JLG 400S 460SJ Service & Maintenance Manual (3120895) – PDF DOWNLOAD

Description

JLG 400S 460SJ Service & Maintenance Manual (3120895) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 400S 460SJ Service & Maintenance Manual (3120895) – 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..................................... 22
	1.5 Torque Requirements..................................................... 23
	1.6 Critical Stability Weights.............................................. 23
	1.7 Major Component Weights................................................. 24
	1.8 Function Speeds......................................................... 24
	1.9 Pressure Settings - PSI (Bar)........................................... 24
	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..................................... 31
Section 2. GENERAL.............................................................. 39
	2.1 Machine Preparation, Inspection, and Maintenance........................ 39
		General................................................................. 39
		Preparation, Inspection, and Maintenance................................ 39
		Pre-Start Inspection.................................................... 39
		Pre-Delivery Inspection and Frequent Inspection......................... 39
		Annual Machine Inspection............................................... 39
		Preventative Maintenance................................................ 39
	2.2 Service and Guidelines.................................................. 40
		General................................................................. 40
		Safety and Workmanship.................................................. 40
		Cleanliness............................................................. 40
		Components Removal and Installation..................................... 40
		Component Disassembly and Reassembly.................................... 41
		Pressure-Fit Parts...................................................... 41
		Bearings................................................................ 41
		Gaskets................................................................. 41
		Bolt Usage and Torque Application....................................... 41
		Hydraulic Lines and Electrical Wiring................................... 41
		Hydraulic System........................................................ 41
		Lubrication............................................................. 41
		Battery................................................................. 41
		Lubrication and Servicing............................................... 41
	2.3 Lubrication and Information............................................. 41
		Hydraulic System........................................................ 41
		Hydraulic Oil........................................................... 42
		Changing Hydraulic Oil.................................................. 42
		Lubrication Specifications.............................................. 42
	2.4 Cylinder Drift Test..................................................... 42
		Platform Drift.......................................................... 42
		Cylinder Drift.......................................................... 42
	2.5 Pins and Composite Bearing Repair Guidelines............................ 43
	2.6 Welding on JLG Equipment................................................ 43
		Do the Following When Welding on JLG Equipment.......................... 43
		Do NOT Do the Following When Welding on JLG Equipment................... 43
Section 3. CHASSIS & TURNTABLE.................................................. 53
	3.1 Tires & Wheels.......................................................... 53
		Tire Inflation.......................................................... 53
		Tire Damage............................................................. 53
		Tire Replacement........................................................ 53
		Wheel Replacement....................................................... 53
		Wheel Installation...................................................... 53
	3.2 Drive Hub Part No. 2780243 (2wd Rear) Part No. 2780244 (4wd Rear)....... 54
		Disassembly............................................................. 54
		Disassembly of Cover Unit (8)........................................... 55
		Disassembly of First Stage Planetary Assembly........................... 55
		Disassembly of the Second Stage Planet Gears (1)........................ 55
		Assembly of First Stage Planetary Assembly (7).......................... 55
		Assembly Of End Cover Unit (8).......................................... 55
		Final Assembly.......................................................... 55
	3.3 Drive Hub Part No. 2780246 (4wd steer axle Prior to S/N 0300076633)..... 57
		Disassembly............................................................. 57
		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).......................... 58
		Assembly of End Cover Unit (8).......................................... 58
		Final Assembly.......................................................... 58
	3.4 Torque Hub - 4WD (Machines built after S/N 0300076633).................. 60
		Roll and Leak Testing................................................... 60
		Tightening and Torquing Bolts........................................... 60
		Oil Information......................................................... 60
		Main Disassembly for ”B” Drives......................................... 60
		Hub-Spindle Disassembly................................................. 61
		Cover Disassembly....................................................... 61
		Carrier Disassembly..................................................... 61
		Assembly of the Carrier................................................. 62
		Cover Sub-Assembly...................................................... 64
		Hub-Spindle Sub-Assembly................................................ 65
		Main Assembly........................................................... 67
		Tool List............................................................... 72
	3.5 Re-Aligning Torque Hub Input Coupling................................... 73
		Equipment Required...................................................... 73
		Procedure............................................................... 73
	3.6 Drive Brake............................................................. 74
		Pre-Installation Checks................................................. 74
		Installation............................................................ 75
		Maintenance............................................................. 75
		Disassembly............................................................. 75
		Examination............................................................. 75
		Assembly................................................................ 75
	3.7 Drive Motor............................................................. 77
		Description............................................................. 77
		Shaft Seal Replacement.................................................. 77
