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JLG 400S HC3 460SJ HC3 Service & Maintenance Manual (31215869) – PDF DOWNLOAD 
JLG 400S HC3 460SJ HC3 Service & Maintenance Manual (31215869) – PDF DOWNLOAD
JLG 400S HC3 460SJ HC3 Service & Maintenance Manual (31215869) – PDF DOWNLOAD (Eng)
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JLG 400S HC3 460SJ HC3 Service & Maintenance Manual (31215869) – PDF DOWNLOAD
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JLG 400S HC3 460SJ HC3 Service & Maintenance Manual (31215869) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 400S HC3 460SJ HC3 Service & Maintenance Manual (31215869) – 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 Operating Specifications............................................................... 21 Machine Specifications 400S HC3........................................................ 21 Machine Specifications 460SJ HC3....................................................... 21 1.2 Capacities............................................................................. 22 1.3 Engine Data............................................................................ 22 1.4 Tires.................................................................................. 23 1.5 Hydraulic Oil.......................................................................... 23 1.6 Critical Stability Weights............................................................. 24 1.7 Maintenance and Lubrication............................................................ 28 1.8 ThreadLocking Compound................................................................. 33 1.9 Torque Charts.......................................................................... 34 SAE Fastener Torque Chart.............................................................. 34 SAE Fastener Torque Chart (Continued).................................................. 35 SAE Fastener Torque Chart (Continued).................................................. 36 SAE Fastener Torque Chart (Continued).................................................. 37 SAE Fastener Torque Chart (Continued).................................................. 38 SAE Fastener Torque Chart (Continued).................................................. 39 Metric Fastener Torque Chart........................................................... 40 Metric Fastener Torque Chart (Continued)............................................... 41 Metric Fastener Torque Chart (Continued)............................................... 42 Metric Fastener Torque Chart (Continued)............................................... 43 Section 2. General............................................................................. 45 2.1 Machine Preparation, Inspection, and Maintenance....................................... 45 General................................................................................ 45 Preparation, Inspection, and Maintenance............................................... 45 Pre-Start Inspection................................................................... 45 Pre-Delivery Inspection and Frequent Inspection........................................ 45 Annual Machine Inspection.............................................................. 45 Preventive Maintenance................................................................. 45 2.2 Service and Guidelines................................................................. 46 General................................................................................ 46 Safety and Workmanship................................................................. 46 Cleanliness............................................................................ 46 Components Removal and Installation.................................................... 46 Component Disassembly and Reassembly................................................... 47 Pressure-Fit Parts..................................................................... 47 Bearings............................................................................... 47 Gaskets................................................................................ 47 Bolt Usage and Torque Application...................................................... 47 Hydraulic Lines and Electrical Wiring.................................................. 47 Hydraulic System....................................................................... 47 Lubrication............................................................................ 47 Battery................................................................................ 47 Lubrication and Servicing.............................................................. 47 2.3 Lubrication and Information............................................................ 48 Hydraulic System....................................................................... 48 Hydraulic Oil.......................................................................... 48 Changing Hydraulic Oil................................................................. 48 Lubrication Specifications............................................................. 48 2.4 Cylinder Drift Test.................................................................... 49 Theory................................................................................. 49 Cylinder Leakage Test.................................................................. 49 Cylinder Thermal Drift................................................................. 49 2.5 Pins and Composite Bearing Repair Guidelines........................................... 50 2.6 Welding on JLG Equipment............................................................... 50 Do the Following When Welding on JLG Equipment......................................... 50 Do NOT Do the Following When Welding on JLG Equipment.................................. 50 Section 3. Chassis & Turntable................................................................. 59 3.1 Tires and Wheels....................................................................... 59 Tire Damage............................................................................ 59 Tire Replacement....................................................................... 59 Wheel Replacement...................................................................... 59 Wheel Installation..................................................................... 59 3.2 Chassis Tilt Indicator System.......................................................... 60 3.3 Drive System........................................................................... 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................................................................... 67 Removal................................................................................ 67 Installation........................................................................... 67 3.9 Torque Hub - 400S HC3.................................................................. 68 Roll and Leak Testing.................................................................. 68 Tightening and Torquing Bolts.......................................................... 68 Main Disassembly for “B” Drives........................................................ 69 Hub-Spindle Disassembly................................................................ 69 Cover Disassembly...................................................................... 