JLG Boom Lift 400SC 460SJC Parts Manual 3122559600

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JLG Boom Lift 400SC 460SJC Parts Manual 3122559600
Size: 36.39 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Manual
Model: JLG 400SC, 460SJC Boom Lift
Part Number: 3122559600
Publication Date: 2025
Number of Pages: 490 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. UNDERCARRIAGE ASSEMBLY - RUBBER TRACKS​

FIGURE 1-2. UNDERCARRIAGE ASSEMBLY - RUBBER TRACKS (NON-MARKING)​

FIGURE 1-3. FRAME UNDERCARRIAGE STEEL TRACKS WITH PADS​

FIGURE 1-4. UNDERCARRIAGE ASSEMBLY - WITH STEEL TRACKS​

FIGURE 1-5. TRACK ASSEMBLY - STEEL​

FIGURE 1-6. DRIVE HUB ASSEMBLY​

FIGURE 1-7. DRIVE MOTOR ASSEMBLY​

SECTION 2 - TURNTABLE

FIGURE 2-1. CONTROL VALVES INSTALLATION (400SC)​

FIGURE 2-2. CONTROL VALVES INSTALLATION (460SJC)​

FIGURE 2-3. MAIN VALVE ASSEMBLY (400SC)​

FIGURE 2-4. MAIN VALVE ASSEMBLY (460SJC)​

FIGURE 2-5. AXLE VALVE ASSEMBLY​

FIGURE 2-6. AUXILIARY PUMP AND BATTERY INSTALLATION (WITHOUT DISCONNECT)​

FIGURE 2-7. AUXILIARY PUMP AND BATTERY INSTALLATION (WITH DISCONNECT)​

FIGURE 2-8. AUXILIARY PUMP ASSEMBLY​

FIGURE 2-9. SWING DRIVE INSTALLATION​

FIGURE 2-10. SWING HUB/MOTOR ASSEMBLY​

FIGURE 2-11. TURNTABLE BEARING INSTALLATION​

FIGURE 2-12. BEARING LUBE INSTALLATION​

FIGURE 2-13. TURNTABLE COVERS INSTALLATION​

FIGURE 2-14. TURNTABLE LOCK INSTALLATION​

FIGURE 2-15. ROTARY COUPLING INSTALLATION​

FIGURE 2-16. TANKS INSTALLATION​

FIGURE 2-17. ELECTRICAL INSTALLATION (400SC)​

FIGURE 2-18. ELECTRICAL INSTALLATION (460SJC)​

FIGURE 2-19. ELECTRICAL PANEL ASSEMBLY​

FIGURE 2-20. GROUND CONTROL ASSEMBLY (400SC)​

FIGURE 2-21. GROUND CONTROL ASSEMBLY (460SJC)​

FIGURE 2-22. KEYSWITCH AND PANEL DECAL INSTALLATION (400SC)​

FIGURE 2-23. KEYSWITCH AND PANEL DECAL INSTALLATION (460SJC)​

FIGURE 2-24. LIGHT PANEL INSTALLATION​

FIGURE 2-25. GROUND CONTROL PANEL MOUNTING (400SC)​

FIGURE 2-26. GROUND CONTROL PANEL MOUNTING (460SJC)​

FIGURE 2-27. WHITE NOISE ALARM (AMBIENT) INSTALLATION​

FIGURE 2-28. WHITE NOISE ALARM (CONSTANT) INSTALLATION​

FIGURE 2-29. HOOD INSTALLATION (ABS)​

FIGURE 2-30. HOOD INSTALLATION (STEEL)​

FIGURE 2-31. ABS HOOD ASSEMBLY - ENGINE SIDE​

FIGURE 2-32. HOOD ASSEMBLY - ENGINE SIDE (STEEL)​

FIGURE 2-33. ABS HOOD ASSEMBLY - TANK SIDE​

FIGURE 2-34. STEEL HOOD ASSEMBLY - TANK SIDE​

FIGURE 2-35. SOUND REDUCTION INSTALLATION - WITH STEEL HOODS​

SECTION 3 - ENGINE

FIGURE 3-1. ENGINE INSTALLATION - DEUTZ D2011 (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-2. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-3. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-4. ENGINE INSTALLATION - DEUTZ D2011 ENGINE (WITH ARCTIC PACKAGE)​

FIGURE 3-5. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2011 ENGINE (WITH ARCTIC PACKAGE)​

FIGURE 3-6. ENGINE ASSEMBLY - DEUTZ D2011 ENGINE (WITH ARCTIC PACKAGE)​

FIGURE 3-7. ENGINE COMPONENTS - DEUTZ D2011​

FIGURE 3-8. ENGINE INSTALLATION - DEUTZ D2.9L4 ERM5 ENGINE (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-9. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ERM5 ENGINE (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-10. ENGINE ASSEMBLY - DEUTZ D2.9L4 ERM5 ENGINE (WITHOUT ARCTIC PACKAGE)​

