JLG 400SC 460SJC PVC 2001 Service and Maintenance Manual (31215019) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 400SC 460SJC PVC 2001 Service and Maintenance Manual (31215019) – PDF DOWNLOAD
31215019 _B_400SC, 460SJC_JLG_Service_English...................................................... 1
Table of Contents.............................................................................. 5
List of Figures................................................................................ 11
List of Tables................................................................................. 19
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
1.2 Capacities............................................................................. 22
1.3 Engine Data............................................................................ 22
1.4 Hydraulic Oil.......................................................................... 23
1.5 Critical Stability Weights............................................................. 24
1.6 Maintenance and Lubrication............................................................ 27
1.7 Threadlocking Compound................................................................. 31
1.8 Torque Charts.......................................................................... 32
SAE Fastener Torque Chart.............................................................. 32
SAE Fastener Torque Chart (Continued).................................................. 33
SAE Fastener Torque Chart (Continued).................................................. 34
SAE Fastener Torque Chart (Continued).................................................. 35
SAE Fastener Torque Chart (Continued).................................................. 36
SAE Fastener Torque Chart (Continued).................................................. 37
Metric Fastener Torque Chart........................................................... 38
Metric Fastener Torque Chart (Continued)............................................... 39
Metric Fastener Torque Chart (Continued)............................................... 40
Metric Fastener Torque Chart (Continued)............................................... 41
Section 2. General............................................................................. 43
2.1 Machine Preparation, Inspection and Maintenance........................................ 43
General................................................................................ 43
Preparation, Inspection, and Maintenance............................................... 43
Pre-Start Inspection................................................................... 43
Pre-Delivery Inspection and Frequent Inspection........................................ 43
Annual Machine Inspection.............................................................. 43
Preventive Maintenance................................................................. 43
2.2 Service and Guidelines................................................................. 44
General................................................................................ 44
Safety and Workmanship................................................................. 44
Cleanliness............................................................................ 44
Components Removal and Installation.................................................... 44
Component Disassembly and Reassembly................................................... 45
Pressure-Fit Parts..................................................................... 45
Bearings............................................................................... 45
Gaskets................................................................................ 45
Bolt Usage and Torque Application...................................................... 45
Hydraulic Lines and Electrical Wiring.................................................. 45
Hydraulic System....................................................................... 45
Lubrication............................................................................ 45
Battery................................................................................ 45
Lubrication and Servicing.............................................................. 45
2.3 Lubrication and Information............................................................ 46
Hydraulic System....................................................................... 46
Hydraulic Oil.......................................................................... 46
Changing Hydraulic Oil................................................................. 46
Lubrication Specifications............................................................. 46
2.4 Cylinder Drift......................................................................... 46
Theory................................................................................. 46
Cylinder Leakage Test.................................................................. 47
Cylinder Thermal Drift................................................................. 47
2.5 Pins and Composite Bearing Repair Guidelines........................................... 47
2.6 Welding on JLG Equipment............................................................... 47
Do the Following When Welding on JLG Equipment......................................... 47
Do Not Do the Following When Welding on JLG Equipment.................................. 47
Section 3. Chassis & Turntable................................................................. 55
3.1 Chassis Components and Servicing....................................................... 55
Track Tension.......................................................................... 56
Replace Rubber Track................................................................... 57
Replace Steel Track.................................................................... 59
Track Shoes............................................................................ 62
Track Pin.............................................................................. 62
Sprocket Wear.......................................................................... 62
3.2 Chassis Tilt Indicator System.......................................................... 62
3.3 Swing Drive Hub........................................................................ 62
Brake Test............................................................................. 63
Spring Checking Procedure.............................................................. 63
Brake Leak Repair Procedure............................................................ 64
Roll and Leak Test..................................................................... 64
Tightening and Torquing Bolts.......................................................... 65
Lubrication Information................................................................ 66
Motor Removal.......................................................................... 66
Input Brake Disassembly................................................................ 68
Main Disassembly....................................................................... 69
Housing-Shaft Disassembly.............................................................. 70
Carrier Disassembly.................................................................... 71
Carrier Assembly....................................................................... 72
Housing - Shaft Assembly............................................................... 74
Main Assembly.......................................................................... 75
Motor and Brake Assembly............................................................... 77
Motor Control Valve Installation....................................................... 79
3.4 Swing Motor............................................................................ 88
Disassembly and Inspection............................................................. 88
Assembly............................................................................... 95
One Piece Stator Construction..........................................................102
3.5 Swing Bearing..........................................................................103
Swing Bearing Wear Tolerance...........................................................103
Turntable Bearing Mounting Bolt Condition Check........................................104
Swing Bearing Removal..................................................................107
Swing Bearing Installation.............................................................107
3.6 Setting Swing Gear Backlash............................................................108
3.7 Swing Bearing Torque Values............................................................109
3.8 Rotary Coupling........................................................................111
