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JLG 400S 460SJ PVC 2007 Service & Maintenance Manual (31217137) -PDF DOWNLOAD 
JLG 400S 460SJ PVC 2007 Service & Maintenance Manual (31217137) -PDF DOWNLOAD
JLG 400S 460SJ PVC 2007 Service & Maintenance Manual (31217137) -PDF DOWNLOAD (ENG)
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JLG 400S 460SJ PVC 2007 Service & Maintenance Manual (31217137) -PDF DOWNLOAD
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JLG 400S 460SJ PVC 2007 Service & Maintenance Manual (31217137) -PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 400S 460SJ PVC 2007 Service & Maintenance Manual (31217137) -PDF DOWNLOAD
31217137_A_400S,460SJ_JLG_Service_English.......................................................... 1 Section A. Introduction - Maintenance Safety Precautions....................................... 3 A General.................................................................................. 3 B Hydraulic System Safety.................................................................. 3 C Maintenance.............................................................................. 3 Table of Contents.............................................................................. 5 List of Figures................................................................................ 12 List of Tables................................................................................. 18 Section 1. Specifications...................................................................... 21 1.1 Operating Specifications............................................................... 21 Machine Specifications - 400S.......................................................... 21 Machine Specifications - 460SJ......................................................... 21 1.2 Capacities............................................................................. 22 1.3 Engine Data............................................................................ 22 1.4 Tires.................................................................................. 23 1.5 Hydraulic Oil.......................................................................... 23 1.6 Critical Stability Weights............................................................. 24 1.7 Maintenance and Lubrication............................................................ 28 1.8 ThreadLocking Compound................................................................. 34 1.9 Torque Charts.......................................................................... 35 SAE Fastener Torque Chart.............................................................. 35 SAE Fastener Torque Chart (Continued).................................................. 36 SAE Fastener Torque Chart (Continued).................................................. 37 SAE Fastener Torque Chart (Continued).................................................. 38 SAE Fastener Torque Chart (Continued).................................................. 39 SAE Fastener Torque Chart (Continued).................................................. 40 Metric Fastener Torque Chart........................................................... 41 Metric Fastener Torque Chart (Continued)............................................... 42 Metric Fastener Torque Chart (Continued)............................................... 43 Metric Fastener Torque Chart (Continued)............................................... 44 Section 2. General............................................................................. 45 2.1 Machine Preparation, Inspection, and Maintenance....................................... 45 General................................................................................ 45 Preparation, Inspection, and Maintenance............................................... 45 Pre-Start Inspection................................................................... 45 Pre-Delivery Inspection and Frequent Inspection........................................ 45 Annual Machine Inspection.............................................................. 45 Preventive Maintenance................................................................. 45 2.2 Service and Guidelines................................................................. 46 General................................................................................ 46 Safety and Workmanship................................................................. 46 Cleanliness............................................................................ 46 Components Removal and Installation.................................................... 46 Component Disassembly and Reassembly................................................... 47 Pressure-Fit Parts..................................................................... 47 Bearings............................................................................... 47 Gaskets................................................................................ 47 Bolt Usage and Torque Application...................................................... 47 Hydraulic Lines and Electrical Wiring.................................................. 47 Hydraulic System....................................................................... 47 Lubrication............................................................................ 47 Battery................................................................................ 47 Lubrication and Servicing.............................................................. 47 2.3 Lubrication and Information............................................................ 48 Hydraulic System....................................................................... 48 Hydraulic Oil.......................................................................... 48 Changing Hydraulic Oil................................................................. 48 Lubrication Specifications............................................................. 48 2.4 Cylinder Drift Test.................................................................... 49 Theory................................................................................. 49 Cylinder Leakage Test.................................................................. 49 Cylinder Thermal Drift................................................................. 49 2.5 Pins and Composite Bearing Repair Guidelines........................................... 50 2.6 Welding on JLG Equipment............................................................... 50 Do the Following When Welding on JLG Equipment......................................... 50 Do NOT Do the Following When Welding on JLG Equipment.................................. 50 Section 3. Chassis & Turntable................................................................. 59 3.1 Tires and Wheels....................................................................... 59 Tire Damage............................................................................ 59 Tire Replacement....................................................................... 59 Wheel Replacement...................................................................... 59 Wheel Installation..................................................................... 59 3.2 Chassis Tilt Indicator System.......................................................... 60 3.3 Drive Orientation System............................................................... 60 3.4 Lockout Cylinder Bleeding.............................................................. 60 3.5 Drive System (4WD & 2WD)............................................................... 