JLG 400S Telescopic Boom Lift Manuals

JLG 400S Telescopic Boom Lift Manuals

Manuals and User Guides for JLG 400S Telescopic Boom Lift. We have 5 JLG 400S Telescopic Boom Lift manuals available for free PDF download: Service And Maintenance Manual, Operation & Maintenance Instructions Manual, Operation And Safety Manual, Operation Manual

JLG 400S Service And Maintenance Manual

JLG 400S Service And Maintenance Manual (662 pages)

Brand: JLG | Category: Lifting Systems | Size: 82 MB

Table of Contents

General
3
Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Specifications

23
General

45
Chassis & Turntable

59
- Tires and Wheels
  59
  - Tire Inflation
    59
  - Tire Damage
    59
  - Tire Replacement
    59
  - Wheel Replacement
    59
  - Wheel Installation
    59
- Chassis Tilt Indicator System
  60
- Drive System (4WD & 2WD)
  60
- Drive Orientation System
  60
- Lockout Cylinder Bleeding
  60
- Oscillating Axle System
  61
- Oscillating Axle Lockout Test
  61
- Axle Installation
  62
- Steer Installation (Without Tow Package)
  63
- Steer Installation (with Tow Package)
  64
  - Wheel Drive Assembly
    65
    
    Installation
    65
    
    Removal
    65
  - Torque Hub
    66
    
    Roll and Leak Testing
    66
    
    Tightening and Torquing Bolts
    66
    
    Hub-Spindle Disassembly
    67
    
    Main Disassembly for "B" Drives
    67
- Drive Hub and Brake Assembly (2WD and 4WD) - Sheet 1 of 2
  68
- Drive Hub and Brake Assembly (2WD and 4WD) - Sheet 2 of 2
  69
- Drive Hub (4WD Front Only) - Sheet 1 of 2
  70
- Drive Hub (4WD Front Only) - Sheet 2Of 2
  71
- Drive Hub (Cross-Section)
  72
  - Cover Disassembly
    73
  - Carrier Disassembly
    73
  - Assemble Carrier
    73
  - Cover Sub-Assembly
    75
  - Hub-Spindle Sub-Assembly
    76
  - Main Assembly
    78
- Cluster Gear Punch Marks
  80
  - Tool List
    83
  - Re-Align Torque Hub Input Coupling
    84
    
    Equipment Required
    84
    
    Procedure
    84
  - Drive Motor
    84
    
    Description
    84
    
    Loop Flushing Valve
    85
    
    Shaft Seal Replacement
    85
    
    Troubleshooting
    86
    
    Disassembly
    87
- End Cap
  88
- Cylinder Kit
  89
  - Swash Plate & Servo Piston
    90
  - Inspection
    91
  - Assembly
    93
- Swash Plate and Journal Bearing
  94
- Cylinder Kit Installation
  95
- End Cap
  96
  - Initial Start-Up Procedures
    97
- Swing System
  98
  - Swing Drive Hub
    99
    
    Brake Test
    99
    
    Brake Leak Repair Procedure
    100
    
    Roll and Leak Test
    100
    
    Spring Checking Procedure
    100
    
    Tightening and Torquing Bolts
    101
    
    Lubrication Information
    102
    
    Motor Removal
    102
    
    Swing Motor Valve Removal
    103
    
    Input Brake Disassembly
    104
    
    Main Disassembly
    105
    
    Housing-Shaft Disassembly
    106
    
    Carrier Disassembly
    107
    
    Carrier Assembly
    108
    
    Housing - Shaft Assembly
    109
    
    Main Assembly
    110
    
    Motor and Brake Assembly
    112
    
    Swing Motor Installation
    113
    
    Motor and Brake Assembly
    114
    
    Motor Control Valve Installation
    115
- Bearing Cone Press Tool
  116
- Bearing Cup Press Tool
  117
- Lockout Wrench Tool
  118
- Bearing Cup Press Tool
  119
- Seal Press Tool
  120
- Leak Test Adapter Plate
  121
- Swing Drive Test Plate
  122
  - Swing Motor
    123
    
    Disassembly and Inspection
    123
- Swing Motor Assembly
  124
  - Assembly
    130
  - One Piece Stator Construction
    137
  - Swing Bearing
    138
    
