JLG 400S / 460SJ Telescopic Boom Lift Service and Maintenance Manual (ANSI)

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This service manual PDF download for the 400S / 460SJ JLG Telescopic Boom Lift has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JLG Lift 400S
JLG Lift 460SJ

TABLE OF CONTENTS :

Section 1. SPECIFICATIONS
1.1 Capacities
1.2 Engine Specifications
1.3 Tires
1.4 Specifications and Performance Data
1.5 Torque Requirements
1.6 Critical Stability Weights
1.7 Major Component Weights
1.8 Function Speeds
1.9 Pressure Settings – PSI (Bar)
1.10 Cylinder Specifications
1.11 Lubrication
1.12 Welder, Hydraulic (option)
1.13 Serial Number Location
1.14 Operator Maintenance and Lubrication

Section 2. GENERAL
2.1 Machine Preparation, Inspection, and Maintenance
2.2 Service and Guidelines
2.3 Lubrication and Information
2.4 Cylinder Drift Test
2.5 Pins and Composite Bearing Repair Guidelines
2.6 Welding on JLG Equipment

Section 3. CHASSIS & TURNTABLE
3.1 Tires & Wheels
3.2 Drive Hub Part No. 2780243 (2wd Rear) Part No. 2780244 (4wd Rear)
3.3 Drive Hub Part No. 2780246 (4wd steer axle Prior to S/N 0300076633)
3.4 Torque Hub – 4WD (Machines built after S/N 0300076633)
3.5 Re-Aligning Torque Hub Input Coupling
3.6 Drive Brake
3.7 Drive Motor
3.8 Adjustment Procedure For Lockout Valve
3.9 Toe-In Adjustment
3.10 2WD Hub
3.11 Oscillating Axle Bleeding Procedure
3.12 Oscillating Axle Lockout Test
3.13 Swing Bearing
3.14 Swing Brake (Prior to S/N 64802)
3.15 Swing Brake S/N 64802 to Present
3.16 Swing Drive Torque Hub
3.17 Semi-Track
3.18 Generator
3.19 Ford EFI Engine
3.20 Throttle Checks and Adjustments – Deutz Engine (Prior to S/N 61718)
3.21 Tilt Alarm Switch (Prior to S/N 61718)
3.22 Hydraulic Welder (225-4)
3.23 Troubleshooting of the Sky Welder
3.24 Deutz EMR 2 (S/N 77682 to Present)
3.25 GM Engine General Maintenance
3.26 GM Engine Dual Fuel System
3.27 GM Engine Fuel System Repair
3.28 GM Engine LPG Fuel System Diagnosis
3.29 Perkins Engine General Maintenance
3.30 Engine Radiator Fill Procedure – Perkins & Caterpillar
3.31 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS
3.32 Diagnostic Trouble Code Fault Descriptions

Section 4. BOOM & PLATFORM
4.1 Boom
4.2 Articulating jib
4.3 Limit Switch Adjustments
4.4 Drive Card Setup Procedures
4.5 Helac Rotary actuator

Section 5. HYDRAULICS
5.1 Cylinders – Theory of Operation
5.2 Cylinder Repair
5.3 Valves – Theory of Operation
5.4 Pressure Setting Procedures
5.5 Hydraulic Motor Repair (H Series Char-lynn)
5.6 Hydraulic Pump “Neutral” Or Null Adjustment
5.7 Non-feedback, Proportional Electrical Control – NFPE
5.8 Hydraulic Component Start-Up Procedures and Recommendations

Section 6. JLG CONTROL SYSTEM (S/N 61718 to Present)
6.1 Introduction
6.2 To Connect the JLG Control System Analyzer
6.3 Using the Analyzer
6.4 Changing the Access Level of the Hand Held Analyzer
6.5 Adjusting Parameters Using the Hand Held Analyzer
6.6 Machine Setup
6.7 Level Vehicle Description
6.8 Machine Personality Settings
6.9 System Test
6.10 Analyzer Diagnostics Menu Structure

