JLG 400SC Service And Maintenance Manual
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JLG 400SC Service And Maintenance Manual

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Service and Maintenance Manual
Models
400SC
460SJC
PVC 2001
31215019
January 02, 2020 - Rev A

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  • Page 1 Service and Maintenance Manual Models 400SC 460SJC PVC 2001 31215019 January 02, 2020 - Rev A...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 3: Bhydraulic System Safety

    • USE ONLY REPLACEMENT PARTS OR COMPONENTS THAT ARE APPROVED BY JLG. TO BE CONSIDERED APPROVED, REPLACEMENT PARTS OR COMPONENTS MUST BE IDENTI- MODIFICATION OR ALTERATION OF A MOBILE ELEVATING WORK PLATFORM CAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS.
  • Page 4 INTRODUCTION REVISON LOG Original Issue A - January 02, 2020 31215019...

  • Page 5: Table Of Contents

    Machine Specifications - 400SC ........
  • Page 6 Do NOT Do the Following When Welding on JLG Equipment....... .
  • Page 7 Removal - 400SC ........
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS O-Ring Lubrication ................. 5-1 Cup and Brush .
  • Page 9 To Connect the JLG Control System Analyzer........
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Deutsch Connectors ................7-11 DT/DTP Series Assembly .
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Maintenance and Lubrication Diagram - Deutz D2011L03 ......... . . 1-6 1-2.
  • Page 12 Cables and Clamps Installation - 400SC (Sheet 1 of 2) .......
  • Page 13 Hydraulic System Installation (400SC) - Sheet 10 of 16 ....... .
  • Page 14 Hydraulic System Installation (400SC) - Sheet 15 of 16 ....... .
  • Page 15 Main Boom Harness - 400SC ........
  • Page 16 400SC Turntable Harness - Sheet 10 of 14 ....... . .
  • Page 17 LIST OF TABLES TABLE NO. TITLE PAGE NO. Deutz D2011L03 ................. . . 1-2 Deutz 2.9L4 .
  • Page 18 Machine Configuration Programming Settings - 400SC ........
  • Page 19 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 20: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS Machine Specifications - 460SJC Maximum Work Load (Capacity): 272 kg (600 lb) Machine Specifications - 400SC Maximum Operating Slope 5° Maximum Work Load (Capacity): Maximum Travel Grade, Stowed Position Unrestricted (CE)

  • Page 21: Capacities

    SECTION 1 - SPECIFICATIONS 1.2 CAPACITIES Table 1-2. Deutz 2.9L4 Fuel Tank (Usable) 83.3 L (22 Gal) Engine Type Four-stroke Diesel Hydraulic Tank (Usable) 136.28 L (36 Gal) Fuel Diesel Final Drive Hub 1 L (33.8 oz) No. of Cylinders Bore 92 mm 1.3 ENGINE DATA...

  • Page 22: Hydraulic Oil

    46 cSt (215SUS) at 65° C (150° F) 22 cSt (106SUS) NOTE: Aside from JLG recommendations, it is not advisable to mix Viscosity Index oils of different brands or types, as they may not contain the same required additives or be of comparable viscosi- ties.

  • Page 23: Critical Stability Weights

    4812 Specific Gravity .910 Counterweight (460SJC) - Turnable 2700 1225 Pour Point -42°C (-44°F) Counterweight (400SC) - Chassis (Front) 1200 Flash Point 260°C (500°F) Counterweight (400SC) - Chassis (Rear) 1210 Operating Temp. -17 to 162°C (0 to 180°F) Counterweight (460SJC) - Chassis (Front)

  • Page 24: Maintenance And Lubrication

    SECTION 1 - SPECIFICATIONS 1.6 MAINTENANCE AND LUBRICATION 2. Hydraulic Return Filter NOTE: The following numbers correspond to those in Figure 1-1. and Figure 1-2. Table 1-9. Lubrication Specifications SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type.
  • Page 25 SECTION 1 - SPECIFICATIONS Figure 1-1. Maintenance and Lubrication Diagram - Deutz D2011L03 31215019...
  • Page 26 SECTION 1 - SPECIFICATIONS Figure 1-2. Maintenance and Lubrication Diagram - Deutz 2.9L4 31215019...
  • Page 27 SECTION 1 - SPECIFICATIONS 4. Hydraulic Tank 6. Oil Change w/Filter - Deutz D2011 Lube Point(s) - Fill Cap Capacity - 32.5 gal tank (123 L) 40.0 gal system (151 L) Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation Lube Point(s) - Fill Cap/Spin-on Element 5.
  • Page 28 SECTION 1 - SPECIFICATIONS 8. Oil Change w/Filter - Deutz 2.9L4 10. Fuel Filter - Deutz 2.9L4 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 9.5 qt (8.9 L) w/Filter Lube - EO Lube Point(s) - Replaceable Element Interval - Check level daily; change every 500 hours or Interval - Every year or 500 hours of operation six months, whichever comes first.
  • Page 29 SECTION 1 - SPECIFICATIONS 12. Air Filter 14. Swing Drive Hub Lube Point(s) - Replaceable Element Lube Point - Level/Fill Plug Interval - Every 6 months or 300 hours of operation or Capacity - 40 oz (1.2 L) as indicated by condition Indicator Lube - 90w80 Gear Oil Comments - Check Dust Valve daily Interval - Check level every 3 months or 150 hours of...

