JLG 400S 460SJ Service & Maintenance Manual (3120788) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 400S 460SJ Service & Maintenance Manual (3120788) – 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 Capacities.............................................................. 21 1.2 Engine Specifications................................................... 21 1.3 Tires................................................................... 22 1.4 Specifications and Performance Data..................................... 23 1.5 Torque Requirements..................................................... 24 1.6 Critical Stability Weights.............................................. 24 1.7 Major Component Weights................................................. 24 1.8 Function Speeds......................................................... 25 1.9 Pressure Settings - PSI (Bar)........................................... 25 1.10 Cylinder Specifications................................................ 25 1.11 Lubrication............................................................ 25 Hydraulic Oil........................................................... 25 1.12 Welder, Hydraulic (option)............................................. 26 1.13 Serial Number Location................................................. 26 1.14 Operator Maintenance and Lubrication................................... 27 Draining Oil Build Up From The Propane Regulator........................ 30 Propane Fuel Filter Replacement......................................... 31 Propane Fuel System Pressure Relief..................................... 32 Section 2. GENERAL.............................................................. 41 2.1 Machine Preparation, Inspection, and Maintenance........................ 41 General................................................................. 41 Preparation, Inspection, and Maintenance................................ 41 Pre-Start Inspection.................................................... 41 Pre-Delivery Inspection and Frequent Inspection......................... 41 Annual Machine Inspection............................................... 41 Preventative Maintenance................................................ 41 2.2 Service and Guidelines.................................................. 42 General................................................................. 42 Safety and Workmanship.................................................. 42 Cleanliness............................................................. 42 Components Removal and Installation..................................... 42 Component Disassembly and Reassembly.................................... 43 Pressure-Fit Parts...................................................... 43 Bearings................................................................ 43 Gaskets................................................................. 43 Bolt Usage and Torque Application....................................... 43 Hydraulic Lines and Electrical Wiring................................... 43 Hydraulic System........................................................ 43 Lubrication............................................................. 43 Battery................................................................. 43 Lubrication and Servicing............................................... 43 2.3 Lubrication and Information............................................. 43 Hydraulic System........................................................ 43 Hydraulic Oil........................................................... 44 Changing Hydraulic Oil.................................................. 44 Lubrication Specifications.............................................. 44 2.4 Cylinder Drift Test..................................................... 44 Platform Drift.......................................................... 44 Cylinder Drift.......................................................... 44 2.5 Pins and Composite Bearing Repair Guidelines............................ 45 2.6 Welding on JLG Equipment................................................ 45 Do the Following When Welding on JLG Equipment.......................... 45 Do NOT Do the Following When Welding on JLG Equipment................... 45 Section 3. CHASSIS & TURNTABLE.................................................. 55 3.1 Tires & Wheels.......................................................... 55 Tire Inflation.......................................................... 55 Tire Damage............................................................. 55 Tire Replacement........................................................ 55 Wheel Replacement....................................................... 55 Wheel Installation...................................................... 55 3.2 Drive Hub Part No. 2780243 (2wd Rear) Part No. 2780244 (4wd Rear)....... 56 Disassembly............................................................. 56 Disassembly of Cover Unit (8)........................................... 57 Disassembly of First Stage Planetary Assembly........................... 57 Disassembly of the Second Stage Planet Gears (1)........................ 57 Assembly of First Stage Planetary Assembly (7).......................... 57 Assembly Of End Cover Unit (8).......................................... 57 Final Assembly.......................................................... 57 3.3 Drive Hub Part No. 2780246 (4wd steer axle Prior to S/N 0300076633)..... 59 Disassembly............................................................. 59 Disassembly of Cover Unit (8)........................................... 59 Disassembly of First Stage Planetary Assembly........................... 59 Disassembly of the Second Stage Planet Gears (1)........................ 59 Assembly of First Stage Planetary Assembly (7).......................... 60 Assembly of End Cover Unit (8).......................................... 60 Final Assembly.......................................................... 60 3.4 Torque Hub - 4WD (Machines built after S/N 0300076633).................. 62 Roll and Leak Testing................................................... 62 Tightening and Torquing Bolts........................................... 62 Oil Information......................................................... 62 Main Disassembly for ”B” Drives......................................... 62 Hub-Spindle Disassembly................................................. 63 Cover Disassembly....................................................... 63 Carrier Disassembly..................................................... 63 Assembly of the Carrier................................................. 64 Cover Sub-Assembly...................................................... 66 Hub-Spindle Sub-Assembly................................................ 67 Main Assembly........................................................... 69 Tool List............................................................... 74 3.5 Re-Aligning Torque Hub Input Coupling................................... 75 Equipment Required...................................................... 75 Procedure............................................................... 