JLG 400S HC3 460SJ HC3 Parts Manual (31215870) – PDF DOWNLOAD

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JLG 400S HC3 460SJ HC3 Parts Manual (31215870) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 400S HC3 460SJ HC3 Parts Manual (31215870) – PDF DOWNLOAD

SECTION 1 - FRAME............................................................................................................................... 13
	FIGURE 1-1. AXLE INSTALLATION............................................................................................................... 14
	FIGURE 1-2. STEER INSTALLATION - WITHOUT TOW PACKAGE (400S HC3)............................................................................. 16
	FIGURE 1-3. STEER INSTALLATION - WITHOUT TOW PACKAGE (460SJ HC3)............................................................................ 18
	FIGURE 1-4. STEER INSTALLATION - WITH TOW PACKAGE (400S HC3)................................................................................ 20
	FIGURE 1-5. STEER INSTALLATION - WITH TOW PACKAGE (460SJ HC3)............................................................................... 22
	FIGURE 1-6. WHEEL DRIVE AND FRAME VALVES INSTALLATION (400S HC3)............................................................................ 24
	FIGURE 1-7. WHEEL DRIVE AND FRAME VALVES INSTALLATION (460SJ HC3)........................................................................... 26
	FIGURE 1-8. DRIVE HUB ASSEMBLY - FRONT (400S HC3)........................................................................................... 28
	FIGURE 1-9. DRIVE HUB/BRAKE ASSEMBLY - REAR (400S HC3)...................................................................................... 30
	FIGURE 1-10. DRIVE HUB/BRAKE ASSEMBLY - REAR (460SJ HC3).................................................................................... 34
	FIGURE 1-11. DRIVE MOTOR ASSEMBLY (400S HC3)................................................................................................ 38
	FIGURE 1-12. DRIVE MOTOR ASSEMBLY (460SJ HC3)............................................................................................... 40
	FIGURE 1-13. TRACTION VALVE ASSEMBLY........................................................................................................ 42
	FIGURE 1-14. TIRE AND WHEEL INSTALLATION - 14 X 176.5 FOAM FILLED (400S HC3 & 460SJ HC3).................................................... 44
	FIGURE 1-15. TIRE AND WHEEL INSTALLATION - 12 X 16.5 FOAM FILLED (400S HC3)................................................................. 46
	FIGURE 1-16. TIRE AND WHEEL INSTALLATION - 33 X 12D610  FOAM-FILLED (460SJ HC3)............................................................. 48
	FIGURE 1-17. TIRE AND WHEEL INSTALLATION - 12 X 16.5 FF NON-MARKING (400S HC3).............................................................. 50
	FIGURE 1-18. TIRE AND WHEEL INSTALLATION - 14 X 17.5 FF NON-MARKING......................................................................... 52
	FIGURE 1-19. LP TANK BRACKETS INSTALLATIONS (Prior to SN E300007713)........................................................................ 54
	FIGURE 1-20. LP TANK BRACKETS INSTALLATIONS (SN E300007713 to Present)...................................................................... 56
	FIGURE 1-21. FRAME SHIELDS INSTALLATION  - WITHOUT TOW PACKAGE.............................................................................. 58
	FIGURE 1-22. FRAME SHIELDS INSTALLATION  - WITH TOW PACKAGE................................................................................. 60
	FIGURE 1-23. TOW PACKAGE INSTALLATION....................................................................................................... 62
	FIGURE 1-24. TOW BAR ASSEMBLY............................................................................................................... 64
SECTION 2 - TURNTABLE........................................................................................................................... 67
	FIGURE 2-1. CONTROL VALVES INSTALLATION (400S HC3).......................................................................................... 68
	FIGURE 2-2. CONTROL VALVES INSTALLATION (460SJ HC3)......................................................................................... 70
	FIGURE 2-3. CONTROL VALVE ASSEMBLY (400S HC3)............................................................................................... 72
	FIGURE 2-4. CONTROL VALVE ASSEMBLY (460SJ HC3).............................................................................................. 76
	FIGURE 2-5. AXLE CONTROL VALVE ASSEMBLY..................................................................................................... 80
	FIGURE 2-6. SWING DRIVE INSTALLATION........................................................................................................ 82
	FIGURE 2-7. SWING DRIVE MOTOR/HUB ASSEMBLY.................................................................................................. 84
	FIGURE 2-8. TURNTABLE BEARING INSTALLATION.................................................................................................. 88
	FIGURE 2-9. BEARING LUBE INSTALLATION....................................................................................................... 90
	FIGURE 2-10. TURNTABLE LOCK INSTALLATION.................................................................................................... 92
	FIGURE 2-11. ROTARY COUPLING INSTALLATION................................................................................................... 94