3.9 Generator and Pulley...................................................................116
3.10 Generator.............................................................................122
Maintenance Schedule...................................................................122
Overload Protection....................................................................122
Inspecting Brushes, Replacing Brushes and Cleaning Slip Rings..........................122
Generator Disassembly and Assembly.....................................................124
Lead Connection List for Generator.....................................................132
3.11 Deutz Engine (D2011L03) - T4i.........................................................133
Checking Oil Level.....................................................................137
Changing Engine Oil....................................................................137
Changing Oil Filter....................................................................138
Replace Fuel Filter....................................................................138
Clean Fuel Strainer....................................................................139
Deutz EMR 2............................................................................140
3.12 Deutz Engine (D2.9L4) - T4f...........................................................152
Check Oil Level........................................................................156
Change Engine Oil......................................................................156
Change Oil Filter......................................................................157
Change Fuel Filters....................................................................157
3.13 Deutz Engine (D2.9L4) - Stage V.......................................................158
General Maintenance....................................................................162
Check Oil Level........................................................................162
Replacing Engine Oil...................................................................162
Replacing the Oil Filter...............................................................162
Replacing the Fuel Filters.............................................................163
Deutz EMR5.............................................................................164
3.14 HRC Engine Emission Characteristics...................................................191
Terminology for Removing Soot..........................................................191
3.15 Diesel Particulate Filter (If Equipped)...............................................191
Standstill Cleaning....................................................................191
Maintenance Standstill Cleaning Initiation Methods.....................................192
Canceling Maintenance Standstill.......................................................192
Unsuccessful Cleaning Event............................................................192
DPF Filter Replacement due to Ash Load.................................................193
3.16 Engine Fault Codes....................................................................195
Section 4. Boom & Platform.....................................................................249
4.1 Boom Systems...........................................................................249
Platform Control Enable System.........................................................249
Platform Load Sensing System (LSS).....................................................249
Above Elevation (Above Horizontal) - Drive Speed Cutback System........................249
Transport Position Interlock System (CE Only)..........................................249
Function Speed Control System..........................................................249
Emergency Decent System................................................................249
Main Boom Lift End of Stroke Damping...................................................250
Jib Lift End of Stroke Damping.........................................................250
Machine Safety Override (MSSO) - (CE Market Only)......................................250
Transport Position Sensing System......................................................250
Dual Capacity Selection and Indicator System...........................................254
4.2 Platform...............................................................................256
Platform/Support Removal...............................................................256
Platform/Support Installation..........................................................257
4.3 Main Boom Powertrack...................................................................259
Removal................................................................................259
Installation...........................................................................259
Powertrack Maintenance.................................................................261
4.4 Boom Maintenance.......................................................................270
Removal - 400SC........................................................................270
Removal - 460SJC.......................................................................274
Disassembly............................................................................278
Inspection.............................................................................280
Assembly...............................................................................280
Installation...........................................................................281
4.5 Jib - 460SJC...........................................................................281
4.6 Boom Cleanliness Guidelines............................................................282
4.7 Boom Shimming Procedure................................................................283
4.8 Rotary Actuator........................................................................288
Theory of Operation....................................................................288
Required Tools.........................................................................288
Disassembly............................................................................290
Inspection.............................................................................294
Assembly...............................................................................295
Installing Counterbalance Valve........................................................ 0
4.9 Skyguard...............................................................................300
Operation..............................................................................300
Function Test..........................................................................300
Diagnostics & Troubleshooting..........................................................301
4.10 Platform Rotate Bleed Procedure.......................................................302
General Notes & Precautions............................................................302
Procedure..............................................................................302
Section 5. Hydraulics and Hydraulic Schematics.................................................303
5.1 O-Ring Lubrication.....................................................................303
Cup and Brush..........................................................................303
Dip Method.............................................................................304
Spray Method...........................................................................304
Brush-on Method........................................................................304
5.2 Hydraulic Connection Assembly and Torque Specification.................................305
Tapered Thread Types...................................................................305
Straight Thread Types, Tube and Hose Connections.......................................305
Straight Thread Types, Port Connections................................................306
Flange Connection Types................................................................306
Tightening Methods.....................................................................306
Assembly And Torque Specifications.....................................................307
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections.....308
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections......309
Assembly Instructions for 37° (JIC) Flare Fittings.....................................310
Assembly Instructions for 45° SAE Flare Fittings.......................................314
Assembly Instructions for O-ring Face Seal (ORFS) Fittings.............................316
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS).............318
Assembly Instructions for Bulkhead (BH) Fittings.......................................320
Assembly Instructions for O-ring Boss (ORB) Fittings...................................324
