Oshkosh JLG 400S Manuals

Manuals and User Guides for Oshkosh JLG 400S. We have 2 Oshkosh JLG 400S manuals available for free PDF download: Service And Maintenance Manual

Oshkosh JLG 400S Service And Maintenance Manual (462 pages)

Aerial Platform

Brand: Oshkosh | Category: Lifting Systems | Size: 30 MB

Bhydraulic System Safety
3
Cmaintenance
3
Table of Contents
5
Section 1 - Specifications
21
Capacities
21
Engine Specifications
21
Tires
22
Specifications and Performance Data
22
Torque Requirements
23
Critical Stability Weights
23
Major Component Weights
24
Function Speeds
24
Pressure Settings - PSI (Bar)
24
Cylinder Specifications
25
Lubrication
25
Hydraulic Oil
25
Welder, Hydraulic (Option)
26
Serial Number Location
26
Operator Maintenance and Lubrication
27
Deutz Engine Dipstick
28
Draining Oil Build up from the Propane Regulator
30
Propane Fuel Filter Replacement
31
Propane Fuel System Pressure Relief
31
Filter Lock Assembly
31
Section 2 - General
39
Machine Preparation, Inspection, and Maintenance
39
General
39
Preparation, Inspection, and Maintenance
39
Pre-Start Inspection
39
Pre-Delivery Inspection and Frequent Inspection
39
Annual Machine Inspection
39
Preventative Maintenance
39
Service and Guidelines
40
General
40
Safety and Workmanship
40
Cleanliness
40
Components Removal and Installation
40
Component Disassembly and Reassembly
41
Pressure-Fit Parts
41
Bearings
41
Gaskets
41
Bolt Usage and Torque Application
41
Hydraulic Lines and Electrical Wiring
41
Hydraulic System
41
Lubrication
41
Battery
41
Lubrication and Servicing
41
Hydraulic Oil
42
Changing Hydraulic Oil
42
Lubrication Specifications
42
Cylinder Drift Test
42
Platform Drift
42
Cylinder Drift
42
Pins and Composite Bearing Repair Guidelines
43
Welding on JLG Equipment
43
Do the Following When Welding on JLG Equipment
43
Do NOT Do the Following When Welding on JLG Equipment
43
Section 3. Chassis & Turntable
53
Tires & Wheels
53
Tire Inflation
53
Tire Damage
53
Tire Replacement
53
Wheel Replacement
53
Wheel Installation
53
Drive Hub Part No. 2780243 (2Wd Rear) Part No. 2780244 (4Wd Rear)
54
Drive Hub (Part No. 2780243-2WD Rear & Part No. 2780244-4WD Rear)
54
Disassembly
54
Disassembly of Cover Unit (8)
55
Disassembly of First Stage Planetary Assembly
55
Disassembly of the Second Stage Planet Gears (1)
55
Assembly of First Stage Planetary Assembly (7)
55
Assembly of End Cover Unit (8)
55
Final Assembly
55
Drive Hub Part No. 2780246 (4Wd Steer Axle Prior to S/N 0300076633)
57
Disassembly
57
Disassembly of Cover Unit (8)
57
Disassembly of First Stage Planetary Assembly
57
Disassembly of the Second Stage Planet Gears (1)
57
Assembly of First Stage Planetary Assembly (7)
58
Assembly of End Cover Unit (8)
58
Final Assembly
58
Drive Hub (Part No. 2780246-4WD Steer)
59
Torque Hub - 4WD (Machines Built after S/N 0300076633)
60
Roll and Leak Testing
60
Tightening and Torquing Bolts
60
Oil Information
60
Main Disassembly for "B" Drives
60
Hub-Spindle Disassembly
61
Cover Disassembly
61
Carrier Disassembly
61
