JLG 400S 460SJ Service & Maintenance Manual (3121671) – PDF DOWNLOAD Eng
TABLE OF CONTENTS:
JLG 400S 460SJ Service & Maintenance Manual (3121671) – PDF DOWNLOAD
3121671_E_400S, 460SJ_JLG_Service_English.............................................................. 1 Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS........................................... 3 A General...................................................................................... 3 B Hydraulic System Safety...................................................................... 3 C Maintenance.................................................................................. 3 Section 1. Specifications.......................................................................... 23 1.1 Operating Specifications................................................................... 23 1.2 Capacities................................................................................. 24 1.3 Engine Data................................................................................ 24 1.4 Tires...................................................................................... 25 1.5 Hydraulic Oil.............................................................................. 25 1.6 Critical Stability Weights................................................................. 27 1.7 Maintenance and Lubrication................................................................ 32 Section 2. General................................................................................. 45 2.1 Machine Preparation, Inspection, and Maintenance........................................... 45 General.................................................................................... 45 Preparation, Inspection, and Maintenance................................................... 45 Pre-Start Inspection....................................................................... 45 Pre-Delivery Inspection and Frequent Inspection............................................ 45 Annual Machine Inspection.................................................................. 45 Preventive Maintenance..................................................................... 45 2.2 Service and Guidelines..................................................................... 46 General.................................................................................... 46 Safety and Workmanship..................................................................... 46 Cleanliness................................................................................ 46 Components Removal and Installation........................................................ 46 Component Disassembly and Reassembly....................................................... 47 Pressure-Fit Parts......................................................................... 47 Bearings................................................................................... 47 Gaskets.................................................................................... 47 Bolt Usage and Torque Application.......................................................... 47 Hydraulic Lines and Electrical Wiring...................................................... 47 Hydraulic System........................................................................... 47 Lubrication................................................................................ 47 Battery.................................................................................... 47 Lubrication and Servicing.................................................................. 47 2.3 Lubrication and Information................................................................ 48 Hydraulic System........................................................................... 48 Hydraulic Oil.............................................................................. 48 Changing Hydraulic Oil..................................................................... 48 Lubrication Specifications................................................................. 48 2.4 Cylinder Drift Test........................................................................ 49 Theory..................................................................................... 49 Cylinder Leakage Test...................................................................... 49 Cylinder Thermal Drift..................................................................... 49 2.5 Pins and Composite Bearing Repair Guidelines............................................... 50 2.6 Welding on JLG Equipment................................................................... 50 Do the Following When Welding on JLG Equipment............................................. 50 Do NOT Do the Following When Welding on JLG Equipment...................................... 50 Section 3. Chassis & Turntable..................................................................... 59 3.1 Tires and Wheels........................................................................... 59 Tire Inflation............................................................................. 59 Tire Damage................................................................................ 59 Tire Replacement........................................................................... 59 Wheel Replacement.......................................................................... 59 Wheel Installation......................................................................... 59 3.2 Chassis Tilt Indicator System.............................................................. 60 3.3 Drive System (4WD & 2WD)................................................................... 60 3.4 Drive Orientation System................................................................... 60 3.5 Lockout Cylinder Bleeding.................................................................. 60 3.6 Oscillating Axle System.................................................................... 61 3.7 Oscillating Axle Lockout Test.............................................................. 61 3.8 Wheel Drive Assembly....................................................................... 65 Removal.................................................................................... 65 Installation............................................................................... 65 3.9 Torque Hub................................................................................. 66 Roll and Leak Testing...................................................................... 66 Tightening and Torquing Bolts.............................................................. 66 Main Disassembly for “B” Drives............................................................ 67 Hub-Spindle Disassembly.................................................................... 67 Cover Disassembly.......................................................................... 73 Carrier Disassembly........................................................................ 73 Assemble Carrier........................................................................... 73 Cover Sub-Assembly......................................................................... 75 Hub-Spindle Sub-Assembly................................................................... 76 Main Assembly.............................................................................. 78 Tool List.................................................................................. 83 3.10 Re-Align Torque Hub Input Coupling........................................................ 84 Equipment Required......................................................................... 84 Procedure.................................................................................. 84 3.11 Drive Motor............................................................................... 84 Description................................................................................ 84 Shaft Seal Replacement..................................................................... 