JLG 460SJ Service Manual User Manual
Service and maintenance manual
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Table of contents
Document Outline
- Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
- 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
- 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)
- 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
- 3.24 Deutz EMR 2 (S/N 77682 to Present)
- 3.25 GM Engine General Maintenance
- 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
- 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
- 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
- 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