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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JLG 400S 460SJ PVC 2007 Service & Maintenance Manual (31217137) – PDF DOWNLOADJLG 400S 460SJ PVC 2007 Service & Maintenance Manual (31217137) – PDF DOWNLOADJLG 400S 460SJ PVC 2007 Service & Maintenance Manual (31217137) – PDF DOWNLOAD
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