JLG 400S 460SJ Service & Maintenance Manual (3121671) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 400S 460SJ Service & Maintenance Manual (3121671) – PDF DOWNLOAD
3121671_E_400S, 460SJ_JLG_Service_English.............................................................. 1
Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS........................................... 3
A General...................................................................................... 3
B Hydraulic System Safety...................................................................... 3
C Maintenance.................................................................................. 3
Section 1. Specifications.......................................................................... 23
1.1 Operating Specifications................................................................... 23
1.2 Capacities................................................................................. 24
1.3 Engine Data................................................................................ 24
1.4 Tires...................................................................................... 25
1.5 Hydraulic Oil.............................................................................. 25
1.6 Critical Stability Weights................................................................. 27
1.7 Maintenance and Lubrication................................................................ 32
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 Inflation............................................................................. 59
Tire Damage................................................................................ 59
Tire Replacement........................................................................... 59
Wheel Replacement.......................................................................... 59
Wheel Installation......................................................................... 59
3.2 Chassis Tilt Indicator System.............................................................. 60
3.3 Drive System (4WD & 2WD)................................................................... 60
3.4 Drive Orientation System................................................................... 60
3.5 Lockout Cylinder Bleeding.................................................................. 60
3.6 Oscillating Axle System.................................................................... 61
3.7 Oscillating Axle Lockout Test.............................................................. 61
3.8 Wheel Drive Assembly....................................................................... 65
Removal.................................................................................... 65
Installation............................................................................... 65
3.9 Torque Hub................................................................................. 66
Roll and Leak Testing...................................................................... 66
Tightening and Torquing Bolts.............................................................. 66
Main Disassembly for “B” Drives............................................................ 67
Hub-Spindle Disassembly.................................................................... 67
Cover Disassembly.......................................................................... 73
Carrier Disassembly........................................................................ 73
Assemble Carrier........................................................................... 73
Cover Sub-Assembly......................................................................... 75
Hub-Spindle Sub-Assembly................................................................... 76
Main Assembly.............................................................................. 78
Tool List.................................................................................. 83
3.10 Re-Align Torque Hub Input Coupling........................................................ 84
Equipment Required......................................................................... 84
Procedure.................................................................................. 84
3.11 Drive Motor............................................................................... 84
Description................................................................................ 84
Shaft Seal Replacement..................................................................... 85
Loop Flushing Valve........................................................................ 85
Troubleshooting............................................................................ 86
Disassembly................................................................................ 87
Inspection................................................................................. 91
Assembly................................................................................... 93
Initial Start-Up Procedures................................................................ 97
3.12 Swing Drive Hub........................................................................... 99
Brake Test................................................................................. 99
Spring Checking Procedure..................................................................100
Brake Leak Repair Procedure................................................................100
Roll and Leak Test.........................................................................100
Tightening and Torquing Bolts..............................................................101
Lubrication Information....................................................................102
Motor Removal..............................................................................102
Input Brake Disassembly....................................................................104
Main Disassembly...........................................................................105
Housing-Shaft Disassembly..................................................................106
Carrier Disassembly........................................................................107
Carrier Assembly...........................................................................108
Housing - Shaft Assembly...................................................................109
Main Assembly..............................................................................110
Motor and Brake Assembly...................................................................112
Motor Control Valve Installation...........................................................115
3.13 Swing Motor...............................................................................123
Disassembly and inspection.................................................................123
Assembly...................................................................................130
One Piece Stator Construction..............................................................137
3.14 Swing Bearing.............................................................................138
Swing Bearing Wear Tolerance...............................................................138
Turntable Bearing Mounting Bolt Condition Check............................................139
Swing Bearing Removal......................................................................143
Swing Bearing Installation.................................................................143
Procedure for Setting Swing Gear Backlash..................................................144
Swing Bearing Torque Values................................................................145
3.15 Rotary Coupling...........................................................................147
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.........................................................161
3.17 Deutz Engine..............................................................................162
3.18 GM Engine.................................................................................167
3.19 Kubota Engine.............................................................................169
3.20 Deutz Engine - D2.9L4.....................................................................171
Glow Plugs.................................................................................171
Check Oil Level............................................................................171
Replacing Engine Oil.......................................................................171
Replacing the Oil Filter...................................................................172
Replacing the Fuel Filters.................................................................172
3.21 Deutz Engine - D2011......................................................................173
Glow Plugs.................................................................................173
Check Oil Level............................................................................173
Replacing Engine Oil.......................................................................174
Replacing the Oil Filter...................................................................175
Replacing the Fuel Filter..................................................................176
3.22 Deutz EMR 2...............................................................................177
3.23 GM Engine General Maintenance.............................................................189
