Jlg 460SJ Service Manual manuals

Jlg 460SJ Service Manual User Manual (462 pages)

Brand: Jlg | Category: Special machinery | Size: 29.09 MB |

English

Table of contents

P/N - 3120895

1

A GENERAL

3

B HYDRAULIC SYSTEM SAFETY

3

CMAINTENANCE

3

REVISON LOG

4

10

TABLE OF CONTENTS

11

LIST OF FIGURES

13

LIST OF TABLES

19

SECTION 1. SPECIFICATIONS

21

1.3 TIRES

22

1.5 TORQUE REQUIREMENTS

23

SECTION 1 - SPECIFICATIONS

24

1.10 CYLINDER SPECIFICATIONS

25

1.11 LUBRICATION

25

Hydraulic Oil

25

1.13 SERIAL NUMBER LOCATION

26

LUBRICATION

27

Regulator

30

SOCKET HEAD CAP SCREWS

34

Magni Coating (Ref 4150701)*

38

SECTION 2. GENERAL

39

2.2 SERVICE AND GUIDELINES

40

Safety and Workmanship

40

Cleanliness

40

SECTION 2 - GENERAL

41

AMBIENT AIR

49

TEMPERATURE

49

3120895 – JLG Lift – 3-1

53

3120895 – JLG Lift – 3-3

55

3-4 – JLG Lift – 3120895

56

3120895 – JLG Lift – 3-5

57

Final Assembly

58

3120895 – JLG Lift – 3-7

59

3-8 – JLG Lift – 3120895

60

Hub-Spindle Disassembly

61

Cover Disassembly

61

Carrier Disassembly

61

Assembly of the Carrier

62

3120895 – JLG Lift – 3-11

63

Cover Sub-Assembly

64

Hub-Spindle Sub-Assembly

65

3-14 – JLG Lift – 3120895

66

Main Assembly

67

3-16 – JLG Lift – 3120895

68

3120895 – JLG Lift – 3-17

69

3-18 – JLG Lift – 3120895

70

3120895 – JLG Lift – 3-19

71

Tool List

72

COUPLING

73

Equipment Required

73

3.6 DRIVE BRAKE

74

Pre-Installation Checks

74

Maintenance

75

Examination

75

3-24 – JLG Lift – 3120895

76

3.7 DRIVE MOTOR

77

Description

77

Shaft Seal Replacement

77

Loop Flushing Valve

78

Troubleshooting

79

3120895 – JLG Lift – 3-29

81

3-30 – JLG Lift – 3120895

82

3120895 – JLG Lift – 3-31

83

Slipper retainer

85

Ball guide

85

(47-61 Nm)

