JLG 400S 460SJ Parts Manual (3121236) – PDF Download (Eng)

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JLG 400S 460SJ Parts Manual (3121236) – PDF Download

TABLE OF CONTENTS:
JLG 400S 460SJ Parts Manual (3121236) – PDF Download

SECTION 1 - FRAME...................................................................................................................................................... 11
	FIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW PACKAGE............................................................................................... 12
	FIGURE 1-2. AXLE AND STEERING INSTALLATION - 2WD WITH TOW PACKAGE.................................................................................................. 18
	FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD (SN 0300096000 through 0300161284)................................................................................ 24
	FIGURE 1-4. AXLE AND STEERING INSTALLATION - 4WD (SN 0300161285 through 0300203770)................................................................................ 28
	FIGURE 1-5. TIRE AND WHEEL DRIVE INSTALLATIONS..................................................................................................................... 32
	FIGURE 1-6. DRIVE HUB AND HUB WITH BRAKE ASSEMBLIES................................................................................................................ 36
	FIGURE 1-7. DRIVE MOTOR ASSEMBLY - 4 BOLT (SN 0300096000 through 0300098501)....................................................................................... 40
	FIGURE 1-8. DRIVE MOTOR ASSEMBLY - 5 BOLT (SN 0300098502 through 0300203770)....................................................................................... 44
	FIGURE 1-9. FRAME VALVES AND SHIELDS INSTALLATION (SN 0300096000 through 0300115395)............................................................................... 48
	FIGURE 1-10. FRAME VALVES AND SHIELDS INSTALLATION (SN 0300115396 through 0300203770).............................................................................. 50
	FIGURE 1-11. SEMI-TRACK INSTALLATION............................................................................................................................... 54
	FIGURE 1-12. TOW PACKAGE INSTALLATION.............................................................................................................................. 58
SECTION 2 - TURNTABLE.................................................................................................................................................. 61
	FIGURE 2-1. VALVES INSTALLATIONS................................................................................................................................... 62
	FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY............................................................................................................................ 64
	FIGURE 2-3. ACCESSORY VALVE ASSEMBLY............................................................................................................................... 68
	FIGURE 2-4. TURNTABLE AND SWING DRIVE INSTALLATIONS................................................................................................................ 70
	FIGURE 2-5. SWING HUB ASSEMBLY (SN 0300096000 through 0300137200).................................................................................................. 74
	FIGURE 2-6. SWING MOTOR ASSEMBLY (SN 0300096000 through 0300137200)................................................................................................ 76
	FIGURE 2-7. SWING MOTOR/BRAKE/HUB ASSEMBLY (SN 0300137201 through 0300203770)...................................................................................... 78
	FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION - WITH ELECTRICAL DRIVEN COOLING FAN (WITHOUT UGM)..................................................................... 82
	FIGURE 2-9. CATERPILLAR ENGINE INSTALLATION - WITH MECHANICAL DRIVEN COOLING FAN (WITHOUT UGM)..................................................................... 90
	FIGURE 2-10. CATERPILLAR ENGINE INSTALLATION (WITH UGM)............................................................................................................ 98
	FIGURE 2-11. DEUTZ D2011 ENGINE INSTALLATION.......................................................................................................................106
	FIGURE 2-12. DEUTZ TD2.9L4 ENGINE INSTALLATION.....................................................................................................................116
	FIGURE 2-13. GM ENGINE INSTALLATION (WITHOUT UGM)..................................................................................................................128
	FIGURE 2-14. GM ENGINE INSTALLATION (WITH UGM).....................................................................................................................134
	FIGURE 2-15. PERKINS ENGINE INSTALLATION - WITH ELECTRICAL DRIVEN COOLING FAN (WITHOUT UGM)........................................................................140
	FIGURE 2-16. PERKINS ENGINE INSTALLATION - WITH MECHANICAL DRIVEN COOLING FAN (WITHOUT UGM)........................................................................150
	FIGURE 2-17. PERKINS ENGINE INSTALLATION (WITH UGM)................................................................................................................158
	FIGURE 2-18. PISTON PUMP ASSEMBLY..................................................................................................................................166
	FIGURE 2-19. AUXILIARY PUMP ASSEMBLY...............................................................................................................................170
	FIGURE 2-20. DUAL FUEL INSTALLATIONS (GM MACHINES ONLY)............................................................................................................174
	FIGURE 2-21. TANK INSTALLATIONS....................................................................................................................................178
	FIGURE 2-22. ROTARY COUPLING INSTALLATION (SN 0300096000 through 0300140364).......................................................................................182
	FIGURE 2-23. ROTARY COUPLING INSTALLATION (SN 0300140365 through 0300203770).......................................................................................184
	FIGURE 2-24. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM).............................................................................................................186
	FIGURE 2-25. GROUND CONTROL BOX ASSEMBLY (WITH UGM) (SN 0300069000 through 0300177682).............................................................................190
	FIGURE 2-26. GROUND CONTROL BOX ASSEMBLY (WITH UGM) (SN 0300177683 through 0300203770).............................................................................194
	FIGURE 2-27. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED)...................................................................................................198
	FIGURE 2-28. HOODS INSTALLATION (SN 0300096000 through 0300126456).................................................................................................202
	FIGURE 2-29. HOODS INSTALLATION (SN 0300126457 through 0300203770).................................................................................................206
