Oshkosh Corporation JLG E400AJPN Manuals

Manuals and User Guides for Oshkosh Corporation JLG E400AJPN. We have 3 Oshkosh Corporation JLG E400AJPN manuals available for free PDF download: Service And Maintenance Manual, Operation And Safety Manual

Oshkosh Corporation JLG E400AJPN Service And Maintenance Manual (492 pages)

Brand: Oshkosh Corporation | Category: Boom Lifts | Size: 58 MB

General
3
Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Specifications
20
Operating Specifications
20
Capacities
20
Tires
20
Dimensional Data
21
Lubrication Specifications
21
Hydraulic Oil
21
Critical Stability Weights
22
Torque Specifications
22
Major Component Weights
23
Serial Number Locations
23
Maintenance and Lubrication
25
General
34
Machine Preparation, Inspection, and Maintenance
34
Preparation, Inspection, and Maintenance
34
Pre-Start Inspection
34
Pre-Delivery Inspection and Frequent Inspection
34
Annual Machine Inspection
34
Preventative Maintenance
34
Service and Guidelines
35
General
35
Safety and Workmanship
35
Cleanliness
35
Components Removal and Installation
35
Component Disassembly and Reassembly
36
Pressure-Fit Parts
36
Bearings
36
Gaskets
36
Bolt Usage and Torque Application
36
Hydraulic Lines and Electrical Wiring
36
Hydraulic System
36
Lubrication
37
Battery
37
Lubrication and Servicing
37
Lubrication and Information
37
Hydraulic System
37
Hydraulic Oil
37
Changing Hydraulic Oil
37
Lubrication Specifications
37
Cylinder Drift
38
Theory
38
Cylinder Leakage Test
38
Cylinder Thermal Drift
38
Pins and Composite Bearing Repair Guidelines
39
Welding on JLG Equipment
39
Do the Following When Welding on JLG Equipment
39
Do NOT Do the Following When Welding on JLG Equipment
39
Chassis & Turntable
45
Tires & Wheels
45
Tire Inflation
45
Tire Damage
45
Tire Replacement
45
Wheel Replacement
45
Wheel Installation
45
Spindle
46
Setting Wheel Bearing End Play
46
Specifications
46
Checking
46
Greasing Requirements
46
Tilt Module
49
Speed Sensor
51
Drive Hub
57
Roll and Leak Testing
57
Tightening and Torquing Bolts
57
Main Disassembly
58
Output Carrier Disassembly
60
Input Carrier Disassembly
62
Hub-Spindle Disassembly
63
Cover Disassembly
64
Input Carrier Assembly
65
Output Planet Gear Assembly
65
Output Carrier Assembly
66
Hub-Spindle Assembly
66
Cover Assembly
67
Main Assembly
67
Drive Motor
70
Removal
70
Disassembly
70
Inspection
70
Assembly
71
Installation
71
Swing Bearing
73
Turntable Bearing Mounting Bolt Condition Check
73
Wear Tolerance
74
Replacement of Swing Bearing
75
Swing Bearing Torque Value
79
Checking Worm Gear End Play
79
Adjusting End Play
79
Swing Motor
81
Preparation before Disassembly
84
Disassembly and Inspection
84
Assembly
91
One Piece Stator Construction
97
Two Piece Stator Construction
98
Final Checks
98
Battery Maintenance and Charging
99
Battery Maintenance, Quarterly
99
Optional on Board Generator
99
Battery Charging (on Board Charger)
99
Battery Charger
101
Operating Instructions
101
