JLG 400S 460SJ Parts Manual (3120896) PDF Download – PDF DOWNLOAD (Eng)

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JLG 400S 460SJ Parts Manual (3120896) PDF Download – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 400S 460SJ Parts Manual (3120896) PDF Download – 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. PISTON PUMP ASSEMBLY...............................................................................................................100
	FIGURE 2-12. GEAR PUMP ASSEMBLY.................................................................................................................104
	FIGURE 2-13. AUXILIARY PUMP ASSEMBLY............................................................................................................106
	FIGURE 2-14. TANK INSTALLATIONS.................................................................................................................110
	FIGURE 2-15. GROUND CONTROL BOX ASSEMBLY WITHOUT ADE SYSTEM.....................................................................................114
	FIGURE 2-16. GROUND CONTROL BOX ASSEMBLY WITH ADE SYSTEM........................................................................................118
	FIGURE 2-17. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED)................................................................................122
	FIGURE 2-18. HOODS INSTALLATION.................................................................................................................126
	FIGURE 2-19. GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL)...........................................................................130
	FIGURE 2-20. GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL).................................................................................132
	FIGURE 2-21. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR AND DEUTZ ENGINES..............................................................136
SECTION 3 - BOOM....................................................................................................................................141
	FIGURE 3-1. BOOM INSTALLATIONS..................................................................................................................142
	FIGURE 3-2. BOOM ASSEMBLY - 400S................................................................................................................146
	FIGURE 3-3. BOOM ASSEMBLY - 460SJ...............................................................................................................150
	FIGURE 3-4. ROTATOR ASSEMBLIES..................................................................................................................154
	FIGURE 3-5. PLATFORM SUPPORT INSTALLATION - WITH LSS............................................................................................158
SECTION 4 - PLATFORM................................................................................................................................161
	FIGURE 4-1. PLATFORM INSTALLATION (FRONT ENTRY PLATFORM)........................................................................................162
	FIGURE 4-2. PLATFORM INSTALLATION - SIDE ENTRY PLATFORM.........................................................................................166
	FIGURE 4-3. SOFT TOUCH INSTALLATION (FRONT ENTRY PLATFORM) (OPTIONAL)...........................................................................170
	FIGURE 4-4. SOFT TOUCH INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL)............................................................................172
	FIGURE 4-5. PLATFORM CONSOLE ASSEMBLY WITHOUT ADE SYSTEM........................................................................................174
	FIGURE 4-6. PLATFORM CONSOLE ASSEMBLY WITH ADE SYSTEM...........................................................................................180
	FIGURE 4-7. CONTROLLER ASSEMBLY (SWING AND LIFT) (WITHOUT ADE SYSTEM)...........................................................................184
	FIGURE 4-8. CONTROLLER ASSEMBLY (LIFT AND SWING) (WITH ADE SYSTEM)..............................................................................186
	FIGURE 4-9. CONTROLLER ASSEMBLY (LIFT AND SWING) (WITH ADE SYSTEM)..............................................................................188
	FIGURE 4-10. CONTROLLER ASSEMBLY (LIFT AND SWING) (WITH ADE SYSTEM).............................................................................190
	FIGURE 4-11. CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITHOUT ADE SYSTEM).........................................................................194
	FIGURE 4-12. CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITH ADE SYSTEM)............................................................................196
	FIGURE 4-13. CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITH ADE SYSTEM)............................................................................198
	FIGURE 4-14. CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITH ADE SYSTEM)............................................................................200
	FIGURE 4-15. SKYCUTTER INSTALLATION.............................................................................................................202
	FIGURE 4-16. PLASMA CUTTER ASSEMBLY.............................................................................................................204
	FIGURE 4-17. SKYWELDER INSTALLATION (Prior to SN 0300068333)....................................................................................206
	FIGURE 4-18. SKYWELDER INSTALLATION (50HZ) (SN 0300068333 through 0300096000)...................................................................212
	FIGURE 4-19. WELDER ASSEMBLY....................................................................................................................214
	FIGURE 4-20. PIPE RACKS INSTALLATION............................................................................................................216
SECTION 5 - CYLINDER................................................................................................................................219
	FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY......................................................................................................220
	FIGURE 5-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY............................................................................................222
	FIGURE 5-3. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY (400S - SERVICE REPLACEMENT CYLINDER)......................................................224
	FIGURE 5-4. LIFT CYLINDER ASSEMBLY - JIB (460SJ) (ORIGINAL EQUIPMENT)...........................................................................226
	FIGURE 5-5. LIFT CYLINDER ASSEMBLY - JIB (460SJ) (USAGE MAY VARY) (SERVICE REPLACEMENT).........................................................228
	FIGURE 5-6. LIFT CYLINDER ASSEMBLY - JIB (460SJ) (USAGE MAY VARY) (SERVICE REPLACEMENT).........................................................230
	FIGURE 5-7. LIFT CYLINDER ASSEMBLY - MAIN.......................................................................................................232
	FIGURE 5-8. MASTER CYLINDER ASSEMBLY (ORIGINAL EQUIPMENT).......................................................................................234
	FIGURE 5-9. MASTER CYLINDER ASSEMBLY (SERVICE REPLACEMENT)......................................................................................236
	FIGURE 5-10. STEER CYLINDER ASSEMBLY (ORIGINAL EQUIPMENT) (Prior to SN 0300087392)..............................................................238
	FIGURE 5-11. STEER CYLINDER ASSEMBLY (SERVICE REPLACEMENT AND ORIGINAL EQUIPMENT) (Prior to SN 0300087392, SN 0300087392 through 0300096000)....240
	FIGURE 5-12. TELESCOPE CYLINDER ASSEMBLY........................................................................................................242
SECTION 6 - HYDRAULIC...............................................................................................................................245
	FIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM......................................................................................................246
	FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD.......................................................................................................248
	FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 4WD.......................................................................................................250
	FIGURE 6-4. STANDARD HYDRAULIC DIAGRAM..........................................................................................................254
	FIGURE 6-5. HYDRAULIC DIAGRAM LIST..............................................................................................................258
SECTION 7 - ELECTRICAL..............................................................................................................................259
	FIGURE 7-1. ELECTRICAL DIAGRAM LIST.............................................................................................................260
	FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT ADE SYSTEM)................................................................................262
	FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITH ADE SYSTEM)...................................................................................270
SECTION 8 - DECALS..................................................................................................................................281
	FIGURE 8-1. DECAL INSTALLATION (Prior to SN 0300085617).........................................................................................282
	FIGURE 8-2. DECAL INSTALLATION (SN 0300085617 through 0300095670)...............................................................................288
	FIGURE 8-3. DECAL INSTALLATION (SN 0300095671 through 0300096000)...............................................................................292
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK.........................................................................................................295
	FIGURE 9-1. MODEL 400S/460SJ STANDARD PARTS.....................................................................................................296
	FIGURE 9-2. MODEL 400S/460SJ VARIABLE PARTS.....................................................................................................298
SECTION 10 - SPECIAL OPTIONS........................................................................................................................299
	FIGURE 10-1. SPECIAL OPTIONS LIST...............................................................................................................300
PART NUMBER INDEX...................................................................................................................................305

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• This is the SAME exact manual used by your dealers to fix your vehicle.
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