JLG M400 Parts Manual User Manual
JLG Special machinery
This manual is related to the following products:
Table of contents
Document Outline
- SECTION 1 - FRAME
- FIGURE 1-1. STEERING INSTALLATION - E400AJP - M400AJP
- FIGURE 1-2. STEERING INSTALLATION - E400AN - E400AJPN - M400AJPN
- FIGURE 1-3. HUB - SPINDLE ASSEMBLY - R.H.
- FIGURE 1-4. HUB - SPINDLE ASSEMBLY - L.H. - E400AJP - M400AJP
- FIGURE 1-5. HUB - SPINDLE ASSEMBLY - R.H. - E400AN - E400AJPN - M400AJPN
- FIGURE 1-6. HUB - SPINDLE ASSEMBLY - L.H. - E400AN - E400AJPN - M400AJPN
- FIGURE 1-7. WHEEL DRIVE - E400AN - E400AJP - E400AJPN
- FIGURE 1-8. WHEEL DRIVE - E400AN - E400AJP - E400AJPN - UL LISTED
- FIGURE 1-9. WHEEL DRIVE - M400AJP - M400AJPN
- FIGURE 1-10. HUB - DRIVE ASSEMBLY
- FIGURE 1-11. DRIVE MOTOR ASSEMBLY
- FIGURE 1-12. TIRE/WHEEL - IN240/55-17.5 PNEUMATIC
- FIGURE 1-13. TIRE/WHEEL - IN240/55 - 17.5 FOAM FILL
- FIGURE 1-14. TIRE/WHEEL - SOLID NON-MARKING
- FIGURE 1-15. TIRE/WHEEL - 26 X 7 X 20 - SOLID NON MARKING
- FIGURE 1-16. TIRE/WHEEL - IN240/55-17.5 PNEUMATIC NON MARKING
- FIGURE 1-17. TIRE/WHEEL - IN240/55-17.5 FOAM FILLNON MARKING
- FIGURE 1-18. TIRE/WHEEL - IN240/55-17.5 PNEUMATIC TS
- FIGURE 1-19. WHEEL COVER INSTALLATION - IN240/55-17.5 TIRES ONLY
- FIGURE 1-20. MOTOR/PUMP/TANK - E400AN - E400AJP - E400AJPN
- FIGURE 1-21. MOTOR/PUMP/TANK - M400AJP
- FIGURE 1-22. MOTOR/PUMP/TANK - E400AN - E400AJP - E400AJPN - UL LISTED
- FIGURE 1-23. MOTOR/PUMP/TANK - M400AJPN
- FIGURE 1-24. MOTOR/PUMP ASSEMBLY
- FIGURE 1-25. HYDRAULIC TANK ASSEMBLY - E400AN - E400AJP - E400AJPN
- FIGURE 1-26. HYDRAULIC TANK ASSEMBLY - M400AJP - M400AJPN
- FIGURE 1-27. VALVE INSTALLATION - FRAME MOUNTED - E400AN
- FIGURE 1-28. VALVE INSTALLATION - FRAME MOUNTED - E400AJP - E400AJPN
- FIGURE 1-29. VALVE INSTALLATION - FRAME MOUNTED - M400AJP - M400AJPN
- FIGURE 1-30. AKE/STEER VALVE ASSEMBLY
- FIGURE 1-31. BATTERY BOX INSTALLATION
- FIGURE 1-32. BATTERY BOX INSTALLATION - AGM BATTERIES
- FIGURE 1-33. BATTERY BOX INSTALLATION - CE
- FIGURE 1-34. BATTERY CHARGER INSTALLATION - E400AN - E400AJP - E400AJPN
- FIGURE 1-35. BATTERY CHARGER INSTALLATION - E00AJP - E400AJPN
- FIGURE 1-36. BATTERY CHARGER INSTALLATION - E400AN - E400AJP - E400AJPN
- FIGURE 1-37. BATTERY CHARGER INSTALLATION - M400AJP
- FIGURE 1-38. BATTERY CHARGER INSTALLATION - M400AJP
- FIGURE 1-39. BATTERY CHARGER INSTALLATION - M400AJP
- FIGURE 1-40. BATTERY CHARGER INSTALLATION - M400AJPN
- FIGURE 1-41. BATTERY CHARGER INSTALLATION - M400AJPN
- FIGURE 1-42. BATTERY CHARGER INSTALLATION - M400AJPN
- FIGURE 1-43. INVERTER INSTALLATION - E400AJP - M400AJP
