JLG 400S 460SJ Parts Manual (3120896) PDF Download – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 400S 460SJ Parts Manual (3120896) PDF Download – PDF DOWNLOAD
SECTION 1 - FRAME................................................................................................................................... 9 FIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW PACKAGE............................................................................ 10 FIGURE 1-2. AXLE AND STEERING INSTALLATION - 2WD WITH TOW PACKAGE............................................................................... 14 FIGURE 1-3. AXLE AND STEERING INSTALLATION - 4WD................................................................................................ 18 FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS.................................................................................................. 24 FIGURE 1-5. DRIVE HUB ASSEMBLY (4WD FRONT) (Prior to SN 0300076633)............................................................................. 28 FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY (REAR) (Prior to SN 0300076633)............................................................................ 30 FIGURE 1-7. DRIVE HUB AND HUB WITH BRAKE ASSEMBLIES (SN 0300076633 through 0300096000).......................................................... 34 FIGURE 1-8. DRIVE MOTOR ASSEMBLY (ORIGINAL EQUIPMENT - 4 BOLT ASSEMBLY)......................................................................... 38 FIGURE 1-9. DRIVE MOTOR ASSEMBLY (FIELD SERVICE REPLACEMENT - 5 BOLT ASSEMBLY).................................................................. 42 FIGURE 1-10. FRAME VALVES AND SHIELDS INSTALLATION.............................................................................................. 46 FIGURE 1-11. SEMI-TRACK INSTALLATION............................................................................................................ 50 FIGURE 1-12. TOW PACKAGE INSTALLATION........................................................................................................... 54 SECTION 2 - TURNTABLE............................................................................................................................... 57 FIGURE 2-1. VALVES AND TILT INDICATOR INSTALLATIONS............................................................................................. 58 FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY......................................................................................................... 62 FIGURE 2-3. ARTICULATING JIB VALVE ASSEMBLY..................................................................................................... 66 FIGURE 2-4. TURNTABLE AND SWING DRIVE INSTALLATIONS............................................................................................. 68 FIGURE 2-5. SWING BRAKE ASSEMBLY................................................................................................................ 72 FIGURE 2-6. SWING HUB ASSEMBLY.................................................................................................................. 74 FIGURE 2-7. SWING MOTOR ASSEMBLY................................................................................................................ 76 FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION..................................................................................................... 78 FIGURE 2-9. DEUTZ ENGINE INSTALLATION (Prior to SN 0300077682).................................................................................. 86 FIGURE 2-10. DEUTZ ENGINE INSTALLATION (SN 0300077682 through 0300096000)....................................................................... 92 FIGURE 2-11. PISTON PUMP ASSEMBLY...............................................................................................................100 FIGURE 2-12. GEAR PUMP ASSEMBLY.................................................................................................................104 FIGURE 2-13. AUXILIARY PUMP ASSEMBLY............................................................................................................106 FIGURE 2-14. TANK INSTALLATIONS.................................................................................................................110 FIGURE 2-15. GROUND CONTROL BOX ASSEMBLY WITHOUT ADE SYSTEM.....................................................................................114 FIGURE 2-16. GROUND CONTROL BOX ASSEMBLY WITH ADE SYSTEM........................................................................................118 FIGURE 2-17. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED)................................................................................122 FIGURE 2-18. HOODS INSTALLATION.................................................................................................................126 FIGURE 2-19. GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL)...........................................................................130 FIGURE 2-20. GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL).................................................................................132 FIGURE 2-21. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR AND DEUTZ ENGINES..............................................................136 SECTION 3 - BOOM....................................................................................................................................141 FIGURE 3-1. BOOM INSTALLATIONS..................................................................................................................142 FIGURE 3-2. BOOM ASSEMBLY - 400S................................................................................................................146 FIGURE 3-3. BOOM ASSEMBLY - 460SJ...............................................................................................................150 FIGURE 3-4. ROTATOR ASSEMBLIES..................................................................................................................154 FIGURE 3-5. PLATFORM SUPPORT INSTALLATION - WITH LSS............................................................................................158 SECTION 4 - PLATFORM................................................................................................................................161 FIGURE 4-1. PLATFORM INSTALLATION (FRONT ENTRY PLATFORM)........................................................................................162 FIGURE 4-2. PLATFORM INSTALLATION - SIDE ENTRY PLATFORM.........................................................................................166 FIGURE 4-3. SOFT TOUCH INSTALLATION (FRONT ENTRY PLATFORM) (OPTIONAL)...........................................................................170 FIGURE 4-4. SOFT TOUCH INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL)............................................................................172 FIGURE 4-5. PLATFORM CONSOLE ASSEMBLY WITHOUT ADE SYSTEM........................................................................................174 FIGURE 4-6. PLATFORM CONSOLE ASSEMBLY WITH ADE