JLG 400SC 460SJC Service and Maintenance Manual (3121705) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 400SC 460SJC Service and Maintenance Manual (3121705) – PDF DOWNLOAD
Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS....................................... 3
A General.................................................................................. 3
B Hydraulic System Safety.................................................................. 3
C Maintenance.............................................................................. 3
Section 1. Specifications...................................................................... 19
1.1 Operating Specifications............................................................... 19
1.2 Capacities............................................................................. 20
1.3 Engine Data............................................................................ 20
1.4 Hydraulic Oil.......................................................................... 21
1.5 Critical Stability Weights............................................................. 22
1.6 Maintenance and Lubrication............................................................ 23
Section 2. General............................................................................. 35
2.1 Machine Preparation, Inspection, and Maintenance....................................... 35
General................................................................................ 35
Preparation, Inspection, and Maintenance............................................... 35
Pre-Start Inspection................................................................... 35
Pre-Delivery Inspection and Frequent Inspection........................................ 35
Annual Machine Inspection.............................................................. 35
Preventive Maintenance................................................................. 35
2.2 Service and Guidelines................................................................. 36
General................................................................................ 36
Safety and Workmanship................................................................. 36
Cleanliness............................................................................ 36
Components Removal and Installation.................................................... 36
Component Disassembly and Reassembly................................................... 37
Pressure-Fit Parts..................................................................... 37
Bearings............................................................................... 37
Gaskets................................................................................ 37
Bolt Usage and Torque Application...................................................... 37
Hydraulic Lines and Electrical Wiring.................................................. 37
Hydraulic System....................................................................... 37
Lubrication............................................................................ 37
Battery................................................................................ 37
Lubrication and Servicing.............................................................. 37
2.3 Lubrication and Information............................................................ 38
Hydraulic System....................................................................... 38
Hydraulic Oil.......................................................................... 38
Changing Hydraulic Oil................................................................. 38
Lubrication Specifications............................................................. 38
2.4 Cylinder Drift......................................................................... 38
Theory................................................................................. 38
Cylinder Leakage Test.................................................................. 39
Cylinder Thermal Drift................................................................. 39
2.5 Pins and Composite Bearing Repair Guidelines........................................... 39
2.6 Welding on JLG Equipment............................................................... 39
Do the Following When Welding on JLG Equipment......................................... 39
Do NOT Do the Following When Welding on JLG Equipment.................................. 39
Section 3. Chassis & Turntable................................................................. 47
3.1 Chassis Components and Servicing....................................................... 47
Track Tension.......................................................................... 48
Replace Rubber Track................................................................... 49
Replace Steel Track.................................................................... 51
Track Shoes............................................................................ 54
Track Pin.............................................................................. 54
Sprocket Wear.......................................................................... 54
3.2 Chassis Tilt Indicator System.......................................................... 54
3.3 Swing Drive Hub........................................................................ 54
Brake Test............................................................................. 55
Spring Checking Procedure.............................................................. 55
Brake Leak Repair Procedure............................................................ 56
Roll and Leak Test..................................................................... 56
Tightening and Torquing Bolts.......................................................... 57
Lubrication Information................................................................ 58
Motor Removal.......................................................................... 58
Input Brake Disassembly................................................................ 60
Main Disassembly....................................................................... 61
Housing-Shaft Disassembly.............................................................. 62
Carrier Disassembly.................................................................... 63
Carrier Assembly....................................................................... 64
Housing - Shaft Assembly............................................................... 66
Main Assembly.......................................................................... 67
Motor and Brake Assembly............................................................... 69
Motor Control Valve Installation....................................................... 71
3.4 Swing Motor............................................................................ 80
Disassembly and inspection............................................................. 80
Assembly............................................................................... 87
One Piece Stator Construction.......................................................... 94
3.5 Swing Bearing.......................................................................... 95
Swing Bearing Wear Tolerance........................................................... 95
Turntable Bearing Mounting Bolt Condition Check........................................ 96
Swing Bearing Removal.................................................................. 99
Swing Bearing Installation............................................................. 99
3.6 Setting Swing Gear Backlash............................................................100
3.7 Swing Bearing Torque Values............................................................101
