JLG 400S 460SJ Service & Maintenance Manual (3120788) – PDF DOWNLOAD

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JLG 400S 460SJ Service & Maintenance Manual (3120788) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 400S 460SJ Service & Maintenance Manual (3120788) – PDF DOWNLOAD

Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS............................  3
	A General.......................................................................  3
	B Hydraulic System Safety.......................................................  3
	C Maintenance...................................................................  3
	Section 1. SPECIFICATIONS....................................................... 21
		1.1 Capacities.............................................................. 21
		1.2 Engine Specifications................................................... 21
		1.3 Tires................................................................... 22
		1.4 Specifications and Performance Data..................................... 23
		1.5 Torque Requirements..................................................... 24
		1.6 Critical Stability Weights.............................................. 24
		1.7 Major Component Weights................................................. 24
		1.8 Function Speeds......................................................... 25
		1.9 Pressure Settings - PSI (Bar)........................................... 25
		1.10 Cylinder Specifications................................................ 25
		1.11 Lubrication............................................................ 25
			Hydraulic Oil........................................................... 25
		1.12 Welder, Hydraulic (option)............................................. 26
		1.13 Serial Number Location................................................. 26
		1.14 Operator Maintenance and Lubrication................................... 27
			Draining Oil Build Up From The Propane Regulator........................ 30
			Propane Fuel Filter Replacement......................................... 31
			Propane Fuel System Pressure Relief..................................... 32
	Section 2. GENERAL.............................................................. 41
		2.1 Machine Preparation, Inspection, and Maintenance........................ 41
			General................................................................. 41
			Preparation, Inspection, and Maintenance................................ 41
			Pre-Start Inspection.................................................... 41
			Pre-Delivery Inspection and Frequent Inspection......................... 41
			Annual Machine Inspection............................................... 41
			Preventative Maintenance................................................ 41
		2.2 Service and Guidelines.................................................. 42
			General................................................................. 42
			Safety and Workmanship.................................................. 42
			Cleanliness............................................................. 42
			Components Removal and Installation..................................... 42
			Component Disassembly and Reassembly.................................... 43
			Pressure-Fit Parts...................................................... 43
			Bearings................................................................ 43
			Gaskets................................................................. 43
			Bolt Usage and Torque Application....................................... 43
			Hydraulic Lines and Electrical Wiring................................... 43
			Hydraulic System........................................................ 43
			Lubrication............................................................. 43
			Battery................................................................. 43
			Lubrication and Servicing............................................... 43
		2.3 Lubrication and Information............................................. 43
			Hydraulic System........................................................ 43
			Hydraulic Oil........................................................... 44
			Changing Hydraulic Oil.................................................. 44
			Lubrication Specifications.............................................. 44
		2.4 Cylinder Drift Test..................................................... 44
			Platform Drift.......................................................... 44
			Cylinder Drift.......................................................... 44
		2.5 Pins and Composite Bearing Repair Guidelines............................ 45
		2.6 Welding on JLG Equipment................................................ 45
			Do the Following When Welding on JLG Equipment.......................... 45
			Do NOT Do the Following When Welding on JLG Equipment................... 45
	Section 3. CHASSIS & TURNTABLE.................................................. 55
		3.1 Tires & Wheels.......................................................... 55
			Tire Inflation.......................................................... 55
			Tire Damage............................................................. 55
			Tire Replacement........................................................ 55
			Wheel Replacement....................................................... 55
			Wheel Installation...................................................... 55
		3.2 Drive Hub Part No. 2780243 (2wd Rear) Part No. 2780244 (4wd Rear)....... 56
			Disassembly............................................................. 56
			Disassembly of Cover Unit (8)........................................... 57
			Disassembly of First Stage Planetary Assembly........................... 57
			Disassembly of the Second Stage Planet Gears (1)........................ 57
			Assembly of First Stage Planetary Assembly (7).......................... 57
			Assembly Of End Cover Unit (8).......................................... 57
			Final Assembly.......................................................... 57