	FIGURE 2-30. 2500W GENERATOR INSTALLATION - CATERPILLAR ENGINE MACHINES (OPTIONAL).................................................................................212
	FIGURE 2-31. 2500W GENERATOR INSTALLATION - DEUTZ D2011 ENGINE MACHINES (OPTIONAL).................................................................................216
	FIGURE 2-32. 2500W GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINE MACHINES (OPTIONAL)...............................................................................220
	FIGURE 2-33. 2500W GENERATOR INSTALLATION - GM ENGINES MACHINES (OPTIONAL).........................................................................................224
	FIGURE 2-34. 4000W GENERATOR INSTALLATION - DEUTZ D2011 ENGINE MACHINES (OPTIONAL).................................................................................228
	FIGURE 2-35. 4000W GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINE MACHINES (OPTIONAL)...............................................................................232
	FIGURE 2-36. 4000W GENERATOR INSTALLATION - GM ENGINES.............................................................................................................236
	FIGURE 2-37. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR, DEUTZ D2011 AND PERKINS ENGINE MACHINES..........................................................240
	FIGURE 2-38. 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINE MACHINES.................................................................................246
	FIGURE 2-39. 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINE MACHINES............................................................................................250
	FIGURE 2-40. SKYAIR AIR COMPRESSOR INSTALLATION....................................................................................................................256
	FIGURE 2-41. AIR COMPRESSOR ASSEMBLY...............................................................................................................................258
SECTION 3 - BOOM.......................................................................................................................................................261
	FIGURE 3-1. BOOM INSTALLATIONS.....................................................................................................................................262
	FIGURE 3-2. BOOM ASSEMBLY - 400S...................................................................................................................................266
	FIGURE 3-3. BOOM ASSEMBLY - 460SJ..................................................................................................................................270
	FIGURE 3-4. ROTATOR ASSEMBLIES (SN 0300096000 through 0300200817)..................................................................................................274
	FIGURE 3-5. ROTATOR ASSEMBLIES (SN 0300200818 through 0300203770)..................................................................................................276
	FIGURE 3-6. PLATFORM SUPPORT INSTALLATION - WITH LSS...............................................................................................................278
	FIGURE 3-7. PLATFORM AND GLAZIER SUPPORT INSTALLATION - WITH LSS (400S ONLY).......................................................................................282
SECTION 4 - PLATFORM...................................................................................................................................................285
	FIGURE 4-1. PLATFORM INSTALLATION..................................................................................................................................286
	FIGURE 4-2. PLATFORM COMPONENTS INSTALLATION (FALL ARREST PLATFORM)................................................................................................292
	FIGURE 4-3. SOFT TOUCH INSTALLATION (OPTIONAL).....................................................................................................................294
	FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY..............................................................................................................................296
	FIGURE 4-5. CONTROLLER ASSEMBLY (LIFT AND SWING)...................................................................................................................302
	FIGURE 4-6. CONTROLLER ASSEMBLY (LIFT AND SWING)...................................................................................................................304
	FIGURE 4-7. CONTROLLER ASSEMBLY (SWING AND LIFT)...................................................................................................................306
	FIGURE 4-8. CONTROLLER ASSEMBLY (DRIVE AND STEER)..................................................................................................................310
	FIGURE 4-9. CONTROLLER ASSEMBLY (DRIVE AND STEER)..................................................................................................................312
	FIGURE 4-10. CONTROLLER ASSEMBLY (DRIVE AND STEER).................................................................................................................314
	FIGURE 4-11. SKYGUARD SYSTEM INSTALLATION..........................................................................................................................316
	FIGURE 4-12. CROSS RAIL INSTALLATION...............................................................................................................................318
	FIGURE 4-13. SKYGLAZIER INSTALLATION...............................................................................................................................320
	FIGURE 4-14. SKYWELDER/SKYCUTTER COMBO INSTALLATION (60HZ).........................................................................................................324
	FIGURE 4-15. SKYWELDER INSTALLATION (50HZ).........................................................................................................................328
	FIGURE 4-16. SKYWELDER INSTALLATION (60HZ).........................................................................................................................330
	FIGURE 4-17. SKYWELDER PREP PACKAGE (60HZ).........................................................................................................................332
	FIGURE 4-18. WELDER ASSEMBLY.......................................................................................................................................334
	FIGURE 4-19. SKYCUTTER INSTALLATION................................................................................................................................336
	FIGURE 4-20. PLASMA CUTTER ASSEMBLY................................................................................................................................338
	FIGURE 4-21. PIPE RACKS INSTALLATION...............................................................................................................................340
SECTION 5 - CYLINDER...................................................................................................................................................343
	FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY (SN 0300096000 through 0300115395)......................................................................................344