	FIGURE 2-12. TANK INSTALLATION - DIESEL ENGINES............................................................................................. 96
	FIGURE 2-13. TANK INSTALLATION - GAS ENGINES................................................................................................ 98
	FIGURE 2-14. HYDRAULIC TANK ASSEMBLY........................................................................................................100
	FIGURE 2-15. AUXILIARY POWER INSTALLATION - WITHOUT BATTERY DISCONNECT......................................................................102
	FIGURE 2-16. AUXILIARY POWER INSTALLATION - WITH BATTERY DISCONNECT.........................................................................104
	FIGURE 2-17. AUXILIARY POWER PUMP/MOTOR ASSEMBLY............................................................................................106
	FIGURE 2-18. ELECTRICAL INSTALLATION (400S HC3) (Prior to SN E300007713)....................................................................108
	FIGURE 2-19. ELECTRICAL INSTALLATION (400S HC3) (SN E300007713 to Present)..................................................................110
	FIGURE 2-20. ELECTRICAL INSTALLATION (460SJ HC3) (Prior to SN E300007713)...................................................................112
	FIGURE 2-21. ELECTRICAL INSTALLATION (460SJ HC3) (SN E300007713 to Present).................................................................114
	FIGURE 2-22. ELECTRICAL INSTALLATION (460SJ HC3 WITH DEUTZ D2.9L4 (STAGE V) ENGINES)........................................................116
	FIGURE 2-23. ELECTRICAL PANEL ASSEMBLY......................................................................................................118
	FIGURE 2-24. GROUND CONTROL BOX ASSEMBLY (400S HC3).........................................................................................120
	FIGURE 2-25. GROUND CONTROL BOX ASSEMBLY (460SJ HC3)........................................................................................122
	FIGURE 2-26. GROUND CONTROL BOX ASSEMBLY (460SJ HC3 WITH DEUTZ D2.9L4 (STAGE V) ENGINES) (CE SPECS).........................................124
	FIGURE 2-27. GROUND CONTROL BRACKET INSTALLATION............................................................................................126
	FIGURE 2-28. GROUND CONTROL BRACKET INSTALLATION (460SJ HC3 WITH DEUTZ D2.9L4 (STAGE V) ENGINES) CE SPECS)..................................128
	FIGURE 2-29. KEYSWITCH AND PANEL DECAL INSTALLATION - 400S HC3 (USA BUILT MACHINES).........................................................130
	FIGURE 2-30. KEYSWITCH AND PANEL DECAL INSTALLATION - 400S HC3 (ROMANIAN BUILT MACHINES) (Prior to SN E300007713)...........................132
	FIGURE 2-31. KEYSWITCH AND PANEL DECAL INSTALLATION - 460SJ HC3 (USA BUILT MACHINES)........................................................134
	FIGURE 2-32. KEYSWITCH AND PANEL DECAL INSTALLATION - 460SJ HC3 AUSTRALIAN SPECS (ROMANIAN BUILT MACHINES)..................................136
	FIGURE 2-33. KEYSWITCH AND PANEL DECAL INSTALLATION - 460SJ HC3 CE SPECS (ROMANIAN BUILT MACHINES) (Prior to SN E300007713).................138
	FIGURE 2-34. KEYSWITCH AND PANEL DECAL INSTALLATION - 460SJ HC3 WITH DEUTZ D2.9L4 (STAGE V) ENGINES (CE SPECS) (ROMANIAN BUILT MACHINES)....140
	FIGURE 2-35. LIGHT PANEL INSTALLATION.......................................................................................................142
	FIGURE 2-36. WHITE NOISE ALARM INSTALLATION.................................................................................................144
	FIGURE 2-37. STROBE LIGHT INSTALLATION (AMBER)..............................................................................................146
	FIGURE 2-38. STROBE LIGHT INSTALLATION (BLUE)...............................................................................................148
	FIGURE 2-39. STROBE LIGHT INSTALLATION (RED)................................................................................................150
	FIGURE 2-40. HOODS INSTALLATION - ABS (DEUTZ  ENGINES) (ANSI, ANSI EXPORT, CHINA & CSA SPECS) (Prior to SN E300007713)......................152
	FIGURE 2-41. HOODS INSTALLATION - ABS (DEUTZ ENGINES) (ANSI, ANSI EXPORT, CHINA & CSA SPECS) (SN E300007713 to Present).....................156
	FIGURE 2-42. HOODS INSTALLATION - ABS (DEUTZ  ENGINES) (AUSTRALIAN & CE SPECS)..............................................................160
	FIGURE 2-43. HOODS INSTALLATION - ABS (KUBOTA ENGINES) (USA BUILT MACHINES).................................................................164
	FIGURE 2-44. HOODS INSTALLATION - STEEL.....................................................................................................168
	FIGURE 2-45. HOOD ASSEMBLY - ENGINE SIDE (ABS) (ANSI, ANSI EXPORT, CHINA & CSA SPECS).......................................................172
	FIGURE 2-46. HOOD ASSEMBLY - ENGINE SIDE (ABS) (AUSTRALIAN & CE SPECS)......................................................................174
	FIGURE 2-47. HOOD ASSEMBLY - ENGINE SIDE (STEEL)............................................................................................176
	FIGURE 2-48. HOOD ASSEMBLY - TANK SIDE (ABS) (ANSI, ANSI EXPORT, CHINA & CSA SPECS).........................................................178
	FIGURE 2-49. HOOD ASSEMBLY - TANK SIDE (ABS) (AUSTRALIAN & CE SPECS)........................................................................180
	FIGURE 2-50. HOOD ASSEMBLY - TANK SIDE (STEEL)..............................................................................................182