FIGURE 3-11. ENGINE INSTALLATION - DEUTZ D2.9L4 ERM5 ENGINE (WITH ARCTIC PACKAGE)​

FIGURE 3-12. ENGINE AND PUMP SUB-ASSEMBLY - DEUTZ D2.9L4 ERM5 ENGINE (WITH ARCTIC PACKAGE)​

FIGURE 3-13. ENGINE ASSEMBLY - DEUTZ D2.9L4 ERM5 ENGINE (WITH ARCTIC PACKAGE)​

FIGURE 3-14. ENGINE COMPONENTS - DEUTZ D2.9L4 ERM5 ENGINE​

FIGURE 3-15. MOTOR MOUNT INSTALLATION (WITH GENERATOR)​

FIGURE 3-16. MOTOR MOUNT INSTALLATION (WITHOUT GENERATOR)​

FIGURE 3-17. BRACKET ASSEMBLY - FUEL PUMP AND FILTER (DEUTZ D2.9L4 (STAGE V) ENGINE)​

FIGURE 3-18. GEAR PUMP ASSEMBLY​

FIGURE 3-19. PISTON PUMP ASSEMBLY (FRONT)​

FIGURE 3-20. PISTON PUMP ASSEMBLY (REAR)​

FIGURE 3-21. PUMP COUPLING KIT​

FIGURE 3-22. BREATHER HEATER INSTALLATION - DEUTZ D2.9L4 ENGINE WITH ARCTIC PACKAGE​

FIGURE 3-23. ENGINE BAFFLE INSTALLATION​

FIGURE 3-24. ENGINE BAFFLE INSTALLATION - STEEL​

FIGURE 3-25. ENGINE TRAY JACK​

FIGURE 3-26. GENERATOR INSTALLATION - 2500W/60HZ (DEUTZ D2011 ENGINE)​

FIGURE 3-27. GENERATOR INSTALLATION - 2500W/60HZ (DEUTZ D2.9L4 ERM5 ENGINE)​

FIGURE 3-28. GENERATOR INSTALLATION - 4000W/50HZ (DEUTZ D2011 ENGINE)​

FIGURE 3-29. GENERATOR INSTALLATION - 4000W/60HZ (DEUTZ D2011 ENGINE)​

FIGURE 3-30. GENERATOR INSTALLATION - 4000W/60HZ (DEUTZ D2.9L4 ERM5 ENGINE)​

FIGURE 3-31. GENERATOR INSTALLATION - 7500W/50HZ (DEUTZ D2011 ENGINE)​

FIGURE 3-32. GENERATOR INSTALLATION - 7500W/60HZ (DEUTZ D2011 ENGINE)​

FIGURE 3-33. GENERATOR INSTALLATION - 7500W/60HZ (DEUTZ D2.9L4 ERM5 ENGINE)​

FIGURE 3-34. OIL COOLER INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 3-35. OIL COOLER INSTALLATION - DEUTZ D2.9L4 ENGINES​

FIGURE 3-36. SPARK ARRESTOR INSTALLATION - ANSI EXPORT SPECS​

SECTION 4 - BOOM

FIGURE 4-1. BOOM AND CYLINDERS INSTALLATION (400SC)​

FIGURE 4-2. BOOM AND CYLINDERS INSTALLATION (460SJC)​

FIGURE 4-3. BOOM REST INSTALLATION (400SC)​

FIGURE 4-4. MAIN BOOM ASSEMBLY (400SC)​

FIGURE 4-5. MAIN BOOM ASSEMBLY (460SJC)​

FIGURE 4-6. JIB BOOM ASSEMBLY (460SJC)​

FIGURE 4-7. PLATFORM ROTATOR ASSEMBLY (400SC)​

FIGURE 4-8. PLATFORM ROTATOR ASSEMBLY (460SJC)​

FIGURE 4-9. CAPACITY SWITCHES INSTALLATION (400SC)​

FIGURE 4-10. RAPID REPLACEABLE PLATFORM SUPPORT INSTALLATION (MACHINES WITH SN STARTING WITH 03) (460SJC)​

FIGURE 4-11. RAPID REPLACEABLE PLATFORM SUPPORT INSTALLATION (MACHINES WITH SN STARTING WITH B3)​

FIGURE 4-12. POWER TRACK INSTALLATION​

FIGURE 4-13. TRANSPORT SWITCHES INSTALLATION​

SECTION 5 - PLATFORM

FIGURE 5-1. TRADITIONAL PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH FALL ARREST (MACHINES WITH SN STARTING WITH 03) (460SJC)​