  • Page 30: Threadlocking Compound

    SECTION 1 - SPECIFICATIONS 1.7 THREADLOCKING COMPOUND JLG PN Loctite® ND Industries Description 0100011 242™ Vibra-TITE™ 121 Medium Strength (Blue) 1001095650 243™ Vibra-TITE™ 122 Medium Strength (Blue) 0100019 271™ High Strength (Red) Vibra-TITE™ 140 0100071 262™ Vibra-TITE™ 131 Medium - High Strength (Red) NOTE: Loctite®...

  • Page 31: Torque Charts

    SECTION 1 - SPECIFICATIONS 1.8 TORQUE CHARTS SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Tensile Clamp Torque Torque Size Bolt Dia (Loctite® 242™ or 271™ or (Loctite®...

  • Page 32: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load...
  • Page 33 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry) Area...

  • Page 34: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry or Loctite®...

  • Page 35: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...

  • Page 36: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...

  • Page 37: Metric Fastener Torque Chart

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Tensile Stress Clamp Load Torque (Loctite® 262™ or 271™ or Size Pitch Torque (Lube) (Loctite®...

  • Page 38: Metric Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAPSCREWS M3 - M5* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp Load (Loctite®...
  • Page 39 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Torque (Loctite® 262™ or Tensile Clamp Load (Lube or Loctite® 242™ or 271™ Size Pitch (Dry or Loctite®...

  • Page 40: Metric Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAPSCREWS M6 AND ABOVE* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp (Loctite®...

  • Page 41: General

    Service Technician as a person who has successfully com- ommendations, and with any and all discrepancies corrected, pleted the JLG Service Training School for the subject JLG this product will be fit for continued use. product model. Reference the machine Service and Mainte-...

  • Page 42: Service And Guidelines

    Service and Maintenance Manual Owner, Dealer, or User Qualified JLG Mechanic Inspection rental delivery. and applicable JLG inspection form. In service for 3 months or 150 hours, whichever comes first; or Service and Maintenance Manual Frequent Inspection Owner, Dealer, or User Qualified JLG Mechanic Out of service for a period of more than 3 months;...

  • Page 43: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly 2. Unless specific torque requirements are given within the text, standard torque values should be used on heat- When disassembling or reassembling a component, complete treated bolts, studs, and steel nuts, in accordance with the procedural steps in sequence.

  • Page 44: Lubrication And Information

    SECTION 2 - GENERAL LUBRICATION AND INFORMATION Changing Hydraulic Oil 1. Filter elements must be changed after the first 50 hours Hydraulic System of operation and every 300 hours (unless specified oth- erwise) thereafter. If it is necessary to change the oil, use 1.

  • Page 45: Cylinder Leakage Test

    • Ground only to structure being welded. ture, usually from a higher oil temperature as it cools and approaches the ambient air temperature. Results of these Do NOT Do the Following When Welding on JLG effects are related to several factors including cylinder length Equipment and change in temperature over the time the cylinder remains stationary.
  • Page 46 SECTION 2 - GENERAL NOTE: Reference the Operation and Safety Manual for completion procedures for the Pre-Start Inspection. Table 2-3. Inspection and Preventive Maintenance Schedule Inspections Pre-Delivery or Frequent Annual AREA (Quarterly) (Yearly) Inspection Inspection Boom Assembly Boom Weldments 1, 2 1, 2 Hose/Cable Carrier Installations 1, 2...
  • Page 47 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule Inspections Pre-Delivery or Frequent Annual AREA (Quarterly) (Yearly) Inspection Inspection Power System Engine Idle, Throttle, and RPM 1, 3, 7 1, 3, 7 Engine Fluids: Oil Engine Fluids: Coolant 1, 4, 7 1, 4, 7 Air Filter...
  • Page 48 Inspection Inspection Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership Footnotes: Prior to each sale, lease, or delivery In service for 3 months; Out of service for 3 months or more; Purchased used Annually, no later than 13 months from the date of the prior inspection, Includes all daily and quarterly inspections, mandated by regulating body Indicates a 50 hour interval required to perform task after initial use of machine.
  • Page 49 SECTION 2 - GENERAL ENGINE OIL OPERATION CHART DEUTZ D2011 SERIES T4I NOTICE: MACHINE OPERATION USING NON-JLG APPROVED ENGINE OIL OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE "ENGINE OIL OPERATION CHART" MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE.
  • Page 50 SECTION 2 - GENERAL ENGINE OIL OPERATION CHART DEUTZ 2.9 L04 T4F AND 3.6L4 TCD NOTICE: MACHINE OPERATION USING NON-JLG APPROVED ENGINE OIL OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE "ENGINE OIL OPERATION CHART" MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE.
  • Page 51 SECTION 2 - GENERAL NOTICE: MACHINE OPERATION USING NON-JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE "HYDRAULIC FLUID OPERATION CHART" MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE HYDRAULIC SYSTEM. 1001206353_B...
  • Page 52 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 53: Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 CHASSIS COMPONENTS AND SERVICING 1. Drive Hub 5. Lower Track Roller 9. Bottom Cover PLat 13. Washer 17. Bolt 2. Drive Sprocket 6. Upper Track Roller 10. Not Used 14.