	FIGURE 2-51. SOUND REDUCTION INSTALLATION (STEEL HOODS).....................................................................................184
	FIGURE 2-52. TURNTABLE COVERS INSTALLATION..................................................................................................186
SECTION 3 - ENGINE..............................................................................................................................189
	FIGURE 3-1. DEUTZ D2011 ENGINE INSTALLATION (WITHOUT ARCTIC PACKAGE)........................................................................190
	FIGURE 3-2. DEUTZ D2011 ENGINE AND PUMP SUB-ASSEMBLY (WITHOUT ARCTIC PACKAGE)...............................................................194
	FIGURE 3-3. DEUTZ D2011 ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)............................................................................196
	FIGURE 3-4. DEUTZ D2011 ENGINE INSTALLATION (WITHOUT ARCTIC PACKAGE) (STAGE V) (Prior to SN E300007713).....................................200
	FIGURE 3-5. DEUTZ D2011 ENGINE AND PUMP SUB-ASSEMBLY (WITHOUT ARCTIC PACKAGE) (STAGE V) (Prior to SN E300007713)............................204
	FIGURE 3-6. DEUTZ D2011 ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE) (STAGE V) (Prior to SN E300007713).........................................206
	FIGURE 3-7. DEUTZ D2011 ENGINE INSTALLATION (WITH ARCTIC PACKAGE)...........................................................................210
	FIGURE 3-8. DEUTZ D2011 ENGINE AND PUMP SUB-ASSEMBLY (WITH ARCTIC PACKAGE)..................................................................214
	FIGURE 3-9. DEUTZ D2011 ENGINE ASSEMBLY (WITH ARCTIC PACKAGE)...............................................................................216
	FIGURE 3-10. DEUTZ D2011 ENGINE COMPONENTS..................................................................................................220
	FIGURE 3-11. DEUTZ D2011 ENGINE COMPONENTS (STAGE V) (Prior to SN E300007713)...............................................................224
	FIGURE 3-12. DEUTZ D2.9L4 ENGINE INSTALLATION (WITHOUT ARCTIC PACKAGE)......................................................................228
	FIGURE 3-13. DEUTZ D2.9L4 ENGINE AND PUMP SUB-ASSEMBLY (WITHOUT ARCTIC PACKAGE).............................................................232
	FIGURE 3-14. DEUTZ D2.9L4 ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)..........................................................................234
	FIGURE 3-15. DEUTZ D2.9L4 ENGINE INSTALLATION (WITH ARCTIC PACKAGE).........................................................................240
	FIGURE 3-16. DEUTZ D2.9L4 ENGINE AND PUMP SUB-ASSEMBLY (WITH ARCTIC PACKAGE)................................................................244
	FIGURE 3-17. DEUTZ D2.9L4 ENGINE ASSEMBLY (WITH ARCTIC PACKAGE).............................................................................246
	FIGURE 3-18. DEUTZ D2.9L4 ENGINE COMPONENTS.................................................................................................252
	FIGURE 3-19. ENGINE INSTALLATION - DEUTZ D2.9L4 (STAGE V) ENGINE (CE SPECS).................................................................256
	FIGURE 3-20. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 (STAGE V) ENGINE (CE SPECS)........................................................262
	FIGURE 3-21. ENGINE ASSEMBLY – DEUTZ D2.9L4 (STAGE V) ENGINE (CE SPECS).....................................................................264
	FIGURE 3-22. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 ENGINES)......................................................................270
	FIGURE 3-23. BREATHER HEATER INST (DEUTZ D2.9L4 ENGINES)....................................................................................272
	FIGURE 3-24. KUBOTA ENGINE INSTALLATION (WITHOUT ARCTIC PACKAGE)............................................................................274
	FIGURE 3-25. KUBOTA ENGINE AND PUMP SUB-ASSEMBLY (WITHOUT ARCTIC PACKAGE)...................................................................280
	FIGURE 3-26. KUBOTA ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)................................................................................282
	FIGURE 3-27. KUBOTA ENGINE INSTALLATION (WITH ARCTIC PACKAGE)...............................................................................288
	FIGURE 3-28. KUBOTA ENGINE AND PUMP SUB-ASSEMBLY (WITH ARCTIC PACKAGE)......................................................................294
	FIGURE 3-29. KUBOTA ENGINE ASSEMBLY (WITH ARCTIC PACKAGE)...................................................................................296
	FIGURE 3-30. KUBOTA ENGINE COMPONENTS.......................................................................................................302
	FIGURE 3-31. PUMP COUPING KIT (DEUTZ ENGINES)...............................................................................................306
	FIGURE 3-32. PUMP COUPING KIT (KUBOTA ENGINES)..............................................................................................308
	FIGURE 3-33. PISTON PUMP ASSEMBLY...........................................................................................................310
	FIGURE 3-34. SPARK ARRESTOR MUFFLER INSTALLATION - DEUTZ D2011 ENGINES (Prior to SN E300007713).............................................314
	FIGURE 3-35. SPARK ARRESTOR MUFFLER INSTALLATION - DEUTZ D2011 STAGE 5 ENGINES..............................................................316
