Jlg 460SJ Parts Manual User Manual

Illustrated Parts ManualModels400S460SJSN 0300096000 to PresentP/N3121236November 27, 2013

1-2 400S 460SJ 3121236SECTION 1 FRAMEFIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW PACKAGE 1171061251251101181081041011011224011

2-38 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-10. CATERPILLAR ENGINE INSTALLATION (WITH UGM)75432335510135634663333333201203576401557301256345335

3121236 400S 460SJ 2-39SECTION 2 TURNTABLE 138138112145108114124126121112116125113112101101106139122119124TO WATERSEPARATERTO FUELTANK VENTLIN

2-40 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-10. CATERPILLAR ENGINE INSTALLATION (WITH UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref NOTE: FO

3121236 400S 460SJ 2-41SECTION 2 TURNTABLE39 3573667 1 Plate, Radiator Support40 3574253 1 Plate, Engine Mounting (Front)41 3574259 2 Plate, Engine Mo

2-42 400S 460SJ 3121236SECTION 2 TURNTABLERef CATERPILLAR ENGINE INSTALLATION1001106469 Ref Without Arctic Package D1001106471 Ref With Arctic Package

3121236 400S 460SJ 2-43SECTION 2 TURNTABLE144 1001094608 2 Latch, Hood145 1001100857 1 Separator, Fuel/Water70002378 1 O-Ring70002377 1 Filter, Fuel14

2-44 400S 460SJ 3121236SECTION 2 TURNTABLE219 2580054 1 Heater, Engine Block (Located on Right Side of Engine)3600405 Ref GEAR PUMP ASSEMBLY WITH FITT

3121236 400S 460SJ 2-45SECTION 2 TURNTABLE423 7026859 1 Gasket, Oil Pan (Not Shown)424 7026862 1 Gasket, Valve Bracket (Not Shown - Located Between Va

2-46 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-11. DEUTZ D2011 ENGINE INSTALLATION 206235253205223A241230A2202492032272312202582462362082344112092

3121236 400S 460SJ 2-47SECTION 2 TURNTABLE 404406232221250403402417401407415SN 0300137656 TOPRESENT206253235262245201211172FUEL TANK REF.ITEM #

3121236 400S 460SJ 1-3SECTION 1 FRAMEFIGURE 1-1. AXLE AND STEERING INSTALLATION - 2WD WITHOUT TOW PACKAGEITEM # PART NUMBER QTY. DESCRIPTION REV.Ref

2-48 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-11. DEUTZ D2011 ENGINE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref DEUTZ ENGINE INSTAL

3121236 400S 460SJ 2-49SECTION 2 TURNTABLE36 2 Latch, Hood Options:Use 1001094608 SN 0300096000 to SN 0300133983 (was p/n 4846096)1001094608 SN 030013

2-50 400S 460SJ 3121236SECTION 2 TURNTABLE107B 7016835 1 Cable - Battery & Auxiliary Pump to Ground (Includes Red Boot at Battery Terminal)107C 70

3121236 400S 460SJ 2-51SECTION 2 TURNTABLE216 0741610 2 Screw, Countersunk 3/8in-16NC x 1-1/4in217 0902740 1 Bracket, Engine Mounting (Right Side)218

2-52 400S 460SJ 3121236SECTION 2 TURNTABLE239 3340399 2 Pad, Wear240 3570808 1 Plate, Relay Mounting241 1 Plate, Radiator Mounting Options:3571692 SN

3121236 400S 460SJ 2-53SECTION 2 TURNTABLERef Note: Following Items (Not Shown) Used on Arctic Package Machines Only. 2580062 1 Heater, Engine Block 3

2-54 400S 460SJ 3121236SECTION 2 TURNTABLE407 Use 70000916 1 Pump Fuel Supply (was p/n 7027238)70001435 1 Repair Kit - Pump1 O-Seal Between Fuel Pump

3121236 400S 460SJ 2-55SECTION 2 TURNTABLE416 7024565 1 Sensor, Speed (Not Shown)70003932 1 Spacer, Sleeve (Not Shown)417 7027792 1 Actuator, Throttle

2-56 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-12. DEUTZ TD2.9L4 ENGINE INSTALLATION AUXILIARY PUMPSHOWN HERE FOR CLARITY2052432432263012432262062

3121236 400S 460SJ 2-57SECTION 2 TURNTABLE A201233201234111031112012112012112012112012141011021071061071061086036026041101015235242682618012911

1-4 400S 460SJ 3121236SECTION 1 FRAMERef OSCILLATING AXLE INSTALLATIONRef All Specs Except CE Spec0272900 Ref SN 0300096000 to SN 0300115396 B10010938

2-58 400S 460SJ 3121236SECTION 2 TURNTABLEGRD.BATTERY+AUX POWERPUMPSTARTERGLOW PLUGSOLENOIDBATTERY CABLE SCHEMATICENGINE BLOCKMTG BOLT FORGLOW PLUG SO

3121236 400S 460SJ 2-59SECTION 2 TURNTABLEFIGURE 2-12. DEUTZ TD2.9L4 ENGINE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref DEUTZ ENGINE INST

2-60 400S 460SJ 3121236SECTION 2 TURNTABLE45 1001110425 4 Spacer46 1001138491 1 Harness, Fuel (Not Shown - See ELECTRICAL SECTION for Breakdown)47 to

3121236 400S 460SJ 2-61SECTION 2 TURNTABLE111 4812100 1 Flatwasher M12112 4891600 2 Flatwasher 3/8in Hardened113 to 114 Not Used115 1001147701 1 Batte

2-62 400S 460SJ 3121236SECTION 2 TURNTABLE227 3340399 2 Pad, Wear228 Not Used229 3740067 1 Relay230 Not Used231 3910408 3 Screw #4-40NC x 1/2in232 393

3121236 400S 460SJ 2-63SECTION 2 TURNTABLE273 1001140564 1 Fitting, Elbow Barbed274 1001142501 1 Fitting, Elbow Barbed275 1001143797 1 Fitting, Straig

2-64 400S 460SJ 3121236SECTION 2 TURNTABLE320 0641412 2 Bolt 1/4in-20NC x 1-1/2in321 4060804 1ft/0.3m Trim322 1001111341 1 Grommet323 1001170435 1 Pip

3121236 400S 460SJ 2-65SECTION 2 TURNTABLE510 70024924 1 Pump, High Pressure (Not Shown - Located Front Left SIde)70025152 1 O-Ring (Between Pump &

2-66 400S 460SJ 3121236SECTION 2 TURNTABLE1001155024 Ref GEAR PUMP ASSEMBLY WITH FITTINGS A601 2220479 2 Fitting, Straight602 2220810 2 Fitting, Reduc

3121236 400S 460SJ 2-67SECTION 2 TURNTABLEFIGURE 2-12. DEUTZ TD2.9L4 ENGINE INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121236 400S 460SJ 1-5SECTION 1 FRAME120 4740158 1 Thrustwasher121 Not Used122 4752000 AR Flatwasher 5/8in Regular (SN 0300096000 to SN 0300140365)123

2-68 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-13. GM ENGINE INSTALLATION (WITHOUT UGM)21225722221024924923124621720324722710510710630430130330530

3121236 400S 460SJ 2-69SECTION 2 TURNTABLEITEM 104 INCLUDES ITEMS 104A-104D104A104D104C104B104A212LOCATED IN BOTTOMOF FUEL TANK53232221420RETURNSUPPLY

2-70 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-13. GM ENGINE INSTALLATION (WITHOUT UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref GM ENGINE INST

3121236 400S 460SJ 2-71SECTION 2 TURNTABLE41 3960469 1 Seal, Foam Gasket42 4070497 2 Shim43 4070498 1 Shim44 4360336 1 Switch, Toggle (Not Shown - Loc

2-72 400S 460SJ 3121236SECTION 2 TURNTABLE207 0641609 6 Bolt 3/8in-16NC x 1-1/8in208 0641610 10 Bolt 3/8in-16NC x 1-1/4in209 0641611 6 Bolt 3/8in-16NC

3121236 400S 460SJ 2-73SECTION 2 TURNTABLE243 4070497 4 Shim (11 Gauge)244 4070498 2 Shim (16 Gauge)245 4569342 1 Tube, Air Intake246 4569345 1 Pipe,

2-74 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-14. GM ENGINE INSTALLATION (WITH UGM)25921626125810710910830430130330530211110210110110321125422026

3121236 400S 460SJ 2-75SECTION 2 TURNTABLEITEM 106 INCLUDES ITEMS 106A-106D106A106D106C106B106A192LOCATED IN BOTTOMOF FUEL TANK49202218RETURNSUPPLY144

2-76 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-14. GM ENGINE INSTALLATION (WITH UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.1001114607 Ref GM ENG

3121236 400S 460SJ 2-77SECTION 2 TURNTABLE48 4791600 1 Starwasher 3/8in49 100109158717.5ft/5.3mHose50 1001094608 2 Weldment, Hood Latch51 Not Used52 0

1-6 400S 460SJ 3121236SECTION 1 FRAME213 2 Tie-Rod Options:3841442 SN 0300096000 to SN 03001612851001140570 SN 0300161285 to Present214 3900109 4 Scre

2-78 400S 460SJ 3121236SECTION 2 TURNTABLE218 1580011 1 Container, Coolant Overflow219 1703162 2 Decal - Caution Fan220 2060025 1 Fan221 2180877 1 Fit

3121236 400S 460SJ 2-79SECTION 2 TURNTABLE260D 70002895 1 Module, Control (ECU)261 0100020 AR Sealant, Pipe (SN 0300096000 to SN 0300161285 Only) 3600

2-80 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-15.PERKINS ENGINE INSTALLATION - WITH ELECTRICAL DRIVEN COOLING FAN (WITHOUT UGM) 68707245447212

3121236 400S 460SJ 2-81SECTION 2 TURNTABLE 65255233848283964107108A108A108B108C23232336485104103748894375819524724721024824524622098978645727214222

2-82 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-15. PERKINS ENGINE INSTALLATION - WITH ELECTRICAL DRIVEN COOLING FAN (WITHOUT UGM)ITEM # PART NUMB

3121236 400S 460SJ 2-83SECTION 2 TURNTABLE38 2901880 1 Battery Cable Kit D38A 7016843 1 Cable - Battery to Relays (Includes Red Boot at Battery Termin

2-84 400S 460SJ 3121236SECTION 2 TURNTABLE72 4751600 42 Flatwasher 3/8in Regular73 4751800 11 Flatwasher 1/2in Regular74 0760612 4 Capscrew M6 x 25mm7

3121236 400S 460SJ 2-85SECTION 2 TURNTABLE104A 7026843 1 Linkage105 410002519in/48cmSleeve, Fiberglass (SN 0300130134 to Present Only)106 1001100825 2

2-86 400S 460SJ 3121236SECTION 2 TURNTABLE227 3340399 1 Pad, Wear228 3572504 1 Plate, Air Control Bottom229 3900255 1 Screw, Shoulder230 39603894ft/1.