Maintenance Instructions
102
Battery Charger Fault Codes
102
Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell
106
Checking/Changing the Battery Charger Algorithm
106
Generator
107
Engine
107
Alternator
107
Dynamo and Dynamo Voltage Regulator
107
Dynamo Output Fuse
107
Control Fuse
107
Start Battery
109
Engine Starter
109
Start Control Relay
109
Fuel Control Relay
110
Glow Plug Control Relay
110
Glow Plug
110
Fuel Pump
111
Fuel Solenoid
111
Engine Low Oil Pressure Switch
111
Engine Oil Temperature Sensor
111
Alternator Output Current Sensor
112
Engine Speed Sensor
112
RBS Engine/Generator Controller
112
Warnings and Safety Precautions
113
System Controls
113
System Status and Performance Monitoring
113
System Settings
113
RBS Start
114
RBS Shutdown
114
RBS Alarms and Flash Codes
115
Resetting the RBS Controller
115
Maintenance Schedule
115
Troubleshooting
116
APU Engine Start Battery Boosting
117
Supplementary Fuse for APU
118
Tools and Material
118
Procedure
118
Boom & Platform
121
Platform
121
Support Removal
121
Support Installation
122
Rotator and Slave Cylinder Removal
124
Removal
124
Installation
124
Main Boom Powertrack
125
Removal
125
Installation
125
Boom Maintenance
126
Removal
126
Disassembly
127
Inspection
127
Assembly
127
Installation
128
Wear Pads
129
Boom Limit Switches
129
Boom Cleanliness Guidelines
129
Articulating Jib Boom
132
Removal
132
Disassembly
132
Inspection
132
Assembly
132
Boom Synchronizing Procedure
133
Footswitch Adjustment
133
Rotary Actuator
134
Theory of Operation
134
Tools Required for Assembly/Disassembly
134
Disassembly
137
Inspection
140
Assembly
141
Installing Counterbalance Valve
145
Greasing Thrust Washers
146
Testing the Actuator
146
Installation and Bleeding
147
Troubleshooting
148
Powertrack Maintenance
149
Removing a Link
149
Installing a New Link
152
Replacing Fixed End Brackets
157
Replacing Moving End Brackets
159
Skyguard
161
Operation
161
Function Test
161
Diagnostics & Troubleshooting
162
Basic Hydraulic Information & Schematics
164
Lubricating O-Rings in the Hydraulic System
164
Cup and Brush
164
Dip Method
165
Spray Method
165
Brush-On Method
165
Hydraulic Connection Assembly and Torque Specification
166
Tapered Thread Types
166
Straight Thread Types, Tube and Hose Connections
166
Straight Thread Types, Port Connections
167
Flange Connection Types
167
Tightening Methods
167
Assembly and Torque Specifications
168
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections
169
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections
170
Assembly Instructions for 37° (JIC) Flare Fittings
171
Assembly Instructions for 45° SAE Flare Fittings
175
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
177
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
179
Assembly Instructions for Bulkhead (BH) Fittings
181
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings
193
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends
201
