JLG M400 Parts Manual
3121646 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 3
4 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 3121646
3121646 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 5
TABLE OF CONTENTS
SECTION 1 - FRAME ......................................................................................................................................................................... 11
FIGURE 1-1. STEERING INSTALLATION - E400AJP - M400AJP................................................................................................. 12
FIGURE 1-2. STEERING INSTALLATION - E400AN - E400AJPN - M400AJPN ........................................................................... 14
FIGURE 1-3. HUB - SPINDLE ASSEMBLY - R.H. ......................................................................................................................... 16
FIGURE 1-4. HUB - SPINDLE ASSEMBLY - L.H. - E400AJP - M400AJP ..................................................................................... 18
FIGURE 1-5. HUB - SPINDLE ASSEMBLY - R.H. - E400AN - E400AJPN - M400AJPN ............................................................... 20
FIGURE 1-6. HUB - SPINDLE ASSEMBLY - L.H. - E400AN - E400AJPN - M400AJPN ................................................................ 22
FIGURE 1-7. WHEEL DRIVE - E400AN - E400AJP - E400AJPN .................................................................................................. 24
FIGURE 1-8. WHEEL DRIVE - E400AN - E400AJP - E400AJPN - UL LISTED ............................................................................. 28
FIGURE 1-9. WHEEL DRIVE - M400AJP - M400AJPN ................................................................................................................. 32
FIGURE 1-10. HUB - DRIVE ASSEMBLY ...................................................................................................................................... 36
FIGURE 1-11. DRIVE MOTOR ASSEMBLY .................................................................................................................................. 40
FIGURE 1-12. TIRE/WHEEL - IN240/55-17.5 PNEUMATIC .......................................................................................................... 42
FIGURE 1-13. TIRE/WHEEL - IN240/55 - 17.5 FOAM FILL ........................................................................................................... 44
FIGURE 1-14. TIRE/WHEEL - SOLID NON-MARKING ................................................................................................................. 46
FIGURE 1-15. TIRE/WHEEL - 26 X 7 X 20 - SOLID NON MARKING ............................................................................................ 48
FIGURE 1-16. TIRE/WHEEL - IN240/55-17.5 PNEUMATIC NON MARKING ................................................................................ 50
FIGURE 1-17. TIRE/WHEEL - IN240/55-17.5 FOAM FILLNON MARKING ................................................................................... 52
FIGURE 1-18. TIRE/WHEEL - IN240/55-17.5 PNEUMATIC TS ..................................................................................................... 54
FIGURE 1-19. WHEEL COVER INSTALLATION - IN240/55-17.5 TIRES ONLY ........................................................................... 56
FIGURE 1-20. MOTOR/PUMP/TANK - E400AN - E400AJP - E400AJPN ...................................................................................... 58
FIGURE 1-21. MOTOR/PUMP/TANK - M400AJP .......................................................................................................................... 60
FIGURE 1-22. MOTOR/PUMP/TANK - E400AN - E400AJP - E400AJPN - UL LISTED ................................................................ 62
FIGURE 1-23. MOTOR/PUMP/TANK - M400AJPN........................................................................................................................ 64
FIGURE 1-24. MOTOR/PUMP ASSEMBLY ................................................................................................................................... 66
FIGURE 1-25. HYDRAULIC TANK ASSEMBLY - E400AN - E400AJP - E400AJPN ..................................................................... 68
FIGURE 1-26. HYDRAULIC TANK ASSEMBLY - M400AJP - M400AJPN ..................................................................................... 70
FIGURE 1-27. VALVE INSTALLATION - FRAME MOUNTED - E400AN ....................................................................................... 72
FIGURE 1-28. VALVE INSTALLATION - FRAME MOUNTED - E400AJP - E400AJPN ................................................................. 74
FIGURE 1-29. VALVE INSTALLATION - FRAME MOUNTED - M400AJP - M400AJPN ............................................................... 76
FIGURE 1-30. AKE/STEER VALVE ASSEMBLY ........................................................................................................................... 78
FIGURE 1-31. BATTERY BOX INSTALLATION............................................................................................................................. 80
FIGURE 1-32. BATTERY BOX INSTALLATION - AGM BATTERIES ............................................................................................ 82
FIGURE 1-33. BATTERY BOX INSTALLATION - CE .................................................................................................................... 84
FIGURE 1-34. BATTERY CHARGER INSTALLATION - E400AN - E400AJP - E400AJPN ........................................................... 86
FIGURE 1-35. BATTERY CHARGER INSTALLATION - E00AJP - E400AJPN ............................................................................. 88
FIGURE 1-36. BATTERY CHARGER INSTALLATION - E400AN - E400AJP - E400AJPN ........................................................... 90
FIGURE 1-37. BATTERY CHARGER INSTALLATION - M400AJP................................................................................................ 92
FIGURE 1-38. BATTERY CHARGER INSTALLATION - M400AJP................................................................................................ 94