		Loop Flushing Valve..................................................... 78
		Troubleshooting......................................................... 79
		Disassembly............................................................. 80
		Inspection.............................................................. 84
		Assembly................................................................ 86
		Initial Start-up Procedures............................................. 91
	3.8 Adjustment Procedure For Lockout Valve.................................. 92
	3.9 Toe-In Adjustment....................................................... 92
	3.10 2WD Hub................................................................ 93
		Removal & Disassembly................................................... 93
		Cleaning & Inspection................................................... 93
		Assembly & Installation................................................. 94
	3.11 Oscillating Axle Bleeding Procedure.................................... 95
	3.12 Oscillating Axle Lockout Test.......................................... 95
	3.13 Swing Bearing.......................................................... 96
		Turntable Bearing Mounting Bolt Condition Check......................... 96
		Wear Tolerance.......................................................... 97
		Replacement of Swing Bearing............................................ 98
		Swing Bearing Torque Value.............................................. 99
		Swing Drive Installation................................................ 99
	3.14 Swing Brake (Prior to S/N 64802).......................................102
		Installation............................................................102
		Brake Disassembly.......................................................102
		Assembly Information....................................................102
	3.15 Swing Brake S/N 64802 to Present.......................................104
		Disassembly.............................................................104
		Assembly................................................................104
	3.16 Swing Drive Torque Hub.................................................106
		Disassembly Procedure...................................................106
		Hub Shaft Sub-Assembly Procedure........................................110
		Carrier Sub-Assembly Procedure..........................................112
	3.17 Semi-Track.............................................................113
		Testing the Track.......................................................113
		Removing the Track......................................................114
		Assuming Normal Wear....................................................114
		Adjustment..............................................................114
	3.18 Generator..............................................................118
		Every 250 hours.........................................................118
		Every 500 hours.........................................................118
		Overload Protection.....................................................118
		Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings..........118
	3.19 Ford EFI Engine........................................................120
		Performing Diagnostics..................................................120
		Visual/Physical Engine Inspection Check.................................120
		EFI Diagnostics (Prior to S/N 61718)....................................120
		ECM and Sensors.........................................................121
		Fuel System.............................................................127
	3.20 Throttle Checks and Adjustments - Deutz Engine (Prior to S/N 61718)....131
		General.................................................................131
		Procedure...............................................................132
		Controller Status.......................................................132
		Failure Modes...........................................................132
	3.21 Tilt Alarm Switch (Prior to S/N 61718).................................135
		Manual Adjustment.......................................................135
	3.22 Hydraulic Welder (225-4)...............................................138
		Replacement of Weld Transformer.........................................138
		Replacement of Hydraulic Motor..........................................138
		Replacement of Fine Control.............................................138
		Rotor Replacement.......................................................139
		Replacement of Flow Regulator...........................................139
		Replacement of Exciting Rectifier Bridge................................139
		Replacement of Weld Rectifier Bridge....................................140
		Replace Brushes on Sky Welder...........................................140
		Replacing Range Switch..................................................140
		Replacing Selector Switch...............................................140
		Replacement of Couplings................................................141
		Voltage Change Over - 120/240 Volt......................................141
	3.23 Troubleshooting of the Sky Welder......................................142
		Low Sky Welder Speed....................................................142
		Low Welding Amps........................................................142
		No Output on Weld Receptacles or AC Receptacles.........................142
		No Ac Output but Weld Output............................................142
		No Output on Weld Receptacle but AC Receptacle Output OK................146
		Welder Completely Dead - No AC or Weld Power............................146
		Intermittent Welder Operation...........................................146
	3.24 Deutz EMR 2 (S/N 77682 to Present).....................................147
	3.25 GM Engine General Maintenance..........................................160
		Maintenance of the Drive Belt...........................................160
		Engine Electrical System Maintenance....................................160
		Checking/Filling Engine Oil Level.......................................160
		Changing The Engine Oil.................................................161
		Coolant Fill Procedure - Dual Fuel Engine...............................161
	3.26 GM Engine Dual Fuel System.............................................163
		Fuel Filter.............................................................163
		Electric Lock Off.......................................................163
		EPR Assembly............................................................164
		Low Pressure Regulator (LPR)............................................164
		Air Fuel Mixer..........................................................165
		Electronic Throttle Control (ETC).......................................165
		Engine Control Module...................................................166
		Heated Exhaust Gas Oxygen Sensor........................................166
