JLG 460SJ Service Manual - Manual (Page 138)

SECTION 3 - CHASSIS & TURNTABLE
3-86 – JLG Lift – 3120895
3.22 HYDRAULIC WELDER (225-4)
1. To remove top cover.
a. Remove 4 screws on each side.
b. Pull cover upward.
2. To remove end cover.
a. Remove air intake(4 screws).
b. Remove 4 screws (5mm x 45mm).
c. Holding receptacle panel to welder disconnect
two orange wires coming from front control.
d. Unplug plastic connector.
Replacement of Weld Transformer
1. Remove top cover.
2. Disconnect three heavy wires (6ga) from weld
impedance (transformer).
3. Remove seven position Selecta switch.
4. Disconnect all wires from seven step Selecta switch.
NOTE: Wire numbers to numbers on switch.
5. Un-bolt weld impedance (transformer) from welder.
6. Mount new transformer.
7. Reconnect the small wires to the seven step Selecta
switch.
NOTE: Be sure wire numbers match terminal umbers.
8. Reconnect heavy wires.
NOTE: Be sure those connections are very tight.
9. Re-mount top cover.
Replacement of Hydraulic Motor
1. Remove coupling cover.
2. Loosen setscrew in motor coupling.
3. Remove pressure line, return line and case drain
line.
NOTE: Mark pressure line so you don’t accidentally reverse
the two lines.
4. Remove flow regulator from motor (four bolts).
5. Remove motor from motor mount (two bolts).
6. Remove coupling from motor shaft.
7. Install coupling on new motor.
8. Mount motor to motor mount.
NOTE: Be sure to align coupling.
9. Slide couplings together and tighten setscrews.
10. Remove back cover from motor and install flow reg-
ulator on back.
11. Re-install pressure line, return line and case drain
line.
NOTE: Be sure to put the pressure line into the aluminum
block (flow regulator).
IF YOU ACCIDENTALLY REVERSE THE PRESSURE LINE AND THE
RETURN LINE THE FLOW REGULATOR WILL NOT LIMIT THE
FLOW AND ALLOW THE WELDER TO ROTATE AT THE SPEED
DETERMINED BY THE FLOW. IT WILL NOT LIMIT THE SPEED.
THIS COULD CAUSE SERIOUS DAMAGE TO THE WELDER DUE TO
OVER SPEED.
Replacement of Fine Control
1. Remove receptacle panel including fine control.
2. Disconnect two wires connecting fine control.
3. Remove knob from fine control.
4. Remove hex nut holding fine control in place.
5. Remove defective fine control and install new fine
control.
6. Reconnect wires (polarity doesn’t matter).
7. Re-mount receptacle panel.