SYSTEM...........................................................................................180 FIGURE 4-7. CONTROLLER ASSEMBLY (SWING AND LIFT) (WITHOUT ADE SYSTEM)...........................................................................184 FIGURE 4-8. CONTROLLER ASSEMBLY (LIFT AND SWING) (WITH ADE SYSTEM)..............................................................................186 FIGURE 4-9. CONTROLLER ASSEMBLY (LIFT AND SWING) (WITH ADE SYSTEM)..............................................................................188 FIGURE 4-10. CONTROLLER ASSEMBLY (LIFT AND SWING) (WITH ADE SYSTEM).............................................................................190 FIGURE 4-11. CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITHOUT ADE SYSTEM).........................................................................194 FIGURE 4-12. CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITH ADE SYSTEM)............................................................................196 FIGURE 4-13. CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITH ADE SYSTEM)............................................................................198 FIGURE 4-14. CONTROLLER ASSEMBLY (DRIVE AND STEER) (WITH ADE SYSTEM)............................................................................200 FIGURE 4-15. SKYCUTTER INSTALLATION.............................................................................................................202 FIGURE 4-16. PLASMA CUTTER ASSEMBLY.............................................................................................................204 FIGURE 4-17. SKYWELDER INSTALLATION (Prior to SN 0300068333)....................................................................................206 FIGURE 4-18. SKYWELDER INSTALLATION (50HZ) (SN 0300068333 through 0300096000)...................................................................212 FIGURE 4-19. WELDER ASSEMBLY....................................................................................................................214 FIGURE 4-20. PIPE RACKS INSTALLATION............................................................................................................216 SECTION 5 - CYLINDER................................................................................................................................219 FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY......................................................................................................220 FIGURE 5-2. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY............................................................................................222 FIGURE 5-3. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY (400S - SERVICE REPLACEMENT CYLINDER)......................................................224 FIGURE 5-4. LIFT CYLINDER ASSEMBLY - JIB (460SJ) (ORIGINAL EQUIPMENT)...........................................................................226 FIGURE 5-5. LIFT CYLINDER ASSEMBLY - JIB (460SJ) (USAGE MAY VARY) (SERVICE REPLACEMENT).........................................................228 FIGURE 5-6. LIFT CYLINDER ASSEMBLY - JIB (460SJ) (USAGE MAY VARY) (SERVICE REPLACEMENT).........................................................230 FIGURE 5-7. LIFT CYLINDER ASSEMBLY - MAIN.......................................................................................................232 FIGURE 5-8. MASTER CYLINDER ASSEMBLY (ORIGINAL EQUIPMENT).......................................................................................234 FIGURE 5-9. MASTER CYLINDER ASSEMBLY (SERVICE REPLACEMENT)......................................................................................236 FIGURE 5-10. STEER CYLINDER ASSEMBLY (ORIGINAL EQUIPMENT) (Prior to SN 0300087392)..............................................................238 FIGURE 5-11. STEER CYLINDER ASSEMBLY (SERVICE REPLACEMENT AND ORIGINAL EQUIPMENT) (Prior to SN 0300087392, SN 0300087392 through 0300096000)....240 FIGURE 5-12. TELESCOPE CYLINDER ASSEMBLY........................................................................................................242 SECTION 6 - HYDRAULIC...............................................................................................................................245 FIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM......................................................................................................246 FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD.......................................................................................................248 FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 4WD.......................................................................................................250 FIGURE 6-4. STANDARD HYDRAULIC DIAGRAM..........................................................................................................254 FIGURE 6-5. HYDRAULIC DIAGRAM LIST..............................................................................................................258 SECTION 7 - ELECTRICAL..............................................................................................................................259 FIGURE 7-1. ELECTRICAL DIAGRAM LIST.............................................................................................................260 FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT ADE SYSTEM)................................................................................262 FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITH ADE SYSTEM)...................................................................................270 SECTION 8 - DECALS..................................................................................................................................281 FIGURE 8-1. DECAL INSTALLATION (Prior to SN 0300085617).........................................................................................282 FIGURE 8-2. DECAL INSTALLATION (SN 0300085617 through 0300095670)...............................................................................288 FIGURE 8-3. DECAL INSTALLATION (SN 0300095671 through 0300096000)...............................................................................292 SECTION 9 - RECOMMENDED SERVICE PARTS STOCK.........................................................................................................295 FIGURE 9-1. MODEL 400S/460SJ STANDARD PARTS.....................................................................................................296 FIGURE 9-2. MODEL 400S/460SJ VARIABLE PARTS.....................................................................................................298 SECTION 10 - SPECIAL OPTIONS........................................................................................................................299 FIGURE 10-1. SPECIAL OPTIONS LIST...............................................................................................................300 PART NUMBER INDEX...................................................................................................................................305
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