Section 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS
7.1 General
7.2 Multimeter Basics
7.3 Checking Switches
7.4 Applying Silicone Dielectric Compound to Electrical Connections
7.5 AMP Connector
7.6 Deutsch Connectors

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 3120788
Total Pages : 464

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Section A. INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS
A General
B Hydraulic System Safety
C Maintenance

Section 1. SPECIFICATIONS
1.1 Capacities
1.2 Engine Specifications
1.3 Tires
1.4 Specifications and Performance Data
1.5 Torque Requirements
1.6 Critical Stability Weights
1.7 Major Component Weights
1.8 Function Speeds
1.9 Pressure Settings – PSI (Bar)
1.10 Cylinder Specifications
1.11 Lubrication
Hydraulic Oil
1.12 Welder, Hydraulic (option)
1.13 Serial Number Location
1.14 Operator Maintenance and Lubrication
Draining Oil Build Up From The Propane Regulator
Propane Fuel Filter Replacement
Propane Fuel System Pressure Relief

Section 2. GENERAL
2.1 Machine Preparation, Inspection, and Maintenance
General
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance
2.2 Service and Guidelines
General
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Lubrication and Servicing
2.3 Lubrication and Information
Hydraulic System
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications
2.4 Cylinder Drift Test
Platform Drift
Cylinder Drift
2.5 Pins and Composite Bearing Repair Guidelines
2.6 Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment

Section 3. CHASSIS & TURNTABLE
3.1 Tires & Wheels
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation
3.2 Drive Hub Part No. 2780243 (2wd Rear) Part No. 2780244 (4wd Rear)
Disassembly
Disassembly of Cover Unit (8)
Disassembly of First Stage Planetary Assembly
Disassembly of the Second Stage Planet Gears (1)
Assembly of First Stage Planetary Assembly (7)
Assembly Of End Cover Unit (8)
Final Assembly
3.3 Drive Hub Part No. 2780246 (4wd steer axle Prior to S/N 0300076633)
Disassembly
Disassembly of Cover Unit (8)
Disassembly of First Stage Planetary Assembly
Disassembly of the Second Stage Planet Gears (1)
Assembly of First Stage Planetary Assembly (7)
Assembly of End Cover Unit (8)
Final Assembly
3.4 Torque Hub – 4WD (Machines built after S/N 0300076633)
Roll and Leak Testing
Tightening and Torquing Bolts
Oil Information
Main Disassembly for ”B” Drives
Hub-Spindle Disassembly
Cover Disassembly
Carrier Disassembly
Assembly of the Carrier
Cover Sub-Assembly
Hub-Spindle Sub-Assembly
Main Assembly
Tool List
3.5 Re-Aligning Torque Hub Input Coupling
Equipment Required
Procedure
3.6 Drive Brake
Pre-Installation Checks
Installation
Maintenance
Disassembly
Examination
Assembly
3.7 Drive Motor
Description
Shaft Seal Replacement
Loop Flushing Valve
Troubleshooting
Disassembly
Inspection
Assembly
Initial Start-up Procedures
3.8 Adjustment Procedure For Lockout Valve
3.9 Toe-In Adjustment
3.10 2WD Hub
Removal & Disassembly
Cleaning & Inspection
Assembly & Installation
3.11 Oscillating Axle Bleeding Procedure
3.12 Oscillating Axle Lockout Test
3.13 Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Replacement of Swing Bearing
Swing Bearing Torque Value
Swing Drive Installation
3.14 Swing Brake (Prior to S/N 64802)
Installation
Brake Disassembly
Assembly Information
3.15 Swing Brake S/N 64802 to Present
Disassembly
Assembly
3.16 Swing Drive Torque Hub
Disassembly Procedure
Hub Shaft Sub-Assembly Procedure
Carrier Sub-Assembly Procedure
3.17 Semi-Track
Testing the Track
Removing the Track
Assuming Normal Wear
Adjustment
3.18 Generator
Every 250 hours
Every 500 hours
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
3.19 Ford EFI Engine
Performing Diagnostics
Visual/Physical Engine Inspection Check
EFI Diagnostics (Prior to S/N 61718)
ECM AND SENSORS
Fuel System
3.20 Throttle Checks and Adjustments – Deutz Engine (Prior to S/N 61718)
General
Procedure
Controller Status
Failure Modes
3.21 Tilt Alarm Switch (Prior to S/N 61718)
Manual Adjustment
3.22 Hydraulic Welder (225-4)
Replacement of Weld Transformer
Replacement of Hydraulic Motor
Replacement of Fine Control
Rotor Replacement
Replacement of Flow Regulator
Replacement of Exciting Rectifier Bridge
Replacement of Weld Rectifier Bridge
Replace Brushes on Sky Welder
Replacing Range Switch
Replacing Selector Switch
Replacement of Couplings
Voltage Change Over – 120/240 Volt
3.23 Troubleshooting of the Sky Welder
Low Sky Welder Speed
Low Welding Amps
No Output on Weld Receptacles or AC Receptacles
No Ac Output but Weld Output
No Output on Weld Receptacle but AC Receptacle Output OK
Welder Completely Dead – No AC or Weld Power
Intermittent Welder Operation
3.24 Deutz EMR 2 (S/N 77682 to Present)
3.25 GM Engine General Maintenance
Maintenance of the Drive Belt
Engine Electrical System Maintenance
Checking/Filling Engine Oil Level
Changing The Engine Oil
Coolant Fill Procedure – Dual Fuel Engine
3.26 GM Engine Dual Fuel System
Fuel Filter
Electric Lock Off
EPR Assembly
Low Pressure Regulator (LPR)
Air Fuel Mixer
Electronic Throttle Control (ETC)
Engine Control Module
Heated Exhaust Gas Oxygen Sensor
Gasoline Multi Point Fuel Injection System (MPFI)
Gasoline Fuel Pump
Gasoline Pressure And Temperature Sensor Manifold
Fuel Filter
Fuel Injector Rail
Fuel Injector
3.27 GM Engine Fuel System Repair
Propane Fuel System Pressure Relief
Propane Fuel System Leak Test
Propane Fuel Filter Replacement
Electronic Pressure Regulator (EPR) Assembly Replacement
Temperature Manifold Absolute Pressure (TMAP) Sensor
Electronic Throttle Control Replacement
Mixer Replacement
Coolant Hose Replacement
Vapor Hose Replacement
Engine Control Module Replacement
Heated Exhaust Gas Oxygen Sensor Replacement
3.28 GM Engine LPG Fuel System Diagnosis
Fuel System Description
Diagnostic Aids
3.29 Perkins Engine General Maintenance
Replacing the Engine Crankcase Breather
Engine Oil Level – Check
Engine Oil and Filter – Change
Fuel Filter/Water Separator
Setting the Actuator
Speed Sensor Installation
3.30 Engine Radiator Fill Procedure – Perkins & Caterpillar
3.31 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS
Section Layout
List of Abbreviations in this Section
Fault Code Broadcast
Diagnostic Trouble Codes
CAN
MIL Output
Diagnostic Calibration Configuration and Corrective Actions
Fault/Diagnostic Trouble Code Interaction
DBW Diagnostic Test
3.32 Diagnostic Trouble Code Fault Descriptions
DTC 116- ECT Higher Than Expected Stage 1
DTC 117- ECT/CHT Low Voltage
DTC 118- ECT/CHT High Voltage
DTC 122- TPS1 Signal Voltage Low
DTC 123- TPS1 Signal Voltage High
DTC 217- ECT Higher Than Expected 2
DTC 219- RPM Higher Than Max Allowed Governed Speed
DTC 336- Crank Signal Input Noise
DTC 337- Loss of Crank Input Signal
DTC 521- Oil Pressure Sender/Switch High Pressure
DTC 524- Oil Pressure Low
DTC 562- Battery Voltage (VBat) Low
DTC 563- Battery Voltage (VBat) High
DTC 601- Microprocessor Failure – FLASH
DTC 604- Microprocessor Failure – RAM
DTC 606- Microprocessor Failure – COP
DTC 642- 5 Volt External Low Voltage
DTC 643- 5 Volt External High Voltage
DTC 1612- Microprocessor Failure – RTI 1
DTC 1613- Microprocessor Failure – RTI 2
DTC 1614- Microprocessor Failure – RTI 3
DTC 1615- Microprocessor Failure – A/D
DTC 1616- Microprocessor Failure – interrupt
DTC 1625- CAN J1939 Shutdown Request
DTC 1626- CAN J1939 Transmit (Tx) Fault
DTC 1627- CAN J1939 Receive (Rx) Fault
DTC 1628- CAN Address Conflict Failure
DTC 1629- J1939 TSC1 Message Reciept Loss
DTC 1652- TPS1 Loss of Communications
DTC 2111- Unable to Reach Lower TPS
DTC 2112- Unable to Reach Higher TPS
DTC 9999- Throttle Actuator Failsafe Spring Failure
DTC to SPN/FMI Table