75 3.6 Drive Brake............................................................. 76 Pre-Installation Checks................................................. 76 Installation............................................................ 77 Maintenance............................................................. 77 Disassembly............................................................. 77 Examination............................................................. 77 Assembly................................................................ 77 3.7 Drive Motor............................................................. 79 Description............................................................. 79 Shaft Seal Replacement.................................................. 79 Loop Flushing Valve..................................................... 80 Troubleshooting......................................................... 81 Disassembly............................................................. 82 Inspection.............................................................. 86 Assembly................................................................ 88 Initial Start-up Procedures............................................. 93 3.8 Adjustment Procedure For Lockout Valve.................................. 94 3.9 Toe-In Adjustment....................................................... 94 3.10 2WD Hub................................................................ 95 Removal & Disassembly................................................... 95 Cleaning & Inspection................................................... 95 Assembly & Installation................................................. 96 3.11 Oscillating Axle Bleeding Procedure.................................... 97 3.12 Oscillating Axle Lockout Test.......................................... 97 3.13 Swing Bearing.......................................................... 98 Turntable Bearing Mounting Bolt Condition Check......................... 98 Wear Tolerance.......................................................... 99 Replacement of Swing Bearing............................................100 Swing Bearing Torque Value..............................................101 Swing Drive Installation................................................101 3.14 Swing Brake (Prior to S/N 64802).......................................104 Installation............................................................104 Brake Disassembly.......................................................104 Assembly Information....................................................104 3.15 Swing Brake S/N 64802 to Present.......................................106 Disassembly.............................................................106 Assembly................................................................106 3.16 Swing Drive Torque Hub.................................................108 Disassembly Procedure...................................................108 Hub Shaft Sub-Assembly Procedure........................................112 Carrier Sub-Assembly Procedure..........................................114 3.17 Semi-Track.............................................................115 Testing the Track.......................................................115 Removing the Track......................................................116 Assuming Normal Wear....................................................116 Adjustment..............................................................116 3.18 Generator..............................................................120 Every 250 hours.........................................................120 Every 500 hours.........................................................120 Overload Protection.....................................................120 Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings..........120 3.19 Ford EFI Engine........................................................122 Performing Diagnostics..................................................122 Visual/Physical Engine Inspection Check.................................122 EFI Diagnostics (Prior to S/N 61718)....................................122 ECM AND SENSORS.........................................................123 Fuel System.............................................................129 3.20 Throttle Checks and Adjustments - Deutz Engine (Prior to S/N 61718)....133 General.................................................................133 Procedure...............................................................134 Controller Status.......................................................134 Failure Modes...........................................................134 3.21 Tilt Alarm Switch (Prior to S/N 61718).................................137 Manual Adjustment.......................................................137 3.22 Hydraulic Welder (225-4)...............................................140 Replacement of Weld Transformer.........................................140 Replacement of Hydraulic Motor..........................................140 Replacement of Fine Control.............................................140 Rotor Replacement.......................................................141 Replacement of Flow Regulator...........................................141 Replacement of Exciting Rectifier Bridge................................141 Replacement of Weld Rectifier Bridge....................................142 Replace Brushes on Sky Welder...........................................142 Replacing Range Switch..................................................142 Replacing Selector Switch...............................................142 Replacement of Couplings................................................143 Voltage Change Over - 120/240 Volt......................................143 3.23 Troubleshooting of the Sky Welder......................................144 Low Sky Welder Speed....................................................144 Low Welding Amps........................................................144 No Output on Weld Receptacles or AC Receptacles.........................144 No Ac Output but Weld Output............................................144 No Output on Weld Receptacle but AC Receptacle Output OK................148 Welder Completely Dead - No AC or Weld Power............................148 Intermittent Welder Operation...........................................148 3.24 Deutz EMR 2 (S/N 77682 to Present).....................................149 3.25 GM Engine General Maintenance..........................................162 Maintenance of the Drive Belt...........................................162 Engine Electrical System Maintenance....................................162 Checking/Filling Engine Oil Level.......................................162 Changing The Engine Oil.................................................163 Coolant Fill Procedure - Dual Fuel Engine...............................163 3.26 GM Engine Dual Fuel System.............................................165 Fuel Filter.............................................................165 Electric Lock