FIGURE 5-2. TRADITIONAL PLATFORM ASSEMBLY - 36IN X 6FT (91.5CM X 1.83M) WITH FALL ARREST (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-3. TRADITIONAL PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH FALL ARREST (MACHINES WITH SN STARTING WITH 03) (460SJC)​

FIGURE 5-4. TRADITIONAL PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH FALL ARREST (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-5. TRADITIONAL PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) TRI-ENTRY WITH DROPBAR (MACHINES WITH SN STARTING WITH 03) (460SJC)​

FIGURE 5-6. TRADITIONAL PLATFORM ASSEMBLY - 36IN X 8FT (91.5CM X 2.44M) WITH TRI-ENTRY (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-7. RAPID REPLACEABLE PLATFORM (30IN X 5FT (76.2CM X 1.52M) (MACHINES WITH SN STARTING WITH 03) (460SJC)​

FIGURE 5-8. RAPID REPLACEABLE PLATFORM (30IN X 5FT (76.2CM X 1.52M) (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-9. RAPID REPLACEABLE PLATFORM (36IN X 6FT (91.5CM X 1.83M) (MACHINES WITH SN STARTING WITH 03) (460SJC)​

FIGURE 5-10. RAPID REPLACEABLE PLATFORM (36IN X 6FT (91.5CM X 1.83M) (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-11. RAPID REPLACEABLE PLATFORM (36IN X 8FT (91.5CM X 2.44M) (MACHINES WITH SN STARTING WITH 03) (460SJC)​

FIGURE 5-12. RAPID REPLACEABLE PLATFORM (36IN X 8FT (91.5CM X 2.44M) (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-13. PLATFORM SWING GATE INSTALLATION (MACHINES WITH SN STARTING WITH 03) (460SJC)​

FIGURE 5-14. PLATFORM SWING GATE INSTALLATION (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-15. PLATFORM - DROP BAR INSTALLATION (MACHINES WITH SN STARTING WITH 03) (460SJC)​

FIGURE 5-16. PLATFORM DROP BAR INSTALLATION (MACHINES WITH SN STARTING WITH B3)​

FIGURE 5-17. PLATFORM CONSOLE BOX INSTALLATION​

FIGURE 5-18. PLATFORM CONSOLE BOX ASSEMBLY​

FIGURE 5-19. FOOTSWITCH ASSEMBLY​

FIGURE 5-20. LIGHT PANEL INSTALLATION​

FIGURE 5-21. SOFT TOUCH INSTALLATION - 36IN X 8FT (91.5CM X 2.44M) PLATFORM​

FIGURE 5-22. SKYWELDER INSTALLATION (50HZ)​

FIGURE 5-23. SKYWELDER INSTALLATION (60HZ)​

FIGURE 5-24. SKYWELDER PREP PACKAGE (60HZ)​

FIGURE 5-25. WELDER ASSEMBLY​

FIGURE 5-26. SKYGLAZIER INSTALLATION​

FIGURE 5-27. SKYLINE INSTALLATION​

FIGURE 5-28. SKYSENSE MID TUBE SENSOR ASSEMBLY​

FIGURE 5-29. SKYSENSE OVERHEAD SENSOR ASSEMBLY​

FIGURE 5-30. TRAY INSTALLATION​

FIGURE 5-31. USB CHARGER INSTALLATION​

SECTION 6 - CYLINDER

FIGURE 6-1. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY​

FIGURE 6-2. LIFT CYLINDER ASSEMBLY - MAIN BOOM​

FIGURE 6-3. LIFT CYLINDER ASSEMBLY - JIB​

FIGURE 6-4. LIFT CYLINDER ASSEMBLY - JIB​

FIGURE 6-5. MASTER CYLINDER ASSEMBLY​

FIGURE 6-6. TELESCOPE CYLINDER ASSEMBLY​

SECTION 7 - HYDRAULIC

FIGURE 7-1. HYDRAULIC DIAGRAM (400SC)​

FIGURE 7-2. HYDRAULIC DIAGRAM (400SC)​

FIGURE 7-3. HYDRAULIC DIAGRAM (400SC)​

FIGURE 7-4. HYDRAULIC DIAGRAM (400SC)​

FIGURE 7-5. HYDRAULIC DIAGRAM (400SC)​

FIGURE 7-6. HYDRAULIC DIAGRAM (400SC)​

FIGURE 7-7. HYDRAULIC DIAGRAM (460SJC)​

SECTION 8 - ELECTRICAL

FIGURE 8-1. AC BOX AT PLATFORM INSTALLATION - 110V​

FIGURE 8-2. AC BOX AT PLATFORM INSTALLATION - 220V CUSTOMER SUPPLIED COMPONENTS (400SC)​

FIGURE 8-3. AC BOX AT PLATFORM INSTALLATION - 220V CUSTOMER SUPPLIED COMPONENTS (ALL SPECS EXCEPT CSA SPECS) (MACHINES WITH SN STARTING WITH 03) (460SJC)​

