JLG 400S 460SJ PVC 2001 2007 Parts Manual (31215017) – PDF DOWNLOAD

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JLG 400S 460SJ PVC 2001 2007 Parts Manual (31215017) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 400S 460SJ PVC 2001 2007 Parts Manual (31215017) – PDF DOWNLOAD

SECTION 1 - FRAME............................................................................................................................ 13
	FIGURE 1-1. AXLE INSTALLATION............................................................................................................ 14
	FIGURE 1-2. STEER INSTALLATION WITHOUT TOW PACKAGE....................................................................................... 16
	FIGURE 1-3. STEER INSTALLATION WITH TOW PACKAGE.......................................................................................... 18
	FIGURE 1-4. WHEEL DRIVE INSTALLATION (2WD)............................................................................................... 20
	FIGURE 1-5. WHEEL DRIVE INSTALLATION (4WD)............................................................................................... 22
	FIGURE 1-6. DRIVE HUB AND BRAKE ASSEMBLY - REAR.......................................................................................... 24
	FIGURE 1-7. DRIVE HUB ASSEMBLY - FRONT................................................................................................... 28
	FIGURE 1-8. HUB - SPINDLE ASSEMBLY (2WD)................................................................................................. 30
	FIGURE 1-9. DRIVE MOTOR ASSEMBLY (2WD)................................................................................................... 32
	FIGURE 1-10. DRIVE MOTOR ASSEMBLY (4WD).................................................................................................. 34
	FIGURE 1-11. TRACTION VALVE ASSEMBLY (2WD)............................................................................................... 36
	FIGURE 1-12. TRACTION VALVE ASSEMBLY (4WD)............................................................................................... 38
	FIGURE 1-13. TIRE AND WHEEL INSTALLATION - 12 X 16.5 FOAM FILLED (AVAILABLE ON ALL SPECS)................................................ 40
	FIGURE 1-14. TIRE AND WHEEL INSTALLATION - 12 X 16.5 FF NON-MARKING (AVAILABLE ON ALL SPECS)............................................. 42
	FIGURE 1-15. TIRE AND WHEEL INSTALLATION - 14 X 17.5 FOAM FILLED (AVAILABLE ON ALL SPECS)................................................ 44
	FIGURE 1-16. FRAME SHIELD INSTALLATION - WITHOUT TOW BAR................................................................................. 46
	FIGURE 1-17. FRAME SHIELD INSTALLATION - WITH TOW BAR.................................................................................... 48
	FIGURE 1-18. TOW BAR INSTALLATION........................................................................................................ 50
	FIGURE 1-19. TOW BAR ASSEMBLY............................................................................................................ 52
	FIGURE 1-20. LP TANK BRACKETS INSTALLATION............................................................................................... 54
SECTION 2 - TURNTABLE........................................................................................................................ 57
	FIGURE 2-1. CONTROL VALVES INSTALLATION - 400S........................................................................................... 58
	FIGURE 2-2. CONTROL VALVES INSTALLATION - 460SJ.......................................................................................... 60
	FIGURE 2-3. MAIN VALVE ASSEMBLY - 400S................................................................................................... 62
	FIGURE 2-4. MAIN VALVE ASSEMBLY - 460SJ.................................................................................................. 66
	FIGURE 2-5. AXLE VALVE ASSEMBLY.......................................................................................................... 70
	FIGURE 2-6. SWING DRIVE INSTALLATION..................................................................................................... 72
	FIGURE 2-7. SWING HUB/MOTOR ASSEMBLY..................................................................................................... 74
	FIGURE 2-8. TURNTABLE BEARING INSTALLATION............................................................................................... 78
	FIGURE 2-9. BEARING LUBE INSTALLATION.................................................................................................... 80
	FIGURE 2-10. TURNTABLE LOCK INSTALLATION................................................................................................. 82
	FIGURE 2-11. ROTARY COUPLING INSTALLATION................................................................................................ 84
	FIGURE 2-12. TANKS INSTALLATION - DIESEL MACHINES........................................................................................ 86