Off.......................................................165 EPR Assembly............................................................166 Low Pressure Regulator (LPR)............................................166 Air Fuel Mixer..........................................................167 Electronic Throttle Control (ETC).......................................167 Engine Control Module...................................................168 Heated Exhaust Gas Oxygen Sensor........................................168 Gasoline Multi Point Fuel Injection System (MPFI).......................168 Gasoline Fuel Pump......................................................169 Gasoline Pressure And Temperature Sensor Manifold.......................169 Fuel Filter.............................................................169 Fuel Injector Rail......................................................169 Fuel Injector...........................................................169 3.27 GM Engine Fuel System Repair...........................................170 Propane Fuel System Pressure Relief.....................................170 Propane Fuel System Leak Test...........................................170 Propane Fuel Filter Replacement.........................................170 Electronic Pressure Regulator (EPR) Assembly Replacement................171 Temperature Manifold Absolute Pressure (TMAP) Sensor....................172 Electronic Throttle Control Replacement.................................173 Mixer Replacement.......................................................174 Coolant Hose Replacement................................................174 Vapor Hose Replacement..................................................174 Engine Control Module Replacement.......................................175 Heated Exhaust Gas Oxygen Sensor Replacement............................175 3.28 GM Engine LPG Fuel System Diagnosis....................................175 Fuel System Description.................................................175 Diagnostic Aids.........................................................176 3.29 Perkins Engine General Maintenance.....................................192 Replacing the Engine Crankcase Breather.................................192 Engine Oil Level - Check................................................192 Engine Oil and Filter - Change..........................................192 Fuel Filter/Water Separator.............................................194 Setting the Actuator....................................................195 Speed Sensor Installation...............................................196 3.30 Engine Radiator Fill Procedure - Perkins & Caterpillar.................196 3.31 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS....................198 Section Layout..........................................................198 List of Abbreviations in this Section...................................199 Fault Code Broadcast....................................................200 Diagnostic Trouble Codes................................................200 CAN.....................................................................200 MIL Output..............................................................201 Diagnostic Calibration Configuration and Corrective Actions.............201 Fault/Diagnostic Trouble Code Interaction...............................202 DBW Diagnostic Test.....................................................207 3.32 Diagnostic Trouble Code Fault Descriptions.............................208 DTC 116- ECT Higher Than Expected Stage 1...............................208 DTC 117- ECT/CHT Low Voltage............................................209 DTC 118- ECT/CHT High Voltage...........................................211 DTC 122- TPS1 Signal Voltage Low........................................213 DTC 123- TPS1 Signal Voltage High.......................................216 DTC 217- ECT Higher Than Expected 2.....................................218 DTC 219- RPM Higher Than Max Allowed Governed Speed.....................219 DTC 336- Crank Signal Input Noise.......................................220 DTC 337- Loss of Crank Input Signal.....................................222 DTC 521- Oil Pressure Sender/Switch High Pressure.......................223 DTC 524- Oil Pressure Low...............................................226 DTC 562- Battery Voltage (VBat) Low.....................................230 DTC 563- Battery Voltage (VBat) High....................................232 DTC 601- Microprocessor Failure - FLASH.................................234 DTC 604- Microprocessor Failure - RAM...................................236 DTC 606- Microprocessor Failure - COP...................................238 DTC 642- 5 Volt External Low Voltage....................................240 DTC 643- 5 Volt External High Voltage...................................242 DTC 1612- Microprocessor Failure - RTI 1................................244 DTC 1613- Microprocessor Failure - RTI 2................................245 DTC 1614- Microprocessor Failure - RTI 3................................247 DTC 1615- Microprocessor Failure - A/D..................................249 DTC 1616- Microprocessor Failure - interrupt............................251 DTC 1625- CAN J1939 Shutdown Request....................................253 DTC 1626- CAN J1939 Transmit (Tx) Fault.................................254 DTC 1627- CAN J1939 Receive (Rx) Fault..................................255 DTC 1628- CAN Address Conflict Failure..................................256 DTC 1629- J1939 TSC1 Message Reciept Loss...............................258 DTC 1652- TPS1 Loss of Communications...................................259 DTC 2111- Unable to Reach Lower TPS.....................................260 DTC 2112- Unable to Reach Higher TPS....................................262 DTC 9999- Throttle Actuator Failsafe Spring Failure.....................263 DTC to SPN/FMI Table....................................................264 Section 4. BOOM & PLATFORM......................................................267 4.1 Boom....................................................................267 Removal.................................................................267 Disassembly.............................................................268 Inspection..............................................................269 Assembly................................................................270 Installation............................................................271 4.2 Articulating jib........................................................272 Removal.................................................................272 4.3 Limit Switch Adjustments................................................272 Boom Horizontal Limit Switch............................................272 Dual Capacity Angle Limit Switch........................................272 Boom Length Limit Switch................................................272 4.4 Drive Card Setup Procedures.............................................276 Machine Orientation When Doing Speed Tests..............................276 Test Notes..............................................................276 