Assembly Instructions for Adjustable Port End (BSPP) Fittings
203
Assembly Instructions for Flange Connections: (FL61 and FL62)
211
Double Wrench Method
214
FFWR and TFFT Methods
215
Adjustable Stud End Assembly
215
O-Ring Installation (Replacement)
216
Hydraulic Cylinders
217
Slave Cylinder (E400AN Only)
217
Slave Cylinder (E400AJP/M400AJP/E400AJPN/M400AJPN Only)
222
Jib Lift Cylinder
227
Lower Lift Cylinder (E400AN Only)
232
Lower Lift Cylinder (E400AJP/M400AJP/E400AJPN/M400AJPN Only)
239
MID Lift Cylinder(E400AN Only)
246
MID Lift Cylinder (E400AJP/M400AJP/E400AJPN/M400AJPN Only)
253
Upper Lift Cylinder
260
Master Cylinder (E400AN Only)
268
Master Cylinder (E400AJP/M400AJP/E400AJPN/M400AJPN Only)
273
Steer Cylinder
278
Telescope Cylinder (E400AN Only)
283
Telescope Cylinder (E400AJP/M400AJP/E400AJPN/M400AJPN Only)
288
Cylinder Removal and Installation
296
Main Boom Lift Cylinder Removal
296
Main Boom Lift Cylinder Installation
296
MID Boom Lift Cylinder Removal
297
MID Boom Lift Cylinder Installation
297
Lower Boom Lift Cylinder Removal
298
Lower Boom Lift Cylinder Installation
298
Main Boom Telescope Cylinder Removal
299
Main Boom Telescope Cylinder Installation
299
Pressure Setting Procedures
300
Main Relief
300
Main Lift down Relief
300
Lower Lift down Relief
300
Telescope Relief
300
Platform Level up Relief
301
Platform Level down Relief
301
Steer Relief
302
Jib Lift (up and Down) Relief
302
Releveling Valve Relief
302
Jlg Control System
329
Introduction
329
To Connect the JLG Control System Analyzer
330
Using the Analyzer
330
Changing the Access Level of the Hand Held Analyzer
331
Adjusting Parameters Using the Hand Held Analyzer
332
Machine Setup
332
Level Vehicle Description
333
Machine Personality Settings
341
Test Notes
351
Function Speed
351
Help Descriptions and Fault Flash Codes
362
Analyzer Diagnostics Menu Structure
369
System Self Test
375
Calibrating Steer
380
Calibrating Tilt Sensor
382
Calibrating Load Sensing
383
LSS System
386
Diagnostic Menu
387
Calibration Procedure
388
Testing & Evaluation
393
Troubleshooting
394
Resetting the MSSO System
395
Basic Electrical Information & Schematics
415
General
415
Multimeter Basics
415
Grounding
415
Backprobing
415
Min/Max
415
Polarity
415
Scale
415
Voltage Measurement
415
Resistance Measurement
416
Continuity Measurement
416
Current Measurement
417
Checking Switches
417
Basic Check
417
Limit Switches
417
Automatic Switches
418
Switch Wiring - Low Side, High Side
418
Installation of Dielectric Grease
419
Deutsch HD, DT, DTM, DRC Series
419
AWP Seal
419
AMP Mate-N-Lok
420
DIN Connectors
420
Exclusions
420
AMP Connector
422
Applying Silicone Dielectric Compound to AMP Connectors
422
Assembly
422
Disassembly
424
Wedge Lock
424
Service - Voltage Reading
424
DEUTSCH Connectors
426
DT/DTP Series Assembly
426
DT/DTP Series Disassembly
426
HD30/HDP20 Series Assembly
427
HD30/HDP20 Series Disassembly
427
Wiring Harness Connector Labels
428
Connector Labels
428
Component Labels
428