61 3.6 Oscillating Axle System................................................................ 62 3.7 Oscillating Axle Lockout Test.......................................................... 62 3.8 Wheel Drive Assembly................................................................... 66 Removal................................................................................ 66 Installation........................................................................... 66 3.9 Torque Hub............................................................................. 67 Roll and Leak Testing.................................................................. 67 Tightening and Torquing Bolts.......................................................... 67 Main Disassembly for “B” Drives........................................................ 68 Hub-Spindle Disassembly................................................................ 68 Cover Disassembly...................................................................... 74 Carrier Disassembly.................................................................... 74 Assemble Carrier....................................................................... 74 Cover Sub-Assembly..................................................................... 76 Hub-Spindle Sub-Assembly............................................................... 77 Main Assembly.......................................................................... 79 Tool List.............................................................................. 84 3.10 Re-Align Torque Hub Input Coupling.................................................... 85 Equipment Required..................................................................... 85 Procedure.............................................................................. 85 3.11 Drive Motor........................................................................... 85 Description............................................................................ 85 Shaft Seal Replacement................................................................. 86 Loop Flushing Valve.................................................................... 86 Troubleshooting........................................................................ 87 Disassembly............................................................................ 88 Inspection............................................................................. 92 Assembly............................................................................... 94 Initial Start-Up Procedures............................................................ 98 3.12 Swing Drive Hub.......................................................................100 Brake Test.............................................................................100 Spring Checking Procedure..............................................................101 Brake Leak Repair Procedure............................................................101 Roll and Leak Test.....................................................................101 Tightening and Torquing Bolts..........................................................102 Lubrication Information................................................................103 Motor Removal..........................................................................103 Input Brake Disassembly................................................................105 Main Disassembly.......................................................................106 Housing-Shaft Disassembly..............................................................107 Carrier Disassembly....................................................................108 Carrier Assembly.......................................................................109 Housing - Shaft Assembly...............................................................110 Main Assembly..........................................................................111 Motor and Brake Assembly...............................................................113 Motor Control Valve Installation.......................................................116 3.13 Swing Motor...........................................................................124 Disassembly and inspection.............................................................124 Assembly...............................................................................131 One Piece Stator Construction..........................................................138 3.14 Swing Bearing.........................................................................139 Swing Bearing Wear Tolerance...........................................................139 Turntable Bearing Mounting Bolt Condition Check........................................140 Swing Bearing Removal..................................................................144 Swing Bearing Installation.............................................................144 Procedure for Setting Swing Gear Backlash..............................................145 Swing Bearing Torque Values............................................................146 3.15 Rotary Coupling.......................................................................148 3.16 Generator.............................................................................152 Maintenance Schedule...................................................................152 Overload Protection....................................................................152 Inspecting Brushes, Replacing Brushes and Cleaning Slip Rings..........................152 Generator Disassembly and Assembly.....................................................154 Lead Connection List for Generator.....................................................162 3.17 Deutz Engine..........................................................................163 3.18 Kubota Engine.........................................................................171 3.19 Deutz Engine - D2.9L4.................................................................173 Glow Plugs.............................................................................173 Check Oil Level........................................................................173 Replacing Engine Oil...................................................................173 Replacing the Oil Filter...............................................................174 Replacing the Fuel Filters.............................................................174 3.20 HRC ENGINE EMISSION CHARACTERISTICS...................................................175 Terminology for Removing Soot..........................................................175 3.21 DIESEL PARTICULATE FILTER (IF EQUIPPED)...............................................175 3.22 Deutz EMR5............................................................................176 3.23 Deutz Engine - D2011..................................................................203 Glow Plugs.............................................................................203 Check Oil Level........................................................................203 Replacing Engine Oil...................................................................204 Replacing the Oil Filter...............................................................205 Replacing the Fuel Filter..............................................................206 Clean Fuel Strainer....................................................................206 3.24 Deutz EMR 2...........................................................................207 3.25 Kubota Engine General