 3-2 TOWER/MID BOOMS AND CYLINDERS INSTALLATION (BELGIUM BUILT

MACHINES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-3 MAIN BOOM INSTALLATION - 450A SERIES II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-4 MAIN BOOM INSTALLATION - 450AJ SERIES II (USA BUILT MACHINES) . . . . . . . . . 3-18

3-5 MAIN BOOM INSTALLATION - 450AJ SERIES II (BELGIUM BUILT MACHINES) . . . . . 3-22

3-6 MAIN BOOM ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3-7 ROTATOR ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-8 PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS (FRONT ENTRY

PLATFORM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

3-9 PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS (SIDE ENTRY

PLATFORM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 PLATFORM INSTALLATION (USA BUILT MACHINES PRIOR TO SN 0300069155) . . . 4-2 4-2 PLATFORM INSTALLATION (USA BUILT MACHINES SN 0300069155 TO

SN 0300124000 & ALL BELGIUM BUILT MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-3 FALL ARREST PLATFORM COMPONENTS INSTALLATION (OPTIONAL). . . . . . . . . . 4-10

4-4 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4-5 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-6 CONTROLLER ASSEMBLY (LIFT AND SWING). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-7 CONTROLLER ASSEMBLY (DRIVE & STEER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-1 USA BUILT MACHINES/AXLE LOCKOUT CYLINDER (PRIOR TO SN 0300107512). . . 5-2 5-2 USA BUILT MACHINES/AXLE LOCKOUT CYLINDER (SN 0300107512 TO

SN 0300124000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 USA BUILT MACHINES/LEVEL (PLATFORM SLAVE) CYLINDER (450A SERIES II)

(ORIGINAL EQUIPMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-4 USA BUILT MACHINES/LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY

(450A SERIES II) (SERVICE REPLACEMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-5 USA BUILT MACHINES/LEVEL (PLATFORM) CYLINDER (450AJ SERIES II)

(ORIGINAL EQUIPMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-6 USA BUILT MACHINES/LEVEL (PLATFORM) CYLINDER (450AJ SERIES II)

(SERVICE REPLACEMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-7 USA BUILT MACHINES/LIFT (JIB) CYLINDER (450AJ SERIES II ONLY)

(ORIGINAL EQUIPMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

ii 450A & 450AJ Series II 3121243

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5-8 USA BUILT MACHINES/LIFT (JIB) CYLINDER (450AJ SERIES II ONLY)

(SERVICE REPLACEMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-9 USA BUILT MACHINES/LIFT (MAIN BOOM) CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-10 USA BUILT MACHINES/LIFT (TOWER BOOM) CYLINDER. . . . . . . . . . . . . . . . . . . . . . 5-20

5-11 USA BUILT MACHINES/MASTER CYLINDER (450A SERIES II)

(ORIGINAL EQUIPMENT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-12 USA BUILT MACHINES/MASTER CYLINDER (450A SERIES II)

(SERVICE REPLACEMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5-13 USA BUILT MACHINES/MASTER CYLINDER (450AJ SERIES II) (ORIGINAL

EQUIPMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-14 USA BUILT MACHINES/MASTER CYLINDER (450AJ SERIES II) (SERVICE

REPLACEMENT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5-15 USA BUILT MACHINES/STEER CYLINDER (PRIOR TO SN 0300087393) . . . . . . . . . . 5-30

5-16 USA BUILT MACHINES/STEER CYLINDER (SN 0300087393 TO SN 0300124000) . . 5-32

5-17 USA BUILT MACHINES/TELESCOPE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-18 BELGIUM BUILT MACHINES/AXLE LOCKOUT CYLINDER (PRIOR TO

SN 1300003222). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

5-19 BELGIUM BUILT MACHINES/AXLE LOCKOUT CYLINDER (SN 1300003222 TO

SN 1300006000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

5-20 BELGIUM BUILT MACHINES/LEVEL (PLATFORM) CYLINDER (450AJ SERIES II) . . . 5-40

5-21 BELGIUM BUILT MACHINES/LIFT (JIB) CYLINDER (450AJ SERIES II ONLY). . . . . . . 5-42

5-22 BELGIUM BUILT MACHINES/LIFT (MAIN BOOM) CYLINDER . . . . . . . . . . . . . . . . . . . 5-44

5-23 BELGIUM BUILT MACHINES/LIFT (TOWER BOOM) CYLINDER . . . . . . . . . . . . . . . . . 5-46

5-24 BELGIUM BUILT MACHINES/MASTER CYLINDER (450AJ SERIES II). . . . . . . . . . . . . 5-48

5-25 BELGIUM BUILT MACHINES/STEER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

5-26 BELGIUM BUILT MACHINES/TELESCOPE CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . 5-52

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-1 AXLE LOCKOUT HYDRAULIC DIAGRAM - 2WD (USA BUILT MACHINES PRIOR TO

SN 0300077285 & BELGIUM BUILT MACHINES PRIOR TO SN 1300000353). . . . . . . 6-2

6-2 AXLE LOCKOUT HYDRAULIC DIAGRAM - 2WD (USA BUILT MACHINES

SN 0300077285 TO SN 0300107512 & BELGIUM BUILT MACHINES SN 1300000353

TO SN 1300003222). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-3 AXLE LOCKOUT HYDRAULIC DIAGRAM - 2WD (USA BUILT MACHINES

SN 0300107512 TO SN 0300124000 & BELGIUM BUILT MACHINES

SN 1300003222 TO SN 1300006000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-4 AXLE LOCKOUT HYDRAULIC DIAGRAM - 4WD (USA BUILT MACHINES PRIOR TO

SN 0300077285 & BELGIUM BUILT MACHINES PRIOR TO SN 1300000353) . . . . . . . 6-8

6-5 AXLE LOCKOUT HYDRAULIC DIAGRAM - 4WD (USA BUILT MACHINES

SN 0300077285 TO SN 0300107512 & BELGIUM BUILT MACHINES SN 1300000353

TO SN 1300003222) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-6 AXLE LOCKOUT HYDRAULIC DIAGRAM - 4WD (USA BUILT MACHINES