Oshkosh Corporation JLG E400AJPN Service And Maintenance Manual (261 pages)

Brand: Oshkosh Corporation | Category: Boom Lifts | Size: 20 MB

Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Section 1 - Specifications
16
Operating Specifications
16
Capacities
16
Battery Charger
16
Drive System
16
Hydraulic Pump/Electric Motor Assembly
16
Generator
16
Tires
16
Dimensional Data
17
Function Speeds
17
Machine Orientation When Doing Function Tests
18
Torque Specifications
18
Cylinder Specifications
19
Major Component Weights
19
Critical Stability Weights
20
Pressure Settings
20
Serial Number Locations
21
Lubrication
21
Lubrication Specifications
21
Operator Maintenance & Lubrication
23
Section 2 - General
34
Machine Preparation, Inspection, and Maintenance
34
General
34
Preparation, Inspection, and Maintenance
34
Pre-Start Inspection
34
Pre-Delivery Inspection and Frequent Inspection
34
Annual Machine Inspection
34
Preventive Maintenance
34
Service and Guidelines
35
General
35
Safety and Workmanship
35
Cleanliness
35
Components Removal and Installation
35
Component Disassembly and Reassembly
36
Pressure-Fit Parts
36
Bearings
36
Gaskets
36
Bolt Usage and Torque Application
36
Hydraulic Lines and Electrical Wiring
36
Hydraulic System
36
Lubrication
36
Battery
36
Lubrication and Servicing
36
Hydraulic Oil
37
Changing Hydraulic Oil
37
Lubrication Specifications
37
Cylinder Drift Test
37
Platform Drift
37
Cylinder Drift
37
Pins and Composite Bearing Repair Guidelines
38
Welding on JLG Equipment
38
Do the Following When Welding on JLG Equipment
38
Do NOT Do the Following When Welding on JLG Equipment
38
Engine Operating Temperature Specifications - Kubota
42
Section 3 - Chassis & Turntable
44
Tires & Wheels
44
Tire Inflation
44
Tire Damage
44
Tire Replacement
44
Wheel Replacement
44
Wheel Installation
44
Spindle
45
Setting Wheel Bearing End Play
45
Specifications
45
Checking
45
Greasing Requirements
45
Drive Hub (Part No. 2780236)
47
Dissembling
47
Disassembly
48
Disassembly of the First Stage Planetary Assembly (7)
48
Disassembly of Second Stage Planet Gears (1)
48
Assembly of First Stage Planetary Assembly (7)
48
Assembly of End Cover Unit (8)
48
Final Assembly
49
Initial Start-Up and after Repairs
49
Maintenance
49
Oil Change Interval-Gear Drive
49
Setting of Tapered Roller Bearings
49
Securing of the Shaft Nut
49
Drive Hub- Cutaway
49
Drive Brake - Mico
51
Disassembly
51
Assembly
51
Bleeding
51
Drive Brake
51
Speed Sensor Adjustment
54
Adjustment Procedure
54
Speed Sensor Orientation
55
Speed Sensor Installation Verification
59
Verification W/ Analyzer Procedure
59
Positrac/Tilt Module
62
Swing Motor - S/N 0300135649 to Present
64
Swing Motor - Cutaway
64
Swing Motor - Exploded View
66
Preparation before Disassembly
67
Disassembly and Inspection
67
Assembly
73
One Piece Stator Construction
80
Two Piece Stator Construction
81
Final Checks
81
Swing Bearing
82
Turntable Bearing Mounting Bolt Condition Check
82
Swing Bearing Feeler Gauge Check
82
Wear Tolerance
83
Swing Bearing Tolerance Boom Placement
83
Replacement of Swing Bearing
84
Swing Bearing Tolerance Measuring Point
84
Swing Bearing Torquing Sequence
85
Swing Bearing Torque Value
86
Checking Worm Gear End Play
86
Adjusting End Play
86
Battery Maintenance and Charging
88
Battery Maintenance, Quarterly
88
Charging Sequence of Remote LED Card
88
Remote LED Card
88
Battery Cable Connections
89
Battery Charging (on Board Charger)
90
Optional on Board Generator
90
Batteries and Battery Charger (Prior to S/N 0300059350)
90
On Board Generator
90
Battery Charger (S/N 0300059350 to Present)
92
Battery Charger ((S/N 0300059350 to Present)
92
Operating Instructions
92
Maintenance Instructions
92
Battery Charger Fault Codes
92
Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell
95
Checking/Changing the Battery Charger Algorithm
96
Generator (Prior to S/N 88539)
97
Alternator
97
Dynamo and Dynamo Voltage Regulator
97
Dynamo Output Fuse
97
Control Fuse
97
Start Battery
97
Engine Starter
97
Start Control Relay
97
Fuel Control Relay
97
Fuel Solenoid