- FIGURE 1-44. INVERTER INSTALLATION - E400AN - E400AJPN - M400AJPN
- FIGURE 1-45. FRAME COVER INSTALLATION - E400AJP
- FIGURE 1-46. FRAME COVER INSTALLATION - M400AJP
- FIGURE 1-47. FRAME COVER INSTALLATION - E400AN - E400AJPN
- FIGURE 1-48. FRAME COVER INSTALLATION - M400AJPN
- SECTION 2 - TURNTABLE
- FIGURE 2-1. VALVE INSTALLATION - TURNTABLE MOUNTED - E400AN
- FIGURE 2-2. VALVE INSTALLATION - TURNTABLE MOUNTED - E400AJP - E400AJPN
- FIGURE 2-3. VALVE INSTALLATION - TURNTABLE MOUNTED - M400AJP - M400AJPN
- FIGURE 2-4. MAIN CONTROL VALVE ASSEMBLY
- FIGURE 2-5. RELEVELING VALVE ASSEMBLY
- FIGURE 2-6. JIB VLAVE ASSEMBLY
- FIGURE 2-7. MOTION ALARM INSTALLATION
- FIGURE 2-8. TURNTABLE BEARING AND SWING DRIVE INSTALLATION
- FIGURE 2-9. SWING BEARING ASSEMBLY
- FIGURE 2-10. SWING MOTOR ASSEMBLY
- FIGURE 2-11. REMOTE BEARING LUBE INSTALLATION - OPTIONAL
- FIGURE 2-12. DRIVE ORIENTATION INSTALLATION
- FIGURE 2-13. FUEL TANK AND BATTERY INSTALLATION - M400AJP - M400AJPN
- FIGURE 2-14. GROUND CONTROL BOX ASSEMBLY
- FIGURE 2-15. GROUND CONTROL BOX ASSEMBLY
- FIGURE 2-16. GROUND CONTROL BOX ASSEMBLY
- FIGURE 2-17. GROUND CONTROL BOX ASSEMBLY
- FIGURE 2-18. MOTOR CONTROLS INSTALLATION - M400AJP - M400AJPN
- FIGURE 2-19. STROBE LIGHT INSTALLATION - OPTIONAL
- FIGURE 2-20. STROBE LIGHT INSTALLATION - UL LISTED - OPTIONAL
- FIGURE 2-21. STROBE LIGHT ASSEMBLY
- FIGURE 2-22. HOOD INSTALLATION - E400AN
- FIGURE 2-23. HOOD INSTALLATION - E400AJP - E400AJPN - M400AJP - M400AJPN
- SECTION 3 - ENGINE
- SECTION 4 - BOOM
- FIGURE 4-1. BOOM AND CYLINDERS INSTALLATION - E400AN
- FIGURE 4-2. BOOM AND CYLINDERS INSTALLATION
- FIGURE 4-3. MAIN BOOM ASSEMBLY - E400AN
- FIGURE 4-4. MAIN BOOM ASSEMBLY - E400AJP - E400AJPN - M400AJP - M400AJPN
- FIGURE 4-5. JIB INSTALLATION
- FIGURE 4-6. ROTATOR ASSEMBLY - E400AN
- FIGURE 4-7. ROTATOR ASSEMBLY - E400AJP - E400AJPN - M400AJP - M400AJPN
- FIGURE 4-8. ROTATOR ASSEMBLY - E400AJP - E400AJPN - M400AJP - M400AJPN
- FIGURE 4-9. PLATFORM SUPPORT INSTALLATION
- FIGURE 4-10. CABLES AND CLAMPS INSTALLATION
- FIGURE 4-11. CABLES AND CLAMPS INSTALLATION
- FIGURE 4-12. LIMIT SWITCHES INSTALLATION
- SECTION 5 - PLATFORM
- FIGURE 5-1. PLATFORM ASSEMBLY - 4FT/1.22M
- FIGURE 5-2. PLATFORM ASSEMBLY - 5FT/1.52M
- FIGURE 5-3. PLATFORM ASSEMBLY - 5FT/1.52M - W/STOP
- FIGURE 5-4. PLATFORM ASSEMBLY - 4FT/1.22M - DROP BAR ENTRY
- FIGURE 5-5. PLATFORM ASSEMBLY - 5FT/1.52M - DROP BAR ENTRY
- FIGURE 5-6. TRAY ASSEMBLY
- FIGURE 5-7. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION
- FIGURE 5-8. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - UL LISTED
- FIGURE 5-9. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION
- FIGURE 5-10. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - UL LISTED
- FIGURE 5-11. PLATFORM CONSOLE ASSEMBLY - SN 0300189901 THROUGH 0300194237
- FIGURE 5-12. PLATFORM CONSOLE ASSEMBLY - SN 0300194238 TO PRESENT
- FIGURE 5-13. PLATFORM CONSOLE ASSEMBLY - UL LISTED - SN 0300189901 THROUGH 0300194237
- FIGURE 5-14. PLATFORM CONSOLE ASSEMBLY - UL LISTED - SN 0300194238 TO PRESENT
- FIGURE 5-15. PLATFORM CONSOLE ASSEMBLY - SN 0300189901 THROUGH 0300194237
- FIGURE 5-16. PLATFORM CONSOLE ASSEMBLY - SN 0300194238 TO PRESENT
- FIGURE 5-17. PLATFORM CONSOLE ASSEMBLY - UL LISTED - SN 0300189901 THROUGH 0300194237
- FIGURE 5-18. PLATFORM CONSOLE ASSEMBLY - UL LISTED - SN 0300194238 TO PRESENT
- FIGURE 5-19. LIGHT PANEL DECAL INSTALLATION
- FIGURE 5-20. SEALED ENCLOSURES - UL LISTED
- FIGURE 5-21. CONTROLLER ASSEMBLY - DRIVE AND STEER - SN 0300189901 THROUGH 0300194237
- FIGURE 5-22. CONTROLLER ASSEMBLY - DRIVE AND STEER - SN 0300194238 TO PRESENT
- FIGURE 5-23. CONTROLLER ASSEMBLY - DRIVE AND STEER - SN 0300189901 THROUGH 0300194237
- FIGURE 5-24. CONTROLLER ASSEMBLY - LIFT AND SWING - SN 0300194238 TO PRESENT
- FIGURE 5-25. FOOTSWITCH ASSEMBLY
- FIGURE 5-26. MOTOR CONTROLS INSTALLATION - M400AJP - M400AJPN
- SECTION 6 - CYLINDER
- FIGURE 6-1. STEER CYLINDER ASSEMBLY
- FIGURE 6-2. LIFT CYLINDER ASSEMBLY - LOWER - E400AN
- FIGURE 6-3. LIFT CYLINDER ASSEMBLY - LOWER - E400AJP - E400AJPN - M400AJP - M400AJPN
- FIGURE 6-4. LIFT CYLINDER ASSEMBLY - MID - E400AN
- FIGURE 6-5. LIFT CYLINDER ASSEMBLY - MID - E400AJP - E400AJPN - M400AJP - M400AJPN
- FIGURE 6-6. LIFT CYLINDER - UPPER - E400AN
- FIGURE 6-7. LIFT CYLINDER - UPPER - E400AJP - E400AJPN - M400AJP - M400AJPN
- FIGURE 6-8. MASTER CYLINDER ASSEMBLY - E400AN
- FIGURE 6-9. MASTER CYLINDER ASSEMBLY - E400AJP - E400AJPN - M400AJP - M400AJPN
- FIGURE 6-10. PLATFORM LEVEL CYLINDER - E400AN
- FIGURE 6-11. PLATFORM LEVEL CYLINDER - JIB - E400AJP - E400AJPN - M400AJP - M400AJPN
- FIGURE 6-12. JIB CYLINDER ASSEMBLY - E400AJP - E400AJPN - M400AJP - M400AJPN
- FIGURE 6-13. TELESCOPE CYLINDER ASSEMBLY - E400AN
- FIGURE 6-14. TELESCOPE CYLINDER ASSEMBLY - E400AJP - E400AJPN - M400AJP - M400AJPN
- FIGURE 6-15. COUNTERBALANCE VALVE ASSEMBLY
- SECTION 7 - HYDRAULIC
- SECTION 8 - ELECTRICAL
- FIGURE 8-1. ELECTRICAL DIAGRAM LIST
- FIGURE 8-2. BATTERY CHARGER HARNESS
- FIGURE 8-3. CONTACTOR CABLE KIT - E400AN - E400AJP - E400AJPN
- FIGURE 8-4. CONTACTOR CABLE KIT - E400AN - E400AJP - E400AJPN - UL LISTED
- FIGURE 8-5. CONTACTOR CABLE KIT - M400AJP - M400AJPN
- FIGURE 8-6. CONTACTOR PLATE ASSEMBLY AND HARNESSES