3121236 400S 460SJ 2-87SECTION 2 TURNTABLE303 0641812 2 Bolt 1/2in-13NC x 1-1/2in304 3600404 1 Piston Pump Assembly (See PISTON PUMP ASSEMBLY for Brea

3121236 400S 460SJ 1-7SECTION 1 FRAME460SJ (CE Spec with Pneumatic Tires)2360653 SN 0300096000 to SN 03001153962360796 SN 0300115396 to SN 03001403651

2-88 400S 460SJ 3121236SECTION 2 TURNTABLE509 70001406 1 Valve, Relief70001407 1 Seal, O-RIng510 70001408 1 Fuel Bowl & Filter Assembly70001409 1

3121236 400S 460SJ 2-89SECTION 2 TURNTABLEFIGURE 2-15. PERKINS ENGINE INSTALLATION - WITH ELECTRICAL DRIVEN COOLING FAN (WITHOUT UGM) (CONTINUED)ITEM

2-90 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-16.PERKINS ENGINE INSTALLATION - WITH MECHANICAL DRIVEN COOLING FAN (WITHOUT UGM) 87244457312157446

3121236 400S 460SJ 2-91SECTION 2 TURNTABLE 6725523384829523434851041037687933577794247210248245246221989797467474142232182152102132222112102012

2-92 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-16. PERKINS ENGINE INSTALLATION - WITH MECHANICAL DRIVEN COOLING FAN (WITHOUT UGM)ITEM # PART NUMB

3121236 400S 460SJ 2-93SECTION 2 TURNTABLE39 2901880 1 Battery Cable Kit E39A 7016843 1 Cable - Battery to Relays (Includes Red Boot at Battery Termin

2-94 400S 460SJ 3121236SECTION 2 TURNTABLE73 4751500 12 Flatwasher 5/16in Regular74 4751600 40 Flatwasher 3/8in Regular75 4751800 11 Flatwasher 1/2in

3121236 400S 460SJ 2-95SECTION 2 TURNTABLERef PERKINS ENGINE INSTALLATION1001130549 Ref Without Arctic Package (All Specs except CE Spec) A1001130550

2-96 400S 460SJ 3121236SECTION 2 TURNTABLE242 1001094608 2 Bracket, Hood Latch243 3290501 1 Nut M5 x 0.8244 3290601 1 Nut M6 x 1245 0641420 1 Bolt 1/4

3121236 400S 460SJ 2-97SECTION 2 TURNTABLE405 4640744 2 Valve, CheckRef ENGINE COMPONENTS1001102131 Ref All Specs except CE Spec1001102270 Ref CE Spec

1-8 400S 460SJ 3121236SECTION 1 FRAMEFIGURE 1-2. AXLE AND STEERING INSTALLATION - 2WD WITH TOW PACKAGE 2052011051012162252152092022132132012012

2-98 400S 460SJ 3121236SECTION 2 TURNTABLE522 70002098 1 Hose, Fuel523 70002108 1 Washer, Drain Plug Sealing524 70002104 1 Pipe, Oil Sump (Not Shown -

3121236 400S 460SJ 2-99SECTION 2 TURNTABLEFIGURE 2-16. PERKINS ENGINE INSTALLATION - WITH MECHANICAL DRIVEN COOLING FAN (WITHOUT UGM) (CONTINUED)ITEM

2-100 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-17.PERKINS ENGINE INSTALLATION (WITH UGM) 75432335510135634408663333333201203576401557301256345

3121236 400S 460SJ 2-101SECTION 2 TURNTABLE 138138112145108114124126121112116125113112101101106139122119124TO WATERSEPARATERTO FUELTANK VENTLINEFUE

2-102 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-17. PERKINS ENGINE INSTALLATION (WITH UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref NOTE: FOR M

3121236 400S 460SJ 2-103SECTION 2 TURNTABLE39 3573667 1 Plate, Radiator Support40 3574253 1 Plate, Engine Mounting (Front)41 3574259 2 Plate, Engine M

2-104 400S 460SJ 3121236SECTION 2 TURNTABLERef PERKINS ENGINE INSTALLATION1001103770 Ref Without Arctic Package B1001106461 Ref With Arctic Package A

3121236 400S 460SJ 2-105SECTION 2 TURNTABLE144 1001094608 2 Bracket, Hood Latch145 1001100857 1 Separator, Fuel/Water70002378 1 O-Ring70002377 1 Filte

2-106 400S 460SJ 3121236SECTION 2 TURNTABLE219 2580054 1 Heater, Engine Block3600405 Ref GEAR PUMP ASSEMBLY WITH FITTINGS A301 2220385 2 Fitting, Tee3

3121236 400S 460SJ 2-107SECTION 2 TURNTABLE419 70001418 1 Valve, Breather420 70001416 1 Gasket, Exhaust Manifold to Engine Block421 70001419 1 Gasket,

3121236 400S 460SJ 1-9SECTION 1 FRAMEFIGURE 1-2. AXLE AND STEERING INSTALLATION - 2WD WITH TOW PACKAGEITEM # PART NUMBER QTY. DESCRIPTION REV.Ref OSC

2-108 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-18. PISTON PUMP ASSEMBLY 656463616256575859606655525153265467707131321023435138284838586873

3121236 400S 460SJ 2-109SECTION 2 TURNTABLEFIGURE 2-18. PISTON PUMP ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.3600385 Ref PISTON PUMP ASSEMBLY

2-110 400S 460SJ 3121236SECTION 2 TURNTABLE46 7021265 2 Bypass Valve Assembly (Includes Items 47-49)47 Use 7021280 2 O-Ring48 Use 7021280 2 Ring, Back

3121236 400S 460SJ 2-111SECTION 2 TURNTABLE3600404 Ref PISTON PUMP SUB-ASSEMBLY B101 2220376 1 Fitting, Straight102 2220498 2 Fitting, Elbow103 222057

2-112 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-19. AUXILIARY PUMP ASSEMBLY 100101101103104105106107108109110112112113113111114114115115116

3121236 400S 460SJ 2-113SECTION 2 TURNTABLEFIGURE 2-19. AUXILIARY PUMP ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref AUXILIARY PUMP ASSEMBLIESR

2-114 400S 460SJ 3121236SECTION 2 TURNTABLE125 Use 70000977 1 Plug126 Use 70000977 8 Screw127 70000975 1 Shaft, Drive128 See Note 1 Label (Note: Not A

3121236 400S 460SJ 2-115SECTION 2 TURNTABLEFIGURE 2-19. AUXILIARY PUMP ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-116 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-20. DUAL FUEL INSTALLATIONS (GM MACHINES ONLY) 11225TOENGINE2314172827261222A32110976515444

3121236 400S 460SJ 2-117SECTION 2 TURNTABLEFIGURE 2-20. DUAL FUEL INSTALLATIONS (GM MACHINES ONLY)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref LP TANK

1-10 400S 460SJ 3121236SECTION 1 FRAME24A 2 Steer Cylinder Mounting Block Assembly Options:0561300 SN 0300096000 to SN 03001313231001100424 SN 0300115

2-118 400S 460SJ 3121236SECTION 2 TURNTABLE108 2180387 1 Fitting109 2180389 1 Fitting, Relief Valve110 2180504 1 Fitting, Elbow111 2220290 1 Fitting,

3121236 400S 460SJ 2-119SECTION 2 TURNTABLEFIGURE 2-20. DUAL FUEL INSTALLATIONS (GM MACHINES ONLY) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV

2-120 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-21. TANK INSTALLATIONS 531121028791012011111103461314308B308D308308A30530130430730930230330

3121236 400S 460SJ 2-121SECTION 2 TURNTABLEFIGURE 2-21. TANK INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref TANKS INSTALLATION 0272731 Ref

2-122 400S 460SJ 3121236SECTION 2 TURNTABLE201 Ref FUEL CAP OPTIONS:1120484 Locking Cap (Red - Gas Machines) (SN 0300096000 to SN 0300109274 Only)1120

3121236 400S 460SJ 2-123SECTION 2 TURNTABLEFIGURE 2-21. TANK INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-124 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-22. ROTARY COUPLING INSTALLATION (SN 0300096000 TO SN 0300140365) 1212774467673385A5B5

3121236 400S 460SJ 2-125SECTION 2 TURNTABLEFIGURE 2-22. ROTARY COUPLING INSTALLATION (SN 0300096000 TO SN 0300140365)ITEM # PART NUMBER QTY. DESCRIPT

2-126 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-23. ROTARY COUPLING INSTALLATION (SN 0300140365 TO PRESENT) 46343651862178B8C8D8F8F8H8J8K8L

3121236 400S 460SJ 2-127SECTION 2 TURNTABLEFIGURE 2-23. ROTARY COUPLING INSTALLATION (SN 0300140365 TO PRESENT)ITEM # PART NUMBER QTY. DESCRIPTION RE

3121236 400S 460SJ 1-11SECTION 1 FRAMERef STEERING INSTALLATION0272804 Ref SN 0300096000 to SN 0300161285 G1001139901 Ref SN 0300161285 to Present B20

2-128 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-24. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM) 204018232222A104121A17192189A9B9C525303111291

3121236 400S 460SJ 2-129SECTION 2 TURNTABLEFIGURE 2-24. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref NOTE: FO

2-130 400S 460SJ 3121236SECTION 2 TURNTABLE9C 7024320 2 Retainer10 2420172 1 Gauge, Hourmeter11 2760105 1 Housing, Display Light12 3300408 AR Locknut,

3121236 400S 460SJ 2-131SECTION 2 TURNTABLE37 (cont’d) 4923583 Deutz Engine Machines (SN 0300099084 to Present)38 to 39 Not Used40 3790012 AR O-Ring41

2-132 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-25. GROUND CONTROL BOX ASSEMBLY (WITH UGM) (SN 0300069000 TO SN 0300177683) 213519242323A11

3121236 400S 460SJ 2-133SECTION 2 TURNTABLEFIGURE 2-25. GROUND CONTROL BOX ASSEMBLY (WITH UGM) (SN 0300069000 TO SN 0300177683)ITEM # PART NUMBER QTY

2-134 400S 460SJ 3121236SECTION 2 TURNTABLE18 3910804 6 Screw #8-32NC x 1/4in19 4060906 1 Shield, Toggle Switch20 4070987 1 Shim.015 21 4360328 6 Swit

3121236 400S 460SJ 2-135SECTION 2 TURNTABLERef 460SJ: Ref Caterpillar & Perkins Engine1001107627 Ref ANSI & ANSI Export Specs) C1001107629 Ref