89

35-45 ft.lbs

89

Initial Start-up Procedures

91

3.8 ADJUSTMENT PROCEDURE FOR

92

LOCKOUT VALVE

92

3.9 TOE-IN ADJUSTMENT

92

3.10 2WD HUB

93

Removal & Disassembly

93

Cleaning & Inspection

93

Assembly & Installation

94

PROCEDURE

95

3.13 SWING BEARING

96

Wear Tolerance

97

Replacement of Swing Bearing

98

Swing Bearing Torque Value

99

Swing Drive Installation

99

3-48 – JLG Lift – 3120895

100

3120895 – JLG Lift – 3-49

101

Installation

102

Brake Disassembly

102

Assembly Information

102

3120895 – JLG Lift – 3-51

103

Assembly

104

Disassembly

104

3.16 SWING DRIVE TORQUE HUB

106

Disassembly Procedure

106

3120895 – JLG Lift – 3-55

107

3-56 – JLG Lift – 3120895

108

3120895 – JLG Lift – 3-57

109

3-58 – JLG Lift – 3120895

110

3120895 – JLG Lift – 3-59

111

3-60 – JLG Lift – 3120895

112

3.17 SEMI-TRACK

113

Testing the Track

113

Removing the Track

114

Assuming Normal Wear

114

Adjustment

114

3120895 – JLG Lift – 3-63

115

3-64 – JLG Lift – 3120895

116

3120895 – JLG Lift – 3-65

117

3-66 – JLG Lift – 3120895

118

INSPECTING BRUSH POSITION

118

INSPECTING BRUSHES

118

CLEANING SLIP RINGS

118

3120895 – JLG Lift – 3-67

119

3.19 FORD EFI ENGINE

120

Performing Diagnostics

120

ECM and Sensors

121

3-70 – JLG Lift – 3120895

122

3120895 – JLG Lift – 3-71

123

READ ONLY MEMORY (EEPROM)

123

HEATED OXYGEN SENSOR

123

3-72 – JLG Lift – 3120895

124

3120895 – JLG Lift – 3-73

125

ENGINE CONTROL MODULE (ECM)

125

3-74 – JLG Lift – 3120895

126

ECM INPUTS/OUTPUTS

126

ECM SERVICE PRECAUTIONS

126

THROTTLE POSITION (TP) SENSOR

126

USE OF CIRCUIT TESTING TOOLS

126

Fuel System

127

3-76 – JLG Lift – 3120895

128

FUEL METERING SYSTEM PURPOSE

128

3-78 – JLG Lift – 3120895

130

ELECTRONIC IGNITION

130

3120895 – JLG Lift – 3-79

131

IGNITION COIL

131

Procedure

132

Controller Status

132

Failure Modes

132

3120895 – JLG Lift – 3-81

133

3-82 – JLG Lift – 3120895

134

Manual Adjustment

135

3-84 – JLG Lift – 3120895

136

3120895 – JLG Lift – 3-85

137

3.22 HYDRAULIC WELDER (225-4)

138

Replacement of Fine Control

138

Rotor Replacement

139

Replacement of Flow Regulator

139

Replace Brushes on Sky Welder

140

Replacing Range Switch

140

Replacing Selector Switch

140

Replacement of Couplings

141

3-90 – JLG Lift – 3120895

142

3120895 – JLG Lift – 3-91

143

3-92 – JLG Lift – 3120895

144

3120895 – JLG Lift – 3-93

145

Receptacle Output OK

146

Intermittent Welder Operation

146

3120895 – JLG Lift – 3-95

147

3-96 – JLG Lift – 3120895

148

3120895 – JLG Lift – 3-97

149

3-98 – JLG Lift – 3120895

150

3120895 – JLG Lift – 3-99

151

3-100 – JLG Lift – 3120895

152

3120895 – JLG Lift – 3-101

153

3-102 – JLG Lift – 3120895

154

3120895 – JLG Lift – 3-103

155

3-104 – JLG Lift – 3120895

156

3120895 – JLG Lift – 3-105

157

3-106 – JLG Lift – 3120895

158

3120895 – JLG Lift – 3-107

159

Maintenance of the Drive Belt

160

Changing The Engine Oil

161

3-110 – JLG Lift – 3120895

162

Fuel Filter

163

Electric Lock Off

163

EPR Assembly

164

Low Pressure Regulator (LPR)