	FIGURE 3-36. SPARK ARRESTOR MUFFLER INSTALLATION INSTALLATION - DEUTZ TD2.9L4 ENGINES (Prior to SN E300007713)..............................318
	FIGURE 3-37. SPARK ARRESTOR MUFFLER INSTALLATION INSTALLATION - KUBOTA ENGINES (Prior to SN E300007713).....................................320
	FIGURE 3-38. ENGINE HOOD BAFFLE INSTALLATION - DEUTZ ENGINES WITH ABS HOODS.................................................................322
	FIGURE 3-39. ENGINE HOOD BAFFLE INSTALLATION - DEUTZ ENGINES WITH STEEL HOODS...............................................................324
	FIGURE 3-40. ENGINE HOOD BAFFLE INSTALLATION - KUBOTA ENGINES...............................................................................326
	FIGURE 3-41. ENGINE TRAY JACK INSTALLATION - DEUTZ ENGINES..................................................................................328
	FIGURE 3-42. ENGINE TRAY JACK INSTALLATION - KUBOTA  ENGINES................................................................................330
	FIGURE 3-43. 2500W/110V/60HZ GENERATOR INSTALLATION - DEUTZ D2011  ENGINES..................................................................332
	FIGURE 3-44. 2500W/110V/60HZ GENERATOR INSTALLATION - DEUTZ D2.9L4  ENGINES.................................................................336
	FIGURE 3-45. 2500W/110V/60HZ GENERATOR INSTALLATION - KUBOTA ENGINES........................................................................340
	FIGURE 3-46. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES........................................................................344
	FIGURE 3-47. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES........................................................................348
	FIGURE 3-48. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ D2.9L4 ENGINES.......................................................................352
	FIGURE 3-49. 4000W/50HZ GENERATOR INSTALLATION (DEUTZ D2.9L4 (STAGE V) ENGINES).............................................................356
	FIGURE 3-50. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011  ENGINES..............................................................360
	FIGURE 3-51. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011  ENGINES..............................................................364
	FIGURE 3-52. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2.9L4 ENGINES..............................................................368
	FIGURE 3-53. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - KUBOTA ENGINES....................................................................372
	FIGURE 3-54. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION (DEUTZ D2.9L4 (STAGE V) ENGINES)....................................................376
SECTION 4 - BOOM................................................................................................................................379
	FIGURE 4-1. BOOM INSTALLATION - 400S HC3....................................................................................................380
	FIGURE 4-2. BOOM INSTALLATION - 460SJ HC3 (USA BUILT MACHINES)..............................................................................382
	FIGURE 4-3. BOOM INSTALLATION - 460SJ HC3 (ROMANIAN BUILT MACHINES).........................................................................384
	FIGURE 4-4. BOOM ASSEMBLY - MAIN (400S HC3).................................................................................................386
	FIGURE 4-5. BOOM ASSEMBLY - MAIN (460SJ HC3) (USA BUILT MACHINES)...........................................................................388
	FIGURE 4-6. MAIN BOOM ASSEMBLY - 460SJ HC3 (ROMANIAN BUILT MACHINES) (Prior to SN E300007713)...............................................390
	FIGURE 4-7. MAIN BOOM ASSEMBLY - 460SJ HC3 (ROMANIAN BUILT MACHINES) (SN E300007713 to Present).............................................392
	FIGURE 4-8. JIB BOOM ASSEMBLY - 460SJ HC3 (USA BUILT MACHINES) (Prior to SN E300007713).....................................................394
	FIGURE 4-9. JIB BOOM ASSEMBLY - 460SJ HC3 (USA BUILT MACHINES) (SN E300007713 to Present)...................................................396
	FIGURE 4-10. JIB BOOM ASSEMBLY - 460SJ HC3 (ROMANIAN BUILT MACHINES) (Prior to SN E300007713)...............................................398
	FIGURE 4-11. JIB BOOM ASSEMBLY - 460SJ HC3 (ROMANIAN BUILT MACHINES) (SN E300007713 to Present).............................................400
	FIGURE 4-12. ROTATOR ASSEMBLY - 400S HC3....................................................................................................402
	FIGURE 4-13. ROTATOR ASSEMBLY - 460SJ HC3...................................................................................................404
	FIGURE 4-14. SUPPORT, PLATFORM INSTALLATION (Prior to SN E300007713)........................................................................406
	FIGURE 4-15. SUPPORT, PLATFORM INSTALLATION (SN E300007713 to Present)......................................................................408
	FIGURE 4-16. POWER TRACK INSTALLATION - 400S HC3 (USA BUILT MACHINES).......................................................................410
	FIGURE 4-17. POWER TRACK INSTALLATION - 460SJ HC3 (USA BUILT MACHINES)......................................................................412
	FIGURE 4-18. POWER TRACK INSTALLATION - 400S HC3 (ROMANIAN BUILT MACHINES) (Prior to SN E300007713).........................................414
	FIGURE 4-19. POWER TRACK INSTALLATION - 460SJ HC3 (ROMANIAN BUILT MACHINES).................................................................416