  • Page 54: Track Tension

    SECTION 3 - CHASSIS & TURNTABLE Track Tension RUBBER TRACK NOTE: Always check rubber track tension with track off ground. Refer to Figure 3-1. NOTE: Always check rubber or steel track tension with track off 1. Locate the ? mark on inside of track towards the edge. ground.

  • Page 55: Replace Rubber Track

    SECTION 3 - CHASSIS & TURNTABLE Replace Rubber Track 6. Jack up chassis to remove weight from lower rollers. 7. Attach a sling through top of the track and lift. This will 1. Thoroughly wash entire chassis and all components. compress the idler cylinder assembly.
  • Page 56 SECTION 3 - CHASSIS & TURNTABLE 11. Attach a board or other long, rigid object to top of tread 14. Use a crowbar to complete installing over idler. Idler as shown below and lift into position along frame. must engage correctly with rubber track. Figure 3-12.

  • Page 57: Replace Steel Track

    SECTION 3 - CHASSIS & TURNTABLE Replace Steel Track 5. Place a hydraulic floor jack beneath front chassis exten- sion nearest idler wheel. 1. Thoroughly wash entire chassis and all components. Note: Steel track assemblies weigh 340 kg (748 lb) each. 2.
  • Page 58 SECTION 3 - CHASSIS & TURNTABLE 11. Check track direction of travel. Lay out track next to 15. Remove triple grouser shoe from first and last chain chassis with end of track under drive sprocket. links. 12. Slide track under chassis and under rollers, drive sprocket, and idler wheel.
  • Page 59 SECTION 3 - CHASSIS & TURNTABLE 18. Overlap chain links and hold in place with rod or large 21. Track is correctly tensioned when track deflection at screwdriver. Insert master pin and drive into place with position indicated in Figure 3-22. is approximately hydraulic press or similar method.

  • Page 60: Track Shoes

    SECTION 3 - CHASSIS & TURNTABLE Track Shoes 3.2 CHASSIS TILT INDICATOR SYSTEM The Chassis Tilt Indicator System measures the turntable angle 1. Visually check for loose or missing bolts at the start of with respect to level ground. The control system reads the each operating shift.

  • Page 61: Brake Test

    SECTION 3 - CHASSIS & TURNTABLE Brake Test Spring Checking Procedure Install two Flat Socket Head Capscrews 0.250-20 UNC, 1/2" Prior to brake check remove Motor, Tubing and Elbow as per length into holes in brake piston. Tighten bolts evenly to Motor disassembly instructions in the following subsections.

  • Page 62: Brake Leak Repair Procedure

    Re-test input brake. If release and/or lockup pressures still do THE ROLL TEST not match the brake chart contact JLG Service Department. The purpose of the roll test is to determine if the unit gears are rotating consistently, easily and properly. Remove Motor and Grease and install O-ring onto motor pilot.

  • Page 63: Tightening And Torquing Bolts

    SECTION 3 - CHASSIS & TURNTABLE THE LEAK TEST Tightening and Torquing Bolts The purpose of a leak test is to make sure the unit is airtight. To If an air impact wrench is used to tighten bolts, extreme care perform a leak test, use the leak test fixture from the table should be taken to ensure the bolts are not tightened beyond below.

  • Page 64: Lubrication Information

    40 cst under normal NOTE: Record oil condition and volume. operating conditions. Some applications require special con- siderations; consult the JLG Service Department for additional 3. Remove Hydraulic Tubing Assembly (35) by loosening information.
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE Figure 3-26. Swing Motor Valve Removal 31215019 3-13...

  • Page 66: Input Brake Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Input Brake Disassembly Refer to Figure 3-28. 1. Insert and tighten 0.250-20 UNC flat Socket Head Capscrews through the Pressure Plate (8M) and into the Brake Piston (8A) to compress springs and relieve pres- sure on the Retaining Ring (8N).