164

Air Fuel Mixer

165

Engine Control Module

166

3120895 – JLG Lift – 3-115

167

Propane Fuel System Leak Test

168

Assembly Replacement

169

(TMAP) Sensor

170

3120895 – JLG Lift – 3-119

171

MIXER REPLACEMENT

172

Coolant Hose Replacement

172

Vapor Hose Replacement

172

3120895 – JLG Lift – 3-121

173

Diagnostic Aids

174

3120895 – JLG Lift – 3-123

175

3-124 – JLG Lift – 3120895

176

3120895 – JLG Lift – 3-125

177

3-126 – JLG Lift – 3120895

178

3120895 – JLG Lift – 3-127

179

3-128 – JLG Lift – 3120895

180

3120895 – JLG Lift – 3-129

181

3-130 – JLG Lift – 3120895

182

3120895 – JLG Lift – 3-131

183

3-132 – JLG Lift – 3120895

184

3120895 – JLG Lift – 3-133

185

3-134 – JLG Lift – 3120895

186

3120895 – JLG Lift – 3-135

187

3-136 – JLG Lift – 3120895

188

3120895 – JLG Lift – 3-137

189

3.29 PERKINS ENGINE GENERAL

190

MAINTENANCE

190

Engine Oil Level - Check

190

3120895 – JLG Lift – 3-139

191

Fuel Filter/Water Separator

192

Setting the Actuator

193

Speed Sensor Installation

194

PERKINS & CATERPILLAR

194

3120895 – JLG Lift – 3-143

195

3-144 – JLG Lift – 3120895

196

3120895 – JLG Lift – 3-145

197

Fault Code Broadcast

198

Diagnostic Trouble Codes

198

MIL Output

199

Corrective Actions

199

3-148 – JLG Lift – 3120895

200

3120895 – JLG Lift – 3-149

201

3-150 – JLG Lift – 3120895

202

3120895 – JLG Lift – 3-151

203

3-152 – JLG Lift – 3120895

204

DBW Diagnostic Test

205

DESCRIPTIONS

206

DTC 117- ECT/CHT Low Voltage

207

3-156 – JLG Lift – 3120895

208

DTC 118- ECT/CHT High Voltage

209

3-158 – JLG Lift – 3120895

210

3120895 – JLG Lift – 3-159

211

3-160 – JLG Lift – 3120895

212

3120895 – JLG Lift – 3-161

213

3-162 – JLG Lift – 3120895

214

3120895 – JLG Lift – 3-163

215

3-166 – JLG Lift – 3120895

218

3120895 – JLG Lift – 3-167

219

Pressure

221

Normally Open Switch

222

Normally Closed Switch

222

Sensor/Transducer Type

223

DTC 524- Oil Pressure Low

224

3-176 – JLG Lift – 3120895

228

3120895 – JLG Lift – 3-177

229

3-178 – JLG Lift – 3120895

230

3120895 – JLG Lift – 3-179

231

3-180 – JLG Lift – 3120895

232

3120895 – JLG Lift – 3-181

233

3-182 – JLG Lift – 3120895

234

3120895 – JLG Lift – 3-183

235

3-184 – JLG Lift – 3120895

236

3120895 – JLG Lift – 3-185

237

3-186 – JLG Lift – 3120895

238

3-188 – JLG Lift – 3120895

240

3-190 – JLG Lift – 3120895

242

3120895 – JLG Lift – 3-191

243

SFC 555- RTI 2 Loss

244

3120895 – JLG Lift – 3-193

245

SFC 556- RTI 3 Loss

246

3120895 – JLG Lift – 3-195

247

SFC 513- A/D Loss

248

3120895 – JLG Lift – 3-197

249

SFC 512- Invalid Interrupt

250

3-202 – JLG Lift – 3120895

254

3120895 – JLG Lift – 3-203

255

3-206 – JLG Lift – 3120895

258

3120895 – JLG Lift – 3-207

259

3-208 – JLG Lift – 3120895

260

DTC to SPN/FMI Table

262

3120895 – JLG Lift – 3-211

263

3-212 – JLG Lift – 3120895