	FIGURE 4-20. CAPACITY SWITCH INSTALLATION - 400S HC3........................................................................................418
	FIGURE 4-21. CAPACITY SWITCH INSTALLATION - 460SJ HC3.......................................................................................420
	FIGURE 4-22. TRANSPORT POSITION SWITCH INSTALLATION.........................................................................................422
SECTION 5 - PLATFORM............................................................................................................................425
	FIGURE 5-1. PLATFORM ASSEMBLY WITH DROP-BAR - 30IN X 3FT (76CM X .91M)......................................................................426
	FIGURE 5-2. PLATFORM ASSEMBLY WITH DROP-BAR - 30IN X 5FT (76CM X 1.52M) (USA BUILT MACHINES)................................................428
	FIGURE 5-3. PLATFORM ASSEMBLY WITH DROP-BAR - 30IN X 5FT (76CM X 1.52M) (ROMANIAN  BUILT MACHINES)..........................................430
	FIGURE 5-4. PLATFORM ASSEMBLY WITH DROP-BAR - 36IN X 6FT (91.5CM X 1.83M) (USA BUILT MACHINES)..............................................432
	FIGURE 5-5. PLATFORM ASSEMBLY WITH DROP-BAR - 36IN X 6FT (91.5CM X 1.83M) (ROMANIAN BUILT MACHINES).........................................434
	FIGURE 5-6. PLATFORM ASSEMBLY WITH DROP-BAR - 36IN X 8FT (91.5CM X 2.44M) (USA BUILT MACHINES)..............................................436
	FIGURE 5-7. PLATFORM ASSEMBLY WITH DROP-BAR - 36IN X 8FT (91.5CM X 2.44M) (ROMANIAN BUILT MACHINES).........................................438
	FIGURE 5-8. PLATFORM ASSEMBLY WITH GATE - 30IN X 5FT (76CM X 1.52M) (USA BUILT MACHINES.....................................................440
	FIGURE 5-9. PLATFORM ASSEMBLY WITH GATE - 30IN X 5FT (76CM X 1.52M) (ROMANIAN  BUILT MACHINES)..............................................442
	FIGURE 5-10. PLATFORM ASSEMBLY WITH GATE- 36IN X 6FT (91.5CM X 1.83M) (USA BUILT MACHINES)..................................................444
	FIGURE 5-11. PLATFORM ASSEMBLY WITH GATE - 36IN X 6FT (91.5CM X 1.83M) (USA BUILT MACHINES).................................................446
	FIGURE 5-12. PLATFORM ASSEMBLY WITH GATE - 36IN X 8FT (91.5CM X 2.44M) (USA BUILT MACHINES).................................................448
	FIGURE 5-13. PLATFORM ASSEMBLY WITH GATE - 36IN X 8FT (91.5CM X 2.44M) (ROMANIAN BUILT MACHINES)............................................450
	FIGURE 5-14. PLATFORM ASSEMBLY WITH FALL ARREST - 36IN X 6FT (91.5CM X 1.83M)...............................................................452
	FIGURE 5-15. PLATFORM ASSEMBLY WITH TRI-ENTRY (1 GATE / 2 DROP BARS) - 36IN X 6FT (91.5CM X 1.83M)..........................................454
	FIGURE 5-16. PLATFORM ASSEMBLY WITH TRI-ENTRY (1 GATE/2 DROP BARS) - 36IN X 8FT (91.5CM X 2.44M)............................................456
	FIGURE 5-17. PLATFORM ASSEMBLY WITH TRI-ENTRY (3 DROP BARS) - 36IN X 6FT (91.5CM X 1.83M)...................................................458
	FIGURE 5-18. PLATFORM ASSEMBLY WITH TRI-ENTRY (3 DROP BARS) - 36IN X 8FT (91.5CM X 2.44M)...................................................460
	FIGURE 5-19. CONSOLE AND FOOT SWITCH INSTALLATION (Prior to SN E300007713)..................................................................462
	FIGURE 5-20. CONSOLE AND FOOT SWITCH INSTALLATION (SN E300007713 to Present)................................................................464
	FIGURE 5-21. CONSOLE BOX ASSEMBLY WITH FOOTSWITCH (Prior to SN E300007713)..................................................................466
	FIGURE 5-22. CONSOLE BOX ASSEMBLY WITH FOOTSWITCH (SN E300007713 to Present)................................................................470
	FIGURE 5-23. FOOTSWITCH ASSEMBLY............................................................................................................474
	FIGURE 5-24. CONTROLLER ASSEMBLY- DRIVE/STEER...............................................................................................476
	FIGURE 5-25. CONTROLLER ASSEMBLY - LIFT/SWING...............................................................................................478
	FIGURE 5-26. LIGHT  PANEL INSTALLATION......................................................................................................482
	FIGURE 5-27. SKYEYE INSTALLATION............................................................................................................484
	FIGURE 5-28. SKYGUARD BAR INSTALLATION......................................................................................................486
	FIGURE 5-29. SKYLINE INSTALLATION...........................................................................................................488
	FIGURE 5-30. STORAGE TRAY INSTALLATION - CENTER.............................................................................................490
	FIGURE 5-31. SKYWELDER INSTALLATION (50HZ)..................................................................................................492
	FIGURE 5-32. SKYWELDER INSTALLATION (60HZ)..................................................................................................494
	FIGURE 5-33. WELDER ASSEMBLY................................................................................................................496
	FIGURE 5-34. SKYWELDER PREP PACKAGE (60HZ) (USA BUILT MACHINES ONLY)........................................................................498
	FIGURE 5-35. SKYGLAZIER INSTALLATION (400S HC3 ANSI, ANSI EXPORT, CE & CSA SPECS/460SJ HC3 ANSI, AUSTRALIAN & CSA SPECS)....................500
