Oshkosh Corporation JLG E400A Narrow Operation And Safety Manual
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Oshkosh Corporation JLG E400A Narrow Operation And Safety Manual

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Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
E400A Narrow
E400AJP
E400AJP Narrow
M400AJP
M400AJP Narrow
S/N 0300189901 to Present
ANSI
3121644
®
January 5, 2015

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  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Boom Lift Models E400A Narrow E400AJP E400AJP Narrow M400AJP M400AJP Narrow S/N 0300189901 to Present ANSI 3121644 ® January 5, 2015...
  • Page 3 FOREWORD FOREWORD This manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. Due to continuous product improvements, JLG Industries, Inc.
  • Page 4 FOREWORD SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death INDICATES A POTENTIALLY HAZARDOUS SITUATION.
  • Page 5 FOREWORD For: • Accident Reporting • Standards and Regulations THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG Compliance Information INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA- • Product Safety Publica- TION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR tions •...
  • Page 6 FOREWORD REVISION LOG Original Issue - June 3, 2014 Revised - January 5, 2015 – JLG Lift – 3121644...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 1 - SAFETY PRECAUTIONS SkyGuard Function Test......2-6 General .
  • Page 8 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Platform Rotation ....... . . 4-9 SECTION - 5 - EMERGENCY PROCEDURES Jib Swing.
  • Page 9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE INTRODUCTION ........6-1 OPERATING SPECIFICATIONS .
  • Page 10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This Page Left Blank Intentionally. – JLG Lift – 3121644...
  • Page 11 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE 2-1. Basic Nomenclature........2-7 2-2.
  • Page 12 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE This Page Left Blank Intentionally. – JLG Lift – 3121644...
  • Page 13 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE Minimum Approach Distances (M.A.D.) ....1-6 Beaufort Scale (For Reference Only)....1-9 Inspection and Maintenance Table .
  • Page 14 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE This Page Left Blank Intentionally. viii – JLG Lift – 3121644...

  • Page 15: Section 1 - Safety Precautions

    SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS GENERAL This section outlines the necessary precautions for proper and FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR safe machine usage and maintenance.

  • Page 16: Workplace Inspection

    SECTION 1 - SAFETY PRECAUTIONS • An operator must not accept operating responsibilities until Workplace Inspection adequate training has been given by competent and autho- • Precautions to avoid all hazards in the work area must be rized persons. taken by the user before and during operation of the machine. •...

  • Page 17: Machine Inspection

    SECTION 1 - SAFETY PRECAUTIONS Machine Inspection OPERATION • Do not operate this machine until the inspections and func- General tional checks as specified in Section 2 of this manual have been performed. • Machine operation requires your full attention. Bring the machine to a full stop before using any device, i.e.

  • Page 18: Trip And Fall Hazards

    SECTION 1 - SAFETY PRECAUTIONS • Do not carry materials directly on platform railing unless • Hydraulic cylinders are subject to thermal expansion and con- approved by JLG. traction. This may result in changes to the boom and/or plat- form position while the machine is stationary. Factors •...

  • Page 19: Electrocution Hazards

    SECTION 1 - SAFETY PRECAUTIONS • Before operating the machine, make sure all gates are closed Electrocution Hazards and fastened in their proper position. • This machine is not insulated and does not provide protection from contact or proximity to electrical current. •...
  • Page 20 SECTION 1 - SAFETY PRECAUTIONS Table 1-1. Minimum Approach Distances (M.A.D.) Voltage Range MINIMUM APPROACH DISTANCE (Phase to Phase) in Feet (Meters) 0 to 50 KV 10 (3) Over 50KV to 200 KV 15 (5) Over 200 KV to 350 KV 20 (6) Over 350 KV to 500 KV 25 (8)

  • Page 21: Tipping Hazards

    SECTION 1 - SAFETY PRECAUTIONS • The minimum approach distance may be reduced if insulating Tipping Hazards barriers are installed to prevent contact, and the barriers are • The user must be familiar with the surface before driving. Do rated for the voltage of the line being guarded. These barriers not exceed the allowable sideslope and grade while driving.
  • Page 22 SECTION 1 - SAFETY PRECAUTIONS • Never exceed the maximum work load as specified on the • Do not operate the machine when wind conditions exceed 28 platform. Keep all loads within the confines of the platform, mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Refer- unless authorized by JLG.
  • Page 23 SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/ Table 1-2. Beaufort Scale (For Reference Only) Wind Speed Beaufort Description Land Conditions Number 0-0.2 Calm Calm. Smoke rises vertically 0.3-1.5 Light air Wind motion visible in smoke 1.6-3.3 Light breeze...

