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


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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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