	FIGURE 5-36. PIPE RACKS INSTALLATION (400S HC3 & 460SJ HC3 ALL SPECS EXCEPT AUSTRALIAN SPECS)...............................................502
	FIGURE 5-37. PIPE RACKS INSTALLATION (460SJ HC3 AUSTRALIAN SPECS) (Prior to SN E300007713)..................................................504
	FIGURE 5-38. PIPE RACKS INSTALLATION (460SJ HC3 AUSTRALIAN SPECS) (SN E300007713 to Present)................................................506
	FIGURE 5-39. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.83M FALL ARREST PLATFORM (USA BUILT MACHINES ONLY)......................................508
	FIGURE 5-40. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M PLATFORM (USA BUILT MACHINES ONLY)..................................................510
SECTION 6 - CYLINDER............................................................................................................................513
	FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY..................................................................................................514
	FIGURE 6-2. LEVEL CYLINDER ASSEMBLY - PLATFORM SLAVE (400S HC3).............................................................................516
	FIGURE 6-3. LEVEL CYLINDER ASSEMBLY - PLATFORM SLAVE (460S HC3).............................................................................518
	FIGURE 6-4. LIFT CYLINDER ASSEMBLY - JIB (460SJ HC3)........................................................................................520
	FIGURE 6-5. LIFT CYLINDER ASSEMBLY - JIB (460SJ HC3) (SN E300007713 to Present).............................................................522
	FIGURE 6-6. LIFT CYLINDER ASSEMBLY - BOOM (400S HC3)........................................................................................524
	FIGURE 6-7. LIFT CYLINDER ASSEMBLY - BOOM (460SJ HC3).......................................................................................526
	FIGURE 6-8. MASTER CYLINDER ASSEMBLY (400S HC3).............................................................................................528
	FIGURE 6-9. MASTER CYLINDER ASSEMBLY (460SJ HC3)............................................................................................530
	FIGURE 6-10. STEER CYLINDER ASSEMBLY........................................................................................................532
	FIGURE 6-11. TELESCOPE CYLINDER ASSEMBLY (400S HC3).........................................................................................534
	FIGURE 6-12. TELESCOPE CYLINDER ASSEMBLY (460SJ HC3)........................................................................................536
SECTION 7 - HYDRAULIC...........................................................................................................................539
	FIGURE 7-1. DRIVE HYDRAULIC DIAGRAM - 400S HC3 (Prior to SN E300007713).....................................................................540
	FIGURE 7-2. HYDRAULIC DIAGRAM - 400S HC3 (SN E300007713 to Present).........................................................................548
	FIGURE 7-3. HYDRAULIC DIAGRAM - 460SJ HC3...................................................................................................556
SECTION 8 - ELECTRICAL..........................................................................................................................565
	FIGURE 8-1. AC BOX AT PLATFORM INSTALLATION - 110V GFI (MACHINES WITH 2500W GENERATOR/NO GENERATOR OPTIONS) (ANSI AND CSA SPECS)............566
	FIGURE 8-2. AC BOX AT PLATFORM INSTALLATION - CUSTOMER SUPPLIED RECEPTACLE (ANSI EXPORT, CE AND CHINA SPECS)................................568
	FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE SPECS) (2500W AND 7500W SKYPOWER GENERATORS)..............................570
	FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 110V IEC YELLOW (CE SPECS) (4000W GENERATOR)..................................................572
	FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE SPECS) (2500W AND 7500W SKYPOWER GENERATORS)................................574
	FIGURE 8-6. AC BOX AT PLATFORM INSTALLATION - 220V IEC BLUE (CE SPECS) (4000W GENERATOR)....................................................576
	FIGURE 8-7. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (CE SPECS) (WITHOUT GENERATOR)..........................................578
	FIGURE 8-8. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 POST GROUND (CE SPECS) (4000W GENERATOR)............................................580
	FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (CE SPECS)  (WITHOUT GENERATOR).........................................582
	FIGURE 8-10. AC BOX AT PLATFORM INSTALLATION - 220V CEE7 SIDE GROUND (CE SPECS)  (4000W GENERATOR)..........................................584
	FIGURE 8-11. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 (CE SPECS) (WITHOUT GENERATOR)...............................................586
	FIGURE 8-12. AC BOX AT PLATFORM INSTALLATION - 220V AFSINT 107 (CE SPECS) (4000W GENERATOR).................................................588
	FIGURE 8-13. AC BOX AT PLATFORM INSTALLATION - 240V GFCI RECEPTACLE (ANSI, ANSI EXPORT AND CSA SPECS WITH 4000W SKYPOWER GENERATOR).........590
	FIGURE 8-14. BATTERY DISCONNECT INSTALLATION................................................................................................592
	FIGURE 8-15. BOOM HARNESS - 400S HC3........................................................................................................594
	FIGURE 8-16. BOOM HARNESS - 460SJ HC3.......................................................................................................596
