INTRODUCTION
3120895
– JLG Lift –
A-1
SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A
GENERAL
This section contains the general safety precautions
which must be observed during maintenance of the aerial
platform. It is of utmost importance that maintenance per-
sonnel pay strict attention to these warnings and precau-
tions to avoid possible injury to themselves or others, or
damage to the equipment. A maintenance program must
be followed to ensure that the machine is safe to operate.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM
SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE
MANUFACTURER.
The specific precautions to be observed during mainte-
nance are inserted at the appropriate point in the manual.
These precautions are, for the most part, those that apply
when servicing hydraulic and larger machine component
parts.
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising
a portion of the equipment, ensure that adequate support
is provided.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON-
TROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY
IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.
B
HYDRAULIC SYSTEM SAFETY
It should be noted that the machines hydraulic systems
operate at extremely high potentially dangerous pres-
sures. Every effort should be made to relieve any system
pressure prior to disconnecting or removing any portion of
the system.
Relieve system pressure by cycling the applicable control
several times with the engine stopped and ignition on, to
direct any line pressure back into the reservoir. Pressure
feed lines to system components can then be discon-
nected with minimal fluid loss.
C
MAINTENANCE
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON-
NEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
• ENSURE REPLACEMENT PARTS OR COMPONENTS
ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS
OR COMPONENTS.
• NO SMOKING IS MANDATORY. NEVER REFUEL DUR-
ING ELECTRICAL STORMS. ENSURE THAT FUEL
CAP IS CLOSED AND SECURE AT ALL OTHER
TIMES.
• REMOVE ALL RINGS, WATCHES AND JEWELRY
WHEN PERFORMING ANY MAINTENANCE.
• DO NOT WEAR LONG HAIR UNRESTRAINED, OR
LOOSE-FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.
• OBSERVE AND OBEY ALL WARNINGS AND CAU-
TIONS ON MACHINE AND IN SERVICEMANUAL.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM
STANDING SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSUR-
IZED COOLANT SYSTEM.
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL
BOOM HAS BEEN SAFELY RESTRAINED FROM ANY
MOVEMENT BY BLOCKING OR OVERHEAD SLING,
OR BOOM SAFETY PROP HAS BEEN ENGAGED.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT
OFF ALL POWER CONTROLS.
• BATTERY SHOULD ALWAYS BE DISCONNECTED-
DURING REPLACEMENT OF ELECTRICAL COMPO-
NENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACH-
MENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
Содержание JLG 400S
Страница 1: ...Service and Maintenance Manual Models 400S 460SJ P N 3120895 December 6 2012...
Страница 2: ......
Страница 20: ...xvi JLG Lift 3120895 LIST OF TABLES TABLE NO TITLE PAGE NO This page left blank intentionally...
Страница 47: ...SECTION 2 GENERAL 3120895 JLG Lift 2 9 Figure 2 1 Engine Operating Temperature Specifications Deutz 4150548 D...
Страница 48: ...SECTION 2 GENERAL 2 10 JLG Lift 3120895 Figure 2 2 Engine Operating Temperature Specifications Ford 4150548 D...
Страница 50: ...SECTION 2 GENERAL 2 12 JLG Lift 3120895 Figure 2 4 Engine Operating Temperature Specifications GM 4150548 D...
Страница 52: ...SECTION 2 GENERAL 2 14 JLG Lift 3120895 NOTES...
Страница 59: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 7 Figure 3 2 Drive Hub Part No 2780246 4WD Steer...
Страница 100: ...SECTION 3 CHASSIS TURNTABLE 3 48 JLG Lift 3120895 Figure 3 35 Swing Drive Installation...
Страница 101: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 49 Figure 3 36 Swing Motor...
Страница 105: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 53 Figure 3 38 Swing Brake S N 64802 to Present...
Страница 107: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 55 Figure 3 39 Swing Torque Hub...
Страница 116: ...SECTION 3 CHASSIS TURNTABLE 3 64 JLG Lift 3120895 A B C D C E Figure 3 40 Auxiliary Pump Sheet 1 of 2...
Страница 124: ...SECTION 3 CHASSIS TURNTABLE 3 72 JLG Lift 3120895 Figure 3 44 EFI Component Location...
Страница 136: ...SECTION 3 CHASSIS TURNTABLE 3 84 JLG Lift 3120895 Figure 3 49 Valve Location Chassis...