FIGURE 1-39. BATTERY CHARGER INSTALLATION - M400AJP................................................................................................ 96
FIGURE 1-40. BATTERY CHARGER INSTALLATION - M400AJPN ............................................................................................. 98
FIGURE 1-41. BATTERY CHARGER INSTALLATION - M400AJPN ........................................................................................... 100
FIGURE 1-42. BATTERY CHARGER INSTALLATION - M400AJPN ........................................................................................... 102
FIGURE 1-43. INVERTER INSTALLATION - E400AJP - M400AJP ............................................................................................. 104
FIGURE 1-44. INVERTER INSTALLATION - E400AN - E400AJPN - M400AJPN ....................................................................... 106
FIGURE 1-45. FRAME COVER INSTALLATION - E400AJP ....................................................................................................... 108
FIGURE 1-46. FRAME COVER INSTALLATION - M400AJP ....................................................................................................... 110
FIGURE 1-47. FRAME COVER INSTALLATION - E400AN - E400AJPN .................................................................................... 112
FIGURE 1-48. FRAME COVER INSTALLATION - M400AJPN .................................................................................................... 114
SECTION 2 - TURNTABLE .............................................................................................................................................................. 117
FIGURE 2-1. VALVE INSTALLATION - TURNTABLE MOUNTED - E400AN .............................................................................. 118
FIGURE 2-2. VALVE INSTALLATION - TURNTABLE MOUNTED - E400AJP - E400AJPN ........................................................ 120
FIGURE 2-3. VALVE INSTALLATION - TURNTABLE MOUNTED - M400AJP - M400AJPN ....................................................... 122
FIGURE 2-4. MAIN CONTROL VALVE ASSEMBLY .................................................................................................................... 124
FIGURE 2-5. RELEVELING VALVE ASSEMBLY ......................................................................................................................... 128
FIGURE 2-6. JIB VLAVE ASSEMBLY .......................................................................................................................................... 130
FIGURE 2-7. MOTION ALARM INSTALLATION .......................................................................................................................... 132
FIGURE 2-8. TURNTABLE BEARING AND SWING DRIVE INSTALLATION .............................................................................. 134
FIGURE 2-9. SWING BEARING ASSEMBLY .............................................................................................................................. 136
FIGURE 2-10. SWING MOTOR ASSEMBLY ............................................................................................................................... 138
FIGURE 2-11. REMOTE BEARING LUBE INSTALLATION - OPTIONAL .................................................................................... 140
FIGURE 2-12. DRIVE ORIENTATION INSTALLATION ............................................................................................................... 142
FIGURE 2-13. FUEL TANK AND BATTERY INSTALLATION - M400AJP - M400AJPN .............................................................. 144
3121646 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 7
TABLE OF CONTENTS
FIGURE 2-14. GROUND CONTROL BOX ASSEMBLY ............................................................................................................... 146
FIGURE 2-15. GROUND CONTROL BOX ASSEMBLY ............................................................................................................... 148
FIGURE 2-16. GROUND CONTROL BOX ASSEMBLY ............................................................................................................... 150
FIGURE 2-17. GROUND CONTROL BOX ASSEMBLY ............................................................................................................... 152
FIGURE 2-18. MOTOR CONTROLS INSTALLATION - M400AJP - M400AJPN .......................................................................... 154
FIGURE 2-19. STROBE LIGHT INSTALLATION - OPTIONAL ..................................................................................................... 156
FIGURE 2-20. STROBE LIGHT INSTALLATION - UL LISTED - OPTIONAL ............................................................................... 158
FIGURE 2-21. STROBE LIGHT ASSEMBLY ................................................................................................................................ 160
FIGURE 2-22. HOOD INSTALLATION - E400AN ......................................................................................................................... 162
FIGURE 2-23. HOOD INSTALLATION - E400AJP - E400AJPN - M400AJP - M400AJPN ........................................................... 164
SECTION 3 - ENGINE ...................................................................................................................................................................... 167
FIGURE 3-1. KUBOTA MOTOR/GENERATOR INSTALLATION - M400AJP - M400AJPN .......................................................... 168
FIGURE 3-2. KUBOTA MOTOR/GENERATOR ASSEMBLY - M400AJP - M400AJPN ................................................................ 170
FIGURE 3-3. KUBOTA MOTOR/GENERATOR COMPONENTS ................................................................................................. 172
SECTION 4 - BOOM ......................................................................................................................................................................... 175
