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
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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