3.8 Rotary Coupling........................................................................103
3.9 Generator..............................................................................108
Maintenance Schedule...................................................................108
Overload Protection....................................................................108
Inspecting Brushes, Replacing Brushes and Cleaning Slip Rings..........................108
Generator Disassembly and Assembly.....................................................110
Lead Connection List for Generator.....................................................117
3.10 Deutz Engine (D2011l03) - T4i.........................................................118
Checking Oil Level.....................................................................122
Changing Engine Oil....................................................................122
Changing Oil Filter....................................................................123
Replace Fuel Filter....................................................................123
Clean Fuel Strainer....................................................................124
3.11 Deutz Engine (D2.9L4) - T4f...........................................................125
Check Oil Level........................................................................129
Change Engine Oil......................................................................129
Change Oil Filter......................................................................130
Change Fuel Filters....................................................................130
3.12 Engine Fault Codes....................................................................131
Section 4. Boom & Platform.....................................................................185
4.1 Boom Systems...........................................................................185
Platform Control Enable System.........................................................185
Platform Load Sensing System (LSS) (If Equipped).......................................185
Above Elevation (Above Horizontal) - Drive Speed Cutback System........................185
Transport Position Interlock System....................................................185
Function Speed Control System..........................................................185
Emergency Decent System................................................................185
Main Boom Lift End of Stroke Damping...................................................186
Jib Lift End of Stroke Damping.........................................................186
Machine Safety Override (MSSO) (CE Market Only)........................................186
Transport Position Sensing System......................................................186
Dual Capacity Selection and Indicator System...........................................190
4.2 Platform...............................................................................192
Platform/Support Removal...............................................................192
Platform/Support Installation..........................................................193
4.3 Main Boom Powertrack...................................................................196
Removal................................................................................196
Installation...........................................................................196
Powertrack Maintenance.................................................................198
4.4 Boom Maintenance.......................................................................207
Removal - 400SC........................................................................207
Removal - 460SJC.......................................................................211
Disassembly............................................................................215
Inspection.............................................................................217
Assembly...............................................................................217
Installation...........................................................................218
4.5 Jib - 460SJC...........................................................................218
4.6 Boom Cleanliness Guidelines............................................................219
4.7 Boom Shimming Procedure................................................................220
4.8 Rotary Actuator........................................................................225
Theory of Operation....................................................................225
Required Tools.........................................................................225
Disassembly............................................................................227
Inspection.............................................................................231
Assembly...............................................................................232
Installing Counterbalance Valve........................................................ 0
4.9 Skyguard...............................................................................237
Operation..............................................................................237
Function Test..........................................................................237
Diagnostics & Troubleshooting..........................................................238
4.10 Platform Rotate Bleed Procedure.......................................................239
General Notes & Precautions............................................................239
Procedure..............................................................................239
Section 5. Hydraulics and Hydraulic Schematics.................................................241
5.1 O-Ring Lubrication.....................................................................241
Cup and Brush..........................................................................241
Dip Method.............................................................................242
Spray Method...........................................................................242
Brush-on Method........................................................................242
5.2 Hydraulic Connection Assembly and Torque Specification.................................243
Tapered Thread Types...................................................................243
Straight Thread Types, Tube and Hose Connections.......................................243
Straight Thread Types, Port Connections................................................244
Flange Connection Types................................................................244
Tightening Methods.....................................................................244
Assembly And Torque Specifications.....................................................245
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections.....246
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections......247
Assembly Instructions for 37° (JIC) Flare Fittings.....................................248
Assembly Instructions for 45° SAE Flare Fittings.......................................251
Assembly Instructions for O-ring Face Seal (ORFS) Fittings.............................253
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS).............255
Assembly Instructions for Bulkhead (BH) Fittings.......................................257
Assembly Instructions for O-ring Boss (ORB) Fittings...................................260
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings....................267
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends................274
Assembly instructions for Adjustable Port End (BSPP) Fittings..........................276
Assembly Instructions for Flange Connections: (FL61 and FL62)..........................283