FIGURE 4-1. BOOM AND CYLINDERS INSTALLATION - E400AN ............................................................................................. 176
FIGURE 4-2. BOOM AND CYLINDERS INSTALLATION ............................................................................................................. 178
FIGURE 4-3. MAIN BOOM ASSEMBLY - E400AN ....................................................................................................................... 182
FIGURE 4-4. MAIN BOOM ASSEMBLY - E400AJP - E400AJPN - M400AJP - M400AJPN ......................................................... 186
FIGURE 4-5. JIB INSTALLATION ................................................................................................................................................. 188
FIGURE 4-6. ROTATOR ASSEMBLY - E400AN .......................................................................................................................... 190
FIGURE 4-7. ROTATOR ASSEMBLY - E400AJP - E400AJPN - M400AJP - M400AJPN ............................................................ 192
FIGURE 4-8. ROTATOR ASSEMBLY - E400AJP - E400AJPN - M400AJP - M400AJPN ............................................................ 194
FIGURE 4-9. PLATFORM SUPPORT INSTALLATION ................................................................................................................ 196
FIGURE 4-10. CABLES AND CLAMPS INSTALLATION .............................................................................................................. 198
FIGURE 4-11. CABLES AND CLAMPS INSTALLATION .............................................................................................................. 200
FIGURE 4-12. LIMIT SWITCHES INSTALLATION ....................................................................................................................... 202
SECTION 5 - PLATFORM ................................................................................................................................................................ 205
FIGURE 5-1. PLATFORM ASSEMBLY - 4FT/1.22M .................................................................................................................... 206
FIGURE 5-2. PLATFORM ASSEMBLY - 5FT/1.52M .................................................................................................................... 208
FIGURE 5-3. PLATFORM ASSEMBLY - 5FT/1.52M - W/STOP ................................................................................................... 210
FIGURE 5-4. PLATFORM ASSEMBLY - 4FT/1.22M - DROP BAR ENTRY ................................................................................. 212
FIGURE 5-5. PLATFORM ASSEMBLY - 5FT/1.52M - DROP BAR ENTRY ................................................................................. 214
FIGURE 5-6. TRAY ASSEMBLY ................................................................................................................................................... 216
FIGURE 5-7. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION ............................................................................... 218
FIGURE 5-8. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - UL LISTED ......................................................... 220
FIGURE 5-9. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION ............................................................................... 222
FIGURE 5-10. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - UL LISTED ....................................................... 224
FIGURE 5-11. PLATFORM CONSOLE ASSEMBLY - SN 0300189901 THROUGH 0300194237 ............................................... 226
FIGURE 5-12. PLATFORM CONSOLE ASSEMBLY - SN 0300194238 TO PRESENT................................................................ 230
FIGURE 5-13. PLATFORM CONSOLE ASSEMBLY - UL LISTED - SN 0300189901 THROUGH 0300194237 .......................... 234
FIGURE 5-14. PLATFORM CONSOLE ASSEMBLY - UL LISTED - SN 0300194238 TO PRESENT .......................................... 238
FIGURE 5-15. PLATFORM CONSOLE ASSEMBLY - SN 0300189901 THROUGH 0300194237 ............................................... 242
FIGURE 5-16. PLATFORM CONSOLE ASSEMBLY - SN 0300194238 TO PRESENT................................................................ 246
FIGURE 5-17. PLATFORM CONSOLE ASSEMBLY - UL LISTED - SN 0300189901 THROUGH 0300194237 .......................... 250
FIGURE 5-18. PLATFORM CONSOLE ASSEMBLY - UL LISTED - SN 0300194238 TO PRESENT .......................................... 254
FIGURE 5-19. LIGHT PANEL DECAL INSTALLATION ................................................................................................................ 258
FIGURE 5-20. SEALED ENCLOSURES - UL LISTED.................................................................................................................. 260
FIGURE 5-21. CONTROLLER ASSEMBLY - DRIVE AND STEER - SN 0300189901 THROUGH 0300194237 ......................... 262
FIGURE 5-22. CONTROLLER ASSEMBLY - DRIVE AND STEER - SN 0300194238 TO PRESENT ......................................... 264
FIGURE 5-23. CONTROLLER ASSEMBLY - DRIVE AND STEER - SN 0300189901 THROUGH 0300194237 ......................... 266
FIGURE 5-24. CONTROLLER ASSEMBLY - LIFT AND SWING - SN 0300194238 TO PRESENT ............................................. 268
FIGURE 5-25. FOOTSWITCH ASSEMBLY .................................................................................................................................. 270
FIGURE 5-26. MOTOR CONTROLS INSTALLATION - M400AJP - M400AJPN .......................................................................... 272
SECTION 6 - CYLINDER .................................................................................................................................................................. 275
FIGURE 6-1. STEER CYLINDER ASSEMBLY ............................................................................................................................. 276
FIGURE 6-2. LIFT CYLINDER ASSEMBLY - LOWER - E400AN ................................................................................................. 278