    Swing Bearing Wear Tolerance
    138
    
    Turntable Bearing Mounting Bolt Condition Check
    139
    
    Swing Bearing Installation
    143
    
    Swing Bearing Removal
    143
    
    Procedure for Setting Swing Gear Backlash
    144
    
    Swing Bearing Torque Values
    145
- Swing Bearing Torque Sequence
  146
  - Rotary Coupling
    147
  - Rotary Coupling Cutaway
    148
- Rotary Coupling Installation
  149
- Rotary Coupling Port Location - (SN 0300203771 through 0300222808)
  150
  - Generator
    152
    
    Inspecting Brushes, Replacing Brushes and Cleaning Slip Rings
    152
    
    Maintenance Schedule
    152
    
    Overload Protection
    152
- Inspecting Generator Brushes, Replacing Brushes and Cleaning Slip Rings
  153
  - Generator Disassembly and Assembly
    154
- Generator Troubleshooting Circuit Diagram - Sheet 1 of 2
  155
- Generator Troubleshooting Circuit Diagram - Sheet 2 of 2
  156
- Power Board PC2 Electrical Circuit Diagram - Sheet 1 of 2
  159
- Power Board PC2 Electrical Circuit Diagram - Sheet 2 of 2
  160
  - Lead Connection List for Generator
    161
  - Deutz Engine
    162
- Deutz D2.9L4 Engine Components - Sheet 2 of 2
  163
- Deutz D2011 Engine Components - Sheet 1 of 3
  164
- Deutz D2011 Engine Components - Sheet 2 of 3
  165
- Deutz D2011 Engine Components - Sheet 3 of 3
  166
  - GM Engine
    167
- GM Engine Components - Sheet 2 of 2
  168
  - Kubota Engine
    169
- Kubota Engine Components - Sheet 2 of 2
  170
  - Deutz Engine - D2.9L4
    171
    
    Check Oil Level
    171
    
    Glow Plugs
    171
    
    Replacing Engine Oil
    171
    
    Replacing the Fuel Filters
    172
    
    Replacing the Oil Filter
    172
  - Deutz Engine - D2011
    173
    
    Check Oil Level
    173
    
    Glow Plugs
    173
    
    Replacing Engine Oil
    174
    
    Replacing the Oil Filter
    175
    
    Replacing the Fuel Filter
    176
  - Deutz EMR 2
    177
- EMR 2 Engine Plug Pin Identification
  182
- EMR 2 Vehicle Plug Pin Identification
  183
  - GM Engine General Maintenance
    189
    
    Checking/Filling Engine Oil Level
    189
    
    Engine Electrical System Maintenance
    189
    
    Maintenance of the Drive Belt
    189
    
    Changing the Engine Oil
    190
    
    Coolant Fill Procedure - Dual Fuel Engine
    190
  - GM Engine Dual Fuel System
    191
    
    Fuel Filter
    191
    
    Electric Lock off
    192
    
    EPR Assembly
    192
    
    Low Pressure Regulator (LPR)
    192
    
    Air Fuel Mixer
    193
    
    Electronic Throttle Control (ETC)
    193
    
    Engine Control Module
    194
    
    Gasoline Multi Point Fuel Injection System (MPFI)
    194
    
    Heated Exhaust Gas Oxygen Sensor
    194
    
    Fuel Filter
    195
    
    Fuel Injector
    195
    
    Fuel Injector Rail
    195
    
    Gasoline Fuel Pump
    195
    
    Gasoline Pressure and Temperature Sensor Manifold
    195
  - GM Engine Fuel System Repair
    196
    
    Propane Fuel System Leak Test
    196
    
    Propane Fuel System Pressure Relief
    196
    
    Propane Fuel Filter Replacement
    197
    
    Electronic Pressure Regulator (EPR) Assembly Replacement
    198
    
    Electronic Throttle Control Replacement
    199
- Mixer Assembly
  200
  - Mixer Replacement
    201
  - Coolant Hose Replacement
    201
  - Vapor Hose Replacement
    201
  - Engine Control Module Replacement
    202
  - Heated Exhaust Gas Oxygen Sensor Replacement
    202
  - GM Engine LPG Fuel System Diagnosis
    203
    