	FIGURE 2-13. TANKS INSTALLATION - GAS MACHINES........................................................................................... 88
	FIGURE 2-14. HYDRAULIC TANK ASSEMBLY..................................................................................................... 90
	FIGURE 2-15. AUXILIARY PUMP AND BATTERY INSTALLATION..................................................................................... 92
	FIGURE 2-16. AUXILIARY PUMP AND BATTERY WITH DISCONNECT SWITCH INSTALLATION.............................................................. 94
	FIGURE 2-17. AUXILIARY PUMP ASSEMBLY..................................................................................................... 96
	FIGURE 2-18. ELECTRICAL INSTALLATION - 400S.............................................................................................. 98
	FIGURE 2-19. ELECTRICAL INSTALLATION - 460SJ.............................................................................................100
	FIGURE 2-20. ELECTRICAL INSTALLATION – 460SJ WITH DEUTZ (STAGE V)........................................................................102
	FIGURE 2-21. ELECTRICAL PANEL ASSEMBLY...................................................................................................104
	FIGURE 2-22. WHITE NOISE ALARM INSTALLATION..............................................................................................106
	FIGURE 2-23. GROUND CONTROL ASSEMBLY – 400S..............................................................................................108
	FIGURE 2-24. GROUND CONTROL ASSEMBLY – 460SJ.............................................................................................110
	FIGURE 2-25. GROUND CONTROL ASSEMBLY - DEUTZ (STAGE V) (460SJ) (CE SPECS)................................................................112
	FIGURE 2-26. GROUND CONTROL DECAL AND KEYSWITCH INSTALLATION - 400S (ALL SPECS EXCEPT AUSTRALIAN AND CE SPECS)...........................114
	FIGURE 2-27. GROUND CONTROL DECAL AND KEYSWITCH INSTALLATION - 400S (ANSI EXPORT SPECS) (PVC 2001).......................................116
	FIGURE 2-28. GROUND CONTROL DECAL AND KEYSWITCH INSTALLATION - 460SJ (ALL SPECS EXCEPT CE SPEC)..........................................118
	FIGURE 2-29. GROUND CONTROL DECAL AND KEYSWITCH INSTALLATION - 460SJ (CE SPEC) (PVC 2001)................................................120
	FIGURE 2-30. GROUND CONTROL DECAL AND KEYSWITCH INSTALLATION - 460SJ (STAGE V) (CE SPECS)................................................122
	FIGURE 2-31. GROUND CONTROL MOUNTING - 400S..............................................................................................124
	FIGURE 2-32. GROUND CONTROL MOUNTING - 460SJ.............................................................................................126
	FIGURE 2-33. GROUND CONTROL MOUNTING - DEUTZ (STAGE V) (460SJ) (CE SPECS)................................................................128
	FIGURE 2-34. LIGHT PANEL INSTALLATION - 400S.............................................................................................130
	FIGURE 2-35. LIGHT PANEL INSTALLATION - 460SJ............................................................................................132
	FIGURE 2-36. BEACON LIGHT INSTALLATION - AMBER...........................................................................................134
	FIGURE 2-37. BEACON LIGHT INSTALLATION - BLUE............................................................................................136
	FIGURE 2-38. BEACON LIGHT INSTALLATION - RED.............................................................................................138
	FIGURE 2-39. HOOD INSTALLATION - ABS (DEUTZ & GM ENGINES)................................................................................140
	FIGURE 2-40. HOOD INSTALLATION - ABS (KUBOTA ENGINES)....................................................................................144
	FIGURE 2-41. HOOD INSTALLATION - ABS (KUBOTA ENGINES) (CE SPECS).........................................................................148
	FIGURE 2-42. ABS HOOD ASSEMBLY - ENGINE SIDE.............................................................................................152
	FIGURE 2-43. ABS HOOD ASSEMBLY - ENGINE SIDE (CE SPEC)...................................................................................154
	FIGURE 2-44. ABS HOOD ASSEMBLY - TANK SIDE...............................................................................................156
	FIGURE 2-45. ABS HOOD ASSEMBLY - TANK SIDE (CE SPEC).....................................................................................158
	FIGURE 2-46. HOOD INSTALLATION - STEEL...................................................................................................160
	FIGURE 2-47. STEEL HOOD ASSEMBLY - ENGINE SIDE...........................................................................................164
	FIGURE 2-48. STEEL HOOD ASSEMBLY - TANK SIDE.............................................................................................166
	FIGURE 2-49. SOUND REDUCTION INSTALLATION - KUBOTA ENGINE MACHINES WITH STEEL HOODS......................................................168