Maintenance.....................................................276 Checking Oil Level.....................................................................276 Replacing Engine Oil...................................................................276 Replacing the Oil Filter...............................................................277 Maintenance of the Drive Belt..........................................................277 REPLACING OIL SEPARATOR................................................................278 3.26 Counterweight.........................................................................282 Section 4. Boom & Platform.....................................................................283 4.1 Boom Systems...........................................................................283 Platform Control Enable System.........................................................283 Platform Load Sensing System (LSS).....................................................283 Above Elevation (Above Horizontal) - Drive Speed Cutback System........................283 Transport Position Interlock System (CE only)..........................................283 Function Speed Control System..........................................................283 Main Boom Lift End of Stroke Dampening.................................................284 Jib Lift End of Stroke Dampening.......................................................284 Machine Safety System Override (MSSO) (CE Only)........................................284 Emergency Decent System................................................................284 Transport Position Sensing System......................................................284 4.2 Platform...............................................................................291 Platform/Support Removal...............................................................291 Platform/Support Installation..........................................................292 4.3 Rotator and Platform Level Cylinder....................................................294 Removal................................................................................294 Installation...........................................................................296 4.4 Main Boom Powertrack...................................................................297 Removal................................................................................297 Installation...........................................................................297 Powertrack Maintenance.................................................................299 4.5 boom assembly..........................................................................308 Removal................................................................................308 Disassembly............................................................................309 Inspection.............................................................................310 Assembly...............................................................................310 Installation...........................................................................312 4.6 Jib (460SJ Only).......................................................................313 Removal................................................................................313 Disassembly............................................................................313 Inspection.............................................................................313 Assembly...............................................................................313 Installation...........................................................................314 4.7 Boom Cleanliness Guidelines............................................................314 4.8 Boom Shimming Procedure................................................................315 4.9 Rotator Assembly.......................................................................316 Theory of Operation....................................................................316 Required Tools.........................................................................317 Before Disassembly.....................................................................317 Disassembly............................................................................320 Inspection.............................................................................324 Assembly...............................................................................324 Installing Counterbalance Valve........................................................330 Greasing Thrust Washers................................................................331 Testing the Actuator...................................................................331 Installation and Bleeding..............................................................332 4.10 Skyguard..............................................................................333 Operation..............................................................................333 Function Test..........................................................................333 Diagnostics & Troubleshooting..........................................................334 4.11 Platform Rotate Bleed Procedure.......................................................335 General Notes & Precautions............................................................335 Procedure..............................................................................335 4.12 Bolt-on External Fall Arrest..........................................................336 Inspection Before Use..................................................................336 Installation...........................................................................336 Section 5. Basic Hydraulics information & Schematics...........................................339 5.1 Lubricating O-Rings in the Hydraulic System............................................339 Cup and Brush..........................................................................339 Dip Method.............................................................................340 Spray Method...........................................................................340 Brush-on Method........................................................................340 5.2 Hydraulic Connection Assembly and Torque Specification.................................341 Tapered Thread Types...................................................................341 Straight Thread Types, Tube and Hose Connections.......................................341 Straight Thread Types, Port Connections................................................342 Flange Connection Types................................................................342 Tightening Methods.....................................................................342 Assembly And Torque Specifications.....................................................343 Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections.....344 Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections......345 Assembly Instructions for 37° (JIC) Flare Fittings.....................................346 Assembly Instructions for 45° SAE Flare Fittings.......................................350 Assembly Instructions for O-ring Face Seal (ORFS) Fittings.............................352 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS).............354 Assembly Instructions for Bulkhead (BH) Fittings.......................................356 Assembly Instructions for O-ring Boss (ORB) Fittings...................................360 Assembly Instructions