2-136 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-26. GROUND CONTROL BOX ASSEMBLY (WITH UGM) (SN 0300177683 TO PRESENT) 15174120918A141842323

3121236 400S 460SJ 2-137SECTION 2 TURNTABLEFIGURE 2-26. GROUND CONTROL BOX ASSEMBLY (WITH UGM) (SN 0300177683 TO PRESENT)ITEM # PART NUMBER QTY. DESC

1-12 400S 460SJ 3121236SECTION 1 FRAME233 1 Tie-Rod Options:3841619 SN 0300096000 to SN 03001612851001140570 SN 0300161285 to Present2780230 Ref HUB A

2-138 400S 460SJ 3121236SECTION 2 TURNTABLE27 4460526 1 Connector, Strain Relief28 4751000 2 Flatwasher #10 Regular29 4751400 12 Flatwasher 1/4in Regu

3121236 400S 460SJ 2-139SECTION 2 TURNTABLE105 3311405 4 Locknut 1/4in-20NC106 3960438 AR Seal107 4750800 6 Flatwasher #8 Regular108 4751400 8 Flatwas

2-140 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-27. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) BEF45465111411611310110110211510911

3121236 400S 460SJ 2-141SECTION 2 TURNTABLEFIGURE 2-27. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED)ITEM # PART NUMBER QTY. DESCRIPTION REV.02

2-142 400S 460SJ 3121236SECTION 2 TURNTABLE13 4751000 4 Flatwasher #10 Regular14 4740362 4 Washer, Fender15 4460234 14 Mount, Tie-Strap (Not Shown)16

3121236 400S 460SJ 2-143SECTION 2 TURNTABLE102 0100035 AR Locking, Compound103 AR Bar, Fiberglass Options:1001106479 1 400S with 500/1000lb Cap. (All

2-144 400S 460SJ 3121236SECTION 2 TURNTABLE119 (cont’d) 4922714 1 460SJ (Includes Items 8.5ft/2.6m of p/n 1060902 18/2 Electrical Cable and Items 109

3121236 400S 460SJ 2-145SECTION 2 TURNTABLEFIGURE 2-27. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED) (CONTINUED)ITEM # PART NUMBER QTY. DESCRI

2-146 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-28. HOODS INSTALLATION (SN 0300096000 TO SN 0300126457) 5123415A15B19201 9 20374233243523

3121236 400S 460SJ 2-147SECTION 2 TURNTABLEFIGURE 2-28. HOODS INSTALLATION (SN 0300096000 TO SN 0300126457)ITEM # PART NUMBER QTY. DESCRIPTION REV.Re

3121236 400S 460SJ 1-13SECTION 1 FRAME460SJ (CE Spec with Foam-Filled Tires)2360652 SN 0300096000 to SN 03001153962360795 SN 0300115396 to SN 03001403

2-148 400S 460SJ 3121236SECTION 2 TURNTABLE32 4751600 74 Flatwasher 3/8in Regular33 4846092 1 Hood Mounting Weldment (Engine Side)34 4846095 1 Hood Mo

3121236 400S 460SJ 2-149SECTION 2 TURNTABLEFIGURE 2-28. HOODS INSTALLATION (SN 0300096000 TO SN 0300126457) (CONTINUED)ITEM # PART NUMBER QTY. DESCRI

2-150 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-29. HOODS INSTALLATION (SN 0300126457 TO PRESENT) 3415A15B19201 9 20374233243523323030191

3121236 400S 460SJ 2-151SECTION 2 TURNTABLEFIGURE 2-29. HOODS INSTALLATION (SN 0300126457 TO PRESENT)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref HOOD

2-152 400S 460SJ 3121236SECTION 2 TURNTABLE15B 0902668 2 Catch, Hood Latch16 2680516 1 Cover, Hood (Front Left Side) 17 2680471 1 Cover, Hood (Front C

3121236 400S 460SJ 2-153SECTION 2 TURNTABLE43 4740500 3 Shoulder Washer, Nylon44 0902673 1 Bracket, Front Cover Support45 0902674 1 Bracket, Front Cov

2-154 400S 460SJ 3121236SECTION 2 TURNTABLE50 1 Insulation, Heat Shield (Silver) (Engine Side) Options:Caterpillar/Perkins Engines1001109403 100114695

3121236 400S 460SJ 3-1SECTION 3BOOM

3-2 400S 460SJ 3121236SECTION 3 BOOMFIGURE 3-1. BOOM INSTALLATIONS 171927 2218252722179822911 1121021091081121131061061061112152141141112013114

3121236 400S 460SJ 3-3SECTION 3 BOOMFIGURE 3-1. BOOM INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref BOOM AND CYLINDERS INSTALLATION 0273065

1-14 400S 460SJ 3121236SECTION 1 FRAMEFIGURE 1-3. AXLE & STEERING INSTALLATION - 4WD (SN 0300096000 TO SN 0300161285) 713669511121201051261

3-4 400S 460SJ 3121236SECTION 3 BOOM104A Gemco Brand Replacement Parts:7006140 AR 1Ft. Repair Section for p/n 1180336 Power Track (Includes 10 Link Pi

3121236 400S 460SJ 3-5SECTION 3 BOOM211 3572165 Cover212 4060919 6ft/1.8m Trim, Protection 213 2 Pad Options:3340897 SN 0300096000 to SN 0300104749334

3-6 400S 460SJ 3121236SECTION 3 BOOMFIGURE 3-2. BOOM ASSEMBLY - 400S 14142525262630306303243 15282730322272121211835424420121013112929341413434

3121236 400S 460SJ 3-7SECTION 3 BOOMFIGURE 3-2. BOOM ASSEMBLY - 400SITEM # PART NUMBER QTY. DESCRIPTION REV.0801359 Ref BOOM ASSEMBLIES E1 0060059 1

3-8 400S 460SJ 3121236SECTION 3 BOOM40 Not Used41 4071007 2 Shim, 20 Gauge42 0741605 AR Screw, Flathead Socket 3/8in-16NC x 5/8in43 2 Pad, Wear Option

3121236 400S 460SJ 3-9SECTION 3 BOOMFIGURE 3-2. BOOM ASSEMBLY - 400S (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3-10 400S 460SJ 3121236SECTION 3 BOOMFIGURE 3-3. BOOM ASSEMBLY - 460SJ 242316430302625141751425264306111130135122195122191111128120212118219511

3121236 400S 460SJ 3-11SECTION 3 BOOMFIGURE 3-3. BOOM ASSEMBLY - 460SJITEM # PART NUMBER QTY. DESCRIPTION REV.0801360 Ref BOOM ASSEMBLIES E1 0100011

3-12 400S 460SJ 3121236SECTION 3 BOOM0272593 Ref JIB ASSEMBLIES D101 0060048 1 Rotator Assembly (See ROTATOR ASSEMBLIES for Breakdown)102 0100011 AR L

3121236 400S 460SJ 3-13SECTION 3 BOOMRef PLATFORM SUPPORT INSTALLATION 0272070 Ref Machines without Load Sensing and without SkyGlazier ESee Note Ref

3121236 400S 460SJ 1-15SECTION 1 FRAMEFIGURE 1-3. AXLE & STEERING INSTALLATION - 4WD (SN 0300096000 TO SN 0300161285)ITEM # PART NUMBER QTY. DESC

3-14 400S 460SJ 3121236SECTION 3 BOOMFIGURE 3-4. ROTATOR ASSEMBLIES 132342532333425272443345B45A23202241B41A1B411A400S460SJ4242100A100B10110310

3121236 400S 460SJ 3-15SECTION 3 BOOMFIGURE 3-4. ROTATOR ASSEMBLIESITEM # PART NUMBER QTY. DESCRIPTION REV.Ref ROTATOR ASSEMBLIES0060059 Ref 400S E00

3-16 400S 460SJ 3121236SECTION 3 BOOMFIGURE 3-4. ROTATOR ASSEMBLIES (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121236 400S 460SJ 4-1SECTION 4PLATFORM

4-2 400S 460SJ 3121236SECTION 4 PLATFORMFIGURE 4-1. PLATFORM INSTALLATION 202203204201202OR2052052053016102104C104B104A10510810510810710311011

3121236 400S 460SJ 4-3SECTION 4 PLATFORMFIGURE 4-1. PLATFORM INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref PLATFORM ASSEMBLIES WITH GATEUse

4-4 400S 460SJ 3121236SECTION 4 PLATFORM56 See Note 1 Platform Weldment (Note: Not Available - Purchase Platform Assembly)57 3520198 2 Cap-Plug58 4010

3121236 400S 460SJ 4-5SECTION 4 PLATFORM104B 1060918 7.5ft/2.3m Cable, Electrical - 18/3 104C 4460071 1 Connector, Strain Relief104D 4460464 1 Pin, Ma

4-6 400S 460SJ 3121236SECTION 4 PLATFORM411 4420037 1 Tape, Insulation (Not Shown)FIGURE 4-1. PLATFORM INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY

3121236 400S 460SJ 4-7SECTION 4 PLATFORMFIGURE 4-1. PLATFORM INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-16 400S 460SJ 3121236SECTION 1 FRAME105 0642012 1 Bolt 5/8in-11NC x 1-1/2in106 0682248 2 Bolt 3/4in-10NC x 6in (Grade 8) (SN 0300096000 to SN 030011

4-8 400S 460SJ 3121236SECTION 4 PLATFORMFIGURE 4-2. PLATFORM COMPONENTS INSTALLATION (FALL ARREST PLATFORM) 5121047392111116812NOTE: OTHER REP

3121236 400S 460SJ 4-9SECTION 4 PLATFORMFIGURE 4-2. PLATFORM COMPONENTS INSTALLATION (FALL ARREST PLATFORM)ITEM # PART NUMBER QTY. DESCRIPTION REV.Re

4-10 400S 460SJ 3121236SECTION 4 PLATFORMFIGURE 4-3. SOFT TOUCH INSTALLATION (OPTIONAL) 6166166166166166166166166166166166163112212211181020412

3121236 400S 460SJ 4-11SECTION 4 PLATFORMFIGURE 4-3. SOFT TOUCH INSTALLATION (OPTIONAL)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref SOFT TOUCH SYSTEM

4-12 400S 460SJ 3121236SECTION 4 PLATFORMFIGURE 4-4. PLATFORM CONSOLE ASSEMBLY 1420212234332626354223183319153726731628252933901501A501B2630140

3121236 400S 460SJ 4-13SECTION 4 PLATFORMFIGURE 4-4. PLATFORM CONSOLE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref PLATFORM CONSOLE ASSEMBLY08

4-14 400S 460SJ 3121236SECTION 4 PLATFORM24 1705132 1 Decal - ADE25 2420197 1 Gauge, Fuel26 3790012 AR O-Ring27 2560136 1 Handle, Knob28 2760109 1 Hou