264

4.1 BOOM

265

Inspection

267

4-6 – JLG Lift – 3120895

270

3120895 – JLG Lift – 4-7

271

4-8 – JLG Lift – 3120895

272

3120895 – JLG Lift – 4-9

273

Test Notes

274

Lift, Swing, and Drive Cards

275

Flow Control Card

275

4-12 – JLG Lift – 3120895

276

4.5 HELAC ROTARY ACTUATOR

277

Theory Of Operation

277

4-14 – JLG Lift – 3120895

278

3120895 – JLG Lift – 4-15

279

3120895 – JLG Lift – 4-17

281

4-18 – JLG Lift – 3120895

282

3120895 – JLG Lift – 4-19

283

3120895 – JLG Lift – 4-21

285

4-22 – JLG Lift – 3120895

286

3120895 – JLG Lift – 4-23

287

4-24 – JLG Lift – 3120895

288

SECTION 5. HYDRAULICS

289

Cleaning and Inspection

291

SECTION 5 - HYDRAULICS

293

Solenoid Control Valve

302

Reassembly Shaft End

308

Gerotor End

310

Timing Procedure

311

Standard Rotation

311

Reverse Rotation

311

PROCEDURES AND

315

RECOMMENDATIONS

315

6.1 INTRODUCTION

317

6-2 – JLG Lift – 3120895

318

SYSTEM ANALYZER

319

6.3 USING THE ANALYZER

319

6-4 – JLG Lift – 3120895

320

HAND HELD ANALYZER

321

6-6 – JLG Lift – 3120895

322

6.6 MACHINE SETUP

324

6.7 LEVEL VEHICLE DESCRIPTION

324

3120895 – JLG Lift – 6-9

325

6-10 – JLG Lift – 3120895

326

3120895 – JLG Lift – 6-11

327

6-12 – JLG Lift – 3120895

328

3120895 – JLG Lift – 6-13

329

6-14 – JLG Lift – 3120895

330

3120895 – JLG Lift – 6-15

331

6-16 – JLG Lift – 3120895

332

3120895 – JLG Lift – 6-17

333

6-18 – JLG Lift – 3120895

334

4150365-3

335

6-20 – JLG Lift – 3120895

336

3120895 – JLG Lift – 6-21

337

6-22 – JLG Lift – 3120895

338

3120895 – JLG Lift – 6-23

339

6-24 – JLG Lift – 3120895

340

3120895 – JLG Lift – 6-25

341

6-26 – JLG Lift – 3120895

342

3120895 – JLG Lift – 6-27

343

6-28 – JLG Lift – 3120895

344

3120895 – JLG Lift – 6-29

345

6-30 – JLG Lift – 3120895

346

3120895 – JLG Lift – 6-31

347

6-32 – JLG Lift – 3120895

348

3120895 – JLG Lift – 6-33

349

6-34 – JLG Lift – 3120895

350

3120895 – JLG Lift – 6-35

351

6-36 – JLG Lift – 3120895

352

3120895 – JLG Lift – 6-37

353

6-38 – JLG Lift – 3120895

354

3120895 – JLG Lift – 6-39

355

6-40 – JLG Lift – 3120895

356

3120895 – JLG Lift – 6-41

357

6-42 – JLG Lift – 3120895

358

3120895 – JLG Lift – 6-43

359

6-44 – JLG Lift – 3120895

360

3120895 – JLG Lift – 6-45

361

6-46 – JLG Lift – 3120895

362

3120895 – JLG Lift – 6-47

363

6-48 – JLG Lift – 3120895

364

3120895 – JLG Lift – 6-49

365

6-50 – JLG Lift – 3120895

366

3120895 – JLG Lift – 6-51

367

6-52 – JLG Lift – 3120895

368

4150364-18

369

6-54 – JLG Lift – 3120895

370

3120895 – JLG Lift – 6-55

371

6-56 – JLG Lift – 3120895

372

3120895 – JLG Lift – 6-57

373

6-58 – JLG Lift – 3120895

374

4150364-19

375

6.9 SYSTEM TEST

378

Test from the Platform

378

3120895 – JLG Lift – 6-63

379

Test from the Ground Station

380

3120895 – JLG Lift – 6-65

381

6-66 – JLG Lift – 3120895