FIGURE 8-4. AC BOX AT PLATFORM INSTALLATION - 240V (WITH 4000W GENERATOR)​

FIGURE 8-5. AC BOX AT PLATFORM INSTALLATION - 240V (WITH 7500W SKYPOWER GENERATOR)​

FIGURE 8-6. BATTERY DISCONNECT SWITCH​

FIGURE 8-7. BEACON HARNESS - AMBER BEACON​

FIGURE 8-8. BOOM TELE IN PROXIMITY SWITCH HARNESS​

FIGURE 8-9. BREAKER BOX KIT - 30MA/16 AMP​

FIGURE 8-10. BREAKER BOX KIT WITH THREE BREAKERS​

FIGURE 8-11. CABLES AND CLAMPS INSTALLATION - WITHOUT GENERATOR (400SC)​

FIGURE 8-12. CABLES AND CLAMPS INSTALLATION - WITHOUT GENERATOR (460SJC)​

FIGURE 8-13. CABLES AND CLAMPS INSTALLATION - WITH 2500W GENERATOR​

FIGURE 8-14. CABLES AND CLAMPS INSTALLATION - WITH 4000W/60HZ GENERATOR (400SC)​

FIGURE 8-15. CABLES AND CLAMPS INSTALLATION - WITH 4000W/60HZ GENERATOR (460SJC)​

FIGURE 8-16. CABLES AND CLAMPS INSTALLATION - WITH 7500W GENERATOR (400SC)​

FIGURE 8-17. CABLES AND CLAMPS INSTALLATION - WITH 7500W GENERATOR (460SJC)​

FIGURE 8-18. CAPACITY SWITCH HARNESS (400SC)​

FIGURE 8-19. CLEARSKY CS550 - BEACON INSTALLATION (WITH PLASTIC HOOD)​

FIGURE 8-20. CLEARSKY CS550 - BEACON INSTALLATION (WITH METAL HOOD)​

FIGURE 8-21. ENGINE HARNESS - DEUTZ D2011​

FIGURE 8-22. ENGINE HARNESS - DEUTZ D2.9L4 EMR5 ENGINE​

FIGURE 8-23. FUEL HARNESS - DEUTZ D2.9L4 ENGINE​

FIGURE 8-24. GROUND CONTROL BOX HARNESS​

FIGURE 8-25. GENERATOR HARNESS - 4000W GENERATOR​

FIGURE 8-26. GENERATOR HARNESS - 2500W GENERATOR​

FIGURE 8-27. LEFT DRIVE HARNESS​

FIGURE 8-28. MAIN BOOM HARNESS (400SC)​

FIGURE 8-29. MAIN BOOM HARNESS (460SJC)​

FIGURE 8-30. PLATFORM CONSOLE BOX HARNESS​

FIGURE 8-31. TURNTABLE HARNESS (400SC)​

FIGURE 8-32. TURNTABLE HARNESS (460SJC)​

FIGURE 8-33. VALVE HARNESS - MAIN VALVE​

FIGURE 8-34. SKYLINE HARNESS​

FIGURE 8-35. USB HARNESS​

FIGURE 8-36. WORKLIGHT HARNESS​

SECTION 9 - DECALS

FIGURE 9-1. DECAL INSTALLATION - ENGLISH (ALL SPECS) (400SC)​

FIGURE 9-2. DECAL INSTALLATION - ENGLISH (ALL SPECS) (460SJC)​

FIGURE 9-3. DECAL INSTALLATION - ENGLISH/JAPANESE (JAPANESE SPEC) (400SC)​

FIGURE 9-4. DECAL INSTALLATION - ENGLISH/JAPANESE (ANSI EXPORT AND JAPANESE SPECS) (460SJC)​

FIGURE 9-5. DECAL INSTALLATION - CSA (CSA SPEC) (460SJC)​

FIGURE 9-6. DECAL INSTALLATION - KOREAN (JAPANESE SPEC) (400SC)​

FIGURE 9-7. DECAL INSTALLATION - KOREAN (ANSI EXPORT AND JAPANESE SPECS) (460SJC)​

FIGURE 9-8. DECAL INSTALLATION - OPTIONS​

FIGURE 9-9. SKYWELDER DECAL INSTALLATION - 50HZ​

FIGURE 9-10. SKYWELDER DECAL INSTALLATION - 60HZ​

SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK​

SECTION 11 - SPECIAL OPTIONS

FIGURE 11-1. SPECIAL OPTIONS/ACCESSORIES/KITS​

PART NUMBER INDEX