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings....................332
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends................340
Assembly instructions for Adjustable Port End (BSPP) Fittings..........................342
Assembly Instructions for Flange Connections: (FL61 and FL62)..........................350
Double Wrench Method...................................................................353
FFWR and TFFT Methods..................................................................354
Adjustable Stud End Assembly...........................................................354
O-ring Installation (Replacement)......................................................355
5.3 Hydraulic Cylinders....................................................................356
Disassembly and Assembly Instructions..................................................358
General Information....................................................................358
Inspection After Assembly..............................................................358
Standard of Maintenance................................................................358
Value of Oil Leakage at Rod Area.......................................................359
5.4 Main Lift, Telescope and Jib Lift Cylinder.............................................360
Disassembly............................................................................360
Assembly...............................................................................362
Master Cylinder........................................................................367
Platform Level Cylinder................................................................372
5.5 Hydraulic System Installation..........................................................377
5.6 Pressure Setting Procedure.............................................................408
Main System Relief.....................................................................408
Steer Left Relief......................................................................408
Steer Right Relief.....................................................................409
Boom Swing Relief......................................................................409
Jib Lift Down Relief (460SJC)..........................................................410
Platform Level Up Relief...............................................................410
Platform Level Down Relief.............................................................411
5.7 Drive Pump Pre-Fill Procedure..........................................................418
5.8 Hydraulic Schematic....................................................................420
Section 6. JLG Control System..................................................................425
6.1 JLG Control System Analyzer Kit Instructions...........................................425
Introduction...........................................................................425
To Connect the JLG Control System Analyzer.............................................426
Using the Analyzer.....................................................................426
Changing the Access Level of the Hand Held Analyzer....................................427
Adjusting Parameters Using Hand Held Analyzer..........................................428
Machine Setup..........................................................................429
Ground Control Console Display Gauge...................................................430
6.2 LSS System.............................................................................459
Diagnostic Menu........................................................................464
Calibration Procedure..................................................................465
Testing & Evaluation...................................................................470
Troubleshooting........................................................................471
6.3 Resetting The MSSO System..............................................................472
6.4 Machine Model Adjustment...............................................................474
Adjustment Notes.......................................................................474
Machine Orientation When Performing Test...............................................474
6.5 System Test............................................................................480
Test from the Platform.................................................................480
Test from the Ground Station...........................................................482
6.6 System Test Messages...................................................................484
6.7 Machine Diagnostics Parameters.........................................................486
6.8 Machine Fault Codes....................................................................498
6.9 Tilt Sensor Calibration................................................................525
6.10 Calibrating Boom Angle................................................................529
6.11 Calibrating Load Sensing..............................................................533
Section 7. Basic Electrical Information & Electrical Schematics................................537
7.1 General................................................................................537
7.2 Multimeter Basics......................................................................537
Grounding..............................................................................537
Backprobing............................................................................537
Min/Max................................................................................537
Polarity...............................................................................537
Scale..................................................................................537
Voltage Measurement....................................................................537
Resistance Measurement.................................................................538
Continuity Measurement.................................................................538
Current Measurement....................................................................539
7.3 Applying Silicone Dielectric Compound to Electrical Connections........................539
7.4 Dielectric Grease Application..........................................................540
Installation...........................................................................540
AMP Mate-N-Lok.........................................................................540
AMP Faston.............................................................................540
AMP Micro-Fit..........................................................................540
AMP Mini Fit Jr........................................................................541
Mini Fit Sr............................................................................541
DIN Connectors.........................................................................541
Exceptions.............................................................................541
7.5 AMP Connector..........................................................................542
Assembly...............................................................................542
Disassembly............................................................................544
Wedge Lock.............................................................................544
Service - Voltage Reading..............................................................544
7.6 Deutsch Connectors.....................................................................546
DT/DTP Series Assembly.................................................................546
DT/DTP Series Disassembly..............................................................546
HD30/HDP20 Series Assembly.............................................................547
HD30/HDP20 Series Disassembly..........................................................547
7.7 Wiring Harness.........................................................................548
Connector Labels.......................................................................548
Component Labels.......................................................................548
7.8 Electrical Installation................................................................550
7.9 Wiring Harness Connector Label Diagrams................................................557
7.10 Electrical Schematics.................................................................667
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JLG 400SC 460SJC PVC 2001 Service and Maintenance Manual (31215019) – PDF DOWNLOADJLG 400SC 460SJC PVC 2001 Service and Maintenance Manual (31215019) – PDF DOWNLOAD
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