		3.3 Drive Hub Part No. 2780246 (4wd steer axle Prior to S/N 0300076633)..... 59
			Disassembly............................................................. 59
			Disassembly of Cover Unit (8)........................................... 59
			Disassembly of First Stage Planetary Assembly........................... 59
			Disassembly of the Second Stage Planet Gears (1)........................ 59
			Assembly of First Stage Planetary Assembly (7).......................... 60
			Assembly of End Cover Unit (8).......................................... 60
			Final Assembly.......................................................... 60
		3.4 Torque Hub - 4WD (Machines built after S/N 0300076633).................. 62
			Roll and Leak Testing................................................... 62
			Tightening and Torquing Bolts........................................... 62
			Oil Information......................................................... 62
			Main Disassembly for ”B” Drives......................................... 62
			Hub-Spindle Disassembly................................................. 63
			Cover Disassembly....................................................... 63
			Carrier Disassembly..................................................... 63
			Assembly of the Carrier................................................. 64
			Cover Sub-Assembly...................................................... 66
			Hub-Spindle Sub-Assembly................................................ 67
			Main Assembly........................................................... 69
			Tool List............................................................... 74
		3.5 Re-Aligning Torque Hub Input Coupling................................... 75
			Equipment Required...................................................... 75
			Procedure............................................................... 75
		3.6 Drive Brake............................................................. 76
			Pre-Installation Checks................................................. 76
			Installation............................................................ 77
			Maintenance............................................................. 77
			Disassembly............................................................. 77
			Examination............................................................. 77
			Assembly................................................................ 77
		3.7 Drive Motor............................................................. 79
			Description............................................................. 79
			Shaft Seal Replacement.................................................. 79
			Loop Flushing Valve..................................................... 80
			Troubleshooting......................................................... 81
			Disassembly............................................................. 82
			Inspection.............................................................. 86
			Assembly................................................................ 88
			Initial Start-up Procedures............................................. 93
		3.8 Adjustment Procedure For Lockout Valve.................................. 94
		3.9 Toe-In Adjustment....................................................... 94
		3.10 2WD Hub................................................................ 95
			Removal & Disassembly................................................... 95
			Cleaning & Inspection................................................... 95
			Assembly & Installation................................................. 96
		3.11 Oscillating Axle Bleeding Procedure.................................... 97
		3.12 Oscillating Axle Lockout Test.......................................... 97
		3.13 Swing Bearing.......................................................... 98
			Turntable Bearing Mounting Bolt Condition Check......................... 98
			Wear Tolerance.......................................................... 99
			Replacement of Swing Bearing............................................100
			Swing Bearing Torque Value..............................................101
			Swing Drive Installation................................................101
		3.14 Swing Brake (Prior to S/N 64802).......................................104
			Installation............................................................104
			Brake Disassembly.......................................................104
			Assembly Information....................................................104
		3.15 Swing Brake S/N 64802 to Present.......................................106
			Disassembly.............................................................106
			Assembly................................................................106
		3.16 Swing Drive Torque Hub.................................................108
			Disassembly Procedure...................................................108
			Hub Shaft Sub-Assembly Procedure........................................112
			Carrier Sub-Assembly Procedure..........................................114
		3.17 Semi-Track.............................................................115
			Testing the Track.......................................................115
			Removing the Track......................................................116
			Assuming Normal Wear....................................................116
			Adjustment..............................................................116
		3.18 Generator..............................................................120
			Every 250 hours.........................................................120
			Every 500 hours.........................................................120
			Overload Protection.....................................................120
			Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings..........120
		3.19 Ford EFI Engine........................................................122
			Performing Diagnostics..................................................122