Lift, Swing, and Drive Cards............................................277 Flow Control Card.......................................................277 4.5 Helac Rotary actuator...................................................279 Theory Of Operation.....................................................279 Tools Required for Assembly/Disassembly.................................282 Disassembly.............................................................282 Inspection..............................................................286 Assembly................................................................286 Installing Counterbalance Valve.........................................289 Section 5. HYDRAULICS...........................................................291 5.1 Cylinders - Theory of Operation.........................................291 Systems Incorporating Double Acting Cylinders...........................291 Systems Incorporating Holding Valves....................................291 5.2 Cylinder Repair.........................................................291 Cylinders Without Counterbalance Valves.................................291 Cylinders With Dual Counterbalance Valves...............................291 Disassembly.............................................................292 Cleaning and Inspection.................................................293 Assembly................................................................294 5.3 Valves - Theory of Operation............................................304 Solenoid Control Valve..................................................304 Relief Valves...........................................................307 5.4 Pressure Setting Procedures.............................................307 1. Bang-Bang Main Relief Valve;.........................................307 2. Steer;...............................................................307 3. Platform Level Up;...................................................307 4. Platform Level Down;.................................................307 5. Articulating Jib Up;.................................................307 6. Articulating Jib Down;...............................................308 7. The Bang-Bang Main Relief Valve;.....................................308 8. The Proportional Main Relief Valve;..................................308 9. Lift Down;...........................................................308 10. Swing;..............................................................308 5.5 Hydraulic Motor Repair (H Series Char-lynn).............................308 Disassembly.............................................................308 Reassembly Shaft End....................................................310 Gerotor End.............................................................312 Timing Procedure........................................................313 Standard Rotation.......................................................313 Reverse Rotation........................................................313 5.6 Hydraulic Pump “Neutral” Or Null Adjustment.............................316 5.7 Non-feedback, Proportional Electrical Control - NFPE....................316 Features and Benefits of the NFPE Control...............................316 Input Signal requirements...............................................316 5.8 Hydraulic Component Start-Up Procedures and Recommendations.............317 Section 6. JLG CONTROL SYSTEM (S/N 61718 to Present)............................319 6.1 Introduction............................................................319 6.2 To Connect the JLG Control System Analyzer..............................321 6.3 Using the Analyzer......................................................321 6.4 Changing the Access Level of the Hand Held Analyzer.....................323 6.5 Adjusting Parameters Using the Hand Held Analyzer.......................325 6.6 Machine Setup...........................................................326 6.7 Level Vehicle Description...............................................326 6.8 Machine Personality Settings............................................335 6.9 System Test.............................................................380 Test from the Platform..................................................380 Test from the Ground Station............................................382 6.10 Analyzer Diagnostics Menu Structure....................................399 Section 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS............................405 7.1 General.................................................................405 7.2 Multimeter Basics.......................................................405 Grounding...............................................................405 Backprobing.............................................................405 Min/Max.................................................................405 Polarity................................................................405 Scale...................................................................405 Voltage Measurement.....................................................405 Resistance Measurement..................................................406 Continuity Measurement..................................................406 Current Measurement.....................................................407 7.3 Checking Switches.......................................................407 Basic Check.............................................................407 Limit Switches..........................................................407 Automatic Switches......................................................408 Switch Wiring - Low Side, High Side.....................................408 7.4 Applying Silicone Dielectric Compound to Electrical Connections.........408 Installation of Dielectric Grease.......................................409 Deutsch HD, DT, DTM, DRC Series.........................................409 AMP Seal................................................................409 AMP Mate-N-Lok..........................................................410 DIN Connectors..........................................................410 Exclusions..............................................................410 7.5 AMP Connector...........................................................412 Applying Silicone Dielectric Compound to AMP Connectors.................412 Assembly................................................................412 Disassembly.............................................................414 Wedge Lock..............................................................414 Service - Voltage Reading...............................................414 7.6 Deutsch Connectors......................................................416 DT/DTP Series Assembly..................................................416 DT/DTP Series Disassembly...............................................416 HD30/HDP20 Series Assembly..............................................417 HD30/HDP20 Series Disassembly...........................................417
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
S.M