Assembly of the Carrier
62
Cover Sub-Assembly
64
Hub-Spindle Sub-Assembly
65
Main Assembly
67
Tool List
72
Re-Aligning Torque Hub Input Coupling
73
Equipment Required
73
Procedure
73
Drive Brake
74
Pre-Installation Checks
74
Installation
75
Maintenance
75
Disassembly
75
Examination
75
Assembly
75
Drive Motor
77
Description
77
Shaft Seal Replacement
77
Endcap
77
Loop Flushing Valve
78
Troubleshooting
79
Disassembly
80
Valve Plate & Rear Shaft Bearing
81
Shaft Seal
82
Shaft & Front Bearing
82
Cylinder Kit Assembly
82
Inspection
84
Assembly
86
Swash Plate and Journal Bearing
87
Shaft and Front Bearing
88
Servo Spring and Minimum Angle Stop
88
Valve Plate and Rear Bearing
89
End Cap
89
Shaft Seal
90
Initial Start-Up Procedures
91
Adjustment Procedure for Lockout Valve
92
Toe-In Adjustment
92
2WD Hub
93
Removal & Disassembly
93
Cleaning & Inspection
93
Assembly & Installation
94
Oscillating Axle Bleeding Procedure
95
Oscillating Axle Lockout Test
95
Swing Bearing
96
Turntable Bearing Mounting Bolt Condition Check
96
Wear Tolerance
97
Replacement of Swing Bearing
98
Swing Bearing Torque Value
99
Swing Drive Installation
99
Swing Brake (Prior to S/N 64802)
102
Installation
102
Brake Disassembly
102
Assembly Information
102
Swing Brake S/N 64802 to Present
104
Disassembly
104
Assembly
104
Swing Drive Torque Hub
106
Disassembly Procedure
106
Hub Shaft Sub-Assembly Procedure
110
Carrier Sub-Assembly Procedure
112
Semi-Track
113
Testing the Track
113
Removing the Track
114
Assuming Normal Wear
114
Adjustment
114
Generator
118
Every 250 Hours
118
Every 500 Hours
118
Overload Protection
118
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
118
Ford EFI Engine
120
Performing Diagnostics
120
Visual/Physical Engine Inspection Check
120
EFI Diagnostics (Prior to S/N 61718)
120
ECM and Sensors
121
Fuel System
127
Throttle Checks and Adjustments - Deutz Engine (Prior to S/N 61718)
131
General
131
Procedure
132
Controller Status
132
Failure Modes
132
Tilt Alarm Switch (Prior to S/N 61718)
135
Manual Adjustment
135
Hydraulic Welder (225-4)
138
Replacement of Weld Transformer
138
Replacement of Hydraulic Motor
138
Replacement of Fine Control
138
Rotor Replacement
139
Replacement of Flow Regulator
139
Replacement of Exciting Rectifier Bridge
139
Replacement of Weld Rectifier Bridge
140
Replace Brushes on Sky Welder
140
Replacing Range Switch
140
Replacing Selector Switch
140
Replacement of Couplings
141
Voltage Change over - 120/240 Volt
141
Troubleshooting of the Sky Welder
142
Low Sky Welder Speed
142
Low Welding Amps
142
No Output on Weld Receptacles or AC Receptacles
142
No Ac Output but Weld Output
142
No Output on Weld Receptacle but AC Receptacle Output OK
146
Welder Completely Dead - no AC or Weld Power
146
Intermittent Welder Operation
146
Deutz EMR 2 (S/N 77682 to Present)
147
GM Engine General Maintenance
160
Maintenance of the Drive Belt
160
Engine Electrical System Maintenance
160
Checking/Filling Engine Oil Level
160
Changing the Engine Oil
161
Coolant Fill Procedure - Dual Fuel Engine
161