85 Loop Flushing Valve........................................................................ 85 Troubleshooting............................................................................ 86 Disassembly................................................................................ 87 Inspection................................................................................. 91 Assembly................................................................................... 93 Initial Start-Up Procedures................................................................ 97 3.12 Swing Drive Hub........................................................................... 99 Brake Test................................................................................. 99 Spring Checking Procedure..................................................................100 Brake Leak Repair Procedure................................................................100 Roll and Leak Test.........................................................................100 Tightening and Torquing Bolts..............................................................101 Lubrication Information....................................................................102 Motor Removal..............................................................................102 Input Brake Disassembly....................................................................104 Main Disassembly...........................................................................105 Housing-Shaft Disassembly..................................................................106 Carrier Disassembly........................................................................107 Carrier Assembly...........................................................................108 Housing - Shaft Assembly...................................................................109 Main Assembly..............................................................................110 Motor and Brake Assembly...................................................................112 Motor Control Valve Installation...........................................................115 3.13 Swing Motor...............................................................................123 Disassembly and inspection.................................................................123 Assembly...................................................................................130 One Piece Stator Construction..............................................................137 3.14 Swing Bearing.............................................................................138 Swing Bearing Wear Tolerance...............................................................138 Turntable Bearing Mounting Bolt Condition Check............................................139 Swing Bearing Removal......................................................................143 Swing Bearing Installation.................................................................143 Procedure for Setting Swing Gear Backlash..................................................144 Swing Bearing Torque Values................................................................145 3.15 Rotary Coupling...........................................................................147 3.16 Generator.................................................................................152 Maintenance Schedule.......................................................................152 Overload Protection........................................................................152 Inspecting Brushes, Replacing Brushes and Cleaning Slip Rings..............................152 Generator Disassembly and Assembly.........................................................154 Lead Connection List for Generator.........................................................161 3.17 Deutz Engine..............................................................................162 3.18 GM Engine.................................................................................167 3.19 Kubota Engine.............................................................................169 3.20 Deutz Engine - D2.9L4.....................................................................171 Glow Plugs.................................................................................171 Check Oil Level............................................................................171 Replacing Engine Oil.......................................................................171 Replacing the Oil Filter...................................................................172 Replacing the Fuel Filters.................................................................172 3.21 Deutz Engine - D2011......................................................................173 Glow Plugs.................................................................................173 Check Oil Level............................................................................173 Replacing Engine Oil.......................................................................174 Replacing the Oil Filter...................................................................175 Replacing the Fuel Filter..................................................................176 3.22 Deutz EMR 2...............................................................................177 3.23 GM Engine General Maintenance.............................................................189 Maintenance of the Drive Belt..............................................................189 Engine Electrical System Maintenance.......................................................189 Checking/Filling Engine Oil Level..........................................................189 Changing the Engine Oil....................................................................190 Coolant Fill Procedure - Dual Fuel Engine..................................................190 3.24 GM Engine Dual Fuel System................................................................191 Fuel Filter................................................................................191 Electric Lock Off..........................................................................192 EPR Assembly...............................................................................192 Low Pressure Regulator (LPR)...............................................................192 Air Fuel Mixer.............................................................................193 Electronic Throttle Control (ETC)..........................................................193 Engine Control Module......................................................................194 Heated Exhaust Gas Oxygen Sensor...........................................................194 Gasoline Multi Point Fuel Injection System (MPFI)..........................................194 Gasoline Fuel Pump.........................................................................195 Gasoline Pressure And Temperature Sensor Manifold..........................................195 Fuel Filter................................................................................195 Fuel Injector Rail.........................................................................195 Fuel Injector..............................................................................195 3.25 GM Engine Fuel System Repair..............................................................196 Propane Fuel System Pressure Relief........................................................196 Propane Fuel System Leak Test..............................................................196 Propane Fuel Filter Replacement............................................................197 Electronic Pressure Regulator (EPR) Assembly Replacement...................................198 Electronic Throttle Control Replacement....................................................199 Mixer Replacement..........................................................................201 Coolant Hose Replacement...................................................................201 