for Adjustable Port End Metric (MFF) Fittings....................368 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends................376 Assembly instructions for Adjustable Port End (BSPP) Fittings..........................378 Assembly Instructions for Flange Connections: (FL61 and FL62)..........................386 Double Wrench Method...................................................................389 FFWR and TFFT Methods..................................................................390 Adjustable Stud End Assembly...........................................................390 O-ring Installation (Replacement)......................................................391 5.3 Hydraulic Cylinders....................................................................392 Axle Lockout Cylinder..................................................................392 Platform Level Cylinder................................................................394 Jib Lift Cylinder (460SJ Only).........................................................399 Main Lift Cylinder.....................................................................405 Master Cylinder........................................................................410 Steer Cylinder.........................................................................415 Telescope Cylinder.....................................................................418 5.4 Pressure Setting Procedure.............................................................423 Main System Relief.....................................................................423 Steer Left Relief......................................................................423 Steer Right Relief.....................................................................424 Swing Relief...........................................................................424 Jib Lift Down Relief (460SJ only)......................................................425 Platform Level Up Relief...............................................................425 Platform Level Down Relief.............................................................426 5.5 Drive Pump Pre-Fill Procedure..........................................................433 5.6 Hydraulic Schematics...................................................................434 Section 6. JLG Control System..................................................................443 6.1 JLG Control System Analyzer Kit Instructions...........................................443 Introduction...........................................................................443 To Connect the JLG Control System Analyzer.............................................444 Using the Analyzer.....................................................................444 Changing the Access Level of the Hand Held Analyzer....................................445 Adjusting Parameters Using the Hand Held Analyzer......................................446 Machine Setup..........................................................................447 Tilt Sensor Calibration................................................................448 Ground Control Console Display Gauge...................................................451 6.2 LSS System.............................................................................479 Diagnostic Menu........................................................................480 Calibration Procedure..................................................................481 Testing & Evaluation...................................................................486 Troubleshooting........................................................................487 6.3 Resetting The MSSO System..............................................................488 6.4 Machine Model Adjustment...............................................................490 Adjustment Notes.......................................................................490 Machine Orientation When Performing Test...............................................490 Section 7. Basic Electrical Information & Schematics...........................................533 7.1 General................................................................................533 7.2 Multimeter Basics......................................................................533 Grounding..............................................................................533 Backprobing............................................................................533 Min/Max................................................................................533 Polarity...............................................................................533 Scale..................................................................................533 Voltage Measurement....................................................................533 Resistance Measurement.................................................................534 Continuity Measurement.................................................................534 Current Measurement....................................................................535 7.3 Applying Silicone Dielectric Compound to Electrical Connections........................535 7.4 Dielectric Grease Application..........................................................536 Installation...........................................................................536 AMP Mate-N-Lok.........................................................................536 AMP Faston.............................................................................536 AMP Micro-Fit..........................................................................536 AMP Mini Fit Jr........................................................................537 Mini Fit Sr............................................................................537 DIN Connectors.........................................................................537 Exceptions.............................................................................537 7.5 AMP Connector..........................................................................538 Applying Silicone Dielectric Compound to AMP Connectors................................538 Assembly...............................................................................538 Disassembly............................................................................540 Wedge Lock.............................................................................540 Service - Voltage Reading..............................................................540 7.6 Deutsch Connectors.....................................................................542 DT/DTP Series Assembly.................................................................542 DT/DTP Series Disassembly..............................................................542 HD30/HDP20 Series Assembly.............................................................543 HD30/HDP20 Series Disassembly..........................................................543 7.7 Telematics Gateway.....................................................................544 Telematics-Ready (TCU) Plug............................................................544 7.8 Wiring Harness Connector Labels and Wiring Harnesses...................................553 Connector Labels.......................................................................553 Component Labels.......................................................................553 7.9 Electrical Schematics..................................................................641
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