- FIGURE 8-7. CONTACTOR PLATE ASSEMBLY AND HARNESSES - UL LISTED
- FIGURE 8-8. STEER/BRAKE HARNESS - E400AN - E400AJP - E400AJPN
- FIGURE 8-9. MOTOR/STEER/BRAKE HARNESS - M400AJP - M400AJPN
- FIGURE 8-10. LED REMOTE HARNESS
- FIGURE 8-11. BATTERY CHARGER COMPONENTS
- FIGURE 8-12. INVERTER HARNESS - SN 0300189901 THROUGH 0300193793
- FIGURE 8-13. INVERTER HARNESS - SN 0300193794 TO PRESENT
- FIGURE 8-14. DRIVE ORIENTATION HARNESS
- FIGURE 8-15. GROUND CONTROL FUNCTION SWITCH HARNESS ASSEMBLY
- FIGURE 8-16. GROUND CONTROL VALVE HARNESS ASSEMBLY
- FIGURE 8-17. TURNTABLE/FRAME HARNESS ASSEMBLY
- FIGURE 8-18. HORN/BEACON HARNESS ASSEMBLY
- FIGURE 8-19. POSI-TRACK MODULE CAN HARNESS ASSEMBLY
- FIGURE 8-20. GROUND CONTROL CAN HARNESS ASSEMBLY
- FIGURE 8-21. GENERATOR HARNESS TO GROUND CONTROL BOX
- FIGURE 8-22. MAIN BOOM HARNESS ASSEMBLY
- FIGURE 8-23. TOWER BOOM HARNESS ASSEMBLY
- FIGURE 8-24. BOOM LIMIT SWITCH HARNESS - LOWER
- FIGURE 8-25. BOOM LIMIT SWITCH HARNESS - UPPER
- FIGURE 8-26. JIB HARNESS - AJP MODELS ONLY
- FIGURE 8-27. INDICATOR LAMP HARNESS ASSEMBLY
- FIGURE 8-28. PLATFORM FUNCTION SWITCH HARNESS ASSEMBLY - E400AN
- FIGURE 8-29. PLATFORM FUNCTION SWITCH HARNESS ASSEMBLY - E400AJP - E400AJPN - M400AJP - M400AJPN
- FIGURE 8-30. PLATFORM CAN BUS HARNESS ASSEMBLY
- FIGURE 8-31. ANALYZER HARNESS ASSEMBLY
- FIGURE 8-32. DRIVE ORIENTATION HARNESS ASSEMBLY
- FIGURE 8-33. PLUG AND RECEPTACLE INSTALLATION - 110V - ANSI SPEC
- FIGURE 8-34. PLUG AND RECEPTACLE INSTALLATION - SUPPLIED LOCALLY
- FIGURE 8-35. PLUG AND RECEPTACLE 220V INSTALLATION - ANSI SPEC
- FIGURE 8-36. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 POST GROUND - 2 X 4 BOX - CE SPEC
- FIGURE 8-37. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 SIDE GROUND - 2 X 4 BOX - CE SPEC
- FIGURE 8-38. PLUG AND RECEPTACLE 220V INSTALLATION - AFSINT 107 KEYED GROUND - 2 X 4 BOX - CE SPEC
- FIGURE 8-39. PLUG AND RECEPTACLE 110V INSTALLATION - IEC 60309 - YELLOW - CE SPEC
- FIGURE 8-40. PLUG AND RECEPTACLE 220V INSTALLATION IEC 60309 BLUE - CE SPEC
- FIGURE 8-41. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 POST GROUND - 70MM X 70MM BOX - CE SPEC
- FIGURE 8-42. PLUG AND RECEPTACLE 220VINSTALLATION - CEE7 SIDE GROUND - 70MM X 70MM BOX - CE SPEC
- FIGURE 8-43. LOWER BOOM 110V HARNESS ASSEMBLY
- FIGURE 8-44. LOWER BOOM 220V HARNESS ASSEMBLY W/BREAKER BOX - CE SPEC
- FIGURE 8-45. LOWER BOOM 220V HARNESS ASSEMBLY WITHOUT BREAKER BOX - CE SPEC
- FIGURE 8-46. MAIN BOOM 110V HARNESS ASSEMBLY
- FIGURE 8-47. MAIN BOOM 220V HARNESS ASSEMBLY - CE SPEC
- FIGURE 8-48. BREAKER BOX KIT WITH TWO BREAKERS - CE SPEC