Vapor Hose Replacement.....................................................................201 Engine Control Module Replacement..........................................................202 Heated Exhaust Gas Oxygen Sensor Replacement...............................................202 3.26 GM Engine LPG Fuel System Diagnosis.......................................................203 Fuel System Description....................................................................203 Diagnostic Aids............................................................................203 3.27 Counterweight.............................................................................273 Section 4. Boom & Platform.........................................................................275 4.1 Boom Systems...............................................................................275 Platform Control Enable System.............................................................275 Platform Load Sensing System (LSS) (If Equipped)...........................................275 Above Elevation (Above Horizontal) - Drive Speed Cutback System............................275 Transport Position Interlock System (CE only)..............................................275 Function Speed Control System..............................................................275 Main Boom Lift End of Stroke Dampening.....................................................276 Jib Lift End of Stroke Dampening...........................................................276 Machine Safety Override (MSSO) (CE Only)...................................................276 Transport Position Sensing System..........................................................276 4.2 Platform...................................................................................283 Platform/Support Removal...................................................................283 Platform/Support Installation..............................................................284 4.3 Rotator and Platform Level Cylinder........................................................287 Removal....................................................................................287 Installation...............................................................................289 4.4 Main Boom Powertrack.......................................................................290 Removal....................................................................................290 Installation...............................................................................290 Powertrack Maintenance.....................................................................292 4.5 boom assembly..............................................................................301 Removal....................................................................................301 Disassembly................................................................................302 Inspection.................................................................................303 Assembly...................................................................................303 Installation...............................................................................305 4.6 Jib (460SJ Only)...........................................................................306 Removal....................................................................................306 Disassembly................................................................................306 Inspection.................................................................................306 Assembly...................................................................................306 Installation...............................................................................307 4.7 Boom Cleanliness Guidelines................................................................307 4.8 Boom Shimming Procedure....................................................................308 4.9 Rotator Assembly...........................................................................309 Theory of Operation........................................................................309 Required Tools.............................................................................310 Making a Seal Tool.........................................................................310 Before Disassembly.........................................................................310 Disassembly................................................................................313 Inspection.................................................................................317 Assembly...................................................................................317 Installing Counterbalance Valve............................................................323 Greasing Thrust Washers....................................................................324 Testing the Actuator.......................................................................324 Installation and Bleeding..................................................................325 4.10 Skyguard..................................................................................326 Operation..................................................................................326 Function Test..............................................................................326 Diagnostics & Troubleshooting..............................................................327 4.11 Platform Rotate Bleed Procedure...........................................................328 General Notes & Precautions................................................................328 Procedure..................................................................................328 4.12 Bolt-on External Fall Arrest..............................................................329 Inspection Before Use......................................................................329 Installation...............................................................................329 Section 5. Basic Hydraulics information & Schematics...............................................333 5.1 Lubricating O-Rings in the Hydraulic System................................................333 Cup and Brush..............................................................................333 Dip Method.................................................................................334 Spray Method...............................................................................334 Brush-on Method............................................................................334 5.2 Hydraulic Connection Assembly and Torque Specification.....................................335 Tapered Thread Types.......................................................................335 Straight Thread Types, Tube and Hose Connections...........................................335 Straight Thread Types, Port Connections....................................................336 Flange Connection Types....................................................................336 Tightening Methods.........................................................................336 Assembly And Torque Specifications.........................................................337 Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections.........338 Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections..........339 Assembly Instructions for 37° (JIC) Flare Fittings.........................................340 Assembly Instructions for 45° SAE Flare Fittings...........................................343 Assembly Instructions for O-ring Face Seal (ORFS) Fittings.................................345 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS).................347 Assembly Instructions for Bulkhead (BH) Fittings...........................................349 Assembly Instructions for O-ring Boss (ORB) Fittings.......................................352 Assembly Instructions for Adjustable Port End Metric (MFF) Fittings........................359 