FIGURE 6-3. LIFT CYLINDER ASSEMBLY - LOWER - E400AJP - E400AJPN - M400AJP - M400AJPN .................................. 280
FIGURE 6-4. LIFT CYLINDER ASSEMBLY - MID - E400AN ........................................................................................................ 282
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TABLE OF CONTENTS
FIGURE 6-5. LIFT CYLINDER ASSEMBLY - MID - E400AJP - E400AJPN - M400AJP - M400AJPN ........................................ 284
FIGURE 6-6. LIFT CYLINDER - UPPER - E400AN...................................................................................................................... 286
FIGURE 6-7. LIFT CYLINDER - UPPER - E400AJP - E400AJPN - M400AJP - M400AJPN ....................................................... 288
FIGURE 6-8. MASTER CYLINDER ASSEMBLY - E400AN ......................................................................................................... 290
FIGURE 6-9. MASTER CYLINDER ASSEMBLY - E400AJP - E400AJPN - M400AJP - M400AJPN .......................................... 292
FIGURE 6-10. PLATFORM LEVEL CYLINDER - E400AN ........................................................................................................... 294
FIGURE 6-11. PLATFORM LEVEL CYLINDER - JIB - E400AJP - E400AJPN - M400AJP - M400AJPN .................................... 296
FIGURE 6-12. JIB CYLINDER ASSEMBLY - E400AJP - E400AJPN - M400AJP - M400AJPN ................................................... 298
FIGURE 6-13. TELESCOPE CYLINDER ASSEMBLY - E400AN ................................................................................................ 300
FIGURE 6-14. TELESCOPE CYLINDER ASSEMBLY - E400AJP - E400AJPN - M400AJP - M400AJPN .................................. 302
FIGURE 6-15. COUNTERBALANCE VALVE ASSEMBLY ........................................................................................................... 304
SECTION 7 - HYDRAULIC .............................................................................................................................................................. 307
FIGURE 7-1. HYDRAULIC DIAGRAM - E400AN ......................................................................................................................... 308
FIGURE 7-2. HYDRAULIC DIAGRAM - E400AJP - E400AJPN ................................................................................................... 312
FIGURE 7-3. HYDRAULIC DIAGRAM - M400AJP - M400AJPN .................................................................................................. 316
FIGURE 7-4. HYDRAULIC DIAGRAM LIST ................................................................................................................................. 320
SECTION 8 - ELECTRICAL ............................................................................................................................................................. 321
FIGURE 8-1. ELECTRICAL DIAGRAM LIST ................................................................................................................................ 322
FIGURE 8-2. BATTERY CHARGER HARNESS .......................................................................................................................... 324
FIGURE 8-3. CONTACTOR CABLE KIT - E400AN - E400AJP - E400AJPN ............................................................................... 326
FIGURE 8-4. CONTACTOR CABLE KIT - E400AN - E400AJP - E400AJPN - UL LISTED .......................................................... 328
FIGURE 8-5. CONTACTOR CABLE KIT - M400AJP - M400AJPN .............................................................................................. 330
FIGURE 8-6. CONTACTOR PLATE ASSEMBLY AND HARNESSES ......................................................................................... 332
FIGURE 8-7. CONTACTOR PLATE ASSEMBLY AND HARNESSES - UL LISTED .................................................................... 334
FIGURE 8-8. STEER/BRAKE HARNESS - E400AN - E400AJP - E400AJPN ............................................................................. 336
FIGURE 8-9. MOTOR/STEER/BRAKE HARNESS - M400AJP - M400AJPN .............................................................................. 338
FIGURE 8-10. LED REMOTE HARNESS .................................................................................................................................... 340
FIGURE 8-11. BATTERY CHARGER COMPONENTS ................................................................................................................ 342
FIGURE 8-12. INVERTER HARNESS - SN 0300189901 THROUGH 0300193793 ..................................................................... 344
FIGURE 8-13. INVERTER HARNESS - SN 0300193794 TO PRESENT ..................................................................................... 346
FIGURE 8-14. DRIVE ORIENTATION HARNESS ....................................................................................................................... 348
FIGURE 8-15. GROUND CONTROL FUNCTION SWITCH HARNESS ASSEMBLY................................................................... 350
FIGURE 8-16. GROUND CONTROL VALVE HARNESS ASSEMBLY ......................................................................................... 352
FIGURE 8-17. TURNTABLE/FRAME HARNESS ASSEMBLY ..................................................................................................... 354
FIGURE 8-18. HORN/BEACON HARNESS ASSEMBLY ................................ ................................................................ ............. 356
FIGURE 8-19. POSI-TRACK MODULE CAN HARNESS ASSEMBLY ......................................................................................... 358
FIGURE 8-20. GROUND CONTROL CAN HARNESS ASSEMBLY............................................................................................. 360
FIGURE 8-21. GENERATOR HARNESS TO GROUND CONTROL BOX ................................................................................... 362
FIGURE 8-22. MAIN BOOM HARNESS ASSEMBLY................................................................................................................... 364