			Visual/Physical Engine Inspection Check.................................122
			EFI Diagnostics (Prior to S/N 61718)....................................122
			ECM AND SENSORS.........................................................123
			Fuel System.............................................................129
		3.20 Throttle Checks and Adjustments - Deutz Engine (Prior to S/N 61718)....133
			General.................................................................133
			Procedure...............................................................134
			Controller Status.......................................................134
			Failure Modes...........................................................134
		3.21 Tilt Alarm Switch (Prior to S/N 61718).................................137
			Manual Adjustment.......................................................137
		3.22 Hydraulic Welder (225-4)...............................................140
			Replacement of Weld Transformer.........................................140
			Replacement of Hydraulic Motor..........................................140
			Replacement of Fine Control.............................................140
			Rotor Replacement.......................................................141
			Replacement of Flow Regulator...........................................141
			Replacement of Exciting Rectifier Bridge................................141
			Replacement of Weld Rectifier Bridge....................................142
			Replace Brushes on Sky Welder...........................................142
			Replacing Range Switch..................................................142
			Replacing Selector Switch...............................................142
			Replacement of Couplings................................................143
			Voltage Change Over - 120/240 Volt......................................143
		3.23 Troubleshooting of the Sky Welder......................................144
			Low Sky Welder Speed....................................................144
			Low Welding Amps........................................................144
			No Output on Weld Receptacles or AC Receptacles.........................144
			No Ac Output but Weld Output............................................144
			No Output on Weld Receptacle but AC Receptacle Output OK................148
			Welder Completely Dead - No AC or Weld Power............................148
			Intermittent Welder Operation...........................................148
		3.24 Deutz EMR 2 (S/N 77682 to Present).....................................149
		3.25 GM Engine General Maintenance..........................................162
			Maintenance of the Drive Belt...........................................162
			Engine Electrical System Maintenance....................................162
			Checking/Filling Engine Oil Level.......................................162
			Changing The Engine Oil.................................................163
			Coolant Fill Procedure - Dual Fuel Engine...............................163
		3.26 GM Engine Dual Fuel System.............................................165
			Fuel Filter.............................................................165
			Electric Lock Off.......................................................165
			EPR Assembly............................................................166
			Low Pressure Regulator (LPR)............................................166
			Air Fuel Mixer..........................................................167
			Electronic Throttle Control (ETC).......................................167
			Engine Control Module...................................................168
			Heated Exhaust Gas Oxygen Sensor........................................168
			Gasoline Multi Point Fuel Injection System (MPFI).......................168
			Gasoline Fuel Pump......................................................169
			Gasoline Pressure And Temperature Sensor Manifold.......................169
			Fuel Filter.............................................................169
			Fuel Injector Rail......................................................169
			Fuel Injector...........................................................169
		3.27 GM Engine Fuel System Repair...........................................170
			Propane Fuel System Pressure Relief.....................................170
			Propane Fuel System Leak Test...........................................170
			Propane Fuel Filter Replacement.........................................170
			Electronic Pressure Regulator (EPR) Assembly Replacement................171
			Temperature Manifold Absolute Pressure (TMAP) Sensor....................172
			Electronic Throttle Control Replacement.................................173
			Mixer Replacement.......................................................174
			Coolant Hose Replacement................................................174
			Vapor Hose Replacement..................................................174
			Engine Control Module Replacement.......................................175
			Heated Exhaust Gas Oxygen Sensor Replacement............................175
		3.28 GM Engine LPG Fuel System Diagnosis....................................175
			Fuel System Description.................................................175
			Diagnostic Aids.........................................................176
		3.29 Perkins Engine General Maintenance.....................................192
			Replacing the Engine Crankcase Breather.................................192
			Engine Oil Level - Check................................................192
			Engine Oil and Filter - Change..........................................192
			Fuel Filter/Water Separator.............................................194
			Setting the Actuator....................................................195
			Speed Sensor Installation...............................................196
		3.30 Engine Radiator Fill Procedure - Perkins & Caterpillar.................196