SN 0300107512 TO SN 0300124000 & BELGIUM BUILT MACHINES

SN 1300003222 TO SN 1300006000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-7 DRIVE HYDRAULIC DIAGRAM - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-8 DRIVE HYDRAULIC DIAGRAM - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6-9 DRIVE HYDRAULIC DIAGRAM - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6-10 DRIVE HYDRAULIC DIAGRAM - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

6-11 DRIVE HYDRAULIC DIAGRAM - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

6-12 STANDARD HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

6-13 TOW BAR HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

6-14 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

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SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 HARNESS COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

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

8-1 DECAL INSTALLATION - ANSI SPEC (USA BUILT MACHINES PRIOR TO

SN 0300069155) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 DECAL INSTALLATION - ANSI SPEC (USA BUILT MACHINES SN 0300069155

TO SN 0300124000 & BELGIUM BUILT MACHINES SN 1300000001 TO

SN 1300006000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8-3 DECAL INSTALLATION - ANSI EXPORT SPECS (USA BUILT MACHINES PRIOR

TO SN 0300069155) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8-4 DECAL INSTALLATION - ANSI EXPORT SPECS (USA BUILT MACHINES

SN 0300069155 TO SN 0300124000 & BELGIUM BUILT MACHINES

SN 1300000001 TO SN 1300006000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8-5 DECAL INSTALLATION - CE & AUSTRALIAN SPECS (USA BUILT MACHINES

PRIOR TO SN 0300069155) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

8-6 DECALS INSTALLATION - AUSTRALIAN & CE SPECS (USA BUILT MACHINES

SN 0300069155 TO SN 0300074819 & BELGIUM BUILT MACHINES SN 1300000001

TO SN 1300000180) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

8-7 DECALS INSTALLATION - AUSTRALIAN & CE SPECS (USA BUILT MACHINES

SN 0300074819 TO SN 0300124000 & BELGIUM BUILT MACHINES SN 1300000180

TO SN 1300006000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK. . . . . . . . . . . . . . . . . . . . . . . . . 9-1

SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

SECTION 11 - PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

iv 450A & 450AJ Series II 3121243

SECTION 1

FRAME

3121243 450A & 450AJ Series II 1-1

SECTION 1 FRAME

206

203

201

204

210

216

217

209

211

212

214

213

207

208

205

208

17A

123A

201

218

215

207

214

206

202

302

303

304

310

308

306

307

309

316

314

311

305

313

315

301

123

16913141211118

103

119

125

109

105

122

116

120

108

112

114

101

110A

110B

107

122

115

104

113

105

127

124

117

124

111

PRIOR TO SN

0300077285

SN 0300077285

TO SN 0300124000

118

126

101

106

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

1-2 450A & 450AJ Series II 3121243

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref FIXED AXLE INSTALLATION 0270971 Ref Prior to SN 0300107512 E 0274690 Ref SN 0300107512 to SN 0300124000 A

Ref Note: USA Manufacture Only.

1 0100011 AR Compound, Locking 2 0362763 4 Bar, Stop 3 0362764 2 Bar, Stop 4 2 Bolt 3/8in-16NC x 7/8in

0641607 Prior to SN 0300069841

See Note SN 0300069841 to SN 0300124000 (See FRAME SHIELDS

INSTALLATION for call out) 5 0641626 2 Bolt 3/8in-16NC x 3-1/4in 6 0642012 1 Bolt 5/8in-11NC x 1-1/2in 7 0961950 2 Bushing, Garmax 8 3422592 1 Pin, Axle Pivot 9 3570901 2 Plate, Stop

10 3841258 1 Keeper, Pin 11 1 Shield, Frame

4061020 Prior to SN 0300069841

See Note SN 0300069841 to SN 0300124000 (See FRAME SHIELDS

INSTALLATION for call out)

12 4070972 AR Shim 3/16in 13 4070973 AR Shim 1/8in 14 4070974 AR Shim 1/16in 15 4740158 1 Thrustwasher 16 4751600 2 Flatwasher 3/8in Regular 17 1 Axle Weldment Options:

4846352 Axle Prior to SN 0300107512 0280200 Axle SN 0300107512 to SN 0300124000

17A 1001100424 2 Steer Cylinder Mounting Block Assy (was p/n 0561300)

18 2220235 3 Fitting, O-Ring (Not Shown)

Ref OSCILLATING AXLE INSTALLATIONS 0270970 Ref Prior to SN 0300077285 G 0273487 Ref SN 0300077285 to SN 0300107512 C 0274685 Ref SN 0300107512 to SN 0300124000 A

Ref Note: USA Manufacture Only.

101 0100011 AR Compound, Locking

0100019 AR Compound, Locking

102 0100038 AR Primer, Locking #7471 103 0641416 4 Bolt 1/4in-20NC x 2in (Prior to SN 0300077285) 104 0641607 2 Bolt 3/8in-16NC x 7/8in (Prior to SN 0300107512) 105 0641814 AR Bolt 1/2in-13NC x 1-3/4in 106 0642012 1 Bolt 5/8in-11NC x 1-1/2in 107 0682248 2 Bolt 3/4in-10NC x 6in (Prior to SN 0300107512) 108 0961950 2 Bushing, Garmax

3121243 450A & 450AJ Series II 1-3

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

109 1 Cam, Lockout Options:

1100127 Prior to SN 0300069337 1100133 SN 0300069337 to SN 0300077285

Not Used SN 0300077285 to SN 0300124000

110 2 Lockout Cylinder Assembly Options (See CYLINDER SECTION

for Breakdown): 110A 1684129 Prior to SN 0300069337 110B 1684465 SN 0300069337 to SN 0300077285

111 3272201 2 Nut 3/4in-10NC (Prior to SN 0300107512) 112 3422592 1 Pin, Axle Pivot 113 3422520 2 Pin (Prior to SN 0300107512) 114 3841258 1 Keeper, Pin 115 3841220 2 Keeper, Pin (Prior to SN 0300107512) 116 1 Shield, Frame

4061020 Prior to SN 0300069841

See Note SN 0300069841 to SN 0300124000 (See FRAME SHIELDS

INSTALLATION for call out) 117 4567462 2 Tube, Mounting (Prior to SN 0300107512) 118 1 Lockout Valve Assembly Options:

4640871 Valve Used Prior to SN 0300077285 7012693 1 Seal Kit - 4640871 Valve 7002840 1 Anti-Rotation Pin Removal Tool

4641265 Valve Used SN 0300077285 to SN 0300124000 119 4711400 8 Flatwasher 1/4in Thin (Prior to SN 0300077285) 120 4740158 1 Thrustwasher 121 Not Used 122 4751800 4 Flatwasher 1/2in Regular (Prior to SN 0300077285) 123 1 Axle Weldment Options:

4846352 Axle Prior to SN 0300107512

0280200 Axle SN 0300107512 to SN 0300124000

123A 1001100424 2 Steer Cylinder Mounting Block Assy (was p/n 0561300)

124 4892200 4 Flatwasher 3/4in Hardened (Prior to SN 0300107512) 125 3311405 4 Locknut 1/4in-20NC (Prior to SN 0300077285) 126 0791506 4 Screw, 5/16in-18NC x 3/4in (SN 0300077285 to

SN 0300124000 Only)

127 4891800 4 Flatwasher, Hardened 1/2in (SN 0300107512 to

SN 0300124000)

0271012 Ref STEERING INSTALLATION G

Ref Note: USA Manufacture Only.

201 0100011 AR Compound, Locking 202 0440162 2 Thrustwasher 203 0641606 4 Bolt 3/8in-16NC x 3/4in 204 0681826 4 Bolt 1/2in-13NC x 3-1/4in 205 1 Steer Cylinder Assembly Options (See CYLINDER SECTION for

Breakdown):

Use 1684412 Prior to SN 0300087392 (was p/n 1683614)

1684412 SN 0300087392 to SN 0300124000 206 2780230 2 Hub/Spindle Assembly (See Items 301 to 316 for Breakdown)

1-4 450A & 450AJ Series II 3121243

SECTION 1 FRAME

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

ITEM # PART NUMBER QTY. DESCRIPTION REV.

207 3312008 4 Nut 5/8in-11NC 208 3322201 2 Nut 3/4in-16NF 209 3323003 2 Nut 1-1/4in-12NF 210 3422692 2 Kingpin 211 3450808 2 Pin, Cotter 1/4in x 2in 212 3841377 2 Tie-Rod 213 3841517 2 Rod-End with Grease Fitting 214 3900109 4 Screw, Shoulder 215 4060950 1 Shield, Frame (Prior to SN 0300074064 Only) 216 4713000 2 Flatwasher 1-1/4in Thin 217 4740086 2 Thrustwasher 218 4751800 4 Flatwasher 1/2in Regular

2780230 Ref HUB ASSEMBLY A

301 7020033 2 Cap, Dust (1 per Assembly) 302 7020034 2 Spindle Assembly (1 per Assembly) 303 0961951 4 Bushing, Garmax (2 per Assembly) 304 0962140 2 Bearing, Garmax (1 per Assembly) 305 7020035 2 Hub (1 per Assembly) (Includes 306 & 307) 306 7020036 2 Cup, Bearing - Inner(1 per Assembly) 307 7020038 2 Cup, Bearing - Outer (1 per Assembly) 308 7020037 2 Cone, Bearing - Inner (1 per Assembly) 309 7020039 2 Cone, Bearing - Outer (1 per Assembly) 310 7020040 2 Seal (1 per Assembly) 311 7020041 18 Stud, Wheel (9 per Assembly) 312 Not Used 313 7020042 18 Lugnut (9 per Assembly) 314 7020054 2 Nut, Castle (1 Per Assembly) 315 3450608 2 Pin, Cotter (1 Per Assembly) 316 7020055 2 Washer, Spindle (1 Per Assembly)

3121243 450A & 450AJ Series II 1-5

SECTION 1 FRAME

205

216

303

302

310

307

309

316

314

301

308

306

311

305

313

315

304

226

211

225

215

218

202

213

221

223

115

115A

222

214

206

201

229

24A

208

212

212 224 228

230

224

207

204

220

217

227

210

224

203

224

228

219

209

167251825

11413

10A

103

102

104

101

114

108

111

112

110

10B

101

106

109

106

113

107

PRIOR TO SN

0300077285

SN 0300077285

TO SN 0300124000

105

FIGURE 1-2.AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR

1-6 450A & 450AJ Series II 3121243

SECTION 1 FRAME

FIGURE 1-2. AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref

0271656 Ref Prior to SN 0300077285 C 0273489 Ref 0274705 Ref SN 0300107512 to SN 0300124000 A

Ref

1 0100011 AR Compound, Locking

0100019 AR Compound, Locking 2 0100038 AR Primer, Locking #7471 3 0641416 4 Bolt 1/4in-20NC x 1-3/4in (Prior to SN 0300077285) 4 0641607 2 Bolt 3/8in-16NC x 7/8in (Prior to SN 0300107512) 5 0641814 AR Bolt 1/2inin-13NC x 1-3/4in 6 0642012 1 Bolt 5/8in-11NC x 1-1/2in 7 0682248 2 Bolt 3/4in-10NC x 6in (Prior to SN 0300107512) 8 0961950 2 Bushing, Garmax 9 1 Cam, Lockout Options:

1100127 Prior to SN 0300069337

1100133 SN 0300069337 to SN 0300077285

Not Used SN 0300077285 to SN 0300124000

10 2 Lockout Cylinder Assembly Options (See CYLINDER SECTION

10A 1684129 Prior to SN 0300107512 10B 1684465 SN 0300107512 to SN 0300124000

11 3272201 2 Nut 3/4in-10NC (Prior to SN 0300107512) 12 3311405 4 Locknut 1/4in-20NC (Prior to SN 0300077285) 13 3422520 2 Pin (Prior to SN 0300107512) 14 3422592 1 Pin, Axle Pivot 15 3841258 2 Keeper, Pin 16 3841520 1 Keeper, Pin (Prior to SN 0300107512) 17 1 Shield, Frame Options:

4061020 Prior to SN 0300069841

See Note SN 0300069841 to SN 0300124000 (See FRAME SHIELDS

18 4567462 2 Tube, Mounting (Prior to SN 0300107512) 19 1 Lockout Valve Assembly Options:

4640871 Valve Used Prior to SN 0300077285

7012693 1 Seal Kit - 4640871 Valve

7002840 1 Anti-Rotation Pin Removal Tool

4641265 Valve Used SN 0300077285 to SN 0300124000

20 4711400 8 Flatwasher 1/4in Thin (Prior to SN 0300077285) 21 4740158 1 Thrustwasher 22 Not Used 23 4751800 4 Flatwasher 1/2in Regular (Prior to SN 0300077285) 24 1 Axle Weldment Options:

4846426 Axle Prior to SN 0300107512

0280201 Axle SN 0300107512 to SN 0300124000

24A 1001100424 2 Steer Cylinder Mounting Block Assy (was p/n 0561300)

25 4892200 4 Flatwasher 3/4in Hardened

OSCILLATING AXLE INSTALLATIONS

SN 0300077285 to SN 0300107512 C

Note: USA Manufacture Only.

for Breakdown):

INSTALLATION for call out)

3121243 450A & 450AJ Series II 1-7

SECTION 1 FRAME

FIGURE 1-2. AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

26 0791506 4 Screw, 5/16in-18NC x 3/4in (SN 0300077285 to

SN 0300124000 Only)

27 4891800 8 Flatwasher, Hardened 1/2in (SN 0300107512 to SN

0300124000)

Ref

0273077 Ref Prior to SN 0300107512 C 0274706 Ref

Ref Note: USA Manufacture Only.

101 0100011 AR Compound, Locking 102 0362763 4 Bar, Stop 103 0362764 2 Bar, Stop 104 0641626 2 Bolt 3/8in-16NC x 3-1/4in 105 0642012 1 Bolt 5/8in-11NC x 1-1/2in 106 0961950 2 Bushing, Garmax 107 3422592 1 Pin, Axle Pivot 108 3570901 2 Plate, Stop 109 3841258 1 Keeper, Pin 110 4070972 AR Shim 3/16in 111 4070973 AR Shim 1/8in 112 4070974 AR Shim 1/16in 113 4740158 1 Thrustwasher 114 4751600 2 Flatwasher 3/8in Regular 115 1 Axle Weldment Options:

4846426 Prior to SN 0300107512 0280201 SN 0300107512 to SN 0300124000

115A 1001100424 2 Steer Cylinder Mounting Block Assy (was p/n 0561300)

116 2220235 4 Fitting, O-Ring (Not Shown - See HYDRAULICS SECTION)

FIXED AXLE INSTALLATION

SN 0300107512 to SN 0300124000 A

0271653 Ref

Ref

201 0100011 AR Compound, Locking 202 0440162 2 Thrustwasher 203 0630544 1 Bolt 1in-8NC x 6in 204 0641508 1 Bolt 5/16in-18NC x 1in 205 0641606 4 Bolt 3/8in-16NC x 3/4in 206 0681824 4 Bolt 1/2in-13NC x 3in 207 0682648 1 Bolt 1in-8NC x 6in 208 1 Steer Cylinder Assembly Options (See CYLINDER SECTION for

Use 1684412 Prior to SN 0300087392 (was p/n 1683614)

1684412 SN 0300087392 to SN 0300124000 209 2160001 2 Fitting, STR Grease 210 2160002 1 Fitting, STR Grease 211 2780230 2 Hub/Spindle Assembly (See 201 to 213 for Breakdown) 212 3272605 2 Locknut 1in-8NC 213 3312008 4 Nut 5/8in-11NC 214 3322201 2 Nut 3/4in-16NF

STEERING INSTALLATION E

Note: USA Manufacture Only.

Breakdown):

1-8 450A & 450AJ Series II 3121243

SECTION 1 FRAME

FIGURE 1-2. AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

215 3323003 2 Nut 1-1/4in-12NF 216 3422692 2 Kingpin 217 3422848 1 Pin, Hitch 218 3450812 2 Pin, Cotter 1/4in x 3in 219 3571975 1 Plate, Tow Bar Pivot 220 3841143 1 Keeper 221 3841458 2 Tie-Rod 222 3841517 2 Rod-End 223 3900109 4 Screw, Shoulder 224 4712600 4 Flatwasher 1in Thin 225 4713000 2 Flatwasher 1-1/4in Thin 226 4740086 2 Thrustwasher 227 4740155 2 Thrustwasher 228 4740491 2 Thrustwasher 229 4751800 4 Flatwasher 1/2in Regular 230 4846162 1 Link

2780230 Ref

HUB ASSEMBLY A

3121243 450A & 450AJ Series II 1-9

SECTION 1 FRAME

MACHINES PRIOR TO SN 0300077285 &

MACHINES PRIOR TO SN 1300000353

MACHINES SN 0300077285 TO SN 0300124000 &

MACHINES SN 1300000353 TO SN 1300006000

118

126

118

103

119

125

109

105

101

122

116

120

108

112

114

101

106

110A

110B

107

104

122

115

104

101

113

127

102

101

128

124

117

124

111

2413

123

218

213

203

214

215

205

202

210

201

217

207

209

211

208

212

216

208

216

206

123A

14A

222

201

223

201

204

250

FIGURE 1-3.AXLE AND STEERING INSTALLATION - 4WD

1-10 450A & 450AJ Series II 3121243

SECTION 1 FRAME

FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref

0270969 Ref Prior to SN 0300107512 E 0274703 Ref

Ref Note: USA Manufacture Only.

1 0100011 AR Compound, Locking 2 AR Bar, Stop Options:

0362763 2 Prior to SN 0300107512 3/8in Bar 0362763 4 SN 0300107512 to SN 0300124000 3/8in Bar 0362764 2 SN 0300107512 to SN 0300124000 1/8in Bar

3 2 Bolt 3/8in-16NC x 7/8in

0641607 Prior to SN 0300069841

See Note SN 0300069841 to SN 0300124000 (See FRAME SHIELDS

4 2 Bolt Options:

0641620 Bolt 3/8in-16NC x 2-1/4in

0641616 Bolt 3/8in-16NC x 2in 5 0642012 1 Bolt 5/8in-11NC x 1-1/2in 6 0961950 2 Bushing, Garmax 7 3422592 1 Pin, Axle Pivot 8 2 Plate, Stop Options:

3570901 Prior to SN 0300107512

4220267 SN 0300107512 to SN 0300124000 9 3841258 1 Keeper, Pin

10 1 Shield, Frame Options:

4061020 Prior to SN 0300069841

See Note SN 0300069841 to SN 0300124000 (See FRAME SHIELDS

11 AR Shim Options:

4070974 Prior to SN 0300107512

4070973 SN 0300107512 to SN 0300124000

12 4740158 1 Thrustwasher 13 4751600 2 Flatwasher 3/8in Regular 14 1 Axle Weldment Options:

4846353 1 Prior to SN 0300107512 Axle Weldment

0280199 1 SN 0300107512 Axle Weldment

14A 0561300 2 Steer Cylinder Mounting Block Assembly

15 2220235 3 Fitting, O-Ring (Not Shown)

FIXED AXLE INSTALLATION

SN 0300107512 to SN 0300124000 A

INSTALLATION for call out)

Note: If kingpin holes in the axle measure 1.503in diameter or larger in any direction, axle weldment must be replaced Note: See Kit Item 250 & additional notes at end of parts list before ordering parts.