FIGURE 8-23. TOWER BOOM HARNESS ASSEMBLY .............................................................................................................. 366
FIGURE 8-24. BOOM LIMIT SWITCH HARNESS - LOWER ....................................................................................................... 368
FIGURE 8-25. BOOM LIMIT SWITCH HARNESS - UPPER ........................................................................................................ 370
FIGURE 8-26. JIB HARNESS - AJP MODELS ONLY .................................................................................................................. 372
FIGURE 8-27. INDICATOR LAMP HARNESS ASSEMBLY ......................................................................................................... 374
FIGURE 8-28. PLATFORM FUNCTION SWITCH HARNESS ASSEMBLY - E400AN ................................................................. 376
FIGURE 8-29. PLATFORM FUNCTION SWITCH HARNESS ASSEMBLY - E400AJP - E400AJPN - M400AJP - M400AJPN ... 378
FIGURE 8-30. PLATFORM CAN BUS HARNESS ASSEMBLY ................................................................................................... 380
FIGURE 8-31. ANALYZER HARNESS ASSEMBLY..................................................................................................................... 382
FIGURE 8-32. DRIVE ORIENTATION HARNESS ASSEMBLY ................................................................................................... 384
FIGURE 8-33. PLUG AND RECEPTACLE INSTALLATION - 110V - ANSI SPEC ....................................................................... 386
FIGURE 8-34. PLUG AND RECEPTACLE INSTALLATION - SUPPLIED LOCALLY................................................................... 388
FIGURE 8-35. PLUG AND RECEPTACLE 220V INSTALLATION - ANSI SPEC ......................................................................... 390
FIGURE 8-36. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 POST GROUND - 2 X 4 BOX - CE SPEC ................ 392
FIGURE 8-37. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 SIDE GROUND - 2 X 4 BOX - CE SPEC.................. 394
FIGURE 8-38. PLUG AND RECEPTACLE 220V INSTALLATION - AFSINT 107 KEYED GROUND - 2 X 4 BOX - CE SPEC ... 396
FIGURE 8-39. PLUG AND RECEPTACLE 110V INSTALLATION - IEC 60309 - YELLOW - CE SPEC ...................................... 398
FIGURE 8-40. PLUG AND RECEPTACLE 220V INSTALLATION IEC 60309 BLUE - CE SPEC ................................................ 400
FIGURE 8-41. PLUG AND RECEPTACLE 220V INSTALLATION - CEE7 POST GROUND - 70MM X 70MM BOX - CE SPEC 402
FIGURE 8-42. PLUG AND RECEPTACLE 220VINSTALLATION - CEE7 SIDE GROUND - 70MM X 70MM BOX - CE SPEC ... 404
FIGURE 8-43. LOWER BOOM 110V HARNESS ASSEMBLY ..................................................................................................... 406
FIGURE 8-44. LOWER BOOM 220V HARNESS ASSEMBLY W/BREAKER BOX - CE SPEC .................................................. 408
FIGURE 8-45. LOWER BOOM 220V HARNESS ASSEMBLY WITHOUT BREAKER BOX - CE SPEC ...................................... 410
FIGURE 8-46. MAIN BOOM 110V HARNESS ASSEMBLY ......................................................................................................... 412
3121646 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 9
TABLE OF CONTENTS
FIGURE 8-47. MAIN BOOM 220V HARNESS ASSEMBLY - CE SPEC ....................................................................................... 414
FIGURE 8-48. BREAKER BOX KIT WITH TWO BREAKERS - CE SPEC .................................................................................... 416
FIGURE 8-49. BREAKER BOX KIT WITH THREE BREAKERS - CE SPEC ................................................................................ 418
FIGURE 8-50. AC PLUGS AND SOCKETS INSTALLATION - CEE7 POST GROUND 2 X 4 BOX - CE SPEC ........................... 420
FIGURE 8-51. AC PLUGS AND SOCKETS INSTALLATION - CEE7 SIDE GROUND 2 X 4 BOX - CE SPEC ............................ 422
FIGURE 8-52. AC PLUGS AND SOCKETS INSTALLATION - AFSINT 107-2-01 KEYED GROUND - 2 X 4 BOX - CE SPEC ... 424
FIGURE 8-53. PLUGS AND SOCKETS INSTALLATION - IEC 60309 YELLOW - CE SPEC ....................................................... 426
FIGURE 8-54. PLUGS AND SOCKETS INSTALLATION - IEC 60309 BLUE - CE SPEC ............................................................ 428
FIGURE 8-55. AC PLUGS AND SOCKETS INSTALLATION - CEE7 POST GROUND - CE SPEC ............................................ 430
FIGURE 8-56. AC PLUGS AND SOCKETS INSTALLATION - CEE7 POST GROUND - CE SPEC ............................................ 432
FIGURE 8-57. STROBE LIGHT - AMBER - HARNESS ................................................................................................................ 434
FIGURE 8-58. STROBE LIGHT HARNESS .................................................................................................................................. 436
FIGURE 8-59. CHARGER CORD PLUG INSTALLATION - 220V - CEE7 POST GROUND - CE SPEC ...................................... 438
FIGURE 8-60. CHARGER CORD PLUG INSTALLATION - 220V - CEE7 SIDE GROUND - CE SPEC ....................................... 440
FIGURE 8-61. CHARGER CORD PLUG INSTALLATION - 220V - AFSINT 107 KEYED GROUND - CE SPEC ......................... 442
FIGURE 8-62. CHARGER CORD PLUG INSTALLATION - 110V - IEC 60309 - YELLOW - CE SPEC ........................................ 444
FIGURE 8-63. CHARGER CORD PLUG INSTALLATION - 220V - IEC 60309 - BLUE- CE SPEC .............................................. 446
SECTION 9 - DECALS ..................................................................................................................................................................... 449
FIGURE 9-1. DECAL INSTALLATION - JLG LOGO - E400AN ..................................................................................................... 450
FIGURE 9-2. DECAL INSTALLATION - JLG LOGO - E400AJP - E400AJPN - M400AJP - M400AJPN ...................................... 452
FIGURE 9-3. DECAL INSTALLATION - ANSI SPEC - E400AN - E400AJP - E400AJPN ............................................................. 454