  • Page 67: Main Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-28. Input Brake Disassembly Main Disassembly 6. Remove Ring Gear (4) from Housing (1G). 7. Remove O-ring (5) between Ring Gear (4) and Housing Refer to Figure 3-29. (1G), discard O-ring. 8. Remove Carrier Sub-Assembly. SAFETY GLASSES MUST BE WORN DURING THESE NEXT STEPS.

  • Page 68: Housing-Shaft Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-29. Main Disassembly Housing-Shaft Disassembly Remove Bearing Cone (1E) from Housing (1G). 6. Use a bearing puller to remove Bearing Cone (1D) from Refer to Figure 3-30. Shaft (1A). 1. Set unit on a bench with Housing (1G) flange down. 7.

  • Page 69: Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-30. Housing Shaft Disassembly Carrier Disassembly 4. Using a hammer and punch, drive pieces of Roll Pin (3G) out of Planet Shaft (3E) and Carrier (3A). Refer to Figure 3-31. 5. Remove both rows of Needle Bearings (3C) and Spacer 1.

  • Page 70: Carrier Assembly

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-31. Carrier Disassembly 3. Place one Spacer (3D) on top of Needle Rollers (3C) Carrier Assembly inside Planet Gear (3F). Refer to Figure 3-32. 4. Install other half of Cluster Gear (3F) with16 Needle Roll- ers (3C).
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE 8. With large end of Cluster Gear (3F) facing roll pin hole in 10. Drive roll pin (3G) through Carrier (3A) and into Planet Carrier, place Cluster Gear in position in Carrier (3A). Shaft (3E) until flush with the bottom of cast slot in Car- Push Planet Shaft (3E) through Cluster Gear (3F) without rier (3A) outside diameter at Thrust Washer (3B) tang.

  • Page 72: Housing - Shaft Assembly

    SECTION 3 - CHASSIS & TURNTABLE Housing - Shaft Assembly 8. Press or tap Bearing Cone (1E) on Output Shaft (1A) until it is just seated in Bearing Cup (1F), while rotating Hous- Refer to Figure 3-33. ing (1G). NOTE: Spray a light film of oil on all component parts during 9.

  • Page 73: Main Assembly

    SECTION 3 - CHASSIS & TURNTABLE Main Assembly 7. After engaging internal gear teeth and before rotating carrier, look at the Carrier sub-assembly in the main Refer to Figure 3-34. assembly and ensure the timing is correct by locating the timing marks in the slots in the carrier and at 1.
  • Page 74 SECTION 3 - CHASSIS & TURNTABLE Figure 3-34. Main Assembly 3-22 31215019...

  • Page 75: Motor And Brake Assembly

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-35. Brake Port Alignment Motor and Brake Assembly 3. Grease O-rings (8D, 8F) and install smaller diameter O-Ring (8F) into smaller diameter O-Ring groove in 1. Starting with a Stator (8K), alternately stack and install Brake Housing (6) and install larger diameter O-Ring Stators (8K) into Lobes of Brake Housing (6) and Rotors (8D) into larger diameter O-Ring groove in Brake Hous-...
  • Page 76 SECTION 3 - CHASSIS & TURNTABLE NOTE: Refer to figure below for installing O-Rings (8D), (8F) and 14. Install Motor (31) in Brake Housing (6). Ensure motor Backup Rings (8E), (8H). valve mounting face is aligned with radial brake release port in Housing (1G).

  • Page 77: Motor Control Valve Installation

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-37. Motor and Brake Assembly Motor Control Valve Installation 6. Install one O-Ring Plug (23) onto Motor Control Valve (32). Torque to 18-20 ft-lb (24.5-27 Nm). NOTE: Verify o-rings are located in between the motor and valve. 7.
  • Page 78 SECTION 3 - CHASSIS & TURNTABLE Figure 3-38. Swing Motor Valve Installation 3-26 31215019...
  • Page 79 SECTION 3 - CHASSIS & TURNTABLE Figure 3-39. Bearing Cone Press Tool Figure 3-40. Bearing Cone Press Tool 31215019 3-27...
  • Page 80 SECTION 3 - CHASSIS & TURNTABLE Figure 3-41. Bearing Cup Press Tool 3-28 31215019...
  • Page 81 SECTION 3 - CHASSIS & TURNTABLE Figure 3-42. Lockout Wrench Tool 31215019 3-29...
  • Page 82 SECTION 3 - CHASSIS & TURNTABLE Figure 3-43. Bearing Cup Press Tool 3-30 31215019...
  • Page 83 SECTION 3 - CHASSIS & TURNTABLE Figure 3-44. Seal Press Tool 31215019 3-31...
  • Page 84 SECTION 3 - CHASSIS & TURNTABLE Figure 3-45. Leak Test Adapter Plate 3-32 31215019...
  • Page 85 SECTION 3 - CHASSIS & TURNTABLE Figure 3-46. Swing Drive Test Plate 31215019 3-33...