    Diagnostic Aids
    203
    
    Fuel System Description
    203
- GM LPG Fuel System Diagnosis
  204
- GM Engine Symptom Diagnosis
  206
- DTC to SPN/FMI Cross Reference Chart
  214
- Deutz Engine Fault Codes
  216
  - Counterweight
    273
Boom & Platform

275
- Boom Systems
  275
- Telescope Retracted Sensors
  277
- Telescope Retracted Sensors Circuit
  278
- Transport Proximity Switch Installation
  279
- Dual Capacity Sensors
  280
- Dual Capacity Sensors Circuit
  281
- Capacity Switch Installation
  282
  - Platform
    283
    
    Platform/Support Removal
    283
    
    Platform/Support Installation
    284
- Platform Support Torque Values (Without LSS)
  285
- Platform Support Torque Values (Single Cell LSS)
  286
  - Rotator and Platform Level Cylinder
    287
    
    Removal
    287
- Removal/Installation of Components - Rotator and Platform Level Cylinder
  288
  - Installation
    289
  - Main Boom Powertrack
    290
    
    Installation
    290
    
    Removal
    290
- Powertrack Installation
  291
  - Powertrack Maintenance
    292
  - Boom Assembly
    301
    
    Removal
    301
    
    Disassembly
    302
    
    Assembly
    303
    
    Inspection
    303
    
    Installation
    305
  - Jib (460SJ Only)
    306
    
    Assembly
    306
    
    Disassembly
    306
    
    Inspection
    306
    
    Removal
    306
    
    Installation
    307
  - Boom Cleanliness Guidelines
    307
  - Boom Shimming Procedure
    308
  - Rotator Assembly
    309
    
    Theory of Operation
    309
    
    Before Disassembly
    310
    
    Making a Seal Tool
    310
    
    Required Tools
    310
- Rotator - Exploded View
  311
- Rotator - Assembly Drawing
  312
  - Disassembly
    313
  - Inspection
    317
  - Assembly
    317
  - Installing Counterbalance Valve
    323
  - Greasing Thrust Washers
    324
  - Testing the Actuator
    324
  - Installation and Bleeding
    325
  - Skyguard
    326
    
    Function Test
    326
    
    Operation
    326
    
    Diagnostics & Troubleshooting
    327
  - Platform Rotate Bleed Procedure
    328
    
    General Notes & Precautions
    328
    
    Procedure
    328
  - Bolt-On External Fall Arrest
    329
    
    Inspection before Use
    329
    
    Installation
    329
- Bolt-On External Fall Arrest System
  331
Basic Hydraulics Information & Schematics

333
Jlg Control System

441

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JLG 400S Operation And Safety Manual

JLG 400S Operation And Safety Manual (145 pages)

Brand: JLG | Category: Construction Equipment | Size: 28 MB

Table of Contents

Table of Contents
8
Section 1 - Safety Precautions

14
- General
  14
- Pre-Operation
  14
  - Operator Training and Knowledge
    14
  - Workplace Inspection
    15
  - Machine Inspection
    16
- Operation
  16
  - General
    16
  - Trip and Fall Hazards
    17
  - Electrocution Hazards
    18
- Minimum Approach Distances (M.A.D.)
  19
  - Tipping Hazards
    20
- Beaufort Scale (for Reference Only)
  22
  - Crushing and Collision Hazards
    23
  - Towing, Lifting, and Hauling
    24
  - Maintenance
    24
    
    Maintenance Hazards
    24
    
    Battery Hazards
    25
Section 2 - User Responsibilities, Machine Preparation, and Inspection

26
- 2.1 Personnel Training
  26
  - Operator Training
    26
  - Training Supervision
    26
  - Operator Responsibility
    27
  - Machine Familiarization
    27
- 2.2 Preparation, Inspection, and Maintenance
  27
- Inspection and Maintenance Table
  28
- Basic Nomenclature
  29
  - Pre-Start Inspection
    30
  - Walk-Around Inspection
    32
  - Function Check
    35
  - Skyguard Function Test
    36
  - Oscillating Axle Lockout Test (if Equipped)
    37
Section 3 - Machine Controls and Indicators