	FIGURE 8-17. BREAKER BOX INSTALLATION - 110V/220V WITH 1 BREAKER (CE SPECS).................................................................598
	FIGURE 8-18. BREAKER BOX INSTALLATION - 110V/220V WITH 3 BREAKERS (CE SPECS)................................................................600
	FIGURE 8-19. BREAKER BOX KIT - 1 DOUBLE BREAKER (CE SPECS)..................................................................................602
	FIGURE 8-20. BREAKER BOX KIT - 1 BREAKER (CE SPECS).........................................................................................604
	FIGURE 8-21. BREAKER BOX KIT - 3 BREAKERS (CE SPECS)........................................................................................606
	FIGURE 8-22. CABLES AND CLAMPS INSTALLATION - 400S HC3 WITH 2500W GENERATOR OR NO GENERATOR.................................................608
	FIGURE 8-23. CABLES AND CLAMPS INSTALLATION - 400S HC3 WITH 4000W/50HZ GENERATOR............................................................610
	FIGURE 8-24. CABLES AND CLAMPS INSTALLATION - 400S HC3 WITH 4000W/60HZ GENERATOR............................................................612
	FIGURE 8-25. CABLES AND CLAMPS INSTALLATION - 400S HC3 WITH 7500W GENERATOR.................................................................614
	FIGURE 8-26. CABLES AND CLAMPS INSTALLATION - 460SJ HC3 WITH 2500W GENERATOR OR NO GENERATOR................................................616
	FIGURE 8-27. CABLES AND CLAMPS INSTALLATION - 460SJ HC3 WITH 4000W/50HZ GENERATOR...........................................................618
	FIGURE 8-28. CABLES AND CLAMPS INSTALLATION - 460SJ HC3 WITH 4000W/60HZ GENERATOR...........................................................620
	FIGURE 8-29. CABLES AND CLAMPS INSTALLATION - 460SJ HC3 WITH 7500W GENERATOR................................................................622
	FIGURE 8-30. CAPACITY SWITCH HARNESS (400S HC3).............................................................................................624
	FIGURE 8-31. CAPACITY SWITCH HARNESS (460SJ HC3)............................................................................................626
	FIGURE 8-32. ENGINE HARNESS ASSEMBLY (DEUTZ D2011)..........................................................................................628
	FIGURE 8-33. ENGINE HARNESS ASSEMBLY (DEUTZ D2.9L4).........................................................................................630
	FIGURE 8-34. ENGINE HARNESS – DEUTZ D2.9L4 (STAGE V) ENGINES................................................................................634
	FIGURE 8-35. ENGINE HARNESS ASSEMBLY (KUBOTA)...............................................................................................638
	FIGURE 8-36. FUEL HARNESS (DEUTZ D2.9L4 ENGINES)............................................................................................640
	FIGURE 8-37. FUEL HARNESS - DEUTZ D2.9L4 (STAGE V) ENGINE...................................................................................642
	FIGURE 8-38. FUEL HARNESS (KUBOTA ENGINES)..................................................................................................644
	FIGURE 8-39. GENERATOR HARNESS - 2500W GENERATOR............................................................................................646
	FIGURE 8-40. GENERATOR HARNESS - 4000W GENERATOR (CONTROL BOX TO GENERATOR) (DEUTZ ENGINES).................................................648
	FIGURE 8-41. GENERATOR HARNESS - 7500W GENERATOR  (CONTROL BOX TO GENERATOR)................................................................650
	FIGURE 8-42. GROUND CONTROL BOX HARNESS.....................................................................................................652
	FIGURE 8-43. HIGH CAPACITY HARNESS (460SJ HC3)..............................................................................................654
	FIGURE 8-44. PLATFORM CONSOLE BOX HARNESS...................................................................................................656
	FIGURE 8-45. RECEPTACLE BOX KIT - 110V IEC YELLOW (CE SPEC).................................................................................658
	FIGURE 8-46. RECEPTACLE BOX KIT - 220V IEC BLUE (CE SPEC)...................................................................................660
	FIGURE 8-47. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND (CE SPEC)...........................................................................662
	FIGURE 8-48. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND (CE SPEC)...........................................................................664
	FIGURE 8-49. RECEPTACLE BOX KIT - 220V AFSINT 107 (CE SPEC).................................................................................666
	FIGURE 8-50. RECEPTACLE/BREAKER BOX ASSEMBLY - 240V (4000W AND 7500W SKYPOWER GENERATORS) (ANSI, ANSI EXPORT AND CSA SPECS).................668
	FIGURE 8-51. SKYEYE EMITTER HARNESS.........................................................................................................670
	FIGURE 8-52. SKYEYE INTERMEDIATE HARNESS....................................................................................................672
	FIGURE 8-53. SKYEYE RECEIVER HARNESS........................................................................................................674
	FIGURE 8-54. SKYGUARD HARNESS...............................................................................................................676
	FIGURE 8-55. SKYGUARD INTERFACE HARNESS.....................................................................................................678
