JLG 400S 460Sj Parts Manual (3120789) – PDF DOWNLOAD

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JLG 400S 460Sj Parts Manual (3120789) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 400S 460Sj Parts Manual (3120789) – PDF DOWNLOAD

SECTION 1 - FRAME...................................................................................................................................  9
	FIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW PACKAGE............................................................................ 10
	FIGURE 1-2. AXLE AND STEERING INSTALLATION - 2WD WITH TOW PACKAGE............................................................................... 14
	FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD................................................................................................ 18
	FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS.................................................................................................. 24
	FIGURE 1-5. DRIVE HUB ASSEMBLY (4WD FRONT) (Prior to SN 0300076633)............................................................................. 28
	FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY (REAR) (Prior to SN 0300076633)............................................................................ 30
	FIGURE 1-7. DRIVE HUB AND HUB WITH BRAKE ASSEMBLIES (SN 0300076633 through 0300096000).......................................................... 34
	FIGURE 1-8. DRIVE MOTOR ASSEMBLY (ORIGINAL EQUIPMENT - 4 BOLT ASSEMBLY)......................................................................... 38
	FIGURE 1-9. DRIVE MOTOR ASSEMBLY (FIELD SERVICE REPLACEMENT - 5 BOLT ASSEMBLY).................................................................. 42
	FIGURE 1-10. FRAME VALVES AND SHIELDS INSTALLATION.............................................................................................. 46
	FIGURE 1-11. SEMI-TRACK INSTALLATION............................................................................................................ 50
	FIGURE 1-12. TOW PACKAGE INSTALLATION........................................................................................................... 54
SECTION 2 - TURNTABLE............................................................................................................................... 57
	FIGURE 2-1. VALVES AND TILT INDICATOR INSTALLATIONS............................................................................................. 58
	FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY......................................................................................................... 62
	FIGURE 2-3. ARTICULATING JIB VALVE ASSEMBLY..................................................................................................... 66
	FIGURE 2-4. TURNTABLE AND SWING DRIVE INSTALLATIONS............................................................................................. 68
	FIGURE 2-5. SWING BRAKE ASSEMBLY................................................................................................................ 72
	FIGURE 2-6. SWING HUB ASSEMBLY.................................................................................................................. 74
	FIGURE 2-7. SWING MOTOR ASSEMBLY................................................................................................................ 76
	FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION..................................................................................................... 78
	FIGURE 2-9. DEUTZ ENGINE INSTALLATION (Prior to SN 0300077682).................................................................................. 86
	FIGURE 2-10. DEUTZ ENGINE INSTALLATION (SN 0300077682 through 0300096000)....................................................................... 92
	FIGURE 2-11. FORD ENGINE INSTALLATION (Prior to SN 0300078473)..................................................................................100
	FIGURE 2-12. FORD ENGINE INSTALLATION (SN 0300078473 through 0300096000)........................................................................108
	FIGURE 2-13. DUAL FUEL INSTALLATIONS (GAS MACHINES ONLY)........................................................................................116
	FIGURE 2-14. GM ENGINE INSTALLATION.............................................................................................................120
	FIGURE 2-15. ISUZU ENGINE INSTALLATION - 4LE1...................................................................................................126
	FIGURE 2-16. PISTON PUMP ASSEMBLY...............................................................................................................130
	FIGURE 2-17. GEAR PUMP ASSEMBLY.................................................................................................................134
	FIGURE 2-18. AUXILIARY PUMP ASSEMBLY............................................................................................................136
	FIGURE 2-19. TANK INSTALLATIONS.................................................................................................................140
	FIGURE 2-20. GROUND CONTROL BOX ASSEMBLY WITHOUT ADE SYSTEM.....................................................................................144
	FIGURE 2-21. GROUND CONTROL BOX ASSEMBLY WITH ADE SYSTEM........................................................................................148
	FIGURE 2-22. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED)................................................................................154
	FIGURE 2-23. HOODS INSTALLATION.................................................................................................................158
	FIGURE 2-24. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL).....................................................................162
	FIGURE 2-25. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)...........................................................................166
	FIGURE 2-26. 2500W GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL) (Prior to SN 0300078473)...................................................170
	FIGURE 2-27. 2500W GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL) (SN 0300078473 through 0300096000).........................................174
	FIGURE 2-28. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL)..............................................................................178
	FIGURE 2-29. 2500W GENERATOR INSTALLATION - ISUZU MACHINES (OPTIONAL)...........................................................................182
	FIGURE 2-30. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR AND DEUTZ ENGINES..............................................................186
	FIGURE 2-31. 7500W SKYPOWER GENERATOR INSTALLATION - FORD ENGINES...............................................................................192
	FIGURE 2-32. 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINES.................................................................................196
	FIGURE 2-33. SKYAIR COMPRESSOR INSTALLATION.....................................................................................................202
	FIGURE 2-34. SKYAIR COMPRESSOR PARTS............................................................................................................204
SECTION 3 - BOOM....................................................................................................................................207
	FIGURE 3-1. BOOM INSTALLATIONS..................................................................................................................208
	FIGURE 3-2. BOOM ASSEMBLY - 400S................................................................................................................212
	FIGURE 3-3. BOOM ASSEMBLY - 460SJ...............................................................................................................216
	FIGURE 3-4. ROTATOR ASSEMBLIES..................................................................................................................220
	FIGURE 3-5. PLATFORM SUPPORT INSTALLATION - WITH LSS & WITHOUT SKYGLAZIER.......................................................................224
SECTION 4 - PLATFORM................................................................................................................................227