39
- General
  39
- Controls and Indicators
  39
- Ground Control Console - 400S
  40
- Ground Control Console - 400S W/Msso (CE Only)
  41
- Ground Control Console - 460SJ
  42
- Ground Control Console - 460SJ W/Msso (CE Only)
  43
  - Ground Control Console
    44
- Ground Control Indicator Panel
  47
  - Ground Control Indicator Panel
    48
  - Ground Control Console Display Gauge
    50
- Splash Screen
  50
- Diagnostic Screen
  51
- Engine Diagnostic Screen
  51
- Ground Control Console Display Gauge
  52
- Platform Control Console
  53
  - Platform Console
    54
  - Platform Control Indicator Panel
    59
Section 4 - Machine Operation

63
- Description
  63
- Boom Operating Characteristics and Limitations
  63
  - Capacities
    63
  - Platform Load Sensing System (LSS)
    64
  - Stability
    64
- Position of Least Forward Stability
  65
- Position of Least Backward Stability
  66
  - Engine Operation
    67
    
    Starting Procedure
    67
    
    Shutdown Procedure
    68
    
    Fuel Reserve / Shut-Off System (Diesel Engines Only)
    69
- Grade and Side Slopes
  70
  - Traveling (Driving)
    71
    
    Traveling Forward and Reverse
    72
    
    Traveling on a Grade
    73
- Steering
  73
- Platform
  73
  - Platform Level Adjustment
    73
  - Platform Rotation
    73
- Boom
  74
- Function Speed Control
  75
- Machine Safety System Override (Msso)
  75
  - (Ce Only)
    75
- 4.10 Skyguard Operation
  75
  - Skyguard
    76
  - Skyguard - Skyline
    76
  - Skyguard - Skyeye
    76
  - Skyguard Function Table
    77
- Shut down and Park
  78
- 4.12 Lifting and Tie down
  78
  - Lifting
    78
  - Tie down
    78
- Lifting and Tie down Chart
  79
- Decal Legend - 400S
  87
- Decal Legend - 460SJ
  90
Section 5 - Emergency Procedures

93
- General
  93
- Incident Notification
  93
- Emergency Operation
  93
  - Operator Unable to Control Machine
    93
  - Platform or Boom Caught Overhead
    94
- Emergency Towing Procedures
  94
  - Machines
    94
- Machine Safety System Override (Msso)
  95
  - (Ce Only)
    95
Section 6 - Accessories

97
- Available Accessories
  97
- Options/Accessories Relationship Table
  98
- Fall Arrest
  99
  - Safety Precautions
    99
- Pipe Racks
  99
  - Capacity Specifications (Australia Only)
    100
  - Safety Precautions
    100
  - Preparation and Inspection
    100
  - Operation
    100
- Skyglazier
  101
  - Capacity Specifications
    101
  - Safety Precautions
    102
  - Preparation and Inspection
    102
  - Operation
    102
- Skypower
  103
  - Generator Output
    103
  - Accessory Ratings
    103
  - Safety Precautions
    104
  - Preparation and Inspection
    104
  - Operation
    104
- Skywelder
  104
  - Accessory Ratings
    105
  - Generator Output
    105
  - Welding Accessories
    105
  - Safety Precautions
    106
    
    Preparation and Inspection
    106
    
    Operation
    106
  - Soft Touch
    107
  - Bolt-On External Fall Arrest
    107
    
    Inspection before Use
    108
- Bolt-On External Fall Arrest Cable Tension
  108
- Bolt-On External Fall Arrest System
  109

JLG 400S Operation & Maintenance Instructions Manual

JLG 400S Operation & Maintenance Instructions Manual (164 pages)

Brand: JLG | Category: Boom Lifts | Size: 7 MB

Table of Contents

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JLG 400S Operation And Safety Manual

JLG 400S Operation And Safety Manual (136 pages)

Brand: JLG | Category: Lifting Systems | Size: 2 MB

Table of Contents

Table of Contents
7
Section - Paragraph, Subject

12
Section 1. Safety Precautions

13
- General
  13
- Pre-Operation
  13
  - Operator Training and Knowledge
    13
  - Workplace Inspection
    14
  - Machine Inspection
    14
- Operation
  15
  - General
    15
  - Trip and Fall Hazards
    15
  - Electrocution Hazards
    16
- Minimum Approach Distances (M.A.D.)
  17
  - Tipping Hazards
    18
  - Crushing and Collision Hazards
    19
  - Towing, Lifting, and Hauling
    20
  - Additional Hazards / Safety
    21
- Beaufort Scale (for Reference Only)
  22
Section 2 - User Responsibilities, Machine Preparation, and Inspection