97
To Connect the JLG Control System Analyzer to the Generator
100
Alarms and Fault Flash Codes
100
Output Current and Voltage Settings
102
Priming the Fuel Line
103
Generator (S/N 88539 to Present)
104
Engine
104
Alternator
104
Dynamo and Dynamo Voltage Regulator
104
Dynamo Output Fuse
104
Control Fuse
104
Start Battery
106
Engine Starter
106
Start Control Relay
106
Fuel Control Relay
107
Glow Plug Control Relay
107
Glow Plug
107
Fuel Pump
108
Fuel Solenoid
108
Engine Low Oil Pressure Switch
108
Engine Oil Temperature Sensor
108
Alternator Output Current Sensor
109
Engine Speed Sensor
109
RBS Engine/Generator Controller
109
Warnings and Safety Precautions
110
System Controls
110
System Status and Performance Monitoring
110
System Settings
110
RBS Start
111
RBS Shutdown
111
RBS Alarms and Flash Codes
112
Resetting the RBS Controller
112
Maintenance Schedule
112
Troubleshooting
113
APU Engine Start Battery Boosting
114
Supplementary Fuse for Apu
115
Tools and Material
115
Procedure
115
Section 4 - Boom & Platform
118
Boom Maintenance
118
Removal
118
Disassembly
118
Inspection
119
Assembly
119
Installation
120
Upper (Main) Boom Lift Cylinder
121
Removal
121
Installation
121
MID Boom Lift Cylinder
121
MID Boom Lift Cylinder Removal
121
Installation
122
Lower Boom Lift Cylinder
122
Removal
122
Lower Boom Lift Cylinder Removal
122
Upper Boom Telescope Cylinder
123
Removal
123
Installation
123
MID and Lower Lift Cylinder Bleeding Procedure
124
Wear Pads
124
Boom Synchronizing Procedure
125
Articulating Jib Boom
125
Removal
125
Disassembly
125
Inspection
125
Assembly
127
Footswitch Adjustment
127
Boom Limit Switches
127
Helac Rotary Actuator
129
Theory of Operation
129
Tools Required for Assembly/Disassembly
132
Disassembly
132
Inspection
136
Assembly
136
Installing Counterbalance Valve
140
Testing the Actuator
140
Installation and Bleeding
142
Troubleshooting
143
Powertrack Maintenance
144
Removing a Link
144
Installing a New Link
147
Replacing Fixed End Brackets
152
Replacing Moving End Brackets
154
Section 5 - Hydraulics
157
Lubricating O-Rings in the Hydraulic System
157
Cup and Brush
157
Dip Method
158
Spray Method
158
Brush-On Method
158
Cylinders - Theory of Operation
159
Double Acting Cylinder
159
Cylinder Checking Procedures
159
Cylinder Without Counterbalance Valves
159
Cylinders with Single Counterbalance Valve
159
Cylinders with Dual Counterbalance Valve
170
Cylinder Repair
170
Disassembly
170
Cleaning and Inspection
171
Assembly
172
Pressure Setting Procedures
176
Main Relief
176
Upper Lift down Relief
176
Lower Lift down Relief
176
Telescope Relief
176
Platform Level up Relief
176
Platform Level down Relief
177
Steer Relief
177
Jib Lift (up and Down) Relief
177
Jib Swing Relief
177
Releveling Valve Relief
177
Section 6 - Jlg Control System
184
JLG Control System Analyzer Kit Instructions
184
Introduction
184
To Connect the JLG Control System Analyzer
185
Using the Analyzer
186
Changing the Access Level of the Hand Held Analyzer
187
Adjusting Parameters Using the Hand Held Analyzer
188
Machine Setup
188
Machine Personality Settings
189
Machine Configuration Programming Information
193
Level Vehicle Description
194
Help Descriptions and Fault Flash Codes
194
Analyzer Diagnostics Menu Structure
204
System Self Test
205
Section 7 - Basic Troubleshooting, Electrical Information, & Schematics
218
General
218
Troubleshooting
218
Multimeter Basics
236
Grounding
236
Backprobing
236
Min/Max
236
Polarity
236
Scale
236
Voltage Measurement
236
Resistance Measurement
237
Continuity Measurement
237
Current Measurement
238
Checking Switches
238
Basic Check
238
Limit Switches
238
Automatic Switches
239
Switch Wiring - Low Side, High Side
239
Applying Silicone Dielectric Compound to Electrical Connections
239
AMP Connector
240
Applying Silicone Dielectric Compound to AMP Connectors
240
Assembly
240
Disassembly
242
Wedge Lock
242
Service - Voltage Reading
242
Deutsch Connectors
244
DT/DTP Series Assembly
244
DT/DTP Series Disassembly
244
HD30/HDP20 Series Assembly
245
HD30/HDP20 Series Disassembly
245