GM Engine Dual Fuel System
163
Fuel Filter
163
Electric Lock off
163
EPR Assembly
164
Low Pressure Regulator (LPR)
164
Air Fuel Mixer
165
Electronic Throttle Control (ETC)
165
Engine Control Module
166
Heated Exhaust Gas Oxygen Sensor
166
Gasoline Multi Point Fuel Injection System (MPFI)
166
Gasoline Fuel Pump
167
Gasoline Pressure and Temperature Sensor Manifold
167
Fuel Filter
167
Fuel Injector Rail
167
Fuel Injector
167
Section no
167
GM Engine Fuel System Repair
168
Propane Fuel System Pressure Relief
168
Propane Fuel System Leak Test
168
Propane Fuel Filter Replacement
168
Electronic Pressure Regulator (EPR) Assembly Replacement
169
Temperature Manifold Absolute Pressure (TMAP) Sensor
170
Electronic Throttle Control Replacement
171
Mixer Replacement
172
Coolant Hose Replacement
172
Vapor Hose Replacement
172
Engine Control Module Replacement
173
Heated Exhaust Gas Oxygen Sensor Replacement
173
GM Engine LPG Fuel System Diagnosis
173
Fuel System Description
173
Diagnostic Aids
174
Perkins Engine General Maintenance
190
Replacing the Engine Crankcase Breather
190
Engine Oil Level - Check
190
Engine Oil and Filter - Change
190
Fuel Filter/Water Separator
192
Setting the Actuator
193
Speed Sensor Installation
194
Engine Radiator Fill Procedure - Perkins & Caterpillar
194
Dgc Diagnostic Support and Trouble Code Definitions
196
Section Layout
196
List of Abbreviations in this Section
197
Fault Code Broadcast
198
Diagnostic Trouble Codes
198
Can
198
MIL Output
199
Diagnostic Calibration Configuration and Corrective Actions
199
Fault/Diagnostic Trouble Code Interaction
200
DBW Diagnostic Test
205
Diagnostic Trouble Code Fault Descriptions
206
DTC 116- ECT Higher than Expected Stage 1
206
DTC 117- ECT/CHT Low Voltage
207
DTC 118- ECT/CHT High Voltage
209
DTC 122- TPS1 Signal Voltage Low
211
DTC 123- TPS1 Signal Voltage High
214
DTC 217- ECT Higher than Expected 2
216
DTC 219- RPM Higher than Max Allowed Governed Speed
217
DTC 336- Crank Signal Input Noise
218
DTC 337- Loss of Crank Input Signal
220
DTC 521- Oil Pressure Sender/Switch High Pressure
221
DTC 524- Oil Pressure Low
224
DTC 562- Battery Voltage (Vbat) Low
228
DTC 563- Battery Voltage (Vbat) High
230
DTC 601- Microprocessor Failure - FLASH
232
DTC 604- Microprocessor Failure - RAM
234
DTC 606- Microprocessor Failure - COP
236
DTC 642- 5 Volt External Low Voltage
238
DTC 643- 5 Volt External High Voltage
240
DTC 1612- Microprocessor Failure - RTI 1
242
DTC 1613- Microprocessor Failure - RTI 2
243
DTC 1614- Microprocessor Failure - RTI 3
245
DTC 1615- Microprocessor Failure - A/D
247
DTC 1616- Microprocessor Failure - Interrupt
249
DTC 1625- CAN J1939 Shutdown Request
251
DTC 1626- CAN J1939 Transmit (Tx) Fault
252
DTC 1627- CAN J1939 Receive (Rx) Fault
253
DTC 1628- CAN Address Conflict Failure
254
DTC 1629- J1939 TSC1 Message Reciept Loss
256
DTC 1652- TPS1 Loss of Communications
257
DTC 2111- Unable to Reach Lower TPS
258
DTC 2112- Unable to Reach Higher TPS
260
DTC 9999- Throttle Actuator Failsafe Spring Failure
261