	FIGURE 2-50. TURNTABLE COVERS INSTALLATION...............................................................................................170
SECTION 3 - ENGINE...........................................................................................................................173
	FIGURE 3-1. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (AUSTRALIAN AND CHINA SPECS)...............................174
	FIGURE 3-2. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (WITHOUT ARCTIC PACKAGE) (AUSTRALIAN AND CHINA SPECS).............................180
	FIGURE 3-3. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE) (AUSTRALIAN AND CHINA SPECS)...................................182
	FIGURE 3-4. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITH ARCTIC PACKAGE) (ANSI EXPORT AND CHINA SPECS).................................186
	FIGURE 3-5. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (WITH ARCTIC PACKAGE) (ANSI EXPORT AND CHINA SPECS)...............................192
	FIGURE 3-6. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (WITH ARCTIC PACKAGE) (ANSI EXPORT AND CHINA SPECS).....................................194
	FIGURE 3-7. ENGINE COMPONENTS - DEUTZ D2011..............................................................................................198
	FIGURE 3-8. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS).......................................202
	FIGURE 3-9. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS).....................................206
	FIGURE 3-10. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (STAGE V) (WITHOUT ARCTIC PACKAGE) (CE SPECS)..........................................208
	FIGURE 3-11. ENGINE COMPONENTS - DEUTZ D2011 (STAGE V)...................................................................................212
	FIGURE 3-12. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT AND CSA SPECS)........................216
	FIGURE 3-13. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT AND CSA SPECS)......................222
	FIGURE 3-14. ENGINE ASSEMBLY - DEUTZ D2.9L4 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT AND CSA SPECS) (PVC 2001).................224
	FIGURE 3-15. ENGINE ASSEMBLY - DEUTZ D2.9L4 ENGINE (WITHOUT ARCTIC PACKAGE) (ANSI, ANSI EXPORT AND CSA SPECS) (PVC 2007).................230
	FIGURE 3-16. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (WITH ARCTIC PACKAGE) (ANSI, ANSI EXPORT AND CSA SPECS)...........................236
	FIGURE 3-17. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 (WITH ARCTIC PACKAGE) (ANSI, ANSI EXPORT AND CSA SPECS).........................242
	FIGURE 3-18. ENGINE ASSEMBLY - DEUTZ D2.9L4 ENGINE (WITH ARCTIC PACKAGE) (ANSI, ANSI EXPORT AND CSA SPECS) (PVC 2001)....................244
	FIGURE 3-19. ENGINE ASSEMBLY - DEUTZ D2.9L4 ENGINE (WITH ARCTIC PACKAGE) (ANSI, ANSI EXPORT AND CSA SPECS) (PVC 2007)....................250
	FIGURE 3-20. ENGINE INSTALLATION - DEUTZ D2.9L4 ENGINE (STAGE V) (CE SPECS)..............................................................256
	FIGURE 3-21. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ENGINE (STAGE V) (CE SPECS).....................................................262
	FIGURE 3-22. ENGINE ASSEMBLY – DEUTZ D2.9L4 ENGINE (STAGE V) (CE SPECS)..................................................................264
	FIGURE 3-23. BREATHER HEATER INSTALLATION - DEUTZ D2.9L4 ENGINE WITH ARCTIC PACKAGE......................................................270
	FIGURE 3-24. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 ENGINE)...............................................................272
	FIGURE 3-25. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 ENGINE) (STAGE V).....................................................274
	FIGURE 3-26. PUMP COUPLING KIT (DEUTZ ENGINES)...........................................................................................276
	FIGURE 3-27. ENGINE INSTALLATION - KUBOTA ENGINE (WITHOUT ARCTIC PACKAGE)................................................................278
	FIGURE 3-28. ENGINE AND PUMP SUB-ASSEMBLY - KUBOTA ENGINE (WITHOUT ARCTIC PACKAGE).......................................................284
	FIGURE 3-29. ENGINE ASSEMBLY - KUBOTA ENGINE (WITHOUT ARCTIC PACKAGE)....................................................................286
	FIGURE 3-30. ENGINE INSTALLATION - KUBOTA ENGINE (WITH ARCTIC PACKAGE)...................................................................292
	FIGURE 3-31. ENGINE AND PUMP SUB-ASSEMBLY - KUBOTA ENGINE (WITH ARCTIC PACKAGE)..........................................................298
	FIGURE 3-32. ENGINE ASSEMBLY - KUBOTA ENGINE (WITH ARCTIC PACKAGE).......................................................................300
	FIGURE 3-33. ENGINE COMPONENTS - KUBOTA..................................................................................................306
	FIGURE 3-34. PUMP COUPLING KIT - KUBOTA ENGINE...........................................................................................310
	FIGURE 3-35. PISTON PUMP ASSEMBLY........................................................................................................312