- FIGURE 8-49. BREAKER BOX KIT WITH THREE BREAKERS - CE SPEC
- FIGURE 8-50. AC PLUGS AND SOCKETS INSTALLATION - CEE7 POST GROUND 2 X 4 BOX - CE SPEC
- FIGURE 8-51. AC PLUGS AND SOCKETS INSTALLATION - CEE7 SIDE GROUND 2 X 4 BOX - CE SPEC
- FIGURE 8-52. AC PLUGS AND SOCKETS INSTALLATION - AFSINT 107-2-01 KEYED GROUND - 2 X 4 BOX - CE SPEC
- FIGURE 8-53. PLUGS AND SOCKETS INSTALLATION - IEC 60309 YELLOW - CE SPEC
- FIGURE 8-54. PLUGS AND SOCKETS INSTALLATION - IEC 60309 BLUE - CE SPEC
- FIGURE 8-55. AC PLUGS AND SOCKETS INSTALLATION - CEE7 POST GROUND - CE SPEC
- FIGURE 8-56. AC PLUGS AND SOCKETS INSTALLATION - CEE7 POST GROUND - CE SPEC
- FIGURE 8-57. STROBE LIGHT - AMBER - HARNESS
- FIGURE 8-58. STROBE LIGHT HARNESS
- FIGURE 8-59. CHARGER CORD PLUG INSTALLATION - 220V - CEE7 POST GROUND - CE SPEC
- FIGURE 8-60. CHARGER CORD PLUG INSTALLATION - 220V - CEE7 SIDE GROUND - CE SPEC
- FIGURE 8-61. CHARGER CORD PLUG INSTALLATION - 220V - AFSINT 107 KEYED GROUND - CE SPEC
- FIGURE 8-62. CHARGER CORD PLUG INSTALLATION - 110V - IEC 60309 - YELLOW - CE SPEC
- FIGURE 8-63. CHARGER CORD PLUG INSTALLATION - 220V - IEC 60309 - BLUE- CE SPEC
- SECTION 9 - DECALS
- FIGURE 9-1. DECAL INSTALLATION - JLG LOGO - E400AN
- FIGURE 9-2. DECAL INSTALLATION - JLG LOGO - E400AJP - E400AJPN - M400AJP - M400AJPN
- FIGURE 9-3. DECAL INSTALLATION - ANSI SPEC - E400AN - E400AJP - E400AJPN
- FIGURE 9-4. DECAL INSTALLATION - ANSI SPEC - M400AJP - M400AJPN
- FIGURE 9-5. DECAL INSTALLATION - CE/AUSTRALIAN SPEC -E400AN - E400AJP - E400AJPN
- FIGURE 9-6. DECAL INSTALLATION - CE/AUSTRALIAN SPEC - M400AJP - M400AJPN
- FIGURE 9-7. DECAL INSTALLATION - JAPANESE SPEC - E400AN - E400AJP - E400AJPN
- FIGURE 9-8. DECAL INSTALLATION - JAPANESE SPEC - M400AJP - M400AJPN
- FIGURE 9-9. DECAL INSTALLATION - KOREAN SPEC - E400AN - E400AJP - E400AJPN
- FIGURE 9-10. DECAL INSTALLATION - KOREAN SPEC - M400AJP - M400AJPN
- FIGURE 9-11. DECAL INSTALLATION - SPANISH/ENGLISH SPECS - E400AN - E400AJP - E400AJPN
- FIGURE 9-12. DECAL INSTALLATION - SPANISH/ENGLISH SPECS - M400AJP - M400AJPN
- FIGURE 9-13. DECAL INSTALLATION - FRENCH/ENGLISH SPECS - E400AN - E400AJP - E400AJPN
- FIGURE 9-14. DECAL INSTALLATION - FRENCH/ENGLISH SPECS - M400AJP - M400AJPN
- FIGURE 9-15. DECAL INSTALLATION - CHINESE/ENGLISH - E400AN - E400AJP - E400AJPN
- FIGURE 9-16. DECAL INSTALLATION - CHINESE/ENGLISH - M400AJP - M400AJPN
- FIGURE 9-17. DECAL INSTALLATION - SPANISH/PORTUGUESE - E400AN - E400AJP - E400AJPN
- FIGURE 9-18. DECAL INSTALLATION - SPANISH/PORTUGUESE SPECS - M400AJP - M400AJPN
- SECTION 10 - RECOMMENDED SERVICE PARTS STOCK
- SECTION 11 - SPECIAL OPTIONS
- PART NUMBER INDEX