3121236 400S 460SJ 4-15SECTION 4 PLATFORM203 3311601 1 Nut 3/8in-16NC204 3470003 2 Hairpin205 0630568 1 Screw 3/8in-16NC x 4-1/2in206 4711500 2 Flatwa

4-16 400S 460SJ 3121236SECTION 4 PLATFORMRef LIGHTS INSTALLATION (OPTIONAL) 0272018 Ref Headlights & Taillights C0274574 Ref Chassis Illumination

3121236 400S 460SJ 4-17SECTION 4 PLATFORMFIGURE 4-4. PLATFORM CONSOLE ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121236 400S 460SJ 1-17SECTION 1 FRAME0272927 Ref STEERING INSTALLATION G201 0100011 AR Locking, Compound202 AR Thrustwasher Options:4740537 AR Thrust

4-18 400S 460SJ 3121236SECTION 4 PLATFORMFIGURE 4-5. CONTROLLER ASSEMBLY (SWING AND LIFT) 222119185936145876391110121A1C1B10210311010410510610

3121236 400S 460SJ 4-19SECTION 4 PLATFORMFIGURE 4-5. CONTROLLER ASSEMBLY (SWING AND LIFT)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Original E

4-20 400S 460SJ 3121236SECTION 4 PLATFORM105 70002732 4 Screw106 7022815 1 Bezel107 70002733 1 Adapter108 70002734 4 Screw109 70002735 1 Can, Enclosur

3121236 400S 460SJ 4-21SECTION 4 PLATFORMFIGURE 4-5. CONTROLLER ASSEMBLY (SWING AND LIFT) (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

4-22 400S 460SJ 3121236SECTION 4 PLATFORMFIGURE 4-6. CONTROLLER ASSEMBLY (DRIVE AND STEER) 2082082072092022022032032042042102052061061201181719

3121236 400S 460SJ 4-23SECTION 4 PLATFORMFIGURE 4-6. CONTROLLER ASSEMBLY (DRIVE AND STEER)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Original

4-24 400S 460SJ 3121236SECTION 4 PLATFORM108 Use 1001118416 1 Mechanical Assembly (Note: Not Available for Purchase)109 7022825 1 Plug, Male - 8 Posit

3121236 400S 460SJ 5-1SECTION 5CYLINDER

5-2 400S 460SJ 3121236SECTION 5 CYLINDERFIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY (SN 0300096000 TO SN 0300115396) 341415161619157810111213171

3121236 400S 460SJ 5-3SECTION 5 CYLINDERFIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY (SN 0300096000 TO SN 0300115396)ITEM # PART NUMBER QTY. DESCRIPTIO

1-18 400S 460SJ 3121236SECTION 1 FRAME401 Ref FRAME WELDMENTS400S with 500Lbs Capacity 2360650 SN 0300096000 to SN 03001153962360756 SN 0300115396 to

5-4 400S 460SJ 3121236SECTION 5 CYLINDERFIGURE 5-2. AXLE LOCKOUT CYLINDER ASSEMBLY (SN 0300115396 TO PRESENT) 1349856572 100

3121236 400S 460SJ 5-5SECTION 5 CYLINDERFIGURE 5-2. AXLE LOCKOUT CYLINDER ASSEMBLY (SN 0300115396 TO PRESENT)ITEM # PART NUMBER QTY. DESCRIPTION REV.

5-6 400S 460SJ 3121236SECTION 5 CYLINDERFIGURE 5-3. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY

3121236 400S 460SJ 5-7SECTION 5 CYLINDERFIGURE 5-3. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Origina

5-8 400S 460SJ 3121236SECTION 5 CYLINDERFIGURE 5-4. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLY 861213121423161771820212219152921252525251A1A2A2A2

3121236 400S 460SJ 5-9SECTION 5 CYLINDERFIGURE 5-4. LEVEL (PLATFORM SLAVE) CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Origina

5-10 400S 460SJ 3121236SECTION 5 CYLINDERFIGURE 5-5. LIFT CYLINDER ASSEMBLY - JIB (460SJ) 6889681 2181912 1616175A1A523241126141415151043212022

3121236 400S 460SJ 5-11SECTION 5 CYLINDERFIGURE 5-5. LIFT CYLINDER ASSEMBLY - JIB (460SJ)ITEM # PART NUMBER QTY. DESCRIPTION REV.1683609 Ref JIB LIFT

5-12 400S 460SJ 3121236SECTION 5 CYLINDERFIGURE 5-6. LIFT CYLINDER ASSEMBLY - MAIN 45118261229666628107913232212172116252020181824151519100

3121236 400S 460SJ 5-13SECTION 5 CYLINDERFIGURE 5-6. LIFT CYLINDER ASSEMBLY - MAINITEM # PART NUMBER QTY. DESCRIPTION REV.1683776 Ref LIFT CYLINDER A

3121236 400S 460SJ 1-19SECTION 1 FRAMEFIGURE 1-3. AXLE & STEERING INSTALLATION - 4WD (SN 0300096000 TO SN 0300161285) ITEM # PART NUMBER QTY. DES

5-14 400S 460SJ 3121236SECTION 5 CYLINDERFIGURE 5-7. MASTER CYLINDER ASSEMBLY (ORIGINAL EQUIPMENT FOR SN 0300096000 TO SN 0300165145) 8 10 6232

3121236 400S 460SJ 5-15SECTION 5 CYLINDERFIGURE 5-7. MASTER CYLINDER ASSEMBLY (ORIGINAL EQUIPMENT FOR SN 0300096000 TO SN 0300165145)ITEM # PART NUMB

5-16 400S 460SJ 3121236SECTION 5 CYLINDERFIGURE 5-8. MASTER CYLINDER ASSEMBLY (SERVICE REPLACEMENT FOR SN 0300096000 TO SN 0300165145 & ORIGINAL E

3121236 400S 460SJ 5-17SECTION 5 CYLINDERFIGURE 5-8. MASTER CYLINDER ASSEMBLY (SERVICE REPLACEMENT FOR SN 0300096000 TO SN 0300165145 & ORIGINAL

5-18 400S 460SJ 3121236SECTION 5 CYLINDERFIGURE 5-9. STEER CYLINDER ASSEMBLY (SN 0300096000 TO SN 0300161285) 1362111239710818107931211100

3121236 400S 460SJ 5-19SECTION 5 CYLINDERFIGURE 5-9. STEER CYLINDER ASSEMBLY (SN 0300096000 TO SN 0300161285)ITEM # PART NUMBER QTY. DESCRIPTION REV.

5-20 400S 460SJ 3121236SECTION 5 CYLINDERFIGURE 5-10. STEER CYLINDER ASSEMBLY (SN 0300161285 TO PRESENT) 34567891121221110345678950

3121236 400S 460SJ 5-21SECTION 5 CYLINDERFIGURE 5-10. STEER CYLINDER ASSEMBLY (SN 0300161285 TO PRESENT)ITEM # PART NUMBER QTY. DESCRIPTION REV.10011

5-22 400S 460SJ 3121236SECTION 5 CYLINDERFIGURE 5-11. TELESCOPE CYLINDER ASSEMBLY 4612221229101414172716131821719222211112024553232262323829312

3121236 400S 460SJ 5-23SECTION 5 CYLINDERFIGURE 5-11. TELESCOPE CYLINDER ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.1684194 Ref TELESCOPE CYLIND

1-20 400S 460SJ 3121236SECTION 1 FRAMEFIGURE 1-4. AXLE & STEERING INSTALLATION - 4WD (SN 0300161285 TO PRESENT) 111125443110410121610887101

5-24 400S 460SJ 3121236SECTION 5 CYLINDERFIGURE 5-11. TELESCOPE CYLINDER ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121236 400S 460SJ 6-1SECTION 6HYDRAULIC

6-2 400S 460SJ 3121236SECTION 6 HYDRAULICFIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM (SN 0300096000 to SN 0300115396)

3121236 400S 460SJ 6-3SECTION 6 HYDRAULICFIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM (SN 0300096000 TO SN 0300115396)ITEM # PART NUMBER QTY. DESCRIPTI

6-4 400S 460SJ 3121236SECTION 6 HYDRAULICFIGURE 6-2. AXLE LOCKOUT HYDRAULIC DIAGRAM (ANSI SPEC - SN 0300115396 TO SN 0300140365) PTALOCK-OUT VA

3121236 400S 460SJ 6-5SECTION 6 HYDRAULICFIGURE 6-2. AXLE LOCKOUT HYDRAULIC DIAGRAM (ANSI SPEC - SN 0300115396 TO SN 0300140365)ITEM # PART NUMBER QT

6-6 400S 460SJ 3121236SECTION 6 HYDRAULICFIGURE 6-3. AXLE LOCKOUT HYDRAULIC DIAGRAM (CE SPEC - SN 0300115396 TO SN 0300140365)

3121236 400S 460SJ 6-7SECTION 6 HYDRAULICFIGURE 6-3. AXLE LOCKOUT HYDRAULIC DIAGRAM (CE SPEC - SN 0300115396 TO SN 0300140365)ITEM # PART NUMBER QTY.

6-8 400S 460SJ 3121236SECTION 6 HYDRAULICFIGURE 6-4. AXLE LOCKOUT HYDRAULIC DIAGRAM (ANSI & CE SPEC - SN 0300140365 TO PRESENT) XXXXVPVP688

3121236 400S 460SJ 6-9SECTION 6 HYDRAULICFIGURE 6-4. AXLE LOCKOUT HYDRAULIC DIAGRAM (ANSI & CE SPEC - SN 0300140365 TO PRESENT)ITEM # PART NUMBER

3121236 400S 460SJ 1-21SECTION 1 FRAMEFIGURE 1-4. AXLE & STEERING INSTALLATION - 4WD (SN 0300161285 TO PRESENT)ITEM # PART NUMBER QTY. DESCRIPTIO

6-10 400S 460SJ 3121236SECTION 6 HYDRAULICFIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300096000 TO SN 0300115396)

3121236 400S 460SJ 6-11SECTION 6 HYDRAULICFIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300096000 TO SN 0300115396)ITEM # PART NUMBER QTY. DESCRIPTI

6-12 400S 460SJ 3121236SECTION 6 HYDRAULICFIGURE 6-6. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300115396 TO SN 0300140365) REAR REARCASE DRAIN2-SPEED

3121236 400S 460SJ 6-13SECTION 6 HYDRAULICFIGURE 6-6. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300115396 TO SN 0300140365)ITEM # PART NUMBER QTY. DESCRIPTI

6-14 400S 460SJ 3121236SECTION 6 HYDRAULICFIGURE 6-7. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300140365 TO PRESENT) REARPORT #7REARPORT #2CASE DRAIN