DTC to SPN/FMI Table
262
Section 4 - Boom & Platform
265
Boom
265
Removal
265
Disassembly
266
Inspection
267
Assembly
268
Installation
269
Articulating Jib
270
Removal
270
Limit Switch Adjustments
270
Boom Horizontal Limit Switch
270
Dual Capacity Angle Limit Switch
270
Boom Length Limit Switch
270
Drive Card Setup Procedures
274
Machine Orientation When Doing Speed Tests
274
Test Notes
274
Lift, Swing, and Drive Cards
275
Flow Control Card
275
Helac Rotary Actuator
277
Theory of Operation
277
Tools Required for Assembly/Disassembly
280
Disassembly
280
Inspection
284
Assembly
284
Installing Counterbalance Valve
287
Section 5 - Hydraulics
289
Cylinders - Theory of Operation
289
Systems Incorporating Double Acting Cylinders
289
Systems Incorporating Holding Valves
289
Cylinder Repair
289
Cylinders Without Counterbalance Valves
289
Cylinders with Dual Counterbalance Valves
289
Disassembly
290
Cleaning and Inspection
291
Assembly
292
Valves - Theory of Operation
302
Solenoid Control Valve
302
Relief Valves
305
Pressure Setting Procedures
305
Bang-Bang Main Relief Valve
305
Steer
305
Platform Level up
305
Platform Level down
305
Articulating Jib up
305
Articulating Jib down
306
The Bang-Bang Main Relief Valve
306
The Proportional Main Relief Valve
306
Lift down
306
Swing
306
Hydraulic Motor Repair (H Series Char-Lynn)
306
Disassembly
306
Reassembly Shaft End
308
Gerotor End
310
Timing Procedure
311
Standard Rotation
311
Reverse Rotation
311
Hydraulic Pump "Neutral" or Null Adjustment
314
Non-Feedback, Proportional Electrical Control - NFPE
314
Features and Benefits of the NFPE Control
314
Input Signal Requirements
314
Hydraulic Component Start-Up Procedures and Recommendations
315
Section 6 - Jlg Control System (S/N 61718 to Present)
317
Introduction
317
To Connect the JLG Control System Analyzer
319
Using the Analyzer
319
Changing the Access Level of the Hand Held Analyzer
321
Adjusting Parameters Using the Hand Held Analyzer
323
Machine Setup
324
Level Vehicle Description
324
Machine Personality Settings
333
System Test
378
Test from the Platform
378
Test from the Ground Station
380
Analyzer Diagnostics Menu Structure
397
Section 7 - Basic Electrical Information & Schematics
403
General
403
Multimeter Basics
403
Grounding
403
Backprobing
403
Min/Max
403
Polarity
403
Scale
403
Voltage Measurement
403
Resistance Measurement
404
Continuity Measurement
404
Current Measurement
405
Checking Switches
405
Basic Check
405
Limit Switches
405
Automatic Switches
406
Switch Wiring - Low Side, High Side
406
Applying Silicone Dielectric Compound to Electrical Connections
406
Installation of Dielectric Grease
407
Deutsch HD, DT, DTM, DRC Series
407
AMP Seal
407
AMP Mate-N-Lok
408
DIN Connectors
408
Exclusions
408
AMP Connector
410
Applying Silicone Dielectric Compound to AMP Connectors
410
Assembly
410
Disassembly
412
Wedge Lock
412
Service - Voltage Reading
412
Deutsch Connectors
414
DT/DTP Series Assembly
414
DT/DTP Series Disassembly
414
HD30/HDP20 Series Assembly
415
HD30/HDP20 Series Disassembly
415