	FIGURE 3-36. SPARK ARRESTOR INSTALLATION - DEUTZ D2011 ENGINE............................................................................316
	FIGURE 3-37. ENGINE BAFFLE INSTALLATION - ABS HOODS (DEUTZ & GM ENGINES).................................................................318
	FIGURE 3-38. ENGINE BAFFLE INSTALLATION - ABS HOODS (KUBOTA ENGINES).....................................................................320
	FIGURE 3-39. ENGINE BAFFLE INSTALLATION - STEEL HOODS....................................................................................322
	FIGURE 3-40. ENGINE TRAY JACK (USA BUILT MACHINES).......................................................................................324
	FIGURE 3-41. ENGINE TRAY JACK (ROMANIAN BUILT MACHINES)..................................................................................326
	FIGURE 3-42. GENERATOR INSTALLATION - 2500W/60HZ (DEUTZ D2011 ENGINE)....................................................................328
	FIGURE 3-43. GENERATOR INSTALLATION - 2500W/60HZ (DEUTZ D2.9L4 ENGINE)...................................................................332
	FIGURE 3-44. GENERATOR INSTALLATION - 2500W/60HZ (KUBOTA ENGINE).........................................................................336
	FIGURE 3-45. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ D2011 ENGINES)...................................................................340
	FIGURE 3-46. GENERATOR INSTALLATION - 4000W/60HZ (DEUTZ D2011 ENGINE)....................................................................344
	FIGURE 3-47. GENERATOR INSTALLATION - 4000W/60HZ (DEUTZ D2.9L4 ENGINE)...................................................................348
	FIGURE 3-48. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ STAGE V ENGINE)..................................................................352
	FIGURE 3-49. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ D2011 ENGINE) (PVC 2001).........................................................356
	FIGURE 3-50. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ D2011 ENGINE) (PVC 2007).........................................................360
	FIGURE 3-51. GENERATOR INSTALLATION - 7500W/60HZ (DEUTZ D2011 ENGINE)....................................................................364
	FIGURE 3-52. GENERATOR INSTALLATION - 7500W/60HZ (DEUTZ D2.9L4 ENGINE)...................................................................368
	FIGURE 3-53. GENERATOR INSTALLATION - 7500W/60HZ (KUBOTA ENGINE).........................................................................372
	FIGURE 3-54. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ STAGE V ENGINE)..................................................................376
SECTION 4 - BOOM.............................................................................................................................379
	FIGURE 4-1. BOOM AND CYLINDERS INSTALLATION - 400S.......................................................................................380
	FIGURE 4-2. BOOM AND CYLINDERS INSTALLATION - 460SJ (USA BUILT MACHINES).................................................................382
	FIGURE 4-3. BOOM AND CYLINDERS INSTALLATION - 460SJ (ROMANIAN BUILT MACHINES)............................................................384
	FIGURE 4-4. MAIN BOOM ASSEMBLY - 400S....................................................................................................386
	FIGURE 4-5. MAIN BOOM ASSEMBLY - 460SJ (USA BUILT MACHINES)..............................................................................388
	FIGURE 4-6. MAIN BOOM ASSEMBLY - 460SJ (ROMANIAN BUILT MACHINES).........................................................................390
	FIGURE 4-7. JIB BOOM ASSEMBLY - 460SJ (USA BUILT MACHINES)...............................................................................392
	FIGURE 4-8. JIB BOOM ASSEMBLY - 460SJ (ROMANIAN BUILT MACHINES)..........................................................................394
	FIGURE 4-9. ROTATOR ASSEMBLY - 400S......................................................................................................396
	FIGURE 4-10. ROTATOR ASSEMBLY - 460SJ....................................................................................................398
	FIGURE 4-11. POWER TRACK INSTALLATION....................................................................................................400
	FIGURE 4-12. POWER TRACK INSTALLATION....................................................................................................402
	FIGURE 4-13. CAPACITY SWITCH INSTALLATION................................................................................................404
	FIGURE 4-14. TRANSPORT SWITCHES INSTALLATION.............................................................................................406
	FIGURE 4-15. PLATFORM SUPPORT INSTALLATION - WITH 1 CELL LSS.............................................................................408
SECTION 5 - PLATFORM.........................................................................................................................411