  • Page 86: Swing Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.4 SWING MOTOR Disassembly and inspection 1. Place Torqlink™ in a soft jawed vice, with coupling shaft (12) pointed down and vise jaws clamping firmly on sides of housing (18) mounting flange or port bosses. Remove manifold port O-Rings (18A) if applicable.
  • Page 87 SECTION 3 - CHASSIS & TURNTABLE 1. Special Bolts 8B. Stator or Stator Vane 15. Thrust Bearing 2. End Cover 8C. Vane 16. Seal 3. Seal Ring-Commutator 8D. Stator Half 17. Backup Washer 4. Seal Ring 9. Wear Plate 18. Housing 5.
  • Page 88 SECTION 3 - CHASSIS & TURNTABLE 6. Thoroughly wash end cover (2) in proper solvent and 8. Remove commutator (5) and seal ring (3) Remove seal blow dry. Be sure the end cover valve apertures, includ- ring from commutator, using an air hose to blow air into ing the internal orifice plug, are free of contamination.
  • Page 89 SECTION 3 - CHASSIS & TURNTABLE NOTE: The manifold is constructed of plates bonded together to form an integral component not subject to further disas- sembly for service. Compare configuration of both sides oft hem an if old to ensure that same surface is reassembled against the rotor set.
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE 12. Remove drive link (10) from coupling shaft (12) if it was 15. Remove coupling shaft (12), by pushing on the output not removed with rotor set and wear plate. Inspect drive end of shaft. Inspect coupling shaft bearing and seal sur- link for cracks and worn or damaged splines.
  • Page 91 SECTION 3 - CHASSIS & TURNTABLE 17. Remove thrust bearing (15) and thrust washer (14) 19. Remove housing (18) from vise, invert it and remove and Inspect for wear, brinelling, corrosion and a full comple- discard seal (20). A blind hole bearing or seal puller is ment of retained rollers.
  • Page 92 SECTION 3 - CHASSIS & TURNTABLE replaced. If the housing has passed this inspection the NOTE: Depth or location of bearing/bushing (13) in relation to the disassembly of the Torqlink™ is completed. housing wear plate surface and the depth or location of bearing/bushing (19) in relation to the beginning of bear- ing/bushing counterbore should be measured and noted before removing the bearings/ bushings.

  • Page 93: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly Replace all seals and seal rings with new ones each time you reassemble the Torqlink™ unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly. NOTE: Individual seals and seal rings as well as a complete seal kit are available.
  • Page 94 SECTION 3 - CHASSIS & TURNTABLE 2. The Torqlink™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to 0.03 inch (.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the outer bearing/ bushing (19).
  • Page 95 SECTION 3 - CHASSIS & TURNTABLE 4. Place housing (18) assembly into a soft jawed vise with 6. Assemble thrust washer (14) then thrust bearing (15) coupling shaft bore down, clamping against the mount- that was removed from the Torqlink™. ing flange.
  • Page 96 SECTION 3 - CHASSIS & TURNTABLE 9. Apply a small amount of clean grease to a new seal ring (4) and insert it in housing (18) seal ring groove. OUTER BEARING (19) IS NOT LUBRICATED BY SYSTEM HYDRAULIC FLUID. BE SURE IT IS THOROUGHLY PACKED WITH RECOMMENDED GREASE, PARKER GEAR GREASE SPECIFICATION #045236, E/M LUBRICANT #K-70M.
  • Page 97 SECTION 3 - CHASSIS & TURNTABLE 11. Assemble wear plate (9) over drive link (10) and align- NOTE: Rotor set rotor counterbore side must be against wear ment studs to housing (18). plate for drive link clearance and to maintain original rotor-drive link spline contact.
  • Page 98 SECTION 3 - CHASSIS & TURNTABLE 16. Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold. 17. Assemble commutator ring (6) over alignment studs 19. If shuttle valve components items #21, were removed onto the manifold.
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE NOTE: If end cover has a valve (24) or has five bolt holes, use the line previously scribed on the cover to radially align end cover into its original position. 21. Assemble five or seven special bolts (1). Screw in finger tight.

  • Page 100: One Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction 4. Assemble six vanes (8C), or as many vanes that will read- ily assemble into the stator vane pockets. A disassembled rotor (8A) stator (8B) and vanes (8C) that can- not be readily assembled by hand can be assembled by the following procedures.

  • Page 101: Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE 3.5 SWING BEARING 6. Verify the dial indicator has not shifted. Record the value for bearing play. Swing Bearing Wear Tolerance 7. Return the machine to Figure 3-49., Swing Bearing Wear Tolerance, Position 1. The dial indicator should to return See Figure 3-49., Swing Bearing Wear Tolerance.