75 Carrier Disassembly.................................................................... 75 Assemble Carrier....................................................................... 75 Cover Sub-Assembly..................................................................... 77 Hub-Spindle Sub-Assembly............................................................... 78 Main Assembly.......................................................................... 80 Tool List.............................................................................. 85 3.10 Re-Align Torque Hub Input Coupling.................................................... 85 Equipment Required..................................................................... 85 Procedure.............................................................................. 85 3.11 Torque Hub - 460SJ HC3................................................................ 86 Roll and Leak Testing.................................................................. 86 Tightening and Torquing Bolts.......................................................... 86 Disassembly............................................................................ 87 Assembly............................................................................... 98 Tool List..............................................................................101 3.12 Drive Motor...........................................................................112 Description............................................................................112 Shaft Seal Replacement.................................................................112 Loop Flushing Valve....................................................................113 Troubleshooting........................................................................114 Disassembly............................................................................115 Inspection.............................................................................119 Assembly...............................................................................121 Initial Start-Up Procedures............................................................125 3.13 Swing Drive Hub.......................................................................127 Brake Test.............................................................................127 Spring Checking Procedure..............................................................128 Brake Leak Repair Procedure............................................................128 Roll and Leak Test.....................................................................128 Tightening and Torquing Bolts..........................................................129 Lubrication Information................................................................130 Motor Removal..........................................................................130 Input Brake Disassembly................................................................132 Main Disassembly.......................................................................133 Housing-Shaft Disassembly..............................................................134 Carrier Disassembly....................................................................135 Carrier Assembly.......................................................................136 Housing - Shaft Assembly...............................................................137 Main Assembly..........................................................................138 Motor and Brake Assembly...............................................................140 Motor Control Valve Installation.......................................................143 3.14 Swing Motor...........................................................................151 Disassembly and Inspection.............................................................151 Assembly...............................................................................158 One Piece Stator Construction..........................................................165 3.15 Swing Bearing.........................................................................166 Swing Bearing Wear Tolerance...........................................................166 Turntable Bearing Mounting Bolt Condition Check........................................167 Swing Bearing Removal..................................................................171 Swing Bearing Installation.............................................................171 Procedure for Setting Swing Gear Backlash..............................................172 Swing Bearing Torque Values............................................................173 3.16 Rotary Coupling.......................................................................175 3.17 Generator.............................................................................179 Maintenance Schedule...................................................................179 Overload Protection....................................................................179 Inspecting Brushes, Replacing Brushes and Cleaning Slip Rings..........................179 Generator Disassembly and Assembly.....................................................181 Lead Connection List for Generator.....................................................188 3.18 Deutz Engine..........................................................................189 3.19 Kubota Engine.........................................................................196 3.20 Deutz Engine - D2.9L4.................................................................198 Glow Plugs.............................................................................198 Check Oil Level........................................................................198 Replacing Engine Oil...................................................................198 Replacing the Oil Filter...............................................................199 Replacing the Fuel Filters.............................................................199 3.21 HRC ENGINE EMISSION CHARACTERISTICS...................................................200 Terminology for Removing Soot..........................................................200 3.22 DIESEL PARTICULATE FILTER (IF EQUIPPED)...............................................200 3.23 Deutz EMR5............................................................................201 3.24 Deutz Engine - D2011L.................................................................228 Glow Plugs.............................................................................228 Check Oil Level........................................................................228 Replacing Engine Oil...................................................................229 Replacing the Oil Filter...............................................................230 Replacing the Fuel Filter..............................................................231 Clean Fuel Strainer....................................................................231 3.25 Deutz EMR 2...........................................................................232 3.26 Counterweight.........................................................................301 Section 4. Boom & Platform.....................................................................303 4.1 Boom Systems...........................................................................303 Platform Control Enable System.........................................................303 