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JLG 400SC 460SJC PVC 2007 Service and Maintenance Manual (31217143 
JLG 400SC 460SJC PVC 2007 Service and Maintenance Manual (31217143
JLG 400SC 460SJC PVC 2007 Service and Maintenance Manual (31217143) – PDF DOWNLOAD Eng
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JLG 400SC 460SJC PVC 2007 Service and Maintenance Manual (31217143) – PDF DOWNLOAD
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JLG 400SC 460SJC PVC 2007 Service and Maintenance Manual (31217143) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 400SC 460SJC PVC 2007 Service and Maintenance Manual (31217143) – PDF DOWNLOAD
31217143 _A_400SC, 460SJC_JLG_Service_English...................................................... 1 Section A. Introduction - Maintenance Safety Precautions....................................... 3 A General.................................................................................. 3 B Hydraulic System Safety.................................................................. 3 C Maintenance.............................................................................. 3 Table of Contents.............................................................................. 5 List of Figures................................................................................ 11 List of Tables................................................................................. 19 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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