  • Page 102: Turntable Bearing Mounting Bolt Condition Check

    NOTE: This check is designed to replace the existing bearing bolt c. Lower the boom to horizontal and fully extend the torque checks on JLG Lifts in service. This check must be boom. performed after the first 50 hours of machine operation d.
  • Page 103 SECTION 3 - CHASSIS & TURNTABLE Measurement Point 2" (50.8 mm) DIAL INDICATOR POSITION LOCATION 1 DIAL INDICATOR FEELER GAUGE MEASURING POINT MEASURING POINT POSITION 2 DIAL INDICATOR & FEELER GAUGE MEASURING POINT POSITION 1 MAF06540 Figure 3-49. Swing Bearing Wear Tolerance 31215019 3-51...
  • Page 104 SECTION 3 - CHASSIS & TURNTABLE 3-52 31215019...

  • Page 105: Swing Bearing Removal

    ING. 2. Attach an adequate support sling to the boom and draw JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING BOLTS BE DIS- CARDED AND REPLACED WITH NEW BOLTS. SINCE THE SWING BEARING IS THE all slack from sling. Prop or block the boom if feasible.

  • Page 106: Setting Swing Gear Backlash

    3.6 SETTING SWING GEAR BACKLASH 1. Set swing gear backlash to 0.005 - 0.010 in (0.127 - 0.254 mm). 2. Place shim (JLG PN 1001190964) between pinion and bearing on high spot. 4. Remove turntable lock pin. NOTE: High spot is marked with yellow paint.

  • Page 107: Swing Bearing Torque Values

    SECTION 3 - CHASSIS & TURNTABLE 6. Tighten jack bolt until pinion is completely snug against 3.7 SWING BEARING TORQUE VALUES shim and bearing. After pinion is snug, loosen jack bolt. 1. Outer Race - 190 ft-lb (258 Nm) with High Strength Threadlocking Compound.
  • Page 108 SECTION 3 - CHASSIS & TURNTABLE Figure 3-51. Swing Bearing Torque Sequence 3-56 31215019...

  • Page 109: Rotary Coupling

    SECTION 3 - CHASSIS & TURNTABLE 3.8 ROTARY COUPLING 6. Remove proximity switch. 7. Assemble seals (3) in direction shown in Figure 3-52., Use the following procedure to install the seal kit. Rotary Coupling Seal Installation. 8. Reassemble O-ring (8). 1.
  • Page 110 SECTION 3 - CHASSIS & TURNTABLE 8, 9 MAF06160 1. Body 4. Thrust Ring 7. Bearing 2. Housing 5. Retaining Ring 8. O-Ring 3. Seal 6. O-Ring 9. Seal Figure 3-53. Rotary Coupling Cutaway 3-58 31215019...
  • Page 111 SECTION 3 - CHASSIS & TURNTABLE MAF04550 1. Bolt 5. Nut 9. Lug 13. Locknut 17. Fitting 2. Bolt 6. Nut 10. Switch Mounting Bracket 14. Washer 18. Fitting 3. Fitting 7. Washer 11. Proximity Switch 15. Screw 19. Fitting 4.
  • Page 112 SECTION 3 - CHASSIS & TURNTABLE MAF04560 1. Bolt 5. Washer 9. Lug 13. Locknut 17. Fitting 2. Bolt 6. Swivel Mount 10. Switch Mounting Bracket 14. Washer 18. Fitting 3. Nut 7. Swivel Mount Shim 11. Proximity Switch 15. Screw 19.
  • Page 113 SECTION 3 - CHASSIS & TURNTABLE 1001189523_G MAF04570 Table 3-3. Coupling Port Information - 7 Port Max Rated Pressure Proof Pressure Port No. Port Size Description PSI (Bar) PSI (Bar) -12 SAE Right Drive, FWD 5000 (345) 7500 (517) -12 SAE Left Drive, FWD 5000 (345) 7500 (517)

  • Page 114: Generator

    SECTION 3 - CHASSIS & TURNTABLE 3.9 GENERATOR Overload Protection STOP ENGINE BEFORE CARRY OUT SCHEDULE MAINTENANCE. STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT BREAKER. NOTE: Do often service, if operating in hostile environment. Maintenance Schedule The circuit breaker protects the generator windings from over- load.
  • Page 115 SECTION 3 - CHASSIS & TURNTABLE Brush Position On Slip Rings # E E GR V C DNG 7 P C E E GR V C DNG Brushes must ride completely on slip rings   K P  O O 1T .