	FIGURE 4-1. PLATFORM INSTALLATION (FRONT ENTRY PLATFORM)........................................................................................228
	FIGURE 4-2. PLATFORM INSTALLATION (SIDE ENTRY PLATFORM).........................................................................................232
	FIGURE 4-3. SOFT TOUCH INSTALLATION (FRONT ENTRY PLATFORM) (OPTIONAL)...........................................................................236
	FIGURE 4-4. SOFT TOUCH INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL)............................................................................238
	FIGURE 4-5. PLATFORM CONSOLE ASSEMBLY WITHOUT ADE SYSTEM........................................................................................240
	FIGURE 4-6. PLATFORM CONSOLE ASSEMBLY WITH ADE SYSTEM...........................................................................................244
	FIGURE 4-7. CONTROLLER ASSEMBLY (SWING AND LIFT) (WITHOUT ADE SYSTEM)...........................................................................248
	FIGURE 4-8. CONTROLLER ASSEMBLY (LIFT AND SWING) (WITH ADE SYSTEM)..............................................................................250
	FIGURE 4-9. CONTROLLER ASSEMBLY (LIFT AND SWING) (WITH ADE SYSTEM)..............................................................................252
	FIGURE 4-10. CONTROLLER ASSEMBLY (LIFT AND SWING) (WITH ADE SYSTEM).............................................................................254
	FIGURE 4-11. CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITHOUT ADE SYSTEM).........................................................................258
	FIGURE 4-12. CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITH ADE SYSTEM)............................................................................260
	FIGURE 4-13. CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITH ADE SYSTEM)............................................................................262
	FIGURE 4-14. CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITH ADE SYSTEM)............................................................................264
	FIGURE 4-15. SKYGLAZIER INSTALLATION............................................................................................................266
	FIGURE 4-16. SKYCUTTER INSTALLATION.............................................................................................................268
	FIGURE 4-17. PLASMA CUTTER ASSEMBLY.............................................................................................................270
	FIGURE 4-18. SKYWELDER/SKYCUTTER COMBO INSTALLATION (60HZ)......................................................................................272
	FIGURE 4-19. SKYWELDER INSTALLATION (Prior to SN 0300068333)....................................................................................276
	FIGURE 4-20. SKYWELDER INSTALLATION (50HZ) (SN 0300068333 through 0300096000)...................................................................282
	FIGURE 4-21. SKYWELDER INSTALLATION (60HZ) (SN 0300068333 through 0300096000)...................................................................284
	FIGURE 4-22. WELDER ASSEMBLY....................................................................................................................286
	FIGURE 4-23. PIPE RACKS INSTALLATION............................................................................................................288
SECTION 5 - CYLINDER................................................................................................................................291
	FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY......................................................................................................292
	FIGURE 5-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY............................................................................................294
	FIGURE 5-3. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY (400S - SERVICE REPLACEMENT CYLINDER)......................................................296
	FIGURE 5-4. LIFT CYLINDER ASSEMBLY - JIB (460SJ) (ORIGINAL EQUIPMENT)...........................................................................298
	FIGURE 5-5. LIFT CYLINDER ASSEMBLY - JIB (460SJ) (USAGE MAY VARY) (SERVICE REPLACEMENT).........................................................300
	FIGURE 5-6. LIFT CYLINDER ASSEMBLY - JIB (460SJ) (USAGE MAY VARY) (SERVICE REPLACEMENT).........................................................302
	FIGURE 5-7. LIFT CYLINDER ASSEMBLY - MAIN.......................................................................................................304
	FIGURE 5-8. MASTER CYLINDER ASSEMBLY (ORIGINAL EQUIPMENT).......................................................................................306
	FIGURE 5-9. MASTER CYLINDER ASSEMBLY (SERVICE REPLACEMENT)......................................................................................308
	FIGURE 5-10. STEER CYLINDER ASSEMBLY (ORIGINAL EQUIPMENT) (Prior to SN 0300087392)..............................................................310
	FIGURE 5-11. STEER CYLINDER ASSEMBLY (SERVICE REPLACEMENT AND ORIGINAL EQUIPMENT) (Prior to SN 0300087392, SN 0300087392 through 0300096000)....312
	FIGURE 5-12. TELESCOPE CYLINDER ASSEMBLY........................................................................................................314
SECTION 6 - HYDRAULIC...............................................................................................................................317
	FIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM......................................................................................................318
	FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD.......................................................................................................320
	FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 4WD.......................................................................................................322
	FIGURE 6-4. STANDARD HYDRAULIC DIAGRAM..........................................................................................................326
	FIGURE 6-5. HYDRAULIC DIAGRAM LIST..............................................................................................................330
SECTION 7 - ELECTRICAL..............................................................................................................................331
	FIGURE 7-1. ELECTRICAL DIAGRAM LIST.............................................................................................................332
	FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT ADE SYSTEM)................................................................................334
	FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITH ADE SYSTEM)...................................................................................342
SECTION 8 - DECALS..................................................................................................................................353
	FIGURE 8-1. DECAL INSTALLATION (ANSI SPEC)......................................................................................................354
	FIGURE 8-2. DECAL INSTALLATION (COUNTRY SPEC)...................................................................................................358
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK.........................................................................................................365
	FIGURE 9-1. MODEL 400S/460SJ STANDARD PARTS.....................................................................................................366
	FIGURE 9-2. MODEL 400S/460SJ VARIABLE PARTS.....................................................................................................368
SECTION 10 - SPECIAL OPTIONS........................................................................................................................369
	FIGURE 10-1. SPECIAL OPTIONS LIST...............................................................................................................370
PART NUMBER INDEX...................................................................................................................................375

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