3121236 400S 460SJ 6-15SECTION 6 HYDRAULICFIGURE 6-7. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300140365 TO PRESENT)ITEM # PART NUMBER QTY. DESCRIPTION REV

6-16 400S 460SJ 3121236SECTION 6 HYDRAULICFIGURE 6-8. DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300096000 TO SN 0300115396)

3121236 400S 460SJ 6-17SECTION 6 HYDRAULICFIGURE 6-8. DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300096000 TO SN 0300115396)ITEM # PART NUMBER QTY. DESCRIPTI

6-18 400S 460SJ 3121236SECTION 6 HYDRAULIC30 2752443 1 Hose31 2754229 2 Hose32 2752506 1 Hose33 2753162 2 Hose34 2753343 2 Hose35 2752496 2 Hose36 464

3121236 400S 460SJ 6-19SECTION 6 HYDRAULICFIGURE 6-8. DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300096000 TO SN 0300115396) ITEM # PART NUMBER QTY. DESCRIPT

3121236 400S 460SJ AREVISION LOGApril 30, 2006 - Original Issue Of Manual (Edited to B/M 0010579 Revision 67)September 12, 2006 - Revised (Edited to B

1-22 400S 460SJ 3121236SECTION 1 FRAME209 2 Kingpin Options: 3423081 Kingpin (SN 0300161285 to SN 0300164034)1001139141 Kingpin (SN 0300164034 to Pres

6-20 400S 460SJ 3121236SECTION 6 HYDRAULICFIGURE 6-9. DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300115396 TO SN 0300140365)

3121236 400S 460SJ 6-21SECTION 6 HYDRAULICFIGURE 6-9. DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300115396 TO SN 0300140365)ITEM # PART NUMBER QTY. DESCRIPTI

6-22 400S 460SJ 3121236SECTION 6 HYDRAULIC39 2 Hose Options:Without Arctic Package:2753345 SN 0300096000 to SN 03001192011001099161 SN 0300119201 to S

3121236 400S 460SJ 6-23SECTION 6 HYDRAULICFIGURE 6-9. DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300115396 TO SN 0300140365) (CONTINUED)ITEM # PART NUMBER QT

6-24 400S 460SJ 3121236SECTION 6 HYDRAULICFIGURE 6-10. DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300140365 TO PRESENT) XXXXXXXLEFTPORT #7REARPORT #2CA

3121236 400S 460SJ 6-25SECTION 6 HYDRAULICFIGURE 6-10. DRIVE HYDRAULIC DIAGRAM - 4WD (SN 0300140365 TO PRESENT)ITEM # PART NUMBER QTY. DESCRIPTION RE

6-26 400S 460SJ 3121236SECTION 6 HYDRAULICFIGURE 6-11. STANDARD HYDRAULIC DIAGRAM 9534545164846424171830345312949371823686753332513276969555443

3121236 400S 460SJ 6-27SECTION 6 HYDRAULICFIGURE 6-11. STANDARD HYDRAULIC DIAGRAMITEM # PART NUMBER QTY. DESCRIPTION REV.USAGE CHART:Machines With Ca

6-28 400S 460SJ 3121236SECTION 6 HYDRAULIC41 2753352 1 Hose42 2753353 1 Hose43 2753354 1 Hose44 2753357 1 Hose45 2753351 2 Hose46 2752942 1 Hose47 275

3121236 400S 460SJ 6-29SECTION 6 HYDRAULICFIGURE 6-11. STANDARD HYDRAULIC DIAGRAM (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121236 400S 460SJ 1-23SECTION 1 FRAMEFIGURE 1-4. AXLE & STEERING INSTALLATION - 4WD (SN 0300161285 TO PRESENT) ITEM # PART NUMBER QTY. DESCRIPTI

6-30 400S 460SJ 3121236SECTION 6 HYDRAULICFIGURE 6-12. STANDARD HYDRAULIC DIAGRAM MAIN VALVE TOP VIEW MAIN VALVE FRONT VIEWM1PSI.CHECK MAINM2P

3121236 400S 460SJ 6-31SECTION 6 HYDRAULICFIGURE 6-12. STANDARD HYDRAULIC DIAGRAMITEM # PART NUMBER QTY. DESCRIPTION REV.USAGE CHART:Machines With Ca

6-32 400S 460SJ 3121236SECTION 6 HYDRAULIC40 2221044 1 Fitting, Elbow41 2753352 1 Hose42 2753353 1 Hose43 2753354 1 Hose44 2753357 1 Hose45 2753351 1

3121236 400S 460SJ 6-33SECTION 6 HYDRAULICFIGURE 6-12. STANDARD HYDRAULIC DIAGRAM (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

6-34 400S 460SJ 3121236SECTION 6 HYDRAULICFIGURE 6-13. STANDARD HYDRAULIC DIAGRAM XXXXXXXXXXXXXXXXXXX MAIN VALVE TOP VIEW MAIN VALVE FRONT VIEW

3121236 400S 460SJ 6-35SECTION 6 HYDRAULICFIGURE 6-13. STANDARD HYDRAULIC DIAGRAMITEM # PART NUMBER QTY. DESCRIPTION REV.USAGE CHART:Machines With Ca

6-36 400S 460SJ 3121236SECTION 6 HYDRAULIC41 2753352 1 Hose42 2753353 1 Hose43 2753354 1 Hose44 2753357 1 Hose45 2753351 1 Hose46 2752433 1 Hose47 275

3121236 400S 460SJ 6-37SECTION 6 HYDRAULICFIGURE 6-13. STANDARD HYDRAULIC DIAGRAM (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

6-38 400S 460SJ 3121236SECTION 6 HYDRAULICFIGURE 6-14. STANDARD HYDRAULIC DIAGRAM SWING MOTORAND BRAKE333131SWING 4656437PSI.18172212111093522E

3121236 400S 460SJ 6-39SECTION 6 HYDRAULICFIGURE 6-14. STANDARD HYDRAULIC DIAGRAMITEM # PART NUMBER QTY. DESCRIPTION REV.USAGE CHART:Machines With De

1-24 400S 460SJ 3121236SECTION 1 FRAMEFIGURE 1-5. TIRE AND WHEEL DRIVE INSTALLATIONS 1213141928252521119OR10226102104105103106101107OR

6-40 400S 460SJ 3121236SECTION 6 HYDRAULIC42 2753353 1 Hose43 2753354 1 Hose44 2753357 1 Hose45 2753351 1 Hose46 2752437 1 Hose47 2752763 2 Hose48 275

3121236 400S 460SJ 6-41SECTION 6 HYDRAULICFIGURE 6-14. STANDARD HYDRAULIC DIAGRAM (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

6-42 400S 460SJ 3121236SECTION 6 HYDRAULICFIGURE 6-15. HYDRAULIC DIAGRAM LIST ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Diagrams with as

3121236 400S 460SJ 6-43SECTION 6 HYDRAULICRef Standard Hydraulic Schematic2792387 Ref SN 0300096000 to SN 03001153961001093691 Ref SN 0300115396 to SN

6-44 400S 460SJ 3121236SECTION 6 HYDRAULICITEM # PART NUMBER QTY. DESCRIPTION REV.

3121236 400S 460SJ 7-1SECTION 7ELECTRICAL

7-2 400S 460SJ 3121236SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LISTITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: Diagrams are available

3121236 400S 460SJ 7-3SECTION 7 ELECTRICALRef With UGM:1001102901 Ref Caterpillar/Perkins Engine MachinesRef Deutz Engine Machines1001109121 Ref SN 03

7-4 400S 460SJ 3121236SECTION 7 ELECTRICALFIGURE 7-2. HARNESS COMPONENTS INSTALLATION (MACHINES WITHOUT UGM) 701N702D702H336335J5J6J7J2J2J1J8J3J1

3121236 400S 460SJ 7-5SECTION 7 ELECTRICAL 701D 701N702D702H 702J702E702A702K2500WGENERATORRELAYGENERATORCONTROL BOX705A709B708AJIBVALVESTROBELIG

3121236 400S 460SJ 1-25SECTION 1 FRAMEFIGURE 1-5. TIRE AND WHEEL DRIVE INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref WHEEL DRIVE INSTALLAT

7-6 400S 460SJ 3121236SECTION 7 ELECTRICALFIGURE 7-2. HARNESS COMPONENTS INSTALLATION (MACHINES WITHOUT UGM)ITEM # PART NUMBER QTY. DESCRIPTION REV.R

3121236 400S 460SJ 7-7SECTION 7 ELECTRICAL126 to 129 Not Used130 4460418 6 Connector - 6 Position4460419 18 Socket, Female131 Not Used132 4120035 10 B

7-8 400S 460SJ 3121236SECTION 7 ELECTRICAL210 AR Harness Assembly (12/4 - 18/8)4922548 1 400S without Arctic Package 3/C1001093918 1 400S with Arctic

3121236 400S 460SJ 7-9SECTION 7 ELECTRICAL336 (cont’d) 4923419 GM Engine Machines337 1 Ground Control Box Harness Assembly 4923456 Caterpillar Engine

7-10 400S 460SJ 3121236SECTION 7 ELECTRICALRef ENGINE HARNESS ASSEMBLY4923356 Ref Caterpillar Engine (SN 0300096000 to SN 0300099084) 2/B4923580 Ref C

3121236 400S 460SJ 7-11SECTION 7 ELECTRICAL453 4460608 4 Seal (GM Engine Only)454 4461109 1 Connector, Plug - 16 Position (GM Engine Only)455 4461111

7-12 400S 460SJ 3121236SECTION 7 ELECTRICAL522 4460539 1 Connector 3 Position (Caterpillar & Perkins Engines Only) (SN 0300099084 to Present)Ref S

3121236 400S 460SJ 7-13SECTION 7 ELECTRICAL611 See Note 2 Pump Harness (Note: Not Available for Purchase)611A 7007497 2 Plug (Pump)611B 7007498 2 Plug

7-14 400S 460SJ 3121236SECTION 7 ELECTRICAL619A 7022825 1 Connector - 8 Position Black)4460871 7 Socket, Female620 1001099926 1 Speed Sensor Harness (

3121236 400S 460SJ 7-15SECTION 7 ELECTRICAL701A (cont’d)See Note 1001091971,1001091972, 1001100328 & 100110329 Installations (Note: Was p/n 086178

1-26 400S 460SJ 3121236SECTION 1 FRAMERef TIRE AND WHEEL INSTALLATIONS0270091 Ref 12 x 16.5 Pneumatic (ANSI & ANSI Export Specs) C0270650 Ref 12 x

7-16 400S 460SJ 3121236SECTION 7 ELECTRICAL701D (cont’d)44612001001091970 & 1001100327 Installation (Female)4461202 1001091973, 1001091971, 100110