Double Wrench Method...................................................................286
FFWR and TFFT Methods..................................................................287
Adjustable Stud End Assembly...........................................................287
O-ring Installation (Replacement)......................................................288
5.3 Hydraulic Cylinders....................................................................289
Lift Cylinder..........................................................................291
Master Cylinder........................................................................297
Telescope Cylinder.....................................................................302
Jib Lift Cylinder (460SJC Only)........................................................309
Platform Level Cylinder................................................................315
5.4 Hydraulic System Installation..........................................................320
5.5 Pressure Setting Procedure.............................................................351
Main System Relief.....................................................................351
Steer Left Relief......................................................................351
Steer Right Relief.....................................................................352
Boom Swing Relief......................................................................352
Jib Lift Down Relief (460SJC)..........................................................353
Platform Level Up Relief...............................................................353
Platform Level Down Relief.............................................................354
5.6 Drive Pump Pre-Fill Procedure..........................................................361
5.7 Hydraulic Schematic....................................................................362
Section 6. JLG Control System..................................................................367
6.1 JLG Control System Analyzer Kit Instructions...........................................367
Introduction...........................................................................367
To Connect the JLG Control System Analyzer.............................................368
Using the Analyzer.....................................................................368
Changing the Access Level of the Hand Held Analyzer....................................369
Adjusting Parameters Using Hand Held Analyzer..........................................370
Machine Setup..........................................................................371
Ground Control Console Display Gauge...................................................372
6.2 LSS System.............................................................................399
Diagnostic Menu........................................................................400
Calibration Procedure..................................................................401
Testing & Evaluation...................................................................406
Troubleshooting........................................................................407
6.3 Resetting The MSSO System..............................................................408
6.4 Machine Model Adjustment...............................................................410
Adjustment Notes.......................................................................410
Machine Orientation When Performing Test...............................................410
6.5 System Test............................................................................416
Test from the Platform.................................................................416
Test from the Ground Station...........................................................418
6.6 System Test Messages...................................................................420
6.7 Machine Diagnostics Parameters.........................................................422
6.8 Machine Fault Codes....................................................................434
6.9 Tilt Sensor Calibration................................................................461
6.10 Calibrating Boom Angle................................................................465
6.11 Calibrating Load Sensing..............................................................469
Section 7. Basic Electrical Information & Electrical Schematics................................473
7.1 General................................................................................473
7.2 Multimeter Basics......................................................................473
Grounding..............................................................................473
Backprobing............................................................................473
Min/Max................................................................................473
Polarity...............................................................................473
Scale..................................................................................473
Voltage Measurement....................................................................473
Resistance Measurement.................................................................474
Continuity Measurement.................................................................474
Current Measurement....................................................................475
7.3 Applying Silicone Dielectric Compound to Electrical Connections........................475
Installation of Dielectric Grease......................................................476
Deutsch HD, DT, DTM, DRC Series........................................................476
AMP Seal...............................................................................476
AMP Mate-N-Lok.........................................................................477
DIN Connectors.........................................................................477
Exclusions.............................................................................477
7.4 AMP Connector..........................................................................479
Assembly...............................................................................479
Disassembly............................................................................481
Wedge Lock.............................................................................481
Service - Voltage Reading..............................................................481
7.5 Deutsch Connectors.....................................................................483
DT/DTP Series Assembly.................................................................483
DT/DTP Series Disassembly..............................................................483
HD30/HDP20 Series Assembly.............................................................484
HD30/HDP20 Series Disassembly..........................................................484
7.6 Wiring Harness.........................................................................485
Connector Labels.......................................................................485
Component Labels.......................................................................485
7.7 Electrical Installation................................................................487
7.8 Wiring Harness Connector Label Diagrams................................................491
7.9 Electrical Schematics..................................................................561
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JLG 400SC 460SJC Service and Maintenance Manual (3121705) – PDF DOWNLOADJLG 400SC 460SJC Service and Maintenance Manual (3121705) – PDF DOWNLOAD
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