3121243 450A & 450AJ Series II 1-11

SECTION 1 FRAME

FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref OSCILLATING AXLE INSTALLATIONS

0270968 Ref USA Built Machines Prior to SN 0300077285 G 0273488 Ref 0274702 Ref USA Built Machines SN 0300107512 to SN 0300124000 A 0270968 Ref 0272639 Ref 0273498 Ref 0274742 Ref Belgium Built Machines SN 1300003222 to SN 1300006000 A

101 0100011 AR Compound, Locking

0100019 AR Compound, Locking 102 0100038 AR Primer, Locking #7471 103 0641416 4 Bolt 1/4in-20NC x 2in (USA Built Machines Prior to SN

104 0641607 2 Bolt 3/8in-16NC x 3/4in (USA Built Machines Prior to SN

105 AR Bolt Options:

0641812 2 1/2in-13NC x 1-1/2in (USA Built Machines Prior to SN

0642010 2 5/8in-11NC x 1-1/4in (Belgium Built Machines Prior to SN

Not Required 0 (USA Built Machines SN 0300077285 to SN 0300124000 &

106 0642012 1 Bolt 5/8in-11NC x 1-1/2in 107 0682248 2 Bolt 3/4in-10NC x 6in (USA Built Machines Prior to SN

108 0961950 2 Bushing, Garmax 109 1 Cam, Lockout Options:

1100107 USA Built Machines Prior to SN 0300069337

1100133 USA Built Machines SN 0300069337 to SN 0300077285

Not Required USA Built Machines SN 0300077285 to SN 0300124000

1100133 Belgium Built Machines SN 1300000001 to SN 1300000005

1100134 Belgium Built Machines SN 1300000005 to SN 1300000353

Not Required Belgium Built Machines SN 1300000353 to SN 1300006000

110 2 Lockout Cylinder Assembly Options (See CYLINDER SECTION

110A 1684129 USA Built Machines Prior to SN 0300107512 & 110A 1684243 Belgium Built Machines Prior to SN 1300003222 110B 1684465 USA Built Machines SN 0300107512 to SN 0300124000 &

111 3272201 2 Nut 3/4in-10NC (USA Built Machines Prior to SN 0300107512 &

112 3422592 1 Pin, Axle Pivot 113 3422520 2 Pin (USA Built Machines Prior to SN 0300107512 & Belgium

114 3841258 1 Keeper, Pin 115 3841520 2 Keeper, Pin (USA Built Machines Prior to S/N 0300107512 &

USA Built Machines SN 0300077285 to SN 0300107512 C

Belgium Built Machines SN1300000001 to SN 1300000005 A Belgium Built Machines SN1300000005 to SN 1300000353 A Belgium Built Machines SN1300000353 to SN 1300003222 C

0300077285 & Belgium Built Machines Prior to SN

1300000353)

0300107512 & Belgium Built Machines Prior to SN

1300003222)

0300077285)

1300000353)

Belgium Built Machines SN 1300000353 to SN 1300006000)

0300107512 & Belgium Built Machines Prior to SN

1300003222)

for Breakdown):

Belgium Built Machines SN 1300003222 to SN 1300006000

Belgium Built Machines Prior to SN 1300003222)

Built Machines Prior to SN 1300003222)

Belgium Built Machines Prior to SN 1300003222)

1-12 450A & 450AJ Series II 3121243

SECTION 1 FRAME

FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

116 1 Shield, Frame Options:

4061020 USA Built Machines Prior to SN 0300069841

See Note USA Built Machines SN 0300069841 to SN 0300124000

(See FRAME SHIELDS INSTALLATION for call out)

See Note Belgium Built Machines SN 1300000001 to SN 1300006000

(See FRAME SHIELDS INSTALLATION for call out)

117 4567462 2 Tube, Mounting (USA Built Machines Prior to SN 0300107512 &

Belgium Built Machines Prior to SN 1300003222)

118 1 Lockout Valve Assembly Options:

4640871 Valve Used USA Built Machines Prior to SN 0300077285 &

Belgium Built Machines Prior to SN 1300000353 7012693 1 Seal Kit - 4640871 Valve 7002840 1 Anti-Rotation Pin Removal Tool 4641265 Valve Used USA Built Machines SN 0300077285 to

SN 0300124000 & Belgium Built Machines SN 1300000353

to SN 1300006000

119 4711400 4 Flatwasher 1/4in Thin (USA Built Machines Prior to

SN 0300077285& Belgium Built Machines Prior to

SN 1300000353 Only)

120 4740158 1 Thrustwasher 121 Not Used 122 AR Flatwasher Options:

4751800 4 1/2in Regular (USA Built Machines Prior to SN 0300077285) 4752000 4 5/8in Regular (Belgium Built Machines Prior to

SN 1300000353)

Not Required 0 (USA Built Machines SN 0300077285 to SN 0300124000 &

Belgium Built Machines SN 1300000353 to SN 1300006000)

123 1 Axle Weldment Options:

Note: If kingpin holes in the axle measure 1.503in diameter or larger in any direction, axle weldment must be replaced. Note: See Kit Item 250 & additional notes at end of parts list before ordering parts.