3121236 400S 460SJ 7-17SECTION 7 ELECTRICAL701K 0903566 1 Bracket, Circuit Breaker Mounting (Only Required on CE Spec Installations)701L AR Breaker, C

7-18 400S 460SJ 3121236SECTION 7 ELECTRICAL0275452 1 Receptacle, Box & Plug Kit (220V CEE 7 Post Ground with 2x4 Box) (Includes Items 701A-701C &a

3121236 400S 460SJ 7-19SECTION 7 ELECTRICAL703 Ref 7500W SkyPower Generator Installation 0273003 Ref60Hz & Caterpillar EngineK0273004 Ref50Hz Spec

7-20 400S 460SJ 3121236SECTION 7 ELECTRICAL704F 1671092 1 Cover (60Hz Spec Only)4460963 1 Connector (60Hz Spec Only)705 Ref 7500W Generator Electrical

3121236 400S 460SJ 7-21SECTION 7 ELECTRICAL710 4933218 1 Soft-Touch System Wiring Diagram 1/B710A 106090223ft/7mCable, Electrical - 18/2710B 4460871 2

7-22 400S 460SJ 3121236SECTION 7 ELECTRICALFIGURE 7-3. HARNESS COMPONENTS INSTALLATION (MACHINES WITH UGM) (SN 0300069000 to SN 0300177683) J3701

3121236 400S 460SJ 7-23SECTION 7 ELECTRICAL 705F702F701D701N702D702G 702H702E702A702J2500WGENERATORRELAYGENERATORCONTROL BOX705A709B708AJIBVALVES

7-24 400S 460SJ 3121236SECTION 7 ELECTRICALFIGURE 7-3. HARNESS COMPONENTS INSTALLATION (MACHINES WITH UGM) (SN 0300069000 TO SN 0300177683)ITEM # PAR

3121236 400S 460SJ 7-25SECTION 7 ELECTRICAL131 Not Used132 4120035 10 Base, Light133 4460226 10 Terminal (16 Gauge)134 4460635 10 Terminal (12 Gauge)1

3121236 400S 460SJ 1-27SECTION 1 FRAME102 1 Tire Options:4520216 12 x 16.5 NHS 4520240 12 x 16.5 NHS (Non-Marking)4520266 12 x 16.5 LT 4520212 14 x 16

7-26 400S 460SJ 3121236SECTION 7 ELECTRICAL210 (cont’d) 4922547 1 460SJ without Arctic Package 3/C1001093921 1 460SJ with Arctic Package AAR Cable, El

3121236 400S 460SJ 7-27SECTION 7 ELECTRICAL338C 4460873 1 Connector - 35 Position (Black)4460871 15 Socket, Female4460905 1 Seal, Plug338D 4120035 6 B

7-28 400S 460SJ 3121236SECTION 7 ELECTRICAL423 4461070 1 Connector - 3 Position with Resistor (Deutz Engine Only)4460944 3 Socket, Female (Deutz Engin

3121236 400S 460SJ 7-29SECTION 7 ELECTRICAL457 Not Used458 4461157 1 Connector - 2 Position4460458 2 Seal, Terminal4460979 2 Pin, Male459 91504088 1 C

7-30 400S 460SJ 3121236SECTION 7 ELECTRICAL602A 7027021 1 Caterpillar/Perkins Engine Machines - Cable, Battery (Red) (Battery to Auxiliary Power Relay

3121236 400S 460SJ 7-31SECTION 7 ELECTRICAL607 (cont’d) 4922714 1 460SJ (Includes Items 8.5ft/2.6m of p/n 1060902 18/2 Electrical Cable) (All Specs Ex

7-32 400S 460SJ 3121236SECTION 7 ELECTRICAL701 cont’d 1001091973 Ref 220V with CEE 7 Post Ground Receptacle & Plug (2x4 Box) C1001091971 Ref 220V

3121236 400S 460SJ 7-33SECTION 7 ELECTRICAL701C 1 Cover Options:4060700 0270022 Installation (Side Hinged)1001110873 0270022 Installation (Top Hinged)

7-34 400S 460SJ 3121236SECTION 7 ELECTRICAL701E (cont’d)4460968 1001091975, 1001091973, 1001091974, 1001100337, 1001100331 & 1001100333 Installati

3121236 400S 460SJ 7-35SECTION 7 ELECTRICAL0275216 1 Receptacle, Box & Plug Kit (110V IEC Yellow) (Includes Items 701A-701C & Male 701D Plug E

1-28 400S 460SJ 3121236SECTION 1 FRAMEFIGURE 1-6. DRIVE HUB AND HUB WITH BRAKE ASSEMBLIES 10510511111011212110211912212310410310310110910710828

7-36 400S 460SJ 3121236SECTION 7 ELECTRICAL702A 4460321 1 Connector - 4 Position4460906 4 Socket, Female702B 4922641 1 Harness - On/Off Switch 1/A702

3121236 400S 460SJ 7-37SECTION 7 ELECTRICAL704 Ref 7500W SkyPower Generator Junction Box Components0861542 Ref60Hz SpecD0861567 Ref50Hz SpecsB704A 2ft

7-38 400S 460SJ 3121236SECTION 7 ELECTRICAL708D 2400070 1 Fuse2400066 1 Holder, Fuse709 AR Platform Floodlights Components709A 2920157 2 Platform Floo

3121236 400S 460SJ 7-39SECTION 7 ELECTRICALFIGURE 7-3. HARNESS COMPONENTS INSTALLATION (MACHINES WITH UGM) (SN 0300069000 TO SN 0300177683) (CONTINUE

7-40 400S 460SJ 3121236SECTION 7 ELECTRICALFIGURE 7-4. HARNESS COMPONENTS INSTALLATION (MACHINES WITH UGM) (SN 0300177683 TO PRESENT) J3701N702D7

3121236 400S 460SJ 7-41SECTION 7 ELECTRICAL 702F701D701N702D702G702H702E702A702J2500WGENERATORRELAYGENERATORCONTROL BOX705A709B708AJIBVALVESTROBE

7-42 400S 460SJ 3121236SECTION 7 ELECTRICALFIGURE 7-4. HARNESS COMPONENTS INSTALLATION (MACHINES WITH UGM) (SN 0300177683 TO PRESENT)ITEM # PART NUMB

3121236 400S 460SJ 7-43SECTION 7 ELECTRICAL134 4460635 10 Terminal (12 Gauge)135 Not Used136 4460225 1 Connector - 6 Position4460268 5 Socket, Female1

7-44 400S 460SJ 3121236SECTION 7 ELECTRICAL210 (cont’d) 106089654ft/16.5m400S without Arctic Package492346254ft/16.5m400S with Arctic Package106089660

3121236 400S 460SJ 7-45SECTION 7 ELECTRICAL335J 4460761 1 Connector - 4 Position 4460227 4 Pin, Male 335K 4460874 1 Connector (Natural)4460871 8 Socke

3121236 400S 460SJ 1-29SECTION 1 FRAMEFIGURE 1-6. DRIVE HUB AND HUB WITH BRAKE ASSEMBLIESITEM # PART NUMBER QTY. DESCRIPTION REV.Ref DRIVE HUB ASSEMB

7-46 400S 460SJ 3121236SECTION 7 ELECTRICALRef ENGINE HARNESS ASSEMBLY1001151211 Ref Deutz D2011 Engine A1001147012 Ref Deutz TD2.9L4 Engine C10011512

3121236 400S 460SJ 7-47SECTION 7 ELECTRICAL552 to 553 Not Used554 4461109 1 Plug, Male - 16 Position (GM Engine Only)4461111 7 Pin, Male (GM Engine On

7-48 400S 460SJ 3121236SECTION 7 ELECTRICAL603 See Note AR Deutz D2011 Engine Harness Components (Deutz Engine Machines Only) (Note: Not Available for

3121236 400S 460SJ 7-49SECTION 7 ELECTRICAL611 See Note 1 Controller Harness Assembly (Lift and Swing) (Note: Not Available for Purchase)611A 7022819

7-50 400S 460SJ 3121236SECTION 7 ELECTRICAL616F 1001138110 1 Plug, Male - 2 Position1001138111 2 Socket, Female1001138113 2 Seal616G 2902443 1 Kit, Re

3121236 400S 460SJ 7-51SECTION 7 ELECTRICAL701 (cont’d) 1001091970 Ref 220V with IEC Blue Receptacle & Plug B1001091975 Ref 220V with AFSINT 107

7-52 400S 460SJ 3121236SECTION 7 ELECTRICAL701B (cont’d)4461246 1001091975 & 1001100337 Installation (Includes Cvr)1001141968 1001100343 & 100

3121236 400S 460SJ 7-53SECTION 7 ELECTRICAL701E (cont’d)1001101191 1001091969, 1001091970, 1001091971,1001091972, 1001100326, 1001100327, 1001100328 &

7-54 400S 460SJ 3121236SECTION 7 ELECTRICAL701N 1060908 Cable, Extension Options (Only Required on CE Spec Installations):6ft/1.8m Without Powermite G

3121236 400S 460SJ 7-55SECTION 7 ELECTRICAL702 Ref Generator Electrical Components1001112588 Ref 110V (Deutz Engines) A4933350 Ref 110V (GM Engines)

1-30 400S 460SJ 3121236SECTION 1 FRAME7C 7000262 1 Spring7D 7000263 2 Spacer, Thrust8 7024713 1 Gear, Sun9 to 10 Not Used11 7000253 1 Thrustwasher12 7

7-56 400S 460SJ 3121236SECTION 7 ELECTRICAL703J 4460225 1 Plug, Male - 6 Position4460226 6 Socket, Female704 Ref 7500W SkyPower Generator Junction Box

3121236 400S 460SJ 7-57SECTION 7 ELECTRICAL707A 3740049 1 Relay 4922643 1 Harness, Bag (Located at Ground Control Box) (Not Shown) 708 AR Platform Wor

7-58 400S 460SJ 3121236SECTION 7 ELECTRICALFIGURE 7-4. HARNESS COMPONENTS INSTALLATION (MACHINES WITH UGM) (SN 0300177683 TO PRESENT) (CONTINUED)ITEM

3121236 400S 460SJ 8-1SECTION 8DECALS

8-2 400S 460SJ 3121236SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) 400S400S9184924 4538383737267350364024265225225156147498244534

3121236 400S 460SJ 8-3SECTION 8 DECALSFIGURE 8-1. DECAL INSTALLATION (ANSI SPEC)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref STANDARD DECAL INSTALLATI

8-4 400S 460SJ 3121236SECTION 8 DECALS17 1701503 1 Decal - Low Oil Level (SN 0300096000 to SN 0300128256)18 1701504 2 Decal - Hydraulic Oil19 1702153

3121236 400S 460SJ 8-5SECTION 8 DECALS50 1704726 4 Decal - Lock Latch51 Not Used 152 1704885 AR Decal - WWW.JLG.COM Options:2 SN 0300096000 to SN 0300