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends....................366 Assembly instructions for Adjustable Port End (BSPP) Fittings..............................368 Assembly Instructions for Flange Connections: (FL61 and FL62)..............................375 Double Wrench Method.......................................................................378 FFWR and TFFT Methods......................................................................379 Adjustable Stud End Assembly...............................................................379 O-ring Installation (Replacement)..........................................................380 5.3 Hydraulic Cylinders........................................................................381 Axle Lockout Cylinder......................................................................381 Platform Level Cylinder....................................................................383 Jib Lift Cylinder (460SJ Only).............................................................388 Main Lift Cylinder (SN 0300203771 through 0300243703, SN E300000100 through E300005607)....394 Main Lift Cylinder (SN 0300243704 to Present, SN E300005608 to Present)....................402 Master Cylinder............................................................................407 Steer Cylinder.............................................................................412 Telescope Cylinder.........................................................................415 5.4 Pressure Setting Procedure.................................................................421 Main System Relief.........................................................................421 Steer Left Relief..........................................................................421 Steer Right Relief.........................................................................422 Swing Relief...............................................................................422 Jib Lift Down Relief (460SJ only)..........................................................423 Platform Level Up Relief...................................................................423 Platform Level Down Relief.................................................................424 5.5 Drive Pump Pre-Fill Procedure..............................................................431 5.6 Hydraulic Schematics.......................................................................432 Section 6. JLG Control System......................................................................441 6.1 JLG Control System Analyzer Kit Instructions...............................................441 Introduction...............................................................................441 To Connect the JLG Control System Analyzer.................................................442 Using the Analyzer.........................................................................442 Changing the Access Level of the Hand Held Analyzer........................................443 Adjusting Parameters Using the Hand Held Analyzer..........................................444 Machine Setup..............................................................................445 Tilt Sensor Calibration....................................................................446 Ground Control Console Display Gauge.......................................................449 6.2 LSS System.................................................................................476 Diagnostic Menu............................................................................477 Calibration Procedure......................................................................478 Testing & Evaluation.......................................................................483 Troubleshooting............................................................................484 6.3 Resetting The MSSO System..................................................................485 6.4 Machine Model Adjustment...................................................................487 Adjustment Notes...........................................................................487 Machine Orientation When Performing Test...................................................487 Section 7. Basic Electrical Information & Schematics...............................................531 7.1 General....................................................................................531 7.2 Multimeter Basics..........................................................................531 Grounding..................................................................................531 Backprobing................................................................................531 Min/Max....................................................................................531 Polarity...................................................................................531 Scale......................................................................................531 Voltage Measurement........................................................................531 Resistance Measurement.....................................................................532 Continuity Measurement.....................................................................532 Current Measurement........................................................................533 7.3 Applying Silicone Dielectric Compound to Electrical Connections............................533 Installation of Dielectric Grease..........................................................534 Deutsch HD, DT, DTM, DRC Series............................................................534 AMP Seal...................................................................................534 AMP Mate-N-Lok.............................................................................535 DIN Connectors.............................................................................535 Exclusions.................................................................................536 Brad Harrison / Phoenix Contact M12........................................................536 Engine Control unit connectors.............................................................536 Sealed Enclosures..........................................................................536 MIL-C-5015 spec connectors.................................................................537 MOLEX CMC series connectors................................................................537 7.4 AMP Connector..............................................................................538 Assembly...................................................................................538 Disassembly................................................................................540 Wedge Lock.................................................................................540 Service - Voltage Reading..................................................................540 7.5 Deutsch Connectors.........................................................................542 DT/DTP Series Assembly.....................................................................542 DT/DTP Series Disassembly..................................................................542 HD30/HDP20 Series Assembly.................................................................543 HD30/HDP20 Series Disassembly..............................................................543 7.6 Telematics Gateway.........................................................................544 Telematics-Ready (TCU) Plug................................................................544 7.7 Wiring Harness Connector Labels and Wiring Harnesses.......................................553 Connector Labels...........................................................................553 Component Labels...........................................................................553 7.8 Electrical Schematics......................................................................633
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