  • Page 116: Generator Disassembly And Assembly

    SECTION 3 - CHASSIS & TURNTABLE Generator Disassembly and Assembly 2. Remove brush holder assembly. 3. Disassemble generator parts shown in Figure 3-58. Refer to Figure 3-59. and Figure 3-60. to determine if trouble is in stator, rotor, control box, or combination of these compo- 4.
  • Page 117 SECTION 3 - CHASSIS & TURNTABLE Figure 3-59. Generator Troubleshooting Circuit Diagram - Sheet 1 of 2 31215019 3-65...
  • Page 118 SECTION 3 - CHASSIS & TURNTABLE Figure 3-60. Generator Troubleshooting Circuit Diagram - Sheet 2 of 2 3-66 31215019...
  • Page 119 SECTION 3 - CHASSIS & TURNTABLE 31215019 3-67...
  • Page 120 SECTION 3 - CHASSIS & TURNTABLE 3-68 31215019...
  • Page 121 SECTION 3 - CHASSIS & TURNTABLE Figure 3-63. Power Board PC2 Electrical Circuit Diagram - Sheet 1 of 2 31215019 3-69...
  • Page 122 SECTION 3 - CHASSIS & TURNTABLE Figure 3-64. Power Board PC2 Electrical Circuit Diagram - Sheet 2 of 2 3-70 31215019...

  • Page 123: Lead Connection List For Generator

    SECTION 3 - CHASSIS & TURNTABLE Lead Connection List for Generator NOTE: Apply small amount of dielectric grade, nonconductive electric grease to connectors where factory-applied grease NOTE: Table shows physical lead connections and should be used had been present. with circuit diagram (table replaces wiring diagram). Table 3-4.
  • Page 124 SECTION 3 - CHASSIS & TURNTABLE 3.10 DEUTZ ENGINE (D2011L03) - T4I MAF06060 1. Air Filter 4. Muffler 7. Pump Coupling 2. Radiator 5. Gear Pump 8. Tray 3. Alternator 6. Piston Pump 9. Fan Figure 3-65. Deutz Engine (D2011L03) - T4i (Sheet 1 of 4) 3-72 31215019...
  • Page 125 SECTION 3 - CHASSIS & TURNTABLE MAF06070 10. Fuel Tank 12. Muffler 14. Battery 11. Air Filter 13. Oil Filter Figure 3-66. Deutz Engine (D2011L03) - T4i (Sheet 2 of 4) 31215019 3-73...
  • Page 126 SECTION 3 - CHASSIS & TURNTABLE ENGINE HARNESS ECM MODULE ENGINE HARNESS 1001190869-F MAF06080 Figure 3-67. Deutz Engine (D2011L03) - T4i (Sheet 3 of 4) 3-74 31215019...
  • Page 127 SECTION 3 - CHASSIS & TURNTABLE TORQUE SCREW TO 38N-M [28 FT-LBS] ORIENT PUMP AS SHOWN ASSEMBLE O-RING BETWEEN REAR AXIAL PISTON PUMP AND GEAR PUMP (INLET PORT DOWN) TORQUE SCREW TO 68N-M [50 FT-LBS] ASSEMBLE O-RING BETWEEN FRONT AXIAL PISTON PUMP AND REAR AXIAL PISTON PUMP 1001190868-D MAF06090...
  • Page 128 SECTION 3 - CHASSIS & TURNTABLE Checking Oil Level Changing Engine Oil 1. Make sure machine and engine are level and switch 1. Allow engine to warm up. Engine oil should reach engine OFF before checking oil level. approximately 176° F (80° C). 2.
  • Page 129 SECTION 3 - CHASSIS & TURNTABLE Changing Oil Filter 6. Screw in new filter by hand until gasket is flush. 1. Wipe area around filter to clean any dirt from area. 2. Using a suitable oil filter removal tool, loosen lube oil fil- ter cartridge and spin off.
  • Page 130 SECTION 3 - CHASSIS & TURNTABLE Clean Fuel Strainer FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL SYSTEM. DO NOT SMOKE WHEN WORKING ON THE FUEL SYSTEM. 1.
  • Page 131 SECTION 3 - CHASSIS & TURNTABLE 3.11 DEUTZ ENGINE (D2.9L4) - T4F MAF06000 1. Air Filter 4. Alternator 7. Gear Pump 10. Pump Coupling 2. Radiator Coolant Tank 5. Oil Filter 8. Exhaust System 11. Fan 3. Radiator 6. Fuel Primary Filter 9.
  • Page 132 SECTION 3 - CHASSIS & TURNTABLE MAF06010 13. Fuel Tank 15. Air Filter 17. Exhaust Pipe 14. Fuel Pre-Filter 16. Coolant Expansion Tank 18. Battery Figure 3-72. Deutz Engine (D2.9L4) - T4F (Sheet 2 of 4) 3-80 31215019...
  • Page 133 SECTION 3 - CHASSIS & TURNTABLE ENGINE HARNESS ECM MODULE ENGINE HARNESS 1001227569-B MAF06020 Figure 3-73. Deutz Engine (D2.9L4) - T4F (Sheet 3 of 4) 31215019 3-81...
  • Page 134 SECTION 3 - CHASSIS & TURNTABLE TORQUE SCREW TO 38 N-M [28 FT-LBS] ORIENT PUMP AS SHOWN ASSEMBLE O-RING BETWEEN REAR AXIAL PISTON PUMP AND TORQUE SCREW TO GEAR PUMP (INLET PORT DOWN) 68 N-M [50 FT-LBS] ASSEMBLE O-RING BETWEEN REAR AXIAL PISTON PUMP AND FRONT AXIAL PISTON PUMP 1001227571-A MAF06030...
  • Page 135 SECTION 3 - CHASSIS & TURNTABLE Check Oil Level Change Engine Oil 1. Make sure machine and engine are level and switch 1. Allow engine to warm up. Engine oil should reach engine OFF before checking oil level. approximately 176° F (80° C). 2.
  • Page 136 SECTION 3 - CHASSIS & TURNTABLE Change Oil Filter Change Fuel Filters 1. Wipe area around filter to clean any dirt from area. 2. Using a suitable oil filter removal tool, loosen lube oil fil- FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE ter cartridge and spin off.
  • Page 137 SECTION 3 - CHASSIS & TURNTABLE 3.12 ENGINE FAULT CODES Table 3-5. Engine Fault Code Chart Error Identification No detail information BusOff error CAN; No detail information Plausibility error between sensor and idle switch, Acceleration Pedal Detection. In case of Hand Throttle with Low Idle Switch, it is the plausibility check between hand throttle and idle switch.
  • Page 138 SECTION 3 - CHASSIS & TURNTABLE Table 3-5. Engine Fault Code Chart Error Identification High oil pressure; shut off threshold exceeded Low oil pressure; warning threshold exceeded Low oil pressure; shut off threshold exceeded Sensor error oil pressure; signal range check high Sensor error oil pressure sensor;...
  • Page 139 SECTION 3 - CHASSIS & TURNTABLE Table 3-5. Engine Fault Code Chart Error Identification Defect fault check for Absolute plausibility test No detail information Sensor error coolant temperature; signal range check high Sensor error coolant temperature; signal range check low Coolant level too low The air mass flow AFS_dm is greater than or equal to AFS_PhysRng.Min_C Physical Range Check low for air mass flow sensor No detail information...
  • Page 140 SECTION 3 - CHASSIS & TURNTABLE Table 3-5. Engine Fault Code Chart Error Identification High oil temperature; shut off threshold exceeded Customer oil temperature: signal unplausible Sensor error oil temperature; signal range check high Sensor error oil temperature; signal range check low Engine speed above warning threshold;...
  • Page 141 SECTION 3 - CHASSIS & TURNTABLE Table 3-5. Engine Fault Code Chart Error Identification Access error EEPROM memory (delete) Access error EEPROM memory (read) Access error EEPROM memory (write) CAN-Bus 0 "BusOff-Status" Injector 1 (in firing order); short circuit Injector 1 (in firing order); interruption of electric connection Injector 2 (in firing order);...
  • Page 142 SECTION 3 - CHASSIS & TURNTABLE Table 3-5. Engine Fault Code Chart Error Identification Cold start aid relay; over temperature error Timeout Error of CAN-Receive-Frame TSC1TE; Set point PWM-Signal Fan, short-circuit to plus PWM-Signal Fan, open load or short circuit to ground PWM-Signal Fan, Open load or short-circuit ground 1079 Failure of sensor supply voltage 1...
  • Page 143 SECTION 3 - CHASSIS & TURNTABLE Table 3-5. Engine Fault Code Chart Error Identification 1188 Wastegate actuator; operating voltage error 1188 Turbocharger wastegate, internal electrical error 1188 Wastegate actuator calibration deviation too large, re-calibration required 1188 Turbocharger wastegate, EOL calibration error 1188 Turbocharger wastegate, learning process aborted 1188...
  • Page 144 SECTION 3 - CHASSIS & TURNTABLE Table 3-5. Engine Fault Code Chart Error Identification 1761 DEF tank, DEF level below second warning threshold 1761 DEF tank, DEF level below third warning threshold 2634 Early opening defect of main relay No detail information 2634 DFC for stuck main relay error No detail information 2659...
  • Page 145 SECTION 3 - CHASSIS & TURNTABLE Table 3-5. Engine Fault Code Chart Error Identification 3031 Urea tank temperature outside of plausible thresholds 3219 DFC SAE J1939 error No detail information 3224 DFC for plausibility error Max for NOx sensor upstream of SCR Cat 3224 DLC Error of CAN-Receive-Frame AT1IG1 NOX Sensor (SCR-system upstream cat;...

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