4846353 USA Built Machines Prior to SN 0300107512 0280199 USA Built Machines SN 0300107512 to SN 0300124000 4846725 Belgium Built Machines Prior to SN 1300003222 0280202 Belgium Built Machines SN 1300003222 to SN 1300006000

123A 2 Steer Cylinder Mounting Block Assembly Options:

0561300 USA Built Machines 0561511 Belgium Built Machines

124 4892200 4 Flatwasher 3/4in Hardened (USA Built Machines Prior to

SN 0300107512 & Belgium Built Machines Prior to SN 1300003222)

125 3311405 4 Locknut 1/4in-20NC (USA Built Machines Prior to

SN 0300077285& Belgium Built Machines Prior to SN 1300000353 Only)

126 0791506 4 Screw, 5/16in-18NC x 3/4in (USA Built Machines

SN 0300077285 to SN 0300124000 & Belgium Built Machines SN 1300000353 to SN 1300006000)

127 0641814 8 Bolt 1/2in-13NC x 1-3/4in (USA Built Machines SN 0300107512

to SN 0300124000 & Belgium Built Machines SN 1300003222 to SN 1300006000)

3121243 450A & 450AJ Series II 1-13

SECTION 1 FRAME

FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

128 4891800 8 Flatwasher, 1/2in Hardened (USA Built Machines

SN 0300107512 to SN 0300124000 & Belgium Built Machines SN 1300003222 to SN 1300006000)

Ref

0271011 Ref Manufactured in USA (SN 1st digit is 0) I 0272652 Ref

201 0100011 AR Compound, Locking 202 AR Thrustwasher Options:

0440161 Prior to SN 0300079126 (Top & Bottom Kingpin Location)

4740537 SN 0300079126 to SN 0300124000 (.0625) (Top Kingpin

4740538 SN 0300079126 to SN 0300124000 (.125) (Top Kingpin

4740539 SN 0300079126 to SN 0300124000 (.188) (Top Kingpin

4740540 SN 0300079126 to SN 0300124000 (.250) (Top Kingpin

0440271 SN 0300079126 to SN 0300124000 (Bottom Kingpin

0440161 Prior to SN 1300000441 (Top & Bottom Kingpin Location)

4740537 SN 1300000441 to SN 1300006000 (.0625) (Top Kingpin

4740538 SN 1300000441 to SN 1300006000 (.125) (Top Kingpin

4740539 SN 1300000441 to SN 1300006000 (.188) (Top Kingpin

4740540 SN 1300000441 to SN 1300006000 (.250) (Top Kingpin

0440271 SN 1300000441 to SN 1300006000 (Bottom Kingpin

203 0641606 16 Bolt 3/8in-16NC x 3/4in 204 0641826 4 1/2in-13NC x 3-1/4in 205 2 Bushing / Bearing Options:

0961951 USA Built Machines Prior to SN 0300079126 &

0440291 USA Built Machines SN 0300079126 to SN 0300124000 &

0440274 USA Built Machines SN 0300079126 to SN 0300124000 &

206 0962140 2 Bearing, Garmax

STEERING INSTALLATIONS

Manufactured in Belgium (SN 1st digit is1) F

USA Built Machines:

(Note: See Kit Item 250 & additional notes at end of parts list before ordering parts.)

Location)

Belgium Built Machines:

(Note: See Kit Item 250 & additional notes at end of parts list before ordering parts.)

Location)

Belgium Built Machines Prior to SN 1300000441 (Top & Bottom Kingpin Location)

additional notes at end of parts list before ordering parts)

Belgium Built Machines SN 1300000441 to SN 1300006000 (Top Kingpin Location)

Belgium Built Machines SN 1300000441 to SN 1300006000 (Bottom Kingpin Location)

(Note: See Kit Item 250 &

1-14 450A & 450AJ Series II 3121243

SECTION 1 FRAME

FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

207 1 Steer Cylinder Assembly Options (See CYLINDER SECTION

for Breakdown):

Use 1684412 USA Built Machine Prior to SN 0300087392 (was p/n

1683614) 1684412 USA Built Machine SN 0300087392 to SN 0300124000 1684246 Belgium Built Machines

208 3312008 4 Nut 5/8in-11NC 209 3322201 2 Nut 3/4in-16NC 210 4 Kingpin Options:

3422716 USA Built Machines Prior to SN 0300079126 &

Belgium Built Machines Prior to SN 1300000441 (2 Bolt Mounting)

notes at end of parts list before ordering parts)

3423081 USA Built Machines SN 0300079126 to SN 0300124000 &

Belgium Built Machines SN 1300000441 to SN 1300006000 (4 Bolt Mounting)

211 2 Rod-End with Grease Fitting Options:

3841517 USA Built Machines 3841367 Belgium Built Machines (Prior to SN 130005313) 3841517 Belgium Built Machines (SN 130005313 to SN 1300006000)

212 3900109 4 Screw, Shoulder 213 4060950 1 Shield, Frame (Used on USA Built Machines Prior to

SN 0300074064 Only)

214 1 Spindle (Left Side) Options:

4130363 USA Built Machines Prior to SN 0300079126 4130405 USA Built Machines SN 0300079126 to SN 0300124000 4130391 Belgium Built Machines Prior to SN 1300000441 4130406 Belgium Built Machines SN 1300000441 to SN 1300006000

215 1 Spindle (Right Side) Options:

4130364 USA Built Machines Prior to SN 0300079126 4130406 USA Built Machines SN 0300079126 to SN 0300124000 4130392 Belgium Built Machines Prior to SN 1300000441 4130407 Belgium Built Machines SN 1300000441 to SN 1300006000

216 4740086 4 Thrustwasher 217 4751800 4 Flatwasher 1/2in Regular 218 2 Tie-Rod Options:

4845711 USA Built Machines 4846733 Belgium Built Machines

219 to 221 Not Used

222 3780182 2 O-Ring (USA Built Machines SN 0300079126 to

SN 0300124000 & Belgium Built Machines SN 1300000441 to SN 1300006000 Only)

223 3020029 AR Grease, Bearing (Not Shown)

224 to 249 Not Used

— — — — — — — — — —

(Note: See Kit Item 250 & additional

3121243 450A & 450AJ Series II 1-15

SECTION 1 FRAME

FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

250 2902400 1 Kingpin and Bushings Update Kit for Machines Built Prior to

SN 0300079126 & SN 1300000441(Includes Newer “SN 0300079126 & SN 1300000441 to SN 0300124000” Design Items 202, 205, 210 and 222). Refer to Field Service Bulletin AWP-04-11.