Oshkosh JLG 400S Service And Maintenance Manual (155 pages)

Brand: Oshkosh | Category: Boom Lifts | Size: 50 MB

Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Specifications

22
- Operating Specifications
  22
  - Machine Specifications - 400S
    22
  - Machine Specifications - 460SJ
    22
- Capacities
  23
- Engine Data
  23
- Tires
  24
- Hydraulic Oil
  24
- Critical Stability Weights
  25
- Maintenance and Lubrication
  29
- Threadlocking Compound
  35
- Torque Charts
  36
  - SAE Fastener Torque Chart
    36
  - Metric Fastener Torque Chart
    42
General

46
- Machine Preparation, Inspection, and Maintenance
  46
- Service and Guidelines
  47
  - General
    47
  - Safety and Workmanship
    47
  - Cleanliness
    47
  - Components Removal and Installation
    47
  - Component Disassembly and Reassembly
    48
  - Pressure-Fit Parts
    48
  - Bearings
    48
  - Gaskets
    48
  - Bolt Usage and Torque Application
    48
  - Hydraulic Lines and Electrical Wiring
    48
  - Hydraulic System
    48
  - Lubrication
    48
  - Battery
    48
  - Lubrication and Servicing
    48
- Lubrication and Information
  49
  - Hydraulic System
    49
  - Hydraulic Oil
    49
  - Changing Hydraulic Oil
    49
  - Lubrication Specifications
    49
- Cylinder Drift Test
  50
  - Theory
    50
  - Cylinder Leakage Test
    50
  - Cylinder Thermal Drift
    50
- Pins and Composite Bearing Repair Guidelines
  51
- Welding on JLG Equipment
  51
  - Do the Following When Welding on JLG Equipment
    51
  - Do NOT Do the Following When Welding on JLG Equipment
    51
Chassis & Turntable

60
- Tires and Wheels
  60
  - Tire Damage
    60
  - Tire Replacement
    60
  - Wheel Replacement
    60
  - Wheel Installation
    60
- Chassis Tilt Indicator System
  61
- Drive Orientation System
  61
- Lockout Cylinder Bleeding
  61
- Drive System (4WD & 2WD)
  62
- Oscillating Axle System
  63
- Oscillating Axle Lockout Test
  63
- Wheel Drive Assembly
  67
  - Removal
    67
  - Installation
    67
- Torque Hub
  68
  - Roll and Leak Testing
    68
  - Tightening and Torquing Bolts
    68
  - Main Disassembly for "B" Drives
    69
  - Hub-Spindle Disassembly
    69
  - Cover Disassembly
    75
  - Carrier Disassembly
    75
  - Assemble Carrier
    75
  - Cover Sub-Assembly
    77
  - Hub-Spindle Sub-Assembly
    78
  - Main Assembly
    80
  - Tool List
    85
- Re-Align Torque Hub Input Coupling
  86
  - Equipment Required
    86
  - Procedure
    86
- Drive Motor
  86
  - Description
    86
  - Shaft Seal Replacement
    87
  - Loop Flushing Valve
    87
  - Troubleshooting
    88
  - Disassembly
    89
  - Inspection
    93
  - Assembly
    95
  - Initial Start-Up Procedures
    99
- Swing Drive Hub
  101
  - Brake Test
    101
  - Spring Checking Procedure
    102
  - Brake Leak Repair Procedure
    102
  - Roll and Leak Test
    102
  - Tightening and Torquing Bolts
    103
  - Lubrication Information
    104
  - Motor Removal
    104
  - Input Brake Disassembly
    106
  - Main Disassembly
    107
  - Housing-Shaft Disassembly
    108
  - Carrier Disassembly
    109
  - Carrier Assembly
    110
  - Housing - Shaft Assembly
    111
  - Main Assembly
    112
  - Motor and Brake Assembly
    114
  - Motor Control Valve Installation
    117
  - Swing Motor
    125
    
    Disassembly and Inspection
    125
    
    Assembly
    132
    
    One Piece Stator Construction
    139
  - Swing Bearing
    140
    
    Swing Bearing Wear Tolerance
    140
    
    Turntable Bearing Mounting Bolt Condition Check
    141
    
    Swing Bearing Removal
    145
    
    Swing Bearing Installation
    145
    
    Procedure for Setting Swing Gear Backlash
    146
    
    Swing Bearing Torque Values
    147
  - Rotary Coupling
    149
  - Generator
    153
    
    Maintenance Schedule
    153
    
    Overload Protection
    153
    
    Inspecting Brushes, Replacing Brushes and Cleaning Slip Rings
    153

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Oshkosh JLG 400S Service And Maintenance Manual (462 pages)

Table of Contents

Oshkosh JLG 400S Service And Maintenance Manual (155 pages)

Table of Contents

Specifications

General

Chassis & Turntable

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