		Gasoline Multi Point Fuel Injection System (MPFI).......................166
		Gasoline Fuel Pump......................................................167
		Gasoline Pressure And Temperature Sensor Manifold.......................167
		Fuel Filter.............................................................167
		Fuel Injector Rail......................................................167
		Fuel Injector...........................................................167
	3.27 GM Engine Fuel System Repair...........................................168
		Propane Fuel System Pressure Relief.....................................168
		Propane Fuel System Leak Test...........................................168
		Propane Fuel Filter Replacement.........................................168
		Electronic Pressure Regulator (EPR) Assembly Replacement................169
		Temperature Manifold Absolute Pressure (TMAP) Sensor....................170
		Electronic Throttle Control Replacement.................................171
		MIXER REPLACEMENT.......................................................172
		Coolant Hose Replacement................................................172
		Vapor Hose Replacement..................................................172
		Engine Control Module Replacement.......................................173
		Heated Exhaust Gas Oxygen Sensor Replacement............................173
	3.28 GM Engine LPG Fuel System Diagnosis....................................173
		Fuel System Description.................................................173
		Diagnostic Aids.........................................................174
	3.29 Perkins Engine General Maintenance.....................................190
		Replacing the Engine Crankcase Breather.................................190
		Engine Oil Level - Check................................................190
		Engine Oil and Filter - Change..........................................190
		Fuel Filter/Water Separator.............................................192
		Setting the Actuator....................................................193
		Speed Sensor Installation...............................................194
	3.30 Engine Radiator Fill Procedure - Perkins & Caterpillar.................194
	3.31 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS....................196
		Section Layout..........................................................196
		List of Abbreviations in this Section...................................197
		Fault Code Broadcast....................................................198
		Diagnostic Trouble Codes................................................198
		CAN.....................................................................198
		MIL Output..............................................................199
		Diagnostic Calibration Configuration and Corrective Actions.............199
		Fault/Diagnostic Trouble Code Interaction...............................200
		DBW Diagnostic Test.....................................................205
	3.32 Diagnostic Trouble Code Fault Descriptions.............................206
		DTC 116- ECT Higher Than Expected Stage 1...............................206
		DTC 117- ECT/CHT Low Voltage............................................207
		DTC 118- ECT/CHT High Voltage...........................................209
		DTC 122- TPS1 Signal Voltage Low........................................211
		DTC 123- TPS1 Signal Voltage High.......................................214
		DTC 217- ECT Higher Than Expected 2.....................................216
		DTC 219- RPM Higher Than Max Allowed Governed Speed.....................217
		DTC 336- Crank Signal Input Noise.......................................218
		DTC 337- Loss of Crank Input Signal.....................................220
		DTC 521- Oil Pressure Sender/Switch High Pressure.......................221
		DTC 524- Oil Pressure Low...............................................224
		DTC 562- Battery Voltage (VBat) Low.....................................228
		DTC 563- Battery Voltage (VBat) High....................................230
		DTC 601- Microprocessor Failure - FLASH.................................232
		DTC 604- Microprocessor Failure - RAM...................................234
		DTC 606- Microprocessor Failure - COP...................................236
		DTC 642- 5 Volt External Low Voltage....................................238
		DTC 643- 5 Volt External High Voltage...................................240
		DTC 1612- Microprocessor Failure - RTI 1................................242
		DTC 1613- Microprocessor Failure - RTI 2................................243
		DTC 1614- Microprocessor Failure - RTI 3................................245
		DTC 1615- Microprocessor Failure - A/D..................................247
		DTC 1616- Microprocessor Failure - interrupt............................249
		DTC 1625- CAN J1939 Shutdown Request....................................251
		DTC 1626- CAN J1939 Transmit (Tx) Fault.................................252
		DTC 1627- CAN J1939 Receive (Rx) Fault..................................253
		DTC 1628- CAN Address Conflict Failure..................................254
		DTC 1629- J1939 TSC1 Message Reciept Loss...............................256
		DTC 1652- TPS1 Loss of Communications...................................257
		DTC 2111- Unable to Reach Lower TPS.....................................258
		DTC 2112- Unable to Reach Higher TPS....................................260
		DTC 9999- Throttle Actuator Failsafe Spring Failure.....................261
		DTC to SPN/FMI Table....................................................262
Section 4. BOOM & PLATFORM......................................................265
	4.1 Boom....................................................................265
		Removal.................................................................265
		Disassembly.............................................................266
		Inspection..............................................................267
		Assembly................................................................268
		Installation............................................................269
	4.2 Articulating jib........................................................270
		Removal.................................................................270
	4.3 Limit Switch Adjustments................................................270
		Boom Horizontal Limit Switch............................................270
		Dual Capacity Angle Limit Switch........................................270
		Boom Length Limit Switch................................................270
	4.4 Drive Card Setup Procedures.............................................274
		Machine Orientation When Doing Speed Tests..............................274
		Test Notes..............................................................274
		Lift, Swing, and Drive Cards............................................275
		Flow Control Card.......................................................275
	4.5 Helac Rotary actuator...................................................277