FIGURE 9-4. DECAL INSTALLATION - ANSI SPEC - M400AJP - M400AJPN ............................................................................ 456
FIGURE 9-5. DECAL INSTALLATION - CE/AUSTRALIAN SPEC -E400AN - E400AJP - E400AJPN .......................................... 458
FIGURE 9-6. DECAL INSTALLATION - CE/AUSTRALIAN SPEC - M400AJP - M400AJPN ........................................................ 460
FIGURE 9-7. DECAL INSTALLATION - JAPANESE SPEC - E400AN - E400AJP - E400AJPN .................................................. 462
FIGURE 9-8. DECAL INSTALLATION - JAPANESE SPEC - M400AJP - M400AJPN .................................................................. 464
FIGURE 9-9. DECAL INSTALLATION - KOREAN SPEC - E400AN - E400AJP - E400AJPN ...................................................... 466
FIGURE 9-10. DECAL INSTALLATION - KOREAN SPEC - M400AJP - M400AJPN ................................................................... 468
FIGURE 9-11. DECAL INSTALLATION - SPANISH/ENGLISH SPECS - E400AN - E400AJP - E400AJPN ................................ 470
FIGURE 9-12. DECAL INSTALLATION - SPANISH/ENGLISH SPECS - M400AJP - M400AJPN ................................................ 472
FIGURE 9-13. DECAL INSTALLATION - FRENCH/ENGLISH SPECS - E400AN - E400AJP - E400AJPN ................................. 474
FIGURE 9-14. DECAL INSTALLATION - FRENCH/ENGLISH SPECS - M400AJP - M400AJPN ................................................ 476
FIGURE 9-15. DECAL INSTALLATION - CHINESE/ENGLISH - E400AN - E400AJP - E400AJPN ............................................. 478
FIGURE 9-16. DECAL INSTALLATION - CHINESE/ENGLISH - M400AJP - M400AJPN............................................................. 480
FIGURE 9-17. DECAL INSTALLATION - SPANISH/PORTUGUESE - E400AN - E400AJP - E400AJPN ................................ .... 482
FIGURE 9-18. DECAL INSTALLATION - SPANISH/PORTUGUESE SPECS - M400AJP - M400AJPN ...................................... 484
SECTION 10 - RECOMMENDED SERVICE PARTS STOCK .......................................................................................................... 487
FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK ....................................................................................................... 488
SECTION 11 - SPECIAL OPTIONS ................................................................................................................................................. 489
FIGURE 11-1. SPECIAL OPTIONS .............................................................................................................................................. 490
PART NUMBER INDEX .................................................................................................................................................................... 493
10 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 3121646
SECTION 1 - FRAME
SECTION 1 - FRAME
3121646 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 11
SECTION 1 - FRAME
FIGURE 1-1. STEERING INSTALLATION - E400AJP - M400AJP
12 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 3121646
SECTION 1 - FRAME
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001166414
Ref
STEERING INSTALLATION - E400AJP/M400AJP
C 1 0100011
AR
Compound, Locking
2 0440162
2
Bearing, Thrust
3 0641606
4
Bolt, 3/8-16 X 3/4
4 0681810
4
Bolt, 1/2-13 X 1-1/4, Grade 8
5 1683591
1
Cylinder, Steering (See CYLINDER SECTION for Breakdown)
6
2780241
1
Spindle, Hub assy R.H. (See HUB - SPINDLE ASSEMBLY for
Breakdown)
7
2780242
1
Spindle, Hub Assy L.H. (See HUB - SPINDLE ASSEMBLY L.H. for
Breakdown)
8
1001153021
2
Link, Steering
9 3312008
4
Nut, 5/8-11 Serrated
10
3322202
2
Nut, Jam
11
3323003
2
Nut, 1-1/4-12, Castle
12
3422692
2
Pin, King
13
3450810
2
Pin, Cotter
14
3841517
2
End, Tie Rod
15
3900109
4
Screw, Shoulder
16
4740156
2
Washer, Thrust
17
4891800
4
Washer, 1/2
21
3300426
18
Lugnut, 5/8-18UNF
FIGURE 1-1. STEERING INSTALLATION - E400AJP - M400AJP
3121646 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 13
SECTION 1 - FRAME
FIGURE 1-2. STEERING INSTALLATION - E400AN - E400AJPN - M400AJPN
14 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 3121646
SECTION 1 - FRAME
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001171075
Ref
STEERING INSTALLATION - E400An/E400AJPn/M400AJPn
B 1 0100011
AR
Compound, Locking
2 0440162
2
Bearing, Thrust
3 0641606
4
Bolt, 3/8-16 X 3/4
4 0681810
4
Bolt, 1/2-13 X 1-1/4, Grade 8
5 1683591
1
Steering, Cylinder (See CYLINDER SECTION for Breakdown)
6
2780251
1
Spindle, Hub Assy R.H. (See HUB-SPINDLE ASSEMBLY R.H. for
Breakdown)
7
2780250
1
Spindle, Hub Assy L.H. (See HUB - SPINDLE ASSEMBLY L.H. for
Breakdown)
8
1001153023
2
Link, Steering
9 3300426
18
Lugnut, 5/8-18UNF
10
3312008
4
Nut, 5/8-11 Serrated
11
3322202
2
Nut, Jam
12
3323003
2
Nut, 1-1/4-12, Castle
13
3422692
2
Pin, King
14
3450810
2
Pin, Cotter
15
3841517
2
End, Tie Rod
16
3900109
4
Screw, Shoulder
17
4740156
2
Washer, Thrust
18
4891800
4
Washer 1/2
FIGURE 1-2. STEERING INSTALLATION - E400AN - E400AJPN - M400AJPN
3121646 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 15
SECTION 1 - FRAME
FIGURE 1-3. HUB - SPINDLE ASSEMBLY - R.H.
16 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 3121646
FIGURE 1-3. HUB - SPINDLE ASSEMBLY - R.H.
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
2780241
Ref
HUB - SPINDLE ASSEMBLY, RH
C 1 4130351
1
Spindle R.H .
2 7020035
1
Hub 3
7020036
1
Cup, Bearing - Inner
4 7020037
1
Cone, Bearing - Inner
5 7020038
1
Cup, Bearing - Outer
6 7020039
1
Cone, Bearing - Outer
7 7020040
1
Seal 8
7020041
9
Stud, Wheel
9 7020042
9
Lugnut 10
7020054
1
Nut, Castle
11
7020055
1
Washer, Spindle
12
7020137
1
Dust Cap
13
7020140
1
Pin, Cotter
14
0962140
1
Bushing
15
0961951
2
Bushing
SECTION 1 - FRAME
3121646 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 17
SECTION 1 - FRAME
FIGURE 1-4. HUB - SPINDLE ASSEMBLY - L.H. - E400AJP - M400AJP
18 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 3121646
SECTION 1 - FRAME
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
2780242
Ref
HUB - SPINDLE ASSEMBLY, LH
C 1 4130350
1
Spindle, L.H.