Maintenance of the Drive Belt..............................................................189
Engine Electrical System Maintenance.......................................................189
Checking/Filling Engine Oil Level..........................................................189
Changing the Engine Oil....................................................................190
Coolant Fill Procedure - Dual Fuel Engine..................................................190
3.24 GM Engine Dual Fuel System................................................................191
Fuel Filter................................................................................191
Electric Lock Off..........................................................................192
EPR Assembly...............................................................................192
Low Pressure Regulator (LPR)...............................................................192
Air Fuel Mixer.............................................................................193
Electronic Throttle Control (ETC)..........................................................193
Engine Control Module......................................................................194
Heated Exhaust Gas Oxygen Sensor...........................................................194
Gasoline Multi Point Fuel Injection System (MPFI)..........................................194
Gasoline Fuel Pump.........................................................................195
Gasoline Pressure And Temperature Sensor Manifold..........................................195
Fuel Filter................................................................................195
Fuel Injector Rail.........................................................................195
Fuel Injector..............................................................................195
3.25 GM Engine Fuel System Repair..............................................................196
Propane Fuel System Pressure Relief........................................................196
Propane Fuel System Leak Test..............................................................196
Propane Fuel Filter Replacement............................................................197
Electronic Pressure Regulator (EPR) Assembly Replacement...................................198
Electronic Throttle Control Replacement....................................................199
Mixer Replacement..........................................................................201
Coolant Hose Replacement...................................................................201
Vapor Hose Replacement.....................................................................201
Engine Control Module Replacement..........................................................202
Heated Exhaust Gas Oxygen Sensor Replacement...............................................202
3.26 GM Engine LPG Fuel System Diagnosis.......................................................203
Fuel System Description....................................................................203
Diagnostic Aids............................................................................203
3.27 Counterweight.............................................................................273
Section 4. Boom & Platform.........................................................................275
4.1 Boom Systems...............................................................................275
Platform Control Enable System.............................................................275
Platform Load Sensing System (LSS) (If Equipped)...........................................275
Above Elevation (Above Horizontal) - Drive Speed Cutback System............................275
Transport Position Interlock System (CE only)..............................................275
Function Speed Control System..............................................................275
Main Boom Lift End of Stroke Dampening.....................................................276
Jib Lift End of Stroke Dampening...........................................................276
Machine Safety Override (MSSO) (CE Only)...................................................276
Transport Position Sensing System..........................................................276
4.2 Platform...................................................................................283
Platform/Support Removal...................................................................283
Platform/Support Installation..............................................................284
4.3 Rotator and Platform Level Cylinder........................................................287
Removal....................................................................................287
Installation...............................................................................289
4.4 Main Boom Powertrack.......................................................................290
Removal....................................................................................290
Installation...............................................................................290
Powertrack Maintenance.....................................................................292
4.5 boom assembly..............................................................................301
Removal....................................................................................301
Disassembly................................................................................302
Inspection.................................................................................303
Assembly...................................................................................303
Installation...............................................................................305
4.6 Jib (460SJ Only)...........................................................................306
Removal....................................................................................306
Disassembly................................................................................306
Inspection.................................................................................306
Assembly...................................................................................306
Installation...............................................................................307
4.7 Boom Cleanliness Guidelines................................................................307
4.8 Boom Shimming Procedure....................................................................308
4.9 Rotator Assembly...........................................................................309
Theory of Operation........................................................................309
Required Tools.............................................................................310
Making a Seal Tool.........................................................................310
Before Disassembly.........................................................................310
Disassembly................................................................................313
Inspection.................................................................................317
Assembly...................................................................................317
Installing Counterbalance Valve............................................................323
Greasing Thrust Washers....................................................................324
Testing the Actuator.......................................................................324
Installation and Bleeding..................................................................325
4.10 Skyguard..................................................................................326
Operation..................................................................................326
Function Test..............................................................................326
Diagnostics & Troubleshooting..............................................................327
4.11 Platform Rotate Bleed Procedure...........................................................328
General Notes & Precautions................................................................328
Procedure..................................................................................328
4.12 Bolt-on External Fall Arrest..............................................................329
Inspection Before Use......................................................................329
Installation...............................................................................329
Section 5. Basic Hydraulics information & Schematics...............................................333
5.1 Lubricating O-Rings in the Hydraulic System................................................333
Cup and Brush..............................................................................333
Dip Method.................................................................................334
Spray Method...............................................................................334
Brush-on Method............................................................................334
5.2 Hydraulic Connection Assembly and Torque Specification.....................................335
Tapered Thread Types.......................................................................335