8-6 400S 460SJ 3121236SECTION 8 DECALSFIGURE 8-2. DECAL INSTALLATION (ANSI EXPORT SPECS) 400S400S9184924453838373726735036352426522522515614749

3121236 400S 460SJ 8-7SECTION 8 DECALSFIGURE 8-2. DECAL INSTALLATION (ANSI EXPORT SPECS)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref DECAL INSTALLATIO

3121236 400S 460SJ 1-31SECTION 1 FRAME201 AR Repair Kit Options:201A Use 7024196 1 Spring Kit - 7024182 Brake (Includes 12 Natural Colored Springs) (w

8-8 400S 460SJ 3121236SECTION 8 DECALS4 3 Decal - Warning Crushing Options:1703952 Brazilian Spec1703949 Chinese Spec 1703948 CSA Spec 1703950 Japanes

3121236 400S 460SJ 8-9SECTION 8 DECALS13 (cont’d) SN 0300100315 to SN 0300142870:1707134 2 Brazilian Spec - 460SJ1707060 2 Chinese Spec - 460SJ1707055

8-10 400S 460SJ 3121236SECTION 8 DECALS14 (cont’d) SN 0300100315 to SN 0300142870:1707131 1 Brazilian Spec - 400S1707133 1 Brazilian Spec - 460SJ17070

3121236 400S 460SJ 8-11SECTION 8 DECALS15 AR Decal - USA Options:3251813 1 Brazilian/CSA/Latin American SpecsNot Required 0 Chinese/Japanese/Korean Sp

8-12 400S 460SJ 3121236SECTION 8 DECALS35 (cont’d) AR SN 0300140365 to Present:Not Required 0 Brazilian/Latin American Specs2 Chinese/CSA/Japanese/Kor

3121236 400S 460SJ 8-13SECTION 8 DECALS1001160080 Ref ADDITIONAL DECAL COMPONENTS101 to 252 Not Used253 1001125387 1 Decal - Emission ComplianceFIGURE

8-14 400S 460SJ 3121236SECTION 8 DECALSFIGURE 8-3. DECAL INSTALLATION (AUSTRALIAN & CE SPECS) 400S400S1849324452675036242625 25214251573495

3121236 400S 460SJ 8-15SECTION 8 DECALSFIGURE 8-3. DECAL INSTALLATION (AUSTRALIAN & CE SPECS)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref STANDARD

8-16 400S 460SJ 3121236SECTION 8 DECALS25 1701500 4 Decal - Lift26 1701529 4 Decal - Arrow27 3251242 1 Nameplate - 240V-50Hz 28 0860520 1 Box, Manual

3121236 400S 460SJ 9-1SECTION 9 RECOMMENDED SERVICEPARTS STOCKMODEL 400S/460SJThe following list will service one machine (built to current production

B 400S 460SJ 3121236REVISION LOG

1-32 400S 460SJ 3121236SECTION 1 FRAMEFIGURE 1-7. DRIVE MOTOR ASSEMBLY (SN 0300096000 TO SN 0300098502 - 4 BOLT) 543542214032363534333433201161

9-2 400S 460SJ 3121236SECTION 9 RECOMMENDED SERVICE PARTS STOCK4360336 Switch, Toggle (GM Machines) (Figures 2-14 & 4-4) 170002895 Module, GM Engi

3121236 400S 460SJ 10-1SECTION 10SPECIAL OPTIONS

10-2 400S 460SJ 3121236SECTION 10 SPECIAL OPTIONS FIGURE 10-1. SPECIAL OPTIONS LISTITEM # PART NUMBER QTY. DESCRIPTION REV.Ref Note: This list is to a

3121236 400S 460SJ 10-3SECTION 10 SPECIAL OPTIONSRef ClearSky (Telematics) KitsRef Without UGM1001117253 1 ANSI Spec1001121609 1 ANSI Export/CE/Japane

10-4 400S 460SJ 3121236SECTION 10 SPECIAL OPTIONSContinued Ref Decal Installations 1702868 2 Decal - No Hands (English Language) (Used with Mesh to To

3121236 400S 460SJ 10-5SECTION 10 SPECIAL OPTIONSRef Filter Kits:1 Combined Filter Kit (Hydraulic/Air & Fuel/Engine Oil)1001111000 Caterpillar Eng

10-6 400S 460SJ 3121236SECTION 10 SPECIAL OPTIONS1001094475 Ref Hourmeter, Generator Ref Hydraulic Oil Cooler Installations1001109766 Ref Caterpillar/

3121236 400S 460SJ 10-7SECTION 10 SPECIAL OPTIONSRef Sky Accessory:Ref Note: For Breakdown of Sky Accessories Refer to Accessory Manual p/n 3124242Ref

10-8 400S 460SJ 3121236SECTION 10 SPECIAL OPTIONSContinued Ref SkyPower Factory Installed - 7500W Generator Options:0273004 Ref 50Hz (Caterpillar Engi

3121236 400S 460SJ 10-9SECTION 10 SPECIAL OPTIONS7002826 1 Seal Installation Tool - 2in7016655 1 Wire Rope Sheave Gauge4922012 1 Horsepower Card S

3121236 400S 460SJ 1-33SECTION 1 FRAMEFIGURE 1-7. DRIVE MOTOR ASSEMBLY (SN 0300096000 TO SN 0300098502 - 4 BOLT)ITEM # PART NUMBER QTY. DESCRIPTION R

10-10 400S 460SJ 3121236SECTION 10 SPECIAL OPTIONSFIGURE 10-1. SPECIAL OPTIONS LIST (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

PagePart Number PagePart Number PagePart NumberPagePart Number3121236 400S 460SJ 11-1SECTION 11 PARTS NUMBER INDEX0020006 ... 1-

PagePart Number PagePart Number PagePart NumberPagePart Number11-2 400S 460SJ 3121236SECTION 11 PARTS NUMBER INDEX0272924 ... 1-

PagePart Number PagePart Number PagePart NumberPagePart Number3121236 400S 460SJ 11-3SECTION 11 PARTS NUMBER INDEX1-15, 1-16, 1-21, 3-30642684 ...

PagePart Number PagePart Number PagePart NumberPagePart Number11-4 400S 460SJ 3121236SECTION 11 PARTS NUMBER INDEX1001096160 ... 6-211

PagePart Number PagePart Number PagePart NumberPagePart Number3121236 400S 460SJ 11-5SECTION 11 PARTS NUMBER INDEX1001110872 7-19, 7-36, 7-5510011108

PagePart Number PagePart Number PagePart NumberPagePart Number11-6 400S 460SJ 3121236SECTION 11 PARTS NUMBER INDEX1001141989 ... 7-3

PagePart Number PagePart Number PagePart NumberPagePart Number3121236 400S 460SJ 11-7SECTION 11 PARTS NUMBER INDEX51, 2-72, 2-77, 2-82, 2-92, 2-102132

PagePart Number PagePart Number PagePart NumberPagePart Number11-8 400S 460SJ 3121236SECTION 11 PARTS NUMBER INDEX1705069 ...

PagePart Number PagePart Number PagePart NumberPagePart Number3121236 400S 460SJ 11-9SECTION 11 PARTS NUMBER INDEX2220622 ...6-32, 6-36, 6-4022206

1-34 400S 460SJ 3121236SECTION 1 FRAME34 Use 7022328 2 O-Ring35 7022321 1 Plug (Items Item 36)36 Use 7022328 1 O-Ring37 1 Piston, Servo Options:702232

PagePart Number PagePart Number PagePart NumberPagePart Number11-10 400S 460SJ 3121236SECTION 11 PARTS NUMBER INDEX2753514 6-28, 6-32, 6-36, 6-40275

PagePart Number PagePart Number PagePart NumberPagePart Number3121236 400S 460SJ 11-11SECTION 11 PARTS NUMBER INDEX3422865 ...

PagePart Number PagePart Number PagePart NumberPagePart Number11-12 400S 460SJ 3121236SECTION 11 PARTS NUMBER INDEX4130406 ... 1-17, 1-22

PagePart Number PagePart Number PagePart NumberPagePart Number3121236 400S 460SJ 11-13SECTION 11 PARTS NUMBER INDEX4460958 ...7-19, 7-36, 7-554460

PagePart Number PagePart Number PagePart NumberPagePart Number11-14 400S 460SJ 3121236SECTION 11 PARTS NUMBER INDEX2-784811700 ...

PagePart Number PagePart Number PagePart NumberPagePart Number3121236 400S 460SJ 11-15SECTION 11 PARTS NUMBER INDEX70002103 .2-88, 2-98, 2-106700021

PagePart Number PagePart Number PagePart NumberPagePart Number11-16 400S 460SJ 3121236SECTION 11 PARTS NUMBER INDEX7002828 ...7-21, 7-38, 7-577002

PagePart Number PagePart Number PagePart NumberPagePart Number3121236 400S 460SJ 11-17SECTION 11 PARTS NUMBER INDEX7020408 ... 2

PagePart Number PagePart Number PagePart NumberPagePart Number11-18 400S 460SJ 3121236SECTION 11 PARTS NUMBER INDEX7026883 ... 2-29, 2-37

3121236 400S 460SJ 1-35SECTION 1 FRAMEFIGURE 1-7. DRIVE MOTOR ASSEMBLY (SN 0300096000 TO SN 0300098502 - 4 BOLT) ITEM # PART NUMBER QTY. DESCRIPTION

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (Au

1-36 400S 460SJ 3121236SECTION 1 FRAMEFIGURE 1-8. DRIVE MOTOR ASSEMBLY (SN 0300098502 TO PRESENT - 5 BOLT) 341340193830343332313231181141001112

3121236 400S 460SJ 1-37SECTION 1 FRAMEFIGURE 1-8. DRIVE MOTOR ASSEMBLY (SN 0300098502 TO PRESENT - 5 BOLT)ITEM # PART NUMBER QTY. DESCRIPTION REV.Ref

1-38 400S 460SJ 3121236SECTION 1 FRAME29 1 Seat, Spring Options:7024853 2WD7022372 4WD30 See Note 1 Housing (Note: Not Available - Purchase Complete D

3121236 400S 460SJ 1-39SECTION 1 FRAMEFIGURE 1-8. DRIVE MOTOR ASSEMBLY (SN 0300098502 TO PRESENT - 5 BOLT) ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-40 400S 460SJ 3121236SECTION 1 FRAMEFIGURE 1-9. FRAME VALVES AND SHIELDS INSTALLATION (SN 0300096000 TO SN 0300115396) 201523415232123621A21B

3121236 400S 460SJ 1-41SECTION 1 FRAMEFIGURE 1-9. FRAME VALVES AND SHIELDS INSTALLATION (SN 0300096000 TO SN 0300115396)ITEM # PART NUMBER QTY. DESCR