		3.31 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS....................198
			Section Layout..........................................................198
			List of Abbreviations in this Section...................................199
			Fault Code Broadcast....................................................200
			Diagnostic Trouble Codes................................................200
			CAN.....................................................................200
			MIL Output..............................................................201
			Diagnostic Calibration Configuration and Corrective Actions.............201
			Fault/Diagnostic Trouble Code Interaction...............................202
			DBW Diagnostic Test.....................................................207
		3.32 Diagnostic Trouble Code Fault Descriptions.............................208
			DTC 116- ECT Higher Than Expected Stage 1...............................208
			DTC 117- ECT/CHT Low Voltage............................................209
			DTC 118- ECT/CHT High Voltage...........................................211
			DTC 122- TPS1 Signal Voltage Low........................................213
			DTC 123- TPS1 Signal Voltage High.......................................216
			DTC 217- ECT Higher Than Expected 2.....................................218
			DTC 219- RPM Higher Than Max Allowed Governed Speed.....................219
			DTC 336- Crank Signal Input Noise.......................................220
			DTC 337- Loss of Crank Input Signal.....................................222
			DTC 521- Oil Pressure Sender/Switch High Pressure.......................223
			DTC 524- Oil Pressure Low...............................................226
			DTC 562- Battery Voltage (VBat) Low.....................................230
			DTC 563- Battery Voltage (VBat) High....................................232
			DTC 601- Microprocessor Failure - FLASH.................................234
			DTC 604- Microprocessor Failure - RAM...................................236
			DTC 606- Microprocessor Failure - COP...................................238
			DTC 642- 5 Volt External Low Voltage....................................240
			DTC 643- 5 Volt External High Voltage...................................242
			DTC 1612- Microprocessor Failure - RTI 1................................244
			DTC 1613- Microprocessor Failure - RTI 2................................245
			DTC 1614- Microprocessor Failure - RTI 3................................247
			DTC 1615- Microprocessor Failure - A/D..................................249
			DTC 1616- Microprocessor Failure - interrupt............................251
			DTC 1625- CAN J1939 Shutdown Request....................................253
			DTC 1626- CAN J1939 Transmit (Tx) Fault.................................254
			DTC 1627- CAN J1939 Receive (Rx) Fault..................................255
			DTC 1628- CAN Address Conflict Failure..................................256
			DTC 1629- J1939 TSC1 Message Reciept Loss...............................258
			DTC 1652- TPS1 Loss of Communications...................................259
			DTC 2111- Unable to Reach Lower TPS.....................................260
			DTC 2112- Unable to Reach Higher TPS....................................262
			DTC 9999- Throttle Actuator Failsafe Spring Failure.....................263
			DTC to SPN/FMI Table....................................................264
	Section 4. BOOM & PLATFORM......................................................267
		4.1 Boom....................................................................267
			Removal.................................................................267
			Disassembly.............................................................268
			Inspection..............................................................269
			Assembly................................................................270
			Installation............................................................271
		4.2 Articulating jib........................................................272
			Removal.................................................................272
		4.3 Limit Switch Adjustments................................................272
			Boom Horizontal Limit Switch............................................272
			Dual Capacity Angle Limit Switch........................................272
			Boom Length Limit Switch................................................272
		4.4 Drive Card Setup Procedures.............................................276
			Machine Orientation When Doing Speed Tests..............................276
			Test Notes..............................................................276
			Lift, Swing, and Drive Cards............................................277
			Flow Control Card.......................................................277
		4.5 Helac Rotary actuator...................................................279
			Theory Of Operation.....................................................279
			Tools Required for Assembly/Disassembly.................................282
			Disassembly.............................................................282
			Inspection..............................................................286
			Assembly................................................................286
			Installing Counterbalance Valve.........................................289
	Section 5. HYDRAULICS...........................................................291
		5.1 Cylinders - Theory of Operation.........................................291
			Systems Incorporating Double Acting Cylinders...........................291
			Systems Incorporating Holding Valves....................................291
		5.2 Cylinder Repair.........................................................291
			Cylinders Without Counterbalance Valves.................................291
			Cylinders With Dual Counterbalance Valves...............................291
			Disassembly.............................................................292