2 7020035
1
Hub 3
7020036
1
Cup, Bearing - Inner
4 7020037
1
Cone, Bearing - Inner
5 7020038
1
Cup, Bearing - Outer
6 7020039
1
Cone, Bearing - Outer
7 7020040
1
Seal 8
7020041
1
Stud, Wheel
9 7020042
1
Lugnut 10
7020054
1
Nut, Castle
11
7020055
1
Washer, Spindle
12
7020137
1
Dust Cap
13
7020140
1
Pin, Cotter
14
0962140
1
Bushing
15
0961951
2
Bushing
FIGURE 1-4. HUB - SPINDLE ASSEMBLY - L.H. - E400AJP - M400AJP
3121646 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 19
SECTION 1 - FRAME
FIGURE 1-5. HUB - SPINDLE ASSEMBLY - R.H. - E400AN - E400AJPN - M400AJPN
20 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 3121646
SECTION 1 - FRAME
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
2780251
Ref
HUB - SPINDLE ASSEMBLY, RH
C 1 7023217
1
Spindle, R.H.
2 7020035
1
Hub 3
7020036
1
Cup, Bearing - Inner
4 7020037
1
Cone, Bearing - Inner
5 7020038
1
Cup, Bearing - Outer
6 7020039
1
Cone, Bearing - Outer
7 7020040
1
Seal 8
7020041
9
Stud, Wheel
9 7020042
9
Lugnut 10
7020054
1
Nut, Castle
11
7020055
1
Washer, Spindle
12
7020137
1
Dust Cap
13
7020140
1
Pin, Cotter
14
0962140
1
Bushing
15
0961951
2
Bushing
FIGURE 1-5. HUB - SPINDLE ASSEMBLY - R.H. - E400AN - E400AJPN - M400AJPN
3121646 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 21
SECTION 1 - FRAME
FIGURE 1-6. HUB - SPINDLE ASSEMBLY - L.H. - E400AN - E400AJPN - M400AJPN
22 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 3121646
SECTION 1 - FRAME
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
2780250
Ref
HUB - SPINDLE ASSEMBLY, L.H.
C 7023216
1
Spindle, L.H.
2 7020035
1
Hub 3
7020036
1
Cup, Bearing - Inner
4 7020037
1
Cone, Bearing - Inner
5 7020038
1
Cup, Bearing - Outer
6 7020039
1
Cone, Bearing - Outer
7 7020040
1
Seal 8
7020041
1
Stud, Wheel
9 7020042
1
Lugnut 10
7020054
1
Nut, Castle
11
7020055
1
Washer, Spindle
12
7020137
1
Dust Cap
13
7020140
1
Pin, Cotter
14
0962140
1
Bushing
15
0961951
2
Bushing
FIGURE 1-6. HUB - SPINDLE ASSEMBLY - L.H. - E400AN - E400AJPN - M400AJPN
3121646 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 23
SECTION 1 - FRAME
FIGURE 1-7. WHEEL DRIVE - E400AN - E400AJP - E400AJPN
24 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 3121646
SECTION 1 - FRAME
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001167252
Ref
WHEEL DRIVE - E400An/E400AJP/E400AJPn
D 1 0100011
AR
Compound, Locking
2 0100019
AR
Compound, Locking
3 0641406
5
Bolt, 1/4-20 X 3/4
4 0641508
1
Bolt, 5/16-18 X 1
5 0641524
4
Bolt, 5/16-18 X 3
6 0641609
8
Bolt, 3/8-16 X 1-1/8
7 0641826
4
Bolt, 1/2-13 X 3-1/4
8 0682014
12
Bolt, 5/8-11 X 1-3/4, Grade 8
9 0840031
6
Boot, Terminal d Shaped
10
0840032
6
Boot, Terminal b Shaped
11
0920113
2
Brake 11
See Note
2
Ring, Sensor (Note: Not Available - Purchase p/n 0920113)
11
7007977
2
Ring, Bearing Retaining (Large) (1 per Assembly)
11
7011716
2
Ring, Bearing Retaining (Small) (1 per Assembly)
11
7007913
4
Bolt
11
7011757
2
Complete Repair Kit (Includes Case and Oil Seals, O-Rings,
Back-up Rings, Stator and Rotor Discs, Return Plate, Springs,
Bearing and Brake to Hub Gasket (1 per Assembly)
11
2900768
2
Bearing Kit (1 per Assembly)
11
7007900
2
Seal, Oil - Front (1 per Assembly)
11
7007933
2
Gasket, Brake to Hub (1 per Assembly)
11
70002408
2
Gasket, Brake to Motor (1 per Assembly) (Not Included in Repair
Kit) 13
1600292
1
Controller, Power Module
14
1600293
1
Module, Positrac/Tilt
15
1600294
1
Controller, Contactor Panel (See ELECTRICAL SECTION for
Breakdown)
16
2780282
2
Drive Hub Assembly (See DRIVE HUB ASSEMBLY for
Breakdown)
17
3020008
1.5 l
Lubricant, Mobilube HD 80W-90
18
3020037
AR
Lube, Coupling Grease
19
3160237
2
Motor, Drive (See DRIVE MOTOR ASSEMBLY for Breakdown)
20
3300426
18
Nut, 5/8-18UNF
21
3300454
5
Nut, 1/4-20