23
Section 3 - Machine Controls and Indicators

35
Section 4 - Machine Operation

55
- Description
  55
- Operating Characteristics and Limitations
  55
  - Capacities
    55
  - Stability
    56
- Position of Least Backward Stability
  56
- Position of Least Forward Stability
  57
  - Engine Operation
    58
    
    Starting Procedure
    58
    
    Shutdown Procedure
    59
  - Traveling (Driving)
    59
- Grades and Sideslopes
  61
  - Traveling Forward or Reverse
    62
Section - Paragraph, Subject Page

63
- Steering
  63
- Parking and Stowing
  63
- Platform
  63
- Boom
  64
- Auxiliary Power - Non Ade Equipped Machines
  66
  - Activating from the Platform Control Station
    66
  - Activating from the Ground Control Station
    66
- 4.10 Auxiliary Power - Ade Equipped
  67
- Machine Tie down - 400S Models
  69
- Machine Tie down - 460SJ Models
  70
- Lifting and Tie down
  71
  - 4.13 Towing
    72
  - 4.14 Placards and Decals
    73
- Decal Installation - Sheet 1 of 4
  74
- Decal Installation - Sheet 2 of 4
  75
- Decal Installation - Sheet 3 of 4
  76
- Decal Installation - Sheet 4 of 4
  77
  - Decals - 400S with 500 Lb (227 or 230 Kg) Capacity
    78
  - Decals - 400S with 750 Lb (340 Kg) Capacity
    82
- Decals - 460SJ
  86
Section 5 - Emergency Procedures

91
- General
  91
- Incident Notification
  91
- Emergency Operation
  91
  - Operator Unable to Control Machine
    91
  - Platform or Boom Caught Overhead
    92
- Emergency Towing Procedures
  92

JLG 400S Operation Manual

JLG 400S Operation Manual (140 pages)

boom lift

Brand: JLG | Category: Lifting Systems | Size: 4 MB

Table of Contents

Table of Contents
7
Section 1. Safety Precautions

15
- General
  15
- Pre-Operation
  15
  - Operator Training and Knowledge
    15
  - Workplace Inspection
    16
  - Machine Inspection
    17
- Operation
  17
  - General
    17
  - Trip and Fall Hazards
    18
  - Electrocution Hazards
    19
  - Tipping Hazards
    21
  - Crushing and Collision Hazards
    24
- Towing, Lifting, and Hauling
  25
- Maintenance
  25
  - Maintenance Hazards
    25
  - Battery Hazards
    27
Section - 2 - User Responsibilities, Machine Preparation

29
And Inspection

29
- 2.1 Personnel Training
  29
  - Operator Training
    29
  - Training Supervision
    29
  - Operator Responsibility
    29
  - 2.2 Preparation, Inspection, and Maintenance
    30
    
    Pre-Start Inspection
    32
    
    Function Check
    33
    
    Skyguard Function Test
    34
    
    General
    37
- Oscillating Axle Lockout Test (if Equipped)
  39
Section 3 - Machine Controls and Indicators

41
- General
  41
- Controls and Indicators
  41
Section 4 - Machine Operation

65
- Description
  65
- Boom Operating Characteristics and Limitations
  66
  - Capacities
    66
  - Stability
    66
- Engine Operation
  66
  - Starting Procedure
    66
  - Shutdown Procedure
    68
  - Fuel Reserve / Shut-Off System
    68
- Traveling (Driving)
  71
  - Traveling Forward and Reverse
    73
  - Traveling on a Grade
    74
- Steering
  74
- Platform
  74
  - Platform Level Adjustment
    74
  - Platform Rotation
    74
- Boom
  75
- Function Speed Control
  76
- Machine Safety System Override
  76
- 4.10 Skyguard Operation
  77
- Shut down and Park
  78
- 4.12 Lifting and Tie down
  78
  - Lifting
    78
  - Tie down
    79
Section 5 - Emergency Procedures

97
- General
  97
- Incident Notification
  97
- Emergency Operation
  97
  - Operator Unable to Control Machine
    97
  - Platform or Boom Caught Overhead
    98
- Emergency Towing Procedures
  98
- Machine Safety System Override
  99

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