Oshkosh Corporation JLG E400AJPN Operation And Safety Manual (103 pages)

Brand: Oshkosh Corporation | Category: Boom Lifts | Size: 19 MB

Table of Contents
7
Section 1 - Safety Precautions
12
General
12
Pre-Operation
12
Operator Training and Knowledge
12
Workplace Inspection
13
Machine Inspection
14
Operation
14
General
14
Trip and Fall Hazards
15
Electrocution Hazards
16
Minimum Approach Distances (M.A.D.)
17
Tipping Hazards
18
Beaufort Scale (for Reference Only)
20
Crushing and Collision Hazards
21
Towing, Lifting, and Hauling
22
Maintenance
22
Maintenance Hazards
22
Battery Hazards
23
Section 2 - User Responsibilities, Machine Preparation, and Inspection
24
2.1 Personnel Training
24
Operator Training
24
Training Supervision
24
Operator Responsibility
25
Machine Familiarization
25
2.2 Preparation, Inspection, and Maintenance
25
Inspection and Maintenance Table
26
Basic Nomenclature
27
Pre-Start Inspection
28
Walk-Around Inspection
30
Function Check
33
Skyguard Function Test
34
Section 3 - Machine Controls and Indicators
35
General
35
Controls and Indicators
35
Ground Control Console
36
Ground Control Console
37
Platform Console
41
Platform Control Console
42
Platform Control Indicator Panel
46
Platform Control Indicator Panel
47
Section 4 - Machine Operation
50
Description
50
Boom Operating Characteristics and Limitations
50
Capacities
50
Platform Load Sensing System (LSS)
51
Stability
51
Position of Least Backward Stability
51
Position of Least Forward Stability
52
Motor Operation
54
Power/Emergency Stop
54
Platform/Ground Select Switch
54
Motor Activation
54
Traveling (Driving)
55
Traveling Forward and Reverse
56
Grade and Side Slopes
57
Traveling on a Grade
58
Steering
58
Platform
58
Loading from Ground Level
58
Loading from Positions above Ground Level
58
Platform Level Adjustment
59
Platform Rotation
59
Jib Swing
59
Boom
59
Swinging the Boom
60
Raising and Lowering the Lower and MID Boom
60
Raising and Lowering the Upper Boom
60
Generator
61
Automatic Operating Mode
61
Battery Only Operating Mode
61
Manual (Charge) Operating Mode
62
Inverter
62
4.10 Machine Function Speeds
63
Machine Safety System Override (Msso)
63
(Ce Only)
63
4.12 Skyguard Operation
64
Skyguard
64
Skyguard - Skyline
64
Skyguard - Skyeye
65
Skyguard Function Table
65
4.13 Boom Synchronizing Procedure
66
4.14 Shut down and Park
66
4.15 Machine Lifting and Tie down
67
Lifting
67
Tie down
67
Lifting Chart
68
E400An/E400Ajpn Decal Legend
75
Section 5 - Emergency Procedures
78
General
78
Incident Notification
78
Emergency Operation
78
Operator Unable to Control Machine
78
Platform or Boom Caught Overhead
79
Emergency Towing Procedures
79
Manual Descent System
80
Manual Swing Override
80
Machine Safety System Override (Msso)
80
(Ce Only)
80
Section 6 - Accessories
81
Available Accessories
81
Pipe Racks
82
Safety Precautions
82
Preparation and Inspection
83
Operation
83
Section 7 - General Specifications & Operator Maintenance
84
Introduction
84
Operating Specifications
84
Capacities
85
Tires
86
Dimensional Data
86
Tire Specifications
86
Torque Specifications
87
Hydraulic Oil
87
Torque Requirements
87
Mobil DTE 10 Excel 15 Specs
88
Mobil EAL Envirosyn H 32 Specs
88
Critical Stability Weights
89
Mobil EAL Envirosyn SHC 32 Specs
89
Serial Number Locations
90
Maintenance and Lubrication
92
Lubrication Specifications
92
Battery Maintenance and Charging
98
Battery Maintenance, Quarterly
98
Optional on Board Generator
98
Battery Charging (on Board Charger)
99
Tires & Wheels
99
Tire Damage
99
Tire Replacement
100
Wheel Replacement
100
Wheel Installation
100
Supplemental Information
101
Wheel Torque Chart
101

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