Straight Thread Types, Tube and Hose Connections...........................................335
Straight Thread Types, Port Connections....................................................336
Flange Connection Types....................................................................336
Tightening Methods.........................................................................336
Assembly And Torque Specifications.........................................................337
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections.........338
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections..........339
Assembly Instructions for 37° (JIC) Flare Fittings.........................................340
Assembly Instructions for 45° SAE Flare Fittings...........................................343
Assembly Instructions for O-ring Face Seal (ORFS) Fittings.................................345
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS).................347
Assembly Instructions for Bulkhead (BH) Fittings...........................................349
Assembly Instructions for O-ring Boss (ORB) Fittings.......................................352
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings........................359
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends....................366
Assembly instructions for Adjustable Port End (BSPP) Fittings..............................368
Assembly Instructions for Flange Connections: (FL61 and FL62)..............................375
Double Wrench Method.......................................................................378
FFWR and TFFT Methods......................................................................379
Adjustable Stud End Assembly...............................................................379
O-ring Installation (Replacement)..........................................................380
5.3 Hydraulic Cylinders........................................................................381
Axle Lockout Cylinder......................................................................381
Platform Level Cylinder....................................................................383
Jib Lift Cylinder (460SJ Only).............................................................388
Main Lift Cylinder (SN 0300203771 through 0300243703, SN E300000100 through E300005607)....394
Main Lift Cylinder (SN 0300243704 to Present, SN E300005608 to Present)....................402
Master Cylinder............................................................................407
Steer Cylinder.............................................................................412
Telescope Cylinder.........................................................................415
5.4 Pressure Setting Procedure.................................................................421
Main System Relief.........................................................................421
Steer Left Relief..........................................................................421
Steer Right Relief.........................................................................422
Swing Relief...............................................................................422
Jib Lift Down Relief (460SJ only)..........................................................423
Platform Level Up Relief...................................................................423
Platform Level Down Relief.................................................................424
5.5 Drive Pump Pre-Fill Procedure..............................................................431
5.6 Hydraulic Schematics.......................................................................432
Section 6. JLG Control System......................................................................441
6.1 JLG Control System Analyzer Kit Instructions...............................................441
Introduction...............................................................................441
To Connect the JLG Control System Analyzer.................................................442
Using the Analyzer.........................................................................442
Changing the Access Level of the Hand Held Analyzer........................................443
Adjusting Parameters Using the Hand Held Analyzer..........................................444
Machine Setup..............................................................................445
Tilt Sensor Calibration....................................................................446
Ground Control Console Display Gauge.......................................................449
6.2 LSS System.................................................................................476
Diagnostic Menu............................................................................477
Calibration Procedure......................................................................478
Testing & Evaluation.......................................................................483
Troubleshooting............................................................................484
6.3 Resetting The MSSO System..................................................................485
6.4 Machine Model Adjustment...................................................................487
Adjustment Notes...........................................................................487
Machine Orientation When Performing Test...................................................487
Section 7. Basic Electrical Information & Schematics...............................................531
7.1 General....................................................................................531
7.2 Multimeter Basics..........................................................................531
Grounding..................................................................................531
Backprobing................................................................................531
Min/Max....................................................................................531
Polarity...................................................................................531
Scale......................................................................................531
Voltage Measurement........................................................................531
Resistance Measurement.....................................................................532
Continuity Measurement.....................................................................532
Current Measurement........................................................................533
7.3 Applying Silicone Dielectric Compound to Electrical Connections............................533
Installation of Dielectric Grease..........................................................534
Deutsch HD, DT, DTM, DRC Series............................................................534
AMP Seal...................................................................................534
AMP Mate-N-Lok.............................................................................535
DIN Connectors.............................................................................535
Exclusions.................................................................................536
Brad Harrison / Phoenix Contact M12........................................................536
Engine Control unit connectors.............................................................536
Sealed Enclosures..........................................................................536
MIL-C-5015 spec connectors.................................................................537
MOLEX CMC series connectors................................................................537
7.4 AMP Connector..............................................................................538
Assembly...................................................................................538
Disassembly................................................................................540
Wedge Lock.................................................................................540
Service - Voltage Reading..................................................................540
7.5 Deutsch Connectors.........................................................................542
DT/DTP Series Assembly.....................................................................542
DT/DTP Series Disassembly..................................................................542
HD30/HDP20 Series Assembly.................................................................543
HD30/HDP20 Series Disassembly..............................................................543
7.6 Telematics Gateway.........................................................................544
Telematics-Ready (TCU) Plug................................................................544
7.7 Wiring Harness Connector Labels and Wiring Harnesses.......................................553
Connector Labels...........................................................................553
Component Labels...........................................................................553
7.8 Electrical Schematics......................................................................633
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JLG 400S 460SJ Service & Maintenance Manual (3121671) – PDF DOWNLOADJLG 400S 460SJ Service & Maintenance Manual (3121671) – PDF DOWNLOADJLG 400S 460SJ Service & Maintenance Manual (3121671) – PDF DOWNLOAD
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