Страница 137: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 85 Figure 3 50 Hyd Tank Installation...
Страница 143: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 91 This page left blank intentionally...
Страница 144: ...SECTION 3 CHASSIS TURNTABLE 3 92 JLG Lift 3120895 Figure 3 51 Hydraulic Welder 225 4 sht 1 of 2...
Страница 149: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 97 Figure 3 54 Deutz EMR 2 Troubleshooting Flow Chart...
Страница 150: ...SECTION 3 CHASSIS TURNTABLE 3 98 JLG Lift 3120895 Figure 3 55 Deutz EMR 2 Vehicle Side Connection Diagram...
Страница 151: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 99 Figure 3 56 Deutz EMR 2 Engine Side Connection Diagram Sheet 1 of 2...
Страница 152: ...SECTION 3 CHASSIS TURNTABLE 3 100 JLG Lift 3120895 Figure 3 57 Deutz EMR 2 Engine Side Connection Diagram Sheet 2 of 2...
Страница 153: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 101 Figure 3 58 EMR 2 Engine Plug Pin Identification...
Страница 154: ...SECTION 3 CHASSIS TURNTABLE 3 102 JLG Lift 3120895 Figure 3 59 EMR 2 Vehicle Plug Pin Identification...
Страница 155: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 103 Figure 3 60 EMR2 Fault Codes Sheet 1 of 5...
Страница 156: ...SECTION 3 CHASSIS TURNTABLE 3 104 JLG Lift 3120895 Figure 3 61 EMR2 Fault Codes Sheet 2 of 5...
Страница 157: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 105 Figure 3 62 EMR2 Fault Codes Sheet 3 of 5...
Страница 158: ...SECTION 3 CHASSIS TURNTABLE 3 106 JLG Lift 3120895 Figure 3 63 EMR2 Fault Codes Sheet 4 of 5...
Страница 159: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 107 Figure 3 64 EMR2 Fault Codes Sheet 5 of 5...
Страница 208: ...SECTION 3 CHASSIS TURNTABLE 3 156 JLG Lift 3120895...
Страница 210: ...SECTION 3 CHASSIS TURNTABLE 3 158 JLG Lift 3120895...
Страница 213: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 161...
Страница 223: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 171 Sensor Transducer Type...
Страница 227: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 175 Sensor Transducer Type...
Страница 229: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 177...
Страница 231: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 179...
Страница 233: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 181...
Страница 235: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 183...
Страница 237: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 185...
Страница 255: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 203...
Страница 259: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 207...
Страница 264: ...SECTION 3 CHASSIS TURNTABLE 3 212 JLG Lift 3120895 NOTES...
Страница 288: ...SECTION 4 BOOM PLATFORM 4 24 JLG Lift 3120895 Figure 4 12 Rotator Counterbalance Valve...
Страница 303: ...SECTION 5 HYDRAULICS 3120895 JLG Lift 5 15 Figure 5 22 Main Valve...
Страница 313: ...SECTION 5 HYDRAULICS 3120895 JLG Lift 5 25 Figure 5 25 Variable Displacement Hydraulic Pump...
Страница 318: ...SECTION 6 JLG CONTROL SYSTEM S N 61718 TO PRESENT 6 2 JLG Lift 3120895 Figure 6 2 ADE Block Diagram...
Страница 322: ...SECTION 6 JLG CONTROL SYSTEM S N 61718 TO PRESENT 6 6 JLG Lift 3120895 Figure 6 4 Control Module Location...
Страница 402: ...SECTION 6 JLG CONTROL SYSTEM S N 61718 TO PRESENT 6 86 JLG Lift 3120895 NOTES...
Страница 413: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 11 Figure 7 13 Connector Installation...
Страница 420: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 18 JLG Lift 3120895 This page left blank intentionally...
Страница 447: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 45 This page left intentionally blank...
Страница 454: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 52 JLG Lift 3120895 Figure 7 56 Hydraulic Schematic Sheet 1 of 6...
Страница 456: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 54 JLG Lift 3120895 Figure 7 58 Hydraulic Schematic Sheet 3 of 6...
Страница 458: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 56 JLG Lift 3120895 Figure 7 60 Hydraulic Schematic Sheet 5 of 6...
Страница 460: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 58 JLG Lift 3120895 NOTES...
Страница 461: ......