	FIGURE 5-1. PLATFORM ASSEMBLY - 30IN X 5FT (76.2CM X 1.52M) WITH SWING GATE (USA BUILT MACHINES).........................................412
	FIGURE 5-2. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH SWING GATE (USA BUILT MACHINES).........................................414
	FIGURE 5-3. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH SWING GATE (USA BUILT MACHINES).........................................416
	FIGURE 5-4. PLATFORM ASSEMBLY - 30IN X 5FT (76.2CM X 1.52M) WITH DROP BAR (USA BUILT MACHINES)...........................................418
	FIGURE 5-5. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH DROP BAR (USA BUILT MACHINES)...........................................420
	FIGURE 5-6. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH DROP BAR (USA BUILT MACHINES)...........................................422
	FIGURE 5-7. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH FALL ARREST (ANSI, ANSI EXPORT AND CHINA SPECS) (USA BUILT MACHINES)....424
	FIGURE 5-8. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) WITH SWING GATE (ROMANIAN BUILT MACHINES)......................................426
	FIGURE 5-9. PLATFORM ASSEMBLY - 36IN X 6FT (92CM X 1.83M) WITH SWING GATE (ROMANIAN BUILT MACHINES)......................................428
	FIGURE 5-10. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH SWING GATE (ROMANIAN BUILT MACHINES)...................................430
	FIGURE 5-11. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH DROP BAR (ROMANIAN BUILT MACHINES).....................................432
	FIGURE 5-12. PLATFORM ASSEMBLY - 30IN X 5FT (76CM X 1.52M) WITH DROP BAR (ROMANIAN BUILT MACHINES).......................................434
	FIGURE 5-13. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH DROP BAR (ROMANIAN BUILT MACHINES).....................................436
	FIGURE 5-14. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) TRI-ENTRY WITH GATE.........................................................438
	FIGURE 5-15. PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) TRI-ENTRY WITH DROPBAR......................................................440
	FIGURE 5-16. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH TRI-ENTRY (1 GATE/2 DROP BARS).........................................442
	FIGURE 5-17. PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH TRI-ENTRY (3 DROP BARS)................................................444
	FIGURE 5-18. PLATFORM ASSEMBLY - 30IN X 3FT (76CM X .91M) - DROP BAR ENTRY...............................................................446
	FIGURE 5-19. PLATFORM CONSOLE BOX INSTALLATION...........................................................................................448
	FIGURE 5-20. PLATFORM CONSOLE BOX ASSEMBLY...............................................................................................450
	FIGURE 5-21. CONTROLLER ASSEMBLY (DRIVE AND STEER).......................................................................................454
	FIGURE 5-22. CONTROLLER ASSEMBLY (LIFT AND SWING)........................................................................................456
	FIGURE 5-23. FOOTSWITCH ASSEMBLY.........................................................................................................460
	FIGURE 5-24. LIGHT PANEL INSTALLATION - 400S.............................................................................................462
	FIGURE 5-25. LIGHT PANEL INSTALLATION - 460SJ............................................................................................464
	FIGURE 5-26. TRAY INSTALLATION...........................................................................................................466
	FIGURE 5-27. SOFT TOUCH INSTALLATION - 6FT (1.83M) FALL ARREST PLATFORM (OPTIONAL).......................................................468
	FIGURE 5-28. SOFT TOUCH INSTALLATION - 8FT (2.4M) PLATFORM (OPTIONAL)....................................................................470
	FIGURE 5-29. SKYGUARD BAR INSTALLATION...................................................................................................472
	FIGURE 5-30. SKYEYE INSTALLATION.........................................................................................................474
	FIGURE 5-31. SKYLINE INSTALLATION........................................................................................................476
	FIGURE 5-32. SKYGLAZIER INSTALLATION.....................................................................................................478
	FIGURE 5-33. SKYWELDER INSTALLATION (50HZ)...............................................................................................480
	FIGURE 5-34. SKYWELDER INSTALLATION (60HZ)...............................................................................................482
	FIGURE 5-35. SKYWELDER PREP PACKAGE (60HZ)...............................................................................................484
	FIGURE 5-36. WELDER ASSEMBLY.............................................................................................................486
