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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