Platform Load Sensing System (LSS) (If Equipped).......................................303 Above Elevation (Above Horizontal) - Drive Speed Cutback System........................303 Transport Position Interlock System (CE only)..........................................303 Function Speed Control System..........................................................303 Main Boom Lift End of Stroke Dampening.................................................304 Jib Lift End of Stroke Dampening.......................................................304 Machine Safety System Override (MSSO) (CE Only)........................................304 Emergency Decent System................................................................304 Transport Position Sensing System......................................................304 4.2 Platform...............................................................................315 Platform/Support Removal...............................................................315 Platform/Support Installation..........................................................316 4.3 Rotator and Platform Level Cylinder....................................................318 Removal................................................................................318 Installation...........................................................................320 4.4 Main Boom Powertrack...................................................................321 Removal................................................................................321 Installation...........................................................................321 Powertrack Maintenance.................................................................324 4.5 Boom Assembly..........................................................................333 Removal................................................................................333 Disassembly............................................................................334 Inspection.............................................................................335 Assembly...............................................................................335 Installation...........................................................................337 4.6 Jib (460SJ HC3 Only)...................................................................338 Removal................................................................................338 Disassembly............................................................................338 Inspection.............................................................................339 Assembly...............................................................................339 Installation...........................................................................339 4.7 Main Lift Cylinder.....................................................................340 Removal................................................................................340 Installation...........................................................................340 4.8 Master Cylinder........................................................................341 Removal................................................................................341 Installation...........................................................................341 4.9 Boom Cleanliness Guidelines............................................................342 4.10 Boom Shimming Procedure...............................................................343 4.11 Rotator Assembly......................................................................344 Theory of Operation....................................................................344 Required Tools.........................................................................345 Before Disassembly.....................................................................345 Disassembly............................................................................348 Inspection.............................................................................352 Assembly...............................................................................352 Installing Counterbalance Valve........................................................358 Greasing Thrust Washers................................................................359 Testing the Actuator...................................................................359 Installation and Bleeding..............................................................360 4.12 Skyguard..............................................................................362 Operation..............................................................................362 Function Test..........................................................................362 Diagnostics & Troubleshooting..........................................................363 4.13 Platform Rotate Bleed Procedure.......................................................364 General Notes & Precautions............................................................364 Procedure..............................................................................364 4.14 Bolt-on External Fall Arrest..........................................................365 Inspection Before Use..................................................................365 Installation...........................................................................366 Section 5. Basic Hydraulics information & Schematics...........................................369 5.1 Lubricating O-Rings in the Hydraulic System............................................369 Cup and Brush..........................................................................369 Dip Method.............................................................................370 Spray Method...........................................................................370 Brush-on Method........................................................................370 5.2 Hydraulic Connection Assembly and Torque Specification.................................371 Tapered Thread Types...................................................................371 Straight Thread Types, Tube and Hose Connections.......................................371 Straight Thread Types, Port Connections................................................372 Flange Connection Types................................................................372 Tightening Methods.....................................................................372 Assembly And Torque Specifications.....................................................373 Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections.....374 Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections......375 Assembly Instructions for 37° (JIC) Flare Fittings.....................................376 Assembly Instructions for 45° SAE Flare Fittings.......................................380 Assembly Instructions for O-ring Face Seal (ORFS) Fittings.............................382 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS).............384 Assembly Instructions for Bulkhead (BH) Fittings.......................................386 Assembly Instructions for O-ring Boss (ORB) Fittings...................................389 Assembly Instructions for Adjustable Port End Metric (MFF) Fittings....................396 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends................403 Assembly instructions