382

3120895 – JLG Lift – 6-67

383

6-68 – JLG Lift – 3120895

384

3120895 – JLG Lift – 6-69

385

6-70 – JLG Lift – 3120895

386

3120895 – JLG Lift – 6-71

387

6-72 – JLG Lift – 3120895

388

3120895 – JLG Lift – 6-73

389

6-74 – JLG Lift – 3120895

390

3120895 – JLG Lift – 6-75

391

6-76 – JLG Lift – 3120895

392

3120895 – JLG Lift – 6-77

393

6-78 – JLG Lift – 3120895

394

3120895 – JLG Lift – 6-79

395

6-80 – JLG Lift – 3120895

396

STRUCTURE

397

6-82 – JLG Lift – 3120895

398

3120895 – JLG Lift – 6-83

399

6-84 – JLG Lift – 3120895

400

3120895 – JLG Lift – 6-85

401

6-86 – JLG Lift – 3120895

402

3120895 – JLG Lift – 7-1

403

Resistance Measurement

404

Continuity Measurement

404

Current Measurement

405

7.3 CHECKING SWITCHES

405

Basic Check

405

Limit Switches

405

Automatic Switches

406

COMPOUND TO ELECTRICAL

406

CONNECTIONS

406

AMP Seal

407

AMP Mate-N-Lok

408

DIN Connectors

408

Exclusions

408

3120895 – JLG Lift – 7-7

409

AMP JUNIOR TIMER

409

SEALED ENCLOSURES

409

MIL-C-5015 SPEC CONNECTORS

409

7.5 AMP CONNECTOR

410

AMP Connectors

410

3120895 – JLG Lift – 7-9

411

Wedge Lock

412

Service - Voltage Reading

412

3120895 – JLG Lift – 7-11

413

7.6 DEUTSCH CONNECTORS

414

DT/DTP Series Assembly

414

DT/DTP Series Disassembly

414

HD30/HDP20 Series Assembly

415

HD30/HDP20 Series Disassembly

415

7-14 – JLG Lift – 3120895

416

3120895 – JLG Lift – 7-15

417

7-16 – JLG Lift – 3120895

418

3120895 – JLG Lift – 7-17

419

7-18 – JLG Lift – 3120895

420

3120895 – JLG Lift – 7-19

421

7-20 – JLG Lift – 3120895

422

3120895 – JLG Lift – 7-21

423

7-22 – JLG Lift – 3120895

424

3120895 – JLG Lift – 7-23

425

7-24 – JLG Lift – 3120895

426

3120895 – JLG Lift – 7-25

427

7-26 – JLG Lift – 3120895

428

3120895 – JLG Lift – 7-27

429

7-28 – JLG Lift – 3120895

430

3120895 – JLG Lift – 7-29

431

7-30 – JLG Lift – 3120895

432

3120895 – JLG Lift – 7-31

433

7-32 – JLG Lift – 3120895

434

3120895 – JLG Lift – 7-33

435

7-34 – JLG Lift – 3120895

436

3120895 – JLG Lift – 7-35

437

7-36 – JLG Lift – 3120895

438

3120895 – JLG Lift – 7-37

439

7-38 – JLG Lift – 3120895

440

3120895 – JLG Lift – 7-39

441

7-40 – JLG Lift – 3120895

442

3120895 – JLG Lift – 7-41

443

7-42 – JLG Lift – 3120895

444

3120895 – JLG Lift – 7-43

445

7-44 – JLG Lift – 3120895

446

3120895 – JLG Lift – 7-45

447

7-46 – JLG Lift – 3120895

448

3120895 – JLG Lift – 7-47

449

7-48 – JLG Lift – 3120895

450

3120895 – JLG Lift – 7-49

451

7-50 – JLG Lift – 3120895

452

3120895 – JLG Lift – 7-51

453

7-52 – JLG Lift – 3120895

454

3120895 – JLG Lift – 7-53

455

7-54 – JLG Lift – 3120895

456

3120895 – JLG Lift – 7-55

457

7-56 – JLG Lift – 3120895

458

3120895 – JLG Lift – 7-57

459

7-58 – JLG Lift – 3120895

460

JLG Worldwide Locations

462

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