	FIGURE 5-37. PIPE RACK INSTALLATION (ANSI AND CSA SPECS).................................................................................488
	FIGURE 5-38. PIPE RACK INSTALLATION (AUSTRALIAN SPEC)....................................................................................490
	FIGURE 5-39. FALL ARREST (BOLT-ON) INSTALLATION - 5FTX3FT PLATFORM (ALL SPECS EXCEPT AUSTRALIAN & CE SPECS) (OPTIONAL)...................492
	FIGURE 5-40. FALL ARREST (BOLT-ON) INSTALLATION - 6FTX3FT PLATFORM (ALL SPECS EXCEPT AUSTRALIAN & CE SPECS) (OPTIONAL)...................494
	FIGURE 5-41. FALL ARREST (BOLT-ON) INSTALLATION - 6FTX3FT TRI-ENTRY PLATFORM (ALL SPECS EXCEPT AUSTRALIAN & CE SPECS) (OPTIONAL).........496
	FIGURE 5-42. FALL ARREST (BOLT-ON) INSTALLATION - 8FTX3FT PLATFORM (ALL SPECS EXCEPT AUSTRALIAN & CE SPECS) (OPTIONAL)...................498
SECTION 6 - CYLINDER.........................................................................................................................501
	FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY...............................................................................................502
	FIGURE 6-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY.....................................................................................504
	FIGURE 6-3. LIFT CYLINDER ASSEMBLY - MAIN BOOM...........................................................................................506
	FIGURE 6-4. LIFT CYLINDER ASSEMBLY - JIB.................................................................................................508
	FIGURE 6-5. MASTER CYLINDER ASSEMBLY.....................................................................................................510
	FIGURE 6-6. STEER CYLINDER ASSEMBLY......................................................................................................512
	FIGURE 6-7. TELESCOPE CYLINDER ASSEMBLY..................................................................................................514
SECTION 7 - HYDRAULIC........................................................................................................................517
	FIGURE 7-1. 400S 2WD HYDRAULIC SYSTEM INSTALLATION.......................................................................................518
	FIGURE 7-2. 400S 4WD HYDRAULIC SYSTEM INSTALLATION (ALL MACHINES)........................................................................526
	FIGURE 7-3. 460SJ 2WD HYDRAULIC SYSTEM INSTALLATION......................................................................................534
	FIGURE 7-4. 460SJ 4WD HYDRAULIC SYSTEM INSTALLATION (ALL MACHINES).......................................................................542
SECTION 8 - ELECTRICAL.......................................................................................................................551
	FIGURE 8-1. AC BOX AT PLATFORM INSTALLATION - 110V (ANSI, ANSI EXPORT, CSA AND CHINA SPECS)..............................................552
	FIGURE 8-2. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE SPECS WITH 4000W/50HZ GENERATOR).......................................554
	FIGURE 8-3. AC BOX AT PLATFORM - 110V IEC YELLOW (CE SPEC WITHOUT GENERATOR).............................................................556
	FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE SPECS WITH 4000W/50HZ GENERATOR).........................................558
	FIGURE 8-5. AC BOX AT PLATFORM - 220V IEC BLUE (CE SPEC WITHOUT GENERATOR)...............................................................560
	FIGURE 8-6. AC BOX AT PLATFORM - 220V CEE7 2IN X 4IN POST GROUND (CE SPEC WITHOUT GENERATOR).............................................562
	FIGURE 8-7. AC BOX AT PLATFORM - 220V CEE7 2IN X 4IN SIDE GROUND (CE SPEC WITHOUT GENERATOR).............................................564
	FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2IN X 4IN POST GROUND (CE SPECS WITH 4000W/50HZ GENERATOR).......................566
	FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 2IN X 4IN SIDE GROUND (CE SPECS WITH 4000W/50HZ GENERATOR).......................568
	FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT107 (CE SPECS WITH 4000W/50HZ GENERATOR).......................................570
	FIGURE 8-11. AC BOX AT PLATFORM - 220V AFSINT107 (CE SPEC WITHOUT GENERATOR).............................................................572
	FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 220V CUSTOMER SUPPLIED COMPONENTS (ANSI EXPORT, CE AND CHINA SPECS).......................574
	FIGURE 8-13. AC BOX AT PLATFORM INSTALLATION - 240V (WITH 4000W GENERATOR) (ALL SPECS EXCEPT AUSTRALIAN & CE SPECS)......................576
	FIGURE 8-14. AC BOX AT PLATFORM INSTALLATION - 240V (WITH 7500W SKYPOWER GENERATOR) (ALL SPECS EXCEPT AUSTRALIAN & CE SPECS).............578
	FIGURE 8-15. AC CABLE INSTALLATION - WITH THREE BREAKERS (CE SPECS)......................................................................580
	FIGURE 8-16. BATTERY DISCONNECT SWITCH...................................................................................................582