Section 4. BOOM & PLATFORM
4.1 Boom
Removal
Disassembly
Inspection
Assembly
Installation
4.2 Articulating jib
Removal
4.3 Limit Switch Adjustments
Boom Horizontal Limit Switch
Dual Capacity Angle Limit Switch
Boom Length Limit Switch
4.4 Drive Card Setup Procedures
Machine Orientation When Doing Speed Tests
Test Notes
Lift, Swing, and Drive Cards
Flow Control Card
4.5 Helac Rotary actuator
Theory Of Operation
Tools Required for Assembly/Disassembly
Disassembly
Inspection
Assembly
Installing Counterbalance Valve

Section 5. HYDRAULICS
5.1 Cylinders – Theory of Operation
Systems Incorporating Double Acting Cylinders
Systems Incorporating Holding Valves
5.2 Cylinder Repair
Cylinders Without Counterbalance Valves
Cylinders With Dual Counterbalance Valves
Disassembly
Cleaning and Inspection
Assembly
5.3 Valves – Theory of Operation
Solenoid Control Valve
Relief Valves
5.4 Pressure Setting Procedures
1. Bang-Bang Main Relief Valve;
2. Steer;
3. Platform Level Up;
4. Platform Level Down;
5. Articulating Jib Up;
6. Articulating Jib Down;
7. The Bang-Bang Main Relief Valve;
8. The Proportional Main Relief Valve;
9. Lift Down;
10. Swing;
5.5 Hydraulic Motor Repair (H Series Char-lynn)
Disassembly
Reassembly Shaft End
Gerotor End
Timing Procedure
Standard Rotation
Reverse Rotation
5.6 Hydraulic Pump “Neutral” Or Null Adjustment
5.7 Non-feedback, Proportional Electrical Control – NFPE
Features and Benefits of the NFPE Control
Input Signal requirements
5.8 Hydraulic Component Start-Up Procedures and Recommendations

Section 6. JLG CONTROL SYSTEM (S/N 61718 to Present)
6.1 Introduction
6.2 To Connect the JLG Control System Analyzer
6.3 Using the Analyzer
6.4 Changing the Access Level of the Hand Held Analyzer
6.5 Adjusting Parameters Using the Hand Held Analyzer
6.6 Machine Setup
6.7 Level Vehicle Description
6.8 Machine Personality Settings
6.9 System Test
Test from the Platform
Test from the Ground Station
6.10 Analyzer Diagnostics Menu Structure

Section 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS
7.1 General
7.2 Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement
7.3 Checking Switches
Basic Check
Limit Switches
Automatic Switches
Switch Wiring – Low Side, High Side
7.4 Applying Silicone Dielectric Compound to Electrical Connections
Installation of Dielectric Grease
Deutsch HD, DT, DTM, DRC Series
AMP Seal
AMP Mate-N-Lok
DIN Connectors
Exclusions
7.5 AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
Assembly
Disassembly
Wedge Lock
Service – Voltage Reading
7.6 Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly

 

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JLG 400S / 460SJ Telescopic Boom Lift Service and Maintenance Manual (ANSI).pdf

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