			Cleaning and Inspection.................................................293
			Assembly................................................................294
		5.3 Valves - Theory of Operation............................................304
			Solenoid Control Valve..................................................304
			Relief Valves...........................................................307
		5.4 Pressure Setting Procedures.............................................307
			1. Bang-Bang Main Relief Valve;.........................................307
			2. Steer;...............................................................307
			3. Platform Level Up;...................................................307
			4. Platform Level Down;.................................................307
			5. Articulating Jib Up;.................................................307
			6. Articulating Jib Down;...............................................308
			7. The Bang-Bang Main Relief Valve;.....................................308
			8. The Proportional Main Relief Valve;..................................308
			9. Lift Down;...........................................................308
			10. Swing;..............................................................308
		5.5 Hydraulic Motor Repair (H Series Char-lynn).............................308
			Disassembly.............................................................308
			Reassembly Shaft End....................................................310
			Gerotor End.............................................................312
			Timing Procedure........................................................313
			Standard Rotation.......................................................313
			Reverse Rotation........................................................313
		5.6 Hydraulic Pump “Neutral” Or Null Adjustment.............................316
		5.7 Non-feedback, Proportional Electrical Control - NFPE....................316
			Features and Benefits of the NFPE Control...............................316
			Input Signal requirements...............................................316
		5.8 Hydraulic Component Start-Up Procedures and Recommendations.............317
	Section 6. JLG CONTROL SYSTEM (S/N 61718 to Present)............................319
		6.1 Introduction............................................................319
		6.2 To Connect the JLG Control System Analyzer..............................321
		6.3 Using the Analyzer......................................................321
		6.4 Changing the Access Level of the Hand Held Analyzer.....................323
		6.5 Adjusting Parameters Using the Hand Held Analyzer.......................325
		6.6 Machine Setup...........................................................326
		6.7 Level Vehicle Description...............................................326
		6.8 Machine Personality Settings............................................335
		6.9 System Test.............................................................380
			Test from the Platform..................................................380
			Test from the Ground Station............................................382
		6.10 Analyzer Diagnostics Menu Structure....................................399
	Section 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS............................405
		7.1 General.................................................................405
		7.2 Multimeter Basics.......................................................405
			Grounding...............................................................405
			Backprobing.............................................................405
			Min/Max.................................................................405
			Polarity................................................................405
			Scale...................................................................405
			Voltage Measurement.....................................................405
			Resistance Measurement..................................................406
			Continuity Measurement..................................................406
			Current Measurement.....................................................407
		7.3 Checking Switches.......................................................407
			Basic Check.............................................................407
			Limit Switches..........................................................407
			Automatic Switches......................................................408
			Switch Wiring - Low Side, High Side.....................................408
		7.4 Applying Silicone Dielectric Compound to Electrical Connections.........408
			Installation of Dielectric Grease.......................................409
			Deutsch HD, DT, DTM, DRC Series.........................................409
			AMP Seal................................................................409
			AMP Mate-N-Lok..........................................................410
			DIN Connectors..........................................................410
			Exclusions..............................................................410
		7.5 AMP Connector...........................................................412
			Applying Silicone Dielectric Compound to AMP Connectors.................412
			Assembly................................................................412
			Disassembly.............................................................414
			Wedge Lock..............................................................414
			Service - Voltage Reading...............................................414
		7.6 Deutsch Connectors......................................................416
			DT/DTP Series Assembly..................................................416
			DT/DTP Series Disassembly...............................................416
			HD30/HDP20 Series Assembly..............................................417
			HD30/HDP20 Series Disassembly...........................................417

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