3121236 400S 460SJ iTABLE OF CONTENTSFIGURE NO. TITLE PAGE NO.SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-42 400S 460SJ 3121236SECTION 1 FRAMERef FRONT SHIELD INSTALLATIONRef With Fixed Axle0272902 Ref 2WD without Tow Package B0272906 Ref 2WD with Tow Pa

3121236 400S 460SJ 1-43SECTION 1 FRAMEFIGURE 1-9. FRAME VALVES AND SHIELDS INSTALLATION (SN 0300096000 TO SN 0300115396) (CONTINUED)ITEM # PART NUMBE

1-44 400S 460SJ 3121236SECTION 1 FRAMEFIGURE 1-10. FRAME VALVES AND SHIELDS INSTALLATION (SN 0300115396 TO PRESENT) 21451051191031153124117OR2W

3121236 400S 460SJ 1-45SECTION 1 FRAMEFIGURE 1-10. FRAME VALVES AND SHIELDS INSTALLATION (SN 0300115396 TO PRESENT)ITEM # PART NUMBER QTY. DESCRIPTIO

1-46 400S 460SJ 3121236SECTION 1 FRAME116C 7021639 2 Valve, Cartridge (Valve 4641509 Only)2900756 AR Seal Kit - 7021639 Cartridge70002390 2 Valve, Car

3121236 400S 460SJ 1-47SECTION 1 FRAMEFIGURE 1-10. FRAME VALVES AND SHIELDS INSTALLATION (SN 0300115396 TO PRESENT) (CONTINUED)ITEM # PART NUMBER QTY

1-48 400S 460SJ 3121236SECTION 1 FRAMEFIGURE 1-11. SEMI-TRACK INSTALLATION 116108114115532 RH1 LH1011061071041141101091121171171038720220410591

3121236 400S 460SJ 1-49SECTION 1 FRAMEFIGURE 1-11. SEMI-TRACK INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref SEMI-TRACK INSTALLATIONS0270193

1-50 400S 460SJ 3121236SECTION 1 FRAME116 1 Bracket Weldment Options:4846394 Left Side 4846393 Right Side117 0100011 AR Locking, CompoundRef WHEEL ASS

3121236 400S 460SJ 1-51SECTION 1 FRAMEFIGURE 1-11. SEMI-TRACK INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

ii 400S 460SJ 3121236FIGURE NO. TITLE PAGE NO.TABLE OF CONTENTSSECTION 3 - BOOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-52 400S 460SJ 3121236SECTION 1 FRAMEFIGURE 1-12. TOW PACKAGE INSTALLATION 2012022022032042044311110205205521112031021071081091031102061041051

3121236 400S 460SJ 1-53SECTION 1 FRAMEFIGURE 1-12. TOW PACKAGE INSTALLATIONITEM # PART NUMBER QTY. DESCRIPTION REV.Ref TOW BAR INSTALLATION - 2WD0272

1-54 400S 460SJ 3121236SECTION 1 FRAMEFIGURE 1-12. TOW PACKAGE INSTALLATION (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121236 400S 460SJ 2-1SECTION 2TURNTABLE

2-2 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-1. VALVES INSTALLATIONS 15141628511351131193112671212410A10D10E10C(460SJ ONLY)10B

3121236 400S 460SJ 2-3SECTION 2 TURNTABLEFIGURE 2-1. VALVES INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref VALVES INSTALLATIONSRef 400S 027

2-4 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY 371211726854910151326222128TORQUE TO60 IN/LBS16252720192418231

3121236 400S 460SJ 2-5SECTION 2 TURNTABLEFIGURE 2-2. MAIN CONTROL VALVE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.4641499 Ref MAIN CONTROL VALV

2-6 400S 460SJ 3121236SECTION 2 TURNTABLE20 7021374 1 Control Valve Assembly (Flow Control)7012773 1 Seal Kit - 7021374 Valve7021375 1 Nut7018991 1 Co

3121236 400S 460SJ 2-7SECTION 2 TURNTABLEFIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121236 400S 460SJ iiiTABLE OF CONTENTSFIGURE NO. TITLE PAGE NO.SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-3.ACCESSORY VALVE ASSEMBLY 16238472B2C2ANOTE: TORQUE ITEMS 6 & 7 TO 60 IN/LBS.

3121236 400S 460SJ 2-9SECTION 2 TURNTABLEFIGURE 2-3. ACCESSORY VALVE ASSEMBLYITEM # PART NUMBER QTY. DESCRIPTION REV.4640921 Ref ARTICULATING JIB VAL

2-10 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-4. TURNTABLE AND SWING DRIVE INSTALLATIONS 7101103105131030130230330530630410256921012411810

3121236 400S 460SJ 2-11SECTION 2 TURNTABLEFIGURE 2-4. TURNTABLE AND SWING DRIVE INSTALLATIONSITEM # PART NUMBER QTY. DESCRIPTION REV.Ref SWING DRIVE

2-12 400S 460SJ 3121236SECTION 2 TURNTABLE104 20 Bolt 5/8in-11NC Options:0682048 Bolt 5/8in-11NC x 6in (Grade 8)0682034 Bolt 5/8in-11NC x 4-1/4in (Gra

3121236 400S 460SJ 2-13SECTION 2 TURNTABLEFIGURE 2-4. TURNTABLE AND SWING DRIVE INSTALLATIONS (CONTINUED)ITEM # PART NUMBER QTY. DESCRIPTION REV.

2-14 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-5. SWING HUB ASSEMBLY (SN 0300096000 TO SN 0300137201) 1A 1B 1J 1D 1C 1F 1E 1H1I1P3B3C3F3D3

3121236 400S 460SJ 2-15SECTION 2 TURNTABLEFIGURE 2-5. SWING HUB ASSEMBLY (SN 0300096000 TO SN 0300137201)ITEM # PART NUMBER QTY. DESCRIPTION REV.2780

2-16 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-6. SWING MOTOR ASSEMBLY (SN 0300096000 TO SN 0300137201) 19171416141514134198765421330222310

3121236 400S 460SJ 2-17SECTION 2 TURNTABLEFIGURE 2-6. SWING MOTOR ASSEMBLY (SN 0300096000 TO SN 0300137201)ITEM # PART NUMBER QTY. DESCRIPTION REV.31

iv 400S 460SJ 3121236FIGURE NO. TITLE PAGE NO.TABLE OF CONTENTS

2-18 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-7.SWING MOTOR/BRAKE/HUB ASSEMBLY (SN 0300137201 TO PRESENT) 124251J1G1A1B1E1H1I1C233B3B3E3G3C3C33A3

3121236 400S 460SJ 2-19SECTION 2 TURNTABLE 26448J8J8J8J8K8K8K8K8K8H8F8A8D8E8L731303521222332120119118117116125126114115113112110109108107106105

2-20 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-7. SWING MOTOR/BRAKE/HUB ASSEMBLY (SN 0300137201 TO PRESENT)ITEM # PART NUMBER QTY. DESCRIPTION RE

3121236 400S 460SJ 2-21SECTION 2 TURNTABLE22 See Note 4 Lockwasher (Note: Not Available - Purchase Locally)23 7017023 2 Plug, Pipe24 See Note 1 Plate,

2-22 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-8. CATERPILLAR ENGINE INSTALLATION - WITH ELECTRICAL DRIVEN COOLING FAN (WITHOUT UGM) 269858552128

3121236 400S 460SJ 2-23SECTION 2 TURNTABLE 30230130730344B44C44A44A100530931032124243043153133203063083162445314317319STARTERBATTERYAUX.PWR.PUM

2-24 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-8. CATERPILLAR ENGINE INSTALLATION - WITH ELECTRICAL DRIVEN COOLING FAN (WITHOUT UGM)ITEM # PART N

3121236 400S 460SJ 2-25SECTION 2 TURNTABLE44 AR Hose, Radiator (Top) Options:44A Use 1001102308 1 Service Kit for SN 0300096000 to SN 0300130134 (was

2-26 400S 460SJ 3121236SECTION 2 TURNTABLE71 3740080 1 Relay72 3790152 1 O-Ring73 3960389 AR Seal10ft/3m SN 0300096000 to SN 03001104806ft/2m SN 03001

3121236 400S 460SJ 2-27SECTION 2 TURNTABLERef CATERPILLAR ENGINE INSTALLATION0274605 Ref Without Arctic Package F1001093899 Ref With Arctic Package E2

3121236 400S 460SJ 1-1SECTION 1 FRAME

2-28 400S 460SJ 3121236SECTION 2 TURNTABLE241 2.7 Gal Coolant, Anti-Freeze Options (Not Shown):2300004 Without Arctic Package2300041 With Arctic Packa

3121236 400S 460SJ 2-29SECTION 2 TURNTABLE314 7026873 1 Pump, Fuel Transfer7026874 1 Seal,315 7026875 4 Injector, Fuel316 See Note 1 Pump, Fuel Inject

2-30 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-9. CATERPILLAR ENGINE INSTALLATION - WITH MECHANICAL DRIVEN COOLING FAN (WITHOUT UGM) 985525386129

3121236 400S 460SJ 2-31SECTION 2 TURNTABLE STARTERBATTERYAUX.PWR.PUMPAUX.PWR.RELAYGLOWPLUGRELAYSTARTRELAYGRD.+2347C9247D47B47A30230130730330931

2-32 400S 460SJ 3121236SECTION 2 TURNTABLEFIGURE 2-9. CATERPILLAR ENGINE INSTALLATION - WITH MECHANICAL DRIVEN COOLING FAN (WITHOUT UGM)ITEM # PART N

3121236 400S 460SJ 2-33SECTION 2 TURNTABLE46 27505326in/25cmHose47 2901880 1 Battery Cable Kit E47A 7016843 1 Cable - Battery to Starter Relay47B 7016

2-34 400S 460SJ 3121236SECTION 2 TURNTABLE83 4740274 4 Washer, Snubbing84 1001102706 1 Radiator70004091 1 Shroud85 4751400 30 Flatwasher 1/4in Regular

3121236 400S 460SJ 2-35SECTION 2 TURNTABLE217 2220794 1 Fitting, Straight Barbed218 272005814ft/4.3mHose219 272027112ft/3.7mHose220 2750532 5ft/1.5m H

2-36 400S 460SJ 3121236SECTION 2 TURNTABLE1001104689 Ref CATERPILLAR ENGINE COMPONENTS B301 7026848 1 Breather, Valve7026846 1 Gauze, Breather Valve30

3121236 400S 460SJ 2-37SECTION 2 TURNTABLE326 7026885 1 Dipstick Oil Level7026886 1 Tube, Dipstick7026881 1 O-Ring, Dipstick Tube327 7026861 1 Plug, D