	FIGURE 8-56. SKYLINE HARNESS................................................................................................................680
	FIGURE 8-57. STROBE LIGHT HARNESS (BLUE AND RED STROBE LIGHTS)..............................................................................682
	FIGURE 8-58. TELESCOPE IN PROXIMITY SENSORS HARNESS (400S HC3)..............................................................................684
	FIGURE 8-59. TELESCOPE IN PROXIMITY SENSORS HARNESS (460SJ HC3).............................................................................686
	FIGURE 8-60. TELESCOPE OUT PROXIMITY SENSORS HARNESS (400S HC3).............................................................................688
	FIGURE 8-61. TURNTABLE HARNESS..............................................................................................................690
	FIGURE 8-62. VALVE HARNESS..................................................................................................................694
SECTION 9 - DECALS..............................................................................................................................697
	FIGURE 9-1. DECAL INSTALLATION - ANSI SPECS (DIESEL MACHINES) (Prior to SN E300007713)......................................................698
	FIGURE 9-2. DECAL INSTALLATION - ANSI SPECS (DIESEL MACHINES) (SN E300007713 to Present)....................................................700
	FIGURE 9-3. DECAL INSTALLATION - ANSI SPECS (GAS MACHINES) (Prior to SN E300007713).........................................................702
	FIGURE 9-4. DECAL INSTALLATION - ANSI SPECS (GAS MACHINES) (SN E300007713 to Present).......................................................704
	FIGURE 9-5. DECAL INSTALLATION - AUSTRALIAN SPECS  (Prior to SN E300007713).................................................................706
	FIGURE 9-6. DECAL INSTALLATION - AUSTRALIAN SPECS (SN E300007713 to Present)................................................................708
	FIGURE 9-7. DECAL INSTALLATION - BRAZIL SPECS (Prior to SN E300007713)......................................................................710
	FIGURE 9-8. DECAL INSTALLATION - BRAZIL SPECS (SN E300007713 to Present)....................................................................712
	FIGURE 9-9. DECAL INSTALLATION - CE SPECS (Prior to SN E300007713)..........................................................................714
	FIGURE 9-10. DECAL INSTALLATION - CE SPECS (SN E300007713 to Present).......................................................................716
	FIGURE 9-11. DECAL INSTALLATION - CHINESE SPECS  (Prior to SN E300007713)...................................................................718
	FIGURE 9-12. DECAL INSTALLATION - CHINESE SPECS (SN E300007713 to Present)..................................................................720
	FIGURE 9-13. DECAL INSTALLATION - CSA SPECS (DIESEL MACHINES) (Prior to SN E300007713)......................................................722
	FIGURE 9-14. DECAL INSTALLATION - CSA SPECS (DIESEL MACHINES) (SN E300007713 to Present)....................................................724
	FIGURE 9-15. DECAL INSTALLATION - CSA SPECS (GAS MACHINES) (Prior to SN E300007713).........................................................726
	FIGURE 9-16. DECAL INSTALLATION - CSA SPECS (GAS MACHINES) (SN E300007713 to Present).......................................................728
	FIGURE 9-17. DECAL INSTALLATION - JAPANESE SPECS  (Prior to SN E300007713)..................................................................730
	FIGURE 9-18. DECAL INSTALLATION - JAPANESE SPECS (SN E300007713 to Present).................................................................732
	FIGURE 9-19. DECAL INSTALLATION - KOREAN SPECS (Prior to SN E300007713).....................................................................734
	FIGURE 9-20. DECAL INSTALLATION - KOREAN SPECS (SN E300007713 to Present)...................................................................736
	FIGURE 9-21. DECAL INSTALLATION - LATIN AMERICAN SPECS  (Prior to SN E300007713)............................................................738
	FIGURE 9-22. DECAL INSTALLATION - LATIN AMERICAN SPECS (SN E300007713 to Present)...........................................................740
	FIGURE 9-23. DECAL INSTALLATION - OPTIONS...................................................................................................742
	FIGURE 9-24. DECAL INSTALLATION - SKYWELDER (50HZ)..........................................................................................746
	FIGURE 9-25. DECAL INSTALLATION - SKYWELDER (60HZ)..........................................................................................748
SECTION 10 - RECOMMENDED SERVICE PARTS STOCK....................................................................................................751
	FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK................................................................................................752
SECTION 11 - SPECIAL OPTIONS....................................................................................................................755
	FIGURE 11-1. SPECIAL OPTIONS................................................................................................................756
PART NUMBER INDEX...............................................................................................................................759

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