	FIGURE 8-17. BEACON HARNESS (BLUE/RED BEACON LIGHT)......................................................................................584
	FIGURE 8-18. BOOM HARNESS - 400S.........................................................................................................586
	FIGURE 8-19. BOOM HARNESS - 460SJ........................................................................................................588
	FIGURE 8-20. BOOM CAPACITY PROXIMITY SWITCH HARNESS (400S ONLY)..........................................................................590
	FIGURE 8-21. BOOM TELE IN PROXIMITY SWITCH HARNESS.......................................................................................592
	FIGURE 8-22. BREAKER BOX INSTALLATION - 110/220V 16AMP BREAKER (CE SPEC).................................................................594
	FIGURE 8-23. BREAKER BOX KIT - 110/220V 16AMP BREAKER (CE SPEC)..........................................................................596
	FIGURE 8-24. BREAKER BOX KIT - 30MA/16 AMP...............................................................................................598
	FIGURE 8-25. BREAKER BOX KIT WITH THREE BREAKERS.........................................................................................600
	FIGURE 8-26. CABLES AND CLAMPS INSTALLATION - 400S (4000W GENERATOR 60HZ) (ANSI AND ANSI EXPORT SPECS)...................................602
	FIGURE 8-27. CABLES AND CLAMPS INSTALLATION - 400S (4000W GENERATOR 50HZ) (ANSI, ANSI EXPORT, CE AND CHINA SPECS) (PVC 2001).............604
	FIGURE 8-28. CABLES AND CLAMPS INSTALLATION - 400S (4000W GENERATOR 50HZ) (ANSI, ANSI EXPORT AND CHINA SPECS) (PVC 2007).................606
	FIGURE 8-29. CABLES AND CLAMPS INSTALLATION - 460SJ (4000W GENERATOR 60HZ) (ANSI AND ANSI EXPORT SPECS) (PVC 2001).......................608
	FIGURE 8-30. CABLES AND CLAMPS INSTALLATION - 460SJ (4000W GENERATOR 60HZ) (ANSI AND ANSI EXPORT SPECS) (PVC 2007).......................610
	FIGURE 8-31. CABLES AND CLAMPS INSTALLATION - 460SJ (4000W GENERATOR 50HZ) (ANSI EXPORT, AUSTRALIAN, CE AND CHINA SPECS) (PVC 2001)......612
	FIGURE 8-32. CABLES AND CLAMPS INSTALLATION - 460SJ (4000W GENERATOR 50HZ) (ANSI EXPORT, AUSTRALIAN, CE AND CHINA SPECS) (PVC 2007)......614
	FIGURE 8-33. CABLES AND CLAMPS INSTALLATION - 400S (7500W GENERATOR) (ANSI, ANSI EXPORT, CE AND CHINA SPECS).............................616
	FIGURE 8-34. CABLES AND CLAMPS INSTALLATION - 460SJ (7500W GENERATOR) (ANSI, ANSI EXPORT, AUSTRALIAN, CE AND CHINA SPECS)................618
	FIGURE 8-35. ENGINE HARNESS - DEUTZ D2011................................................................................................620
	FIGURE 8-36. ENGINE HARNESS - DEUTZ D2.9L4 (PVC 2001)....................................................................................622
	FIGURE 8-37. ENGINE HARNESS - DEUTZ D2.9L4 (PVC 2007)....................................................................................626
	FIGURE 8-38. ENGINE HARNESS - DEUTZ (STAGE V)............................................................................................630
	FIGURE 8-39. ENGINE HARNESS - KUBOTA.....................................................................................................634
	FIGURE 8-40. FUEL HARNESS - DEUTZ D2.9L4 ENGINE..........................................................................................636
	FIGURE 8-41. FUEL HARNESS - DEUTZ (STAGE V) ENGINE.......................................................................................638
	FIGURE 8-42. FUEL HARNESS - KUBOTA ENGINE................................................................................................640
	FIGURE 8-43. GENERATOR HARNESS - 2500W...................................................................................................642
	FIGURE 8-44. GENERATOR HARNESS - 4000W...................................................................................................644
	FIGURE 8-45. GROUND CONTROL BOX HARNESS..................................................................................................646
	FIGURE 8-46. INTERFACE HARNESS - WITH 1 CELL LSS (PVC 2001)..............................................................................648
	FIGURE 8-47. INTERFACE HARNESS - WITH 1 CELL LSS (PVC 2007)..............................................................................650
	FIGURE 8-48. PLATFORM CONSOLE BOX HARNESS................................................................................................652
	FIGURE 8-49. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE SPEC)..............................................................................654
	FIGURE 8-50. RECEPTACLE BOX KIT - 220V IEC BLUE (CE SPEC)................................................................................656
	FIGURE 8-51. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2IN X 4IN (CE SPEC)..............................................................658
	FIGURE 8-52. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2IN X 4IN (CE SPEC)..............................................................660