		Theory Of Operation.....................................................277
		Tools Required for Assembly/Disassembly.................................280
		Disassembly.............................................................280
		Inspection..............................................................284
		Assembly................................................................284
		Installing Counterbalance Valve.........................................287
Section 5. HYDRAULICS...........................................................289
	5.1 Cylinders - Theory of Operation.........................................289
		Systems Incorporating Double Acting Cylinders...........................289
		Systems Incorporating Holding Valves....................................289
	5.2 Cylinder Repair.........................................................289
		Cylinders Without Counterbalance Valves.................................289
		Cylinders With Dual Counterbalance Valves...............................289
		Disassembly.............................................................290
		Cleaning and Inspection.................................................291
		Assembly................................................................292
	5.3 Valves - Theory of Operation............................................302
		Solenoid Control Valve..................................................302
		Relief Valves...........................................................305
	5.4 Pressure Setting Procedures.............................................305
		1. Bang-Bang Main Relief Valve;.........................................305
		2. Steer;...............................................................305
		3. Platform Level Up;...................................................305
		4. Platform Level Down;.................................................305
		5. Articulating Jib Up;.................................................305
		6. Articulating Jib Down;...............................................306
		7. The Bang-Bang Main Relief Valve;.....................................306
		8. The Proportional Main relief valve;..................................306
		9. Lift Down;...........................................................306
		10. Swing;..............................................................306
	5.5 Hydraulic Motor Repair (H Series Char-lynn).............................306
		Disassembly.............................................................306
		Reassembly Shaft End....................................................308
		Gerotor End.............................................................310
		Timing Procedure........................................................311
		Standard Rotation.......................................................311
		Reverse Rotation........................................................311
	5.6 Hydraulic Pump “Neutral” Or Null Adjustment.............................314
	5.7 Non-feedback, Proportional Electrical Control - NFPE....................314
		Features and Benefits of the NFPE Control...............................314
		Input Signal requirements...............................................314
	5.8 Hydraulic Component Start-Up Procedures and Recommendations.............315
Section 6. JLG CONTROL SYSTEM (S/N 61718 to Present)............................317
	6.1 Introduction............................................................317
	6.2 To Connect the JLG Control System Analyzer..............................319
	6.3 Using the Analyzer......................................................319
	6.4 Changing the Access Level of the Hand Held Analyzer.....................321
	6.5 Adjusting Parameters Using the Hand Held Analyzer.......................323
	6.6 Machine Setup...........................................................324
	6.7 Level Vehicle Description...............................................324
	6.8 Machine Personality Settings............................................333
	6.9 System Test.............................................................378
		Test from the Platform..................................................378
		Test from the Ground Station............................................380
	6.10 Analyzer Diagnostics Menu Structure....................................397
Section 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS............................403
	7.1 General.................................................................403
	7.2 Multimeter Basics.......................................................403
		Grounding...............................................................403
		Backprobing.............................................................403
		Min/Max.................................................................403
		Polarity................................................................403
		Scale...................................................................403
		Voltage Measurement.....................................................403
		Resistance Measurement..................................................404
		Continuity Measurement..................................................404
		Current Measurement.....................................................405
	7.3 Checking Switches.......................................................405
		Basic Check.............................................................405
		Limit Switches..........................................................405
		Automatic Switches......................................................406
		Switch Wiring - Low Side, High Side.....................................406
	7.4 Applying Silicone Dielectric Compound to Electrical Connections.........406
		Installation of Dielectric Grease.......................................407
		Deutsch HD, DT, DTM, DRC Series.........................................407
		AMP Seal................................................................407
		AMP Mate-N-Lok..........................................................408
		DIN Connectors..........................................................408
		Exclusions..............................................................408
	7.5 AMP Connector...........................................................410
		Applying Silicone Dielectric Compound to AMP Connectors.................410
		Assembly................................................................410
		Disassembly.............................................................412
		Wedge Lock..............................................................412
		Service - Voltage Reading...............................................412
	7.6 Deutsch Connectors......................................................414
		DT/DTP Series Assembly..................................................414
		DT/DTP Series Disassembly...............................................414
		HD30/HDP20 Series Assembly..............................................415
		HD30/HDP20 Series Disassembly...........................................415

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

S.M