	FIGURE 5-2. AXLE LOCKOUT CYLINDER ASSEMBLY (SN 0300115396 through 0300203770)......................................................................................346
	FIGURE 5-3. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY...............................................................................................................348
	FIGURE 5-4. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY - 400S........................................................................................................350
	FIGURE 5-5. LIFT CYLINDER ASSEMBLY - JIB (460SJ) (ORIGINAL EQUIPMENT)..............................................................................................352
	FIGURE 5-6. LIFT CYLINDER ASSEMBLY - JIB (460SJ) (USAGE MAY VARY) (SERVICE REPLACEMENT)............................................................................354
	FIGURE 5-7. LIFT CYLINDER ASSEMBLY - JIB (460SJ) (USAGE MAY VARY) (SERVICE REPLACEMENT)............................................................................356
	FIGURE 5-8. LIFT CYLINDER ASSEMBLY - MAIN..........................................................................................................................358
	FIGURE 5-9. MASTER CYLINDER ASSEMBLY (ORIGINAL EQUIPMENT FOR) (SN 0300096000 through 0300165144)...................................................................360
	FIGURE 5-10. MASTER CYLINDER ASSEMBLY (SERVICE REPLACEMENT FOR SN 0300096000 THROUGH SN 0300165144 AND ORIGINAL EQUIPMENT FOR SN 0300165145 THROUGH 0300203770)....362
	FIGURE 5-11. STEER CYLINDER ASSEMBLY (SN 0300096000 through 0300161284)............................................................................................364
	FIGURE 5-12. STEER CYLINDER ASSEMBLY (SN 0300161285 through 0300203770)............................................................................................366
	FIGURE 5-13. TELESCOPE CYLINDER ASSEMBLY...........................................................................................................................368
SECTION 6 - HYDRAULIC..................................................................................................................................................371
	FIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM (SN 0300096000 through 0300115395)......................................................................................372
	FIGURE 6-2. AXLE LOCKOUT HYDRAULIC DIAGRAM (ANSI SPEC) (SN 0300115396 through 0300140364)..........................................................................374
	FIGURE 6-3. AXLE LOCKOUT HYDRAULIC DIAGRAM (CE SPEC) (SN 0300115396 through 0300140364)............................................................................376
	FIGURE 6-4. AXLE LOCKOUT HYDRAULIC DIAGRAM (ANSI AND CE SPEC) (SN 0300140365 through 0300203770)...................................................................378
	FIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300096000 through 0300115395).......................................................................................380
	FIGURE 6-6. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300115396 through 0300140364).......................................................................................382
	FIGURE 6-7. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300140365 through 0300203770).......................................................................................384
	FIGURE 6-8. DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300096000 through 0300115395).......................................................................................386
	FIGURE 6-9. DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300115396 through 0300140364).......................................................................................390
	FIGURE 6-10. DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300140365 through 0300203770)......................................................................................392
	FIGURE 6-11. STANDARD HYDRAULIC DIAGRAM............................................................................................................................394
	FIGURE 6-12. STANDARD HYDRAULIC DIAGRAM............................................................................................................................398
	FIGURE 6-13. STANDARD HYDRAULIC DIAGRAM............................................................................................................................402
	FIGURE 6-14. STANDARD HYDRAULIC DIAGRAM............................................................................................................................406
	FIGURE 6-15. HYDRAULIC DIAGRAM LIST................................................................................................................................410
SECTION 7 - ELECTRICAL.................................................................................................................................................413
	FIGURE 7-1. ELECTRICAL DIAGRAM LIST................................................................................................................................414
	FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (MACHINES WITHOUT UGM).................................................................................................416
	FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (MACHINES WITH UGM) (SN 0300069000 through 0300177682).................................................................432
	FIGURE 7-4. HARNESS COMPONENTS INSTALLATION (MACHINES WITH UGM) (SN 0300177683 through 0300203770).................................................................448
SECTION 8 - DECALS.....................................................................................................................................................465
	FIGURE 8-1. DECAL INSTALLATION (ANSI SPEC).........................................................................................................................466
	FIGURE 8-2. DECAL INSTALLATION (ANSI EXPORT SPECS).................................................................................................................470
	FIGURE 8-3. DECAL INSTALLATION (AUSTRALIAN AND CE SPECS)...........................................................................................................478
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK............................................................................................................................481
	FIGURE 9-1. MODEL 400S/460SJ STANDARD PARTS........................................................................................................................482
	FIGURE 9-2. MODEL 400S/460SJ VARIABLE PARTS........................................................................................................................484
SECTION 10 - SPECIAL OPTIONS...........................................................................................................................................485
	FIGURE 10-1. SPECIAL OPTIONS LIST..................................................................................................................................486
PART NUMBER INDEX......................................................................................................................................................493

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