	FIGURE 8-53. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE SPEC)..............................................................................662
	FIGURE 8-54. TURNTABLE HARNESS...........................................................................................................664
	FIGURE 8-55. VALVE HARNESS - MAIN VALVE..................................................................................................668
	FIGURE 8-56. SKYLINE HARNESS.............................................................................................................670
	FIGURE 8-57. SKYEYE INTERMEDIATE HARNESS.................................................................................................672
	FIGURE 8-58. SKYEYE RECEIVER HARNESS (PVC 2001)..........................................................................................674
	FIGURE 8-59. SKYEYE RECEIVER HARNESS (PVC 2007)..........................................................................................676
	FIGURE 8-60. SKYEYE EMITTER HARNESS (PVC 2001)...........................................................................................678
	FIGURE 8-61. SKYEYE EMITTER HARNESS (PVC 2007)...........................................................................................680
SECTION 9 - DECAL............................................................................................................................683
	FIGURE 9-1. DECAL INSTALLATION - ANSI, ANSI EXPORT AND CSA SPECS - ENGLISH (400S)........................................................684
	FIGURE 9-2. DECAL INSTALLATION - ANSI, ANSI EXPORT AND CSA SPECS - ENGLISH (460SJ).......................................................686
	FIGURE 9-3. DECAL INSTALLATION - AUSTRALIAN SPEC (460SJ).................................................................................688
	FIGURE 9-4. DECAL INSTALLATION - CE SPEC (400S) (PVC 2001)...............................................................................690
	FIGURE 9-5. DECAL INSTALLATION - CE SPEC (460SJ).........................................................................................692
	FIGURE 9-6. INSTALLATION - BRAZIL SPEC (DUAL LANGUAGE - PORTUGUESE/SPANISH) (400S).......................................................694
	FIGURE 9-7. DECAL INSTALLATION - BRAZIL SPEC (DUAL LANGUAGE - PORTUGUESE/SPANISH) (460SJ)................................................696
	FIGURE 9-8. DECAL INSTALLATION - CHINESE SPEC (DUAL LANGUAGE - ENGLISH/CHINESE) (400S)...................................................698
	FIGURE 9-9. DECAL INSTALLATION - CHINESE SPEC (DUAL LANGUAGE - ENGLISH/CHINESE) (460SJ)..................................................700
	FIGURE 9-10. DECAL INSTALLATION - CSA SPEC (DUAL LANGUAGE - ENGLISH/FRENCH) (400S).......................................................702
	FIGURE 9-11. DECAL INSTALLATION - CSA SPEC (DUAL LANGUAGE - ENGLISH/FRENCH) (460SJ)......................................................704
	FIGURE 9-12. DECAL INSTALLATION - JAPANESE SPEC (DUAL LANGUAGE - ENGLISH/JAPANESE) (400S)................................................706
	FIGURE 9-13. DECAL INSTALLATION - JAPANESE SPEC (DUAL LANGUAGE - ENGLISH/JAPANESE) (460SJ)...............................................708
	FIGURE 9-14. DECAL INSTALLATION - KOREAN SPEC (DUAL LANGUAGE - ENGLISH/KOREAN) (400S)....................................................710
	FIGURE 9-15. DECAL INSTALLATION - KOREAN SPEC (DUAL LANGUAGE - ENGLISH/KOREAN) (460SJ)...................................................712
	FIGURE 9-16. DECAL INSTALLATION - LATIN AMERICAN SPEC (DUAL LANGUAGE - ENGLISH/SPANISH) (400S)...........................................714
	FIGURE 9-17. DECAL INSTALLATION - LATIN AMERICAN SPEC (DUAL LANGUAGE - ENGLISH/SPANISH) (460SJ)..........................................716
	FIGURE 9-18. DECAL INSTALLATION - OPTIONS................................................................................................718
	FIGURE 9-19. SKYWELDER DECAL INSTALLATION - 50HZ (ANSI EXPORT SPECS).....................................................................722
	FIGURE 9-20. SKYWELDER DECAL INSTALLATION - 60HZ (ANSI EXPORT SPECS) (PVC 2001)..........................................................724
	FIGURE 9-21. SKYWELDER DECAL INSTALLATION - 60HZ (ANSI EXPORT SPECS) (PVC 2007)..........................................................726
SECTION 10 - RECOMMENDED SERVICE PARTS STOCK.................................................................................................729
	FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK.............................................................................................730
SECTION 11 - SPECIAL OPTIONS.................................................................................................................733
	FIGURE 11-1. SPECIAL OPTIONS.............................................................................................................734
PART NUMBER INDEX............................................................................................................................737

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