Ref

Ref Note: Spindles require drilling and tapping for 8 additional

Note: Newer bushings will fit in “Prior to SN 0300079126 & SN 1300000441” axles however if kingpin holes measure

1.503in diameter or larger in any direction, axle weldment must be replaced before installation of kit.

kingpin mounting bolts. Newer design kingpins require 4 mounting bolts each.

1-16 450A & 450AJ Series II 3121243

SECTION 1 FRAME

FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121243 450A & 450AJ Series II 1-17

SECTION 1 FRAME

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS

1-18 450A & 450AJ Series II 3121243

SECTION 1 FRAME

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref

0270870 Ref Caterpillar/Deutz/ Ford Engine Machines Prior to SN

0272907 Ref

0275470 Ref

0275470 Ref 0275853 Ref

Ref

1 0100011 AR Compound, Locking

0100019 AR Compound, Locking

2 to 3 Not Used

4 2 Bolt 3/8in-16NC x 7/8in

0641607 Prior to SN 0300069841

See Note SN 0300069841 to SN 0300124000 (See FRAME SHIELDS

5 4 Hardware Options:

0681810 Bolt 1/2in-13NC x 1-1/4in (Grade 8) (Prior to

3311801 Nut 1/2in-13NC (Not Shown) (SN 0300071527 to

6 0682014 12 Bolt 5/8in-11NC x 1-3/4in (Grade 8) 7 2 Drive Hub/Brake Assembly Options:

2780256 Prior to SN 0300071527 (See DRIVEHUB/BRAKE

2780267 SN 0300071527 to SN 0300124000 (See DRIVE HUB/

8 2 Drive Motor Assembly Options:

3160158 Caterpillar/Deutz/Ford Engine Machines Prior to SN

3160351 Caterpillar/Deutz/Ford Engine Machines SN 0300100514 to

3160298 GM Engine Machines Prior to SN 0300099085 (See DRIVE

3160351 GM Engine Machines SN 0300099085 to SN 0300124000

9 3300106 18 Lugnut 10 Not Used 11 3790045 2 O-Ring (Prior to SN 0300075079) 12 1 Shield, Frame Options:

4061021 Prior to SN 0300077285

See Note SN 0300077285 to SN 0300124000 (See FRAME SHIELDS

13 to 16 Not Used

17 4751600 2 Flatwasher 3/8in Regular 18 4891800 4 Flatwasher 1/2in Hardened

WHEEL DRIVE INSTALLATION (2WD)

0300071527 Caterpillar/Deutz/ Ford Engine Machines SN 0300071527 to

SN 0300100514 Caterpillar/Deutz/ Ford Engine Machines SN 0300100514 to

SN 0300107512 GM Engine Machines Prior to SN 0300107512 D Caterpillar/Deutz/ Ford/GM/Perkins Engine Machines SN

0300107512 to SN 0300124000

Note: USA Manufacture Only.

INSTALLATION for call out)

SN 0300071527)

SN 0300124000)

ASSEMBLY(REAR) For Breakdown)

BRAKE ASSEMBLY (REAR) for Breakdown)

0300100514 (See DRIVE MOTOR ASSEMBLY (2WD) for Breakdown)

SN 0300124000 (See DRIVE MOTOR ASSEMBLY (2WD) For Breakdown)

MOTOR ASSEMBLY (2WD) for Breakdown)

(See DRIVE MOTOR ASSEMBLY (2WD) for Breakdown)

INSTALLATION for call out)

3121243 450A & 450AJ Series II 1-19

SECTION 1 FRAME

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

19 4892000 12 Flatwasher 5/8in Hardened

Ref

0270871 Ref USA Built Machines Prior to SN 0300069155 F 0272320 Ref 0272895 Ref 0275854 Ref 0272320 Ref Belgium Built Machines SN 1300000001 to SN 1300000162 C 0272895 Ref 0275854 Ref

101 0100011 AR Compound, Locking 102 0100019 AR Compound, Locking

103 to 107 Not Used

108 2 Bolt Options:

0641607 USA Built Machines Prior to SN 0300069841

See Note USA Built Machines SN 0300069841 to SN 0300124000 (See

See Note Belgium Built Machines (See FRAME SHIELDS

109 AR Hardware Options:

0681810 8 Bolt 1/2in-13NC x 1-1/4in (Grade 8) (Prior to

0681810 4 Bolt 1/2in-13NC x 1-1/4in (Grade 8) (Front Axle)

3311801 4 Nut 1/2in-13NC (Not Shown) (Rear Axle)

0681810 4 Bolt 1/2in-13NC x 1-1/4in (Grade 8) (Front Axle)

3311801 4 Nut 1/2in-13NC (Not Shown) (Rear Axle)

110 0682014 24 Bolt 5/8in-11NC x 1-3/4in (Grade 8) 111 2 Drive Hub/Brake Assembly (Rear) Options:

2780256 USA Built Machines Prior to SN 0300071527 (See DRIVE

2780267 USA Built Machines SN 0300071527 to SN 0300124000

2780256 Belgium Built Machines SN 1300000001 to SN 1300000162

2780267 Belgium Built Machines SN 1300000162 to SN 1300006000

WHEEL DRIVE INSTALLATIONS (4WD)

USA Built Machines SN 0300069155 to SN 0300071527 C USA Built Machines SN 0300071527 to SN 0300107512 G USA Built Machines SN 0300107512 to SN 0300124000 B

Belgium Built Machines SN 1300000162 to SN 1300003222 G Belgium Built Machines SN 1300003222 to SN 1300006000 B

FRAME SHIELDS INSTALLATION for call out)

INSTALLATION for call out)

USA Built Machines:

SN 0300071527)

(SN 0300071527 to SN 0300124000)

Belgium Built Machines:

(SN 1300000001 to SN 1300006000)

HUB/BRAKE ASSEMBLY(REAR) for Breakdown)

(See DRIVE HUB/BRAKE ASSEMBLY(REAR) for Breakdown)

1-20 450A & 450AJ Series II 3121243

SECTION 1 FRAME

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

112 2 Drive Hub Assembly (Front - Not Shown) Options:

2780257 USA Built Machines Prior to SN 0300071527 (See DRIVE

HUB/BRAKE ASSEMBLY(FRONT) (4WD ONLY) for Breakdown)

2780268 USA Built Machines SN 0300071527 to SN 0300124000 (See

DRIVE HUB/BRAKE ASSEMBLY(FRONT) (4WD ONLY) for Breakdown)

2780257 Belgium Built Machines SN 1300000001 to 1300000162

(See DRIVE HUB/BRAKE ASSEMBLY(FRONT) (4WD ONLY) for Breakdown)

2780268 Belgium Built Machines SN 1300000162 to SN 1300006000

(See DRIVE HUB/BRAKE ASSEMBLY(FRONT) (4WD ONLY) for Breakdown)

113 4 Drive Motor Assembly Options:

3160260 USA Built Machines Prior to SN 0300069155 (See DRIVE

MOTOR ASSEMBLY (4WD) for Breakdown)

3160266 USA Built Machines SN 0300069155 to SN 0300098503

(See DRIVE MOTOR ASSEMBLY (4WD) for Breakdown)

3160348 USA Built Machines SN 0300098503 to SN 0300124000 (See

DRIVE MOTOR ASSEMBLY (4WD) for Breakdown)

3160266 Belgium Built Machines Prior to SN 1300002248 (See DRIVE

MOTOR ASSEMBLY (4WD) for Breakdown)

3160348 Belgium Built Machines SN 1300002248 to SN 1300006000

(See DRIVE MOTOR ASSEMBLY (4WD) for Breakdown)

114 3300106 36 Lugnut

115 to 117 Not Used

118 AR Seal Options:

118A 3790045 2 O-Ring (USA Built Machines Prior to SN 0300103382 &

Belgium Built Machines Prior to SN 1300002637)

118B 3960526 4 Gasket (USA Built Machines SN 0300103382 to SN

0300124000 & Belgium Built Machines SN 1300002637 to

SN 1300006000) 119 Not Used 120 1 Shield, Frame

4061021 USA Built Machines Prior to SN 0300069841

See Note USA Built Machines SN 0300069841 to SN 0300124000 (See

FRAME SHIELDS INSTALLATION for call out)

See Note Belgium Built Machines (See FRAME SHIELDS

INSTALLATION for call out)

121 to 125 Not Used

126 4751600 6 Flatwasher 3/8in Regular 127 4891800 8 Flatwasher 1/2in Hardened 128 4892000 24 Flatwasher 5/8in Hardened

129 to 130 Not Used

131 2300016 AR Fluid, Hydraulic (Not Shown) 132 3020008 AR Lubricant, Mobilube HD 80W - 90 (Not Shown)

3121243 450A & 450AJ Series II 1-21

SECTION 1 FRAME

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref TIRE AND WHEEL INSTALLATIONS

0258028 Ref 12 x 16.5 Pneumatic (Available on ANSI, ANSI Export &

Japanese Specs)

0272299 Ref 0258030 Ref 0270671 Ref

0270674 Ref 0258029 Ref 33/1550 x 16.5 Pneumatic (Available on ANSI, ANSI Export &

0272300 Ref 0258031 Ref 0258831 Ref

0259129 Ref

0257740 2 12 x 16.5 Pneumatic Right Side C 0272357 2 12 x 16.5 Pneumatic TS Right Side A 0257746 2 12 x 16.5 Pneumatic Left Side C 0272356 2 12 x 16.5 Pneumatic TS Left Side A 0258009 2 12 x 16.5 Foam-Filled Right Side C 0258010 2 12 x 16.5 Foam-Filled Left Side C 0270672 2 12 x 16.5 Pneumatic Non-Marking Right Side A 0270673 2 12 x 16.5 Pneumatic Non-Marking Left Side A 0270675 2 12 x 16.5 Foam-Filled Non-Marking Right Side A 0270676 2 12 x 16.5 Foam-Filled Non-Marking Left Side A 0257755 2 33/1550 x 16.5 Pneumatic Right Side C 0272360 2 33/1550 x 16.5 Pneumatic TS Right Side A 0257756 2 33/1550 x 16.5 Pneumatic Left Side C 0272361 2 33/1550 x 16.5 Pneumatic TS Left Side A 0258011 2 33/1550 x 16.5 Foam-Filled Right Side D 0258012 2 33/1550 x 16.5 Foam-Filled Left Side D 0258830 4 33/16LL x 16.1 Pneumatic (Requires special counterweighting) 0259128 4 33/16LL x 16.1 Foam-Filled

Ref

201 1 Decal Options (Pneumatic Only):

1702740 1 Decal - 90PSI 1703067 1 Decal - 40PSI

202 1 Tire Options:

4520216 12 x 16.5 NHS (OTR Brand) 4520240 12 x 16.5 Non-Marking 4520217 33/1550 x 16.5 NHS (OTR Brand) 4520212 33/16LL x 16.1

12 x 16.5 Pneumatic TS (Available on ANSI Specs) 1 12 x 16.5 Foam-Filled (Available on All Specs) A 12 x 16.5 Pneumatic Non-Marking (Available on ANSI, ANSI

Export & Japanese Specs) 12 x 16.5 Foam-Filled Non-Marking (Available on All Specs) B

Japanese Specs) 33/1550 x 16.5 Pneumatic TS (Available on ANSI Specs) 1 33/1550 x 16.5 Foam-Filled (Available on All Specs) B 33/16LL x 16.1 Pneumatic (Available on ANSI, ANSI Export &

Japanese Specs) (Requires special counterweighting)

33/16LL x 16.1 Foam-Filled (Available on All Specs) (Requires special counterweighting)

(Requires special counterweighting)

Note: Assemblies may require ballast/foam filling to manufacture’s specifications prior to installing on a machine. Refer to Operation & Safety or Service & Maintenance Manuals. Purchase individual tire and/or rim only if able to foam fill tire & wheel assembly, otherwise, purchase complete assembly.

1-22 450A & 450AJ Series II 3121243

+ 464 hidden pages

JLG 450A-AJ Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

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

FIGURE 1-2.AXLE AND STEERING INSTALLATION - 2WD WITH TOW BAR

FIGURE 1-3.AXLE AND STEERING INSTALLATION - 4WD

FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS