Jlg M400 Service Manual Service Manual manuals

Owner’s manuals and user’s guides for Special machinery Jlg M400 Service Manual Service Manual.
We providing 1 pdf manuals Jlg M400 Service Manual Service Manual for download free by document types: User Manual

Jlg M400 Service Manual Service Manual User Manual (258 pages)

Brand: Jlg | Category: Special machinery | Size: 15.82 MB |

English

Table of contents

E400A/AJP

1

E400A/AJPnarrow

1

M400A/AJP

1

M400A/AJPnarrow

1

A GENERAL

3

B HYDRAULIC SYSTEM SAFETY

3

C MAINTENANCE

3

REVISON LOG

4

TABLE OF CONTENTS

5

10

LIST OF FIGURES

11

SECTION 1. SPECIFICATIONS

15

SECTION 1 - SPECIFICATIONS

16

1.10 TORQUE SPECIFICATIONS

17

1.11 CYLINDER SPECIFICATIONS

18

1.12 MAJOR COMPONENT WEIGHTS

18

1.14 PRESSURE SETTINGS

19

1.15 SERIAL NUMBER LOCATIONS

20

1.16 LUBRICATION

20

Lubrication Specifications

20

LUBRICATION

22

SOCKET HEAD CAP SCREWS

27

Magni Coating (Ref 4150701)*

31

SECTION 2. GENERAL

33

2.2 SERVICE AND GUIDELINES

34

Safety and Workmanship

34

Cleanliness

34

SECTION 2 - GENERAL

35

3121827 – JLG Lift – 3-1

43

3.2 SPINDLE

44

Specifications

44

Checking

44

Greasing Requirements

44

3121827 – JLG Lift – 3-3

45

Dissembling

46

3121827 – JLG Lift – 3-5

47

3-6 – JLG Lift – 3121827

48

3121827 – JLG Lift – 3-7

49

3.4 DRIVE BRAKE - MICO

50

Bleeding

50

3121827 – JLG Lift – 3-9

51

3-10 – JLG Lift – 3121827

52

3.5 SPEED SENSOR ADJUSTMENT

53

Adjustment Procedure

53

3-12 – JLG Lift – 3121827

54

3121827 – JLG Lift – 3-13

55

3-14 – JLG Lift – 3121827

56

3121827 – JLG Lift – 3-15

57

3-16 – JLG Lift – 3121827

58

3121827 – JLG Lift – 3-17

59

3-18 – JLG Lift – 3121827

60

3.6 POSITRAC/TILT MODULE

61

3-20 – JLG Lift – 3121827

62

3121827 – JLG Lift – 3-21

63

3-22 – JLG Lift – 3121827

64

3121827 – JLG Lift – 3-23

65

Disassembly and Inspection

66

3121827 – JLG Lift – 3-25

67

3-26 – JLG Lift – 3121827

68

3121827 – JLG Lift – 3-27

69

3-28 – JLG Lift – 3121827

70

3121827 – JLG Lift – 3-29

71

3121827 – JLG Lift – 3-31

73

3-32 – JLG Lift – 3121827

74

3121827 – JLG Lift – 3-33

75

3-34 – JLG Lift – 3121827

76

3121827 – JLG Lift – 3-35

77

3-36 – JLG Lift – 3121827

78

One Piece Stator Construction

79

Two Piece Stator Construction

80

Final Checks

80

3.8 SWING BEARING

81

Wear Tolerance

82

Replacement of Swing Bearing

83

3-42 – JLG Lift – 3121827

84

Swing Bearing Torque Value

85

Checking Worm Gear End Play

85

Adjusting End Play

85

3-44 – JLG Lift – 3121827

86

3.9 BATTERY MAINTENANCE AND

87

CHARGING

87

3-46 – JLG Lift – 3121827

88

Optional On Board Generator

89

3-48 – JLG Lift – 3121827

90

TO PRESENT)

91

Operating Instructions

91

Maintenance Instructions

91

Battery Charger Fault Codes

91

3-50 – JLG Lift – 3121827

92

3121827 – JLG Lift – 3-51

93

NO LIGHTS AT ALL

93

FAULT LED FLASHING

93

3-52 – JLG Lift – 3121827

94

Algorithm

95

3-54 – JLG Lift – 3121827

96

3121827 – JLG Lift – 3-55

97

3-56 – JLG Lift – 3121827

98

Alarms and Fault Flash Codes

99

3-58 – JLG Lift – 3121827

100

3121827 – JLG Lift – 3-59

101

Priming the Fuel Line

102

3121827 – JLG Lift – 3-61

103

3-62 – JLG Lift – 3121827

104

Start Battery

105

Engine Starter

105

Start Control Relay

105

Fuel Control Relay

106

Glow Plug Control Relay

106

Glow Plug

106

Fuel Pump

107

Fuel Solenoid

107

Engine Oil Temperature Sensor

107

Engine Speed Sensor

108

System Controls

109

System Settings

109

RBS Start RBS shutdown

110

RBS Alarms and Flash Codes

111

Resetting the RBS Controller

111

Maintenance Schedule

111

Troubleshooting

112

3121827 – JLG Lift – 3-71

113

Tools And Material

114

Procedure

114

3121827 – JLG Lift – 3-73

115

3-74 – JLG Lift – 3121827

116

4.1 BOOM MAINTENANCE

117

Disassembly

117

Inspection

118

Assembly

118

Installation

119

4.3 MID BOOM LIFT CYLINDER

120

4.4 LOWER BOOM LIFT CYLINDER

121

BLEEDING PROCEDURE

123

4.7 WEAR PADS

123

4.9 ARTICULATING JIB BOOM

124

3121827 – JLG Lift – 4-9

125

4.10 FOOTSWITCH ADJUSTMENT

126

4.11 BOOM LIMIT SWITCHES

126

3121827 – JLG Lift – 4-11

127

4.12 HELAC ROTARY ACTUATOR

128

Theory Of Operation

128

3121827 – JLG Lift – 4-13

129

4-14 – JLG Lift – 3121827

130

4-16 – JLG Lift – 3121827

132

3121827 – JLG Lift – 4-17

133

4-18 – JLG Lift – 3121827

134

4-20 – JLG Lift – 3121827

136

3121827 – JLG Lift – 4-21

137

4-22 – JLG Lift – 3121827

138

Testing the Actuator

139

4-24 – JLG Lift – 3121827

140

Installation and Bleeding

141

4.13 POWERTRACK MAINTENANCE

143

Removing a Link

143

4-28 – JLG Lift – 3121827

144

3121827 – JLG Lift – 4-29

145

Installing a New Link

146

3121827 – JLG Lift – 4-31

147

4-32 – JLG Lift – 3121827

148

3121827 – JLG Lift – 4-33

149

4-34 – JLG Lift – 3121827

150

Replacing Fixed End Brackets

151

4-36 – JLG Lift – 3121827

152

Replacing Moving End Brackets

153

4-38 – JLG Lift – 3121827

154

SECTION 5. HYDRAULICS

155

Dip Method

156

Spray Method

156

Brush-on Method

156

SECTION 5 - HYDRAULICS

157

5-4 – JLG Lift – 3121827

158

5.4 CYLINDER REPAIR

168

Cleaning and Inspection

169

5-20 – JLG Lift – 3121827

174

Platform Level Down Relief

175

Steer Relief

175

Jib Lift (Up and Down) Relief

175

Jib Swing Relief

175

Releveling Valve Relief

175

3121827 – JLG Lift – 5-23

177

5-26 – JLG Lift – 3121827

180

INSTRUCTIONS

181

Introduction

181

6-2 – JLG Lift – 3121827

182

Using the Analyzer

183

Analyzer

184

Machine Setup

185

Machine Personality Settings

186

3121827 – JLG Lift – 6-7

187

6-8 – JLG Lift – 3121827

188

3121827 – JLG Lift – 6-9

189

4150285-6

189

Information

190

Level Vehicle Description

191

6-12 – JLG Lift – 3121827

192

3121827 – JLG Lift – 6-13

193

6-14 – JLG Lift – 3121827

194

3121827 – JLG Lift – 6-15

195

6-16 – JLG Lift – 3121827

196

3121827 – JLG Lift – 6-17

197

To Sheet 2

198

From Sheet 2

200

3121827 – JLG Lift – 6-21

201

System Self Test

202

3121827 – JLG Lift – 6-23

203

6-24 – JLG Lift – 3121827

204

3121827 – JLG Lift – 6-25

205

6-26 – JLG Lift – 3121827

206

3121827 – JLG Lift – 6-27

207

6-28 – JLG Lift – 3121827

208

3121827 – JLG Lift – 6-29

209

6-30 – JLG Lift – 3121827

210

3121827 – JLG Lift – 6-31

211

6-32 – JLG Lift – 3121827

212

3121827 – JLG Lift – 6-33

213

6-34 – JLG Lift – 3121827

214

7.1 GENERAL

215

7.2 TROUBLESHOOTING

215

7-2 – JLG Lift – 3121827

216

3121827 – JLG Lift – 7-3

217

7-4 – JLG Lift – 3121827

218

3121827 – JLG Lift – 7-5

219

7-6 – JLG Lift – 3121827

220

3121827 – JLG Lift – 7-7

221

7-8 – JLG Lift – 3121827

222

3121827 – JLG Lift – 7-9

223

7-10 – JLG Lift – 3121827

224

3121827 – JLG Lift – 7-11

225

7-12 – JLG Lift – 3121827

226

3121827 – JLG Lift – 7-13

227

7-14 – JLG Lift – 3121827

228

3121827 – JLG Lift – 7-15

229

7-16 – JLG Lift – 3121827

230

3121827 – JLG Lift – 7-17

231

7-18 – JLG Lift – 3121827

232

3121827 – JLG Lift – 7-19

233

Resistance Measurement

234

Continuity Measurement

234

Current Measurement

235

7.4 CHECKING SWITCHES

235

Basic Check

235

Limit Switches

235

Automatic Switches

236

COMPOUND TO ELECTRICAL

236

CONNECTIONS

236

7.6 AMP CONNECTOR

237

AMP Connectors

237

7-24 – JLG Lift – 3121827

238

Wedge Lock

239

Service - Voltage Reading

239

7-26 – JLG Lift – 3121827

240

7.7 DEUTSCH CONNECTORS

241

DT/DTP Series Assembly

241

DT/DTP Series Disassembly

241

HD30/HDP20 Series Assembly

242

HD30/HDP20 Series Disassembly

242

3121827 – JLG Lift – 7-29

243

7-30 – JLG Lift – 3121827

244

3121827 – JLG Lift – 7-31

245

7-32 – JLG Lift – 3121827

246

1870227 B

247

7-34 – JLG Lift – 3121827

248

7-36 – JLG Lift – 3121827

250

2792505D

251

7-38 – JLG Lift – 3121827

252

7-40 – JLG Lift – 3121827

254

7-42 – JLG Lift – 3121827

256

(717) 485-5161

258

(717) 485-6417

258

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