for Adjustable Port End (BSPP) Fittings..........................405 Assembly Instructions for Flange Connections: (FL61 and FL62)..........................412 Double Wrench Method...................................................................415 FFWR and TFFT Methods..................................................................416 Adjustable Stud End Assembly...........................................................416 O-ring Installation (Replacement)......................................................417 5.3 Hydraulic Cylinders....................................................................418 Axle Lockout Cylinder..................................................................418 Platform Level Cylinder................................................................420 Jib Lift Cylinder (460SJ HC3 Only).....................................................426 Main Lift Cylinder.....................................................................432 Master Cylinder........................................................................437 Steer Cylinder.........................................................................443 Telescope Cylinder.....................................................................446 5.4 Pressure Setting Procedure.............................................................452 Main System Relief.....................................................................452 Steer Left Relief......................................................................452 Steer Right Relief.....................................................................453 Swing Relief...........................................................................453 Jib Lift Down Relief (460SJ HC3 only)..................................................454 Platform Level Up Relief...............................................................454 Platform Level Down Relief.............................................................455 5.5 Drive Pump Pre-Fill Procedure..........................................................464 5.6 Hydraulic Schematics...................................................................465 Section 6. JLG Control System..................................................................473 6.1 JLG Control System Analyzer Kit Instructions...........................................473 Introduction...........................................................................473 To Connect the JLG Control System Analyzer.............................................474 Using the Analyzer.....................................................................474 Changing the Access Level of the Hand Held Analyzer....................................475 Adjusting Parameters Using the Hand Held Analyzer......................................476 Machine Setup..........................................................................477 Tilt Sensor Calibration................................................................478 Ground Control Console Display Gauge...................................................481 6.2 LSS System.............................................................................506 Diagnostic Menu........................................................................507 Calibration Procedure..................................................................508 Testing & Evaluation...................................................................513 Troubleshooting........................................................................514 6.3 Resetting The MSSO System..............................................................515 6.4 Machine Model Adjustment...............................................................516 Adjustment Notes.......................................................................516 Machine Orientation When Performing Test...............................................517 Section 7. Basic Electrical Information & Schematics...........................................559 7.1 General................................................................................559 7.2 Multimeter Basics......................................................................559 Grounding..............................................................................559 Backprobing............................................................................559 Min/Max................................................................................559 Polarity...............................................................................559 Scale..................................................................................559 Voltage Measurement....................................................................559 Resistance Measurement.................................................................560 Continuity Measurement.................................................................560 Current Measurement....................................................................561 7.3 Applying Silicone Dielectric Compound to Electrical Connections........................561 7.4 Dielectric Grease Application..........................................................562 Installation...........................................................................562 AMP Mate-N-Lok.........................................................................562 AMP Faston.............................................................................562 AMP Micro-Fit..........................................................................562 AMP Mini Fit Jr........................................................................563 Mini Fit Sr............................................................................563 DIN Connectors.........................................................................563 Exceptions.............................................................................563 7.5 AMP Connector..........................................................................564 Assembly...............................................................................564 Disassembly............................................................................566 Wedge Lock.............................................................................566 Service - Voltage Reading..............................................................566 7.6 Deutsch Connectors.....................................................................568 DT/DTP Series Assembly.................................................................568 DT/DTP Series Disassembly..............................................................568 HD30/HDP20 Series Assembly.............................................................569 HD30/HDP20 Series Disassembly..........................................................569 7.7 Telematics Gateway.....................................................................570 Telematics-Ready (TCU) Plug............................................................570 7.8 Wiring Harness Connector Labels and Wiring Harnesses...................................579 Connector Labels.......................................................................579 Component Labels.......................................................................579 7.9 Electrical Harness.....................................................................581 7.10 Electrical Schematics.................................................................669
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