22
3310601
4
Nut, #6-32
23
3311505
5
Nut, Lock, 5/16-18
24
3910624
4
Screw, 6-32 X 1-1/2
25
3990105
2
Sensor, Speed
26
4240084
1
Strap, Anti-Static
27
4568114
6
Spacer, Tube
28
4711400
7
Washer, 1/4
29
4711600
8
Washer, 3/8
30
4750600
8
Washer, #6
31
4751500
10
Washer, 5/16
32
4760600
4
Washer, Lock, #6
33
4892000
12
Washer, 5/8
43
4922103
1
Harness, Battery (Not Shown - See ELECTRICAL SECTION for
Breakdown)
48
0641430
2
Bolt, 1/4-20 X 3-3/4
50
1320172
1
Handle, Pull
FIGURE 1-7. WHEEL DRIVE - E400AN - E400AJP - E400AJPN
3121646 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 25
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
51
3311401
2
Nut, 1/4-20
100
1001176310
1
Cable, Kit (See ELECTRICAL SECTION for Breakdown)
SECTION 1 - FRAME
26 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 3121646
SECTION 1 - FRAME
FIGURE 1-8. WHEEL DRIVE - E400AN - E400AJP - E400AJPN - UL LISTED
28 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 3121646
SECTION 1 - FRAME
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001167645
Ref
WHEEL DRIVE - E400An/E400AJP/E400AJPn - UL LISTED
D 1 0100011
AR
Locking Compound
2 0100019
AR
Locking Compound
3 0641406
5
Bolt, 1/4-20 X 3/4
4 0641508
1
Bolt, 5/16-18 X 1
5 0641524
4
Bolt, 5/16-18 X 3
6 0641609
8
Bolt, 3/8-16 X 1-1/8
7 0641826
4
Bolt, 1/2-13 X 3-1/4
8 0682014
12
Bolt , 5/8-11 X 1-3/4, Grade 8
9 0840031
6
Boot, Terminal d Shaped
10
0840032
6
Boot, Terminal b Shaped
11
0920113
2
Brake, Mulit-Disc
11
See Note
2
Ring, Sensor (Note: Not Available - Purchase p/n 0920113)
11
7007977
2
Ring, Bearing Retaining (Large) (1 per Assembly)
11
7011716
2
Ring, Bearing Retaining (Small) (1 per Assembly)
11
7007913
4
Bolt
11
7011757
2
Complete Repair Kit (Includes Case and Oil Seals, O-Rings,
Back-up Rings, Stator and Rotor Discs, Return Plate, Springs,
Bearing and Brake to Hub Gasket (1 per Assembly)
11
2900768
2
Bearing Kit (1 per Assembly)
11
7007900
2
Seal, Oil - Front (1 per Assembly)
11
7007933
2
Gasket, Brake to Hub (1 per Assembly)
11
70002408
2
Gasket, Brake to Motor (1 per Assembly) (Not Included in Repair
Kit) 13
1600292
1
Controller, Power Module
14
1600293
1
Module, Positrac/Tilt
15
1600300
1
Controller, UL Contactor Panel (See ELECTRICAL SECTION for
Breakdown)
16
2780282
2
Drive Hub Assembly (See DRIVE HUB ASSEMBLY for
Breakdown)
17
3020008
1.5 l
Lubricant, Mobilube HD 80W-90
18
3020037
AR
Lube, Coupling Grease
19
3160237
2
Motor, Drive (See DRIVE MOTOR ASSEMBLY for Breakdown)
20
3300426
18
Nut, Flange, 5/8-18UNF
21
3300454
5
Nut, 1/4-20
22
3310601
4
Nut, #6-32
23
3311505
5
Nut, Lock, 5/16-18
24
3910624
4
Screw, 6-32 X 1-1/2
25
3990105
2
Speed Sensor, Assembly
26
4240084
1
Strap, Anti-Static
27
4568114
6
Tube, Spacer
28
4711400
7
Washer, 1/4
29
4711600
8
Washer, 3/8
30
4750600
8
Washer, #6
31
4751500
10
Washer, 5/16
32
4760600
4
Washer, Lock, #6
33
4892000
12
Washer, 5/8
43
4922103
1
Harness, Battery Charger (Not Shown - See ELECTRICAL
SECTION for Breakdown)
48
0340047
2
Band, Motor
49
0721006
4
Bolt, #10-24 X .750
FIGURE 1-8. WHEEL DRIVE - E400AN - E400AJP - E400AJPN - UL LISTED
3121646 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 29
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
50
0861375
1
Cover 52
1704712
1
Decal, 300Amp Fuse
53
2400044
1
Fuse, Mounting Block
54
2400062
1
Fuse, 300 Amp
55
2540037
2
Grommet
56
3311001
6
Nut, #10-24
57
3311501
2
Nut, 5/16-18
58
4711500
4
Washer, 5/16
59
4751000
12
Washer, #10
60
0641430
2
Bolt, 1/4-20 X 3-3/4
62
1320172
1
Handle, Pull
63
3311401
2
Nut, 1/4-20
100
1001176309
1
Cable, Kit (See ELECTRICAL SECTION for Breakdown)
SECTION 1 - FRAME
30 E400An/E400AJP/E400AJPn/M400AJP/M400AJPn 3121646
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