  • Page 24: Crushing And Collision Hazards

    SECTION 1 - SAFETY PRECAUTIONS Crushing and Collision Hazards • Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving and swing operations. • Approved head gear must be worn by all operating and • Under all travel conditions, the operator must limit travel ground personnel.

  • Page 25: Towing, Lifting, And Hauling

    SECTION 1 - SAFETY PRECAUTIONS TOWING, LIFTING, AND HAULING MAINTENANCE • Never allow personnel in platform while towing, lifting, or This sub-section contains general safety precautions which must hauling. be observed during maintenance of this machine. Additional pre- cautions to be observed during machine maintenance are •...
  • Page 26 SECTION 1 - SAFETY PRECAUTIONS • DO NOT use your hand to check for leaks. Use a piece of card- • Do not use machine as a ground for welding. board or paper to search for leaks. Wear gloves to help protect •...

  • Page 27: Battery Hazards

    SECTION 1 - SAFETY PRECAUTIONS Battery Hazards • Always disconnect batteries when servicing electrical compo- BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND nents or when performing welding on the machine. CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION.
  • Page 28 SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-14 – JLG Lift – 3121644...

  • Page 29: Section 2 - User Responsibilities, Machine Preparation, And Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.1 PERSONNEL TRAINING 6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, The aerial platform is a personnel handling device; so it is neces- depressions, holes, drop-offs.

  • Page 30: Preparation, Inspection, And Maintenance

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION PREPARATION, INSPECTION, AND MAINTENANCE JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A The following table covers the periodic machine inspections and PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL maintenance recommended by JLG Industries, Inc.
  • Page 31 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Table 2-1.Inspection and Maintenance Table Primary Service Type Frequency Reference Responsibility Qualification Pre-Start Inspection Before using each day; or User or Operator User or Operator Operator and Safety Manual whenever there’s an Operator change. Pre-Delivery Inspection (See Note) Before each sale, lease, or rental delivery.

  • Page 32: Pre-Start Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection 5. “Walk-Around” Inspection – Refer to Figure 2-2. thru Fig- ure 2-4. The Pre-Start Inspection should include each of the following: 6. Battery – Charge as required. 1. Cleanliness – Check all surfaces for leakage (oil, fuel, or bat- 7.

  • Page 33: Function Check

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Function Check 3. If tower boom does not rest on stop with machine in the stowed position, this indicates upright is out of plumb. A functional check of all systems should be performed, once the 4.
  • Page 34 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 7. Check that platform self-leveling system functions properly 12. Place the GROUND/PLATFORM SELECT switch to GROUND. during raising and lowering of boom. Platform controls should not operate. 8. Check rotator for smooth operation and assure platform will 13.

  • Page 35: Skyguard Function Test

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SkyGuard Function Test NOTE: If the machine is equipped with both SkyGuard and Soft Touch, functions will not reverse, only stop. From the Platform Console: NOTE: If equipped, ensure the blue beacon illuminates when SkyGuard Test the SkyGuard feature by operating the telescope out func- is activated.
  • Page 36 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 1. Platform Control Console 2. Platform 3. Upper Boom 4. Telescope Cylinder (inside) 5. Master Cylinder 6. Upper Upright 7. Upper Lift Cylinder 8. Mid Lift Cylinder 9. Lower Boom 10. Turntable 11.
  • Page 37 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-2. Daily Walk-Around Inspection - Sheet 1 of 3 3121644 – JLG Lift –...

  • Page 38: General

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION General 1. Platform and Gate Assembly - Platform mounting pins secure. Footswitch in good working order; not modified, Begin the “Walk-Around Inspection” at Item 1, as noted on the disabled or blocked; Bar slides freely. diagram.
  • Page 39 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 9. Drive Axle and Motor - See Note. 16. Battery Charger - See Note. 10. Wheel/Tire Assembly - No loose or missing lug nuts. 17. Brake/Steer Valve - See Note. Inspect for worn tread, cuts, tears or other discrepancies. 18.
  • Page 40 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTES: 2-12 – JLG Lift – 3121644...

  • Page 41: Section 3 - Machine Controls And Indicators

    SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS GENERAL NOTE: The indicator panels use different shaped symbols to alert the operator to different types of operational situations that could arise. The meaning of those symbols are explained below. Indicates a potentially hazardous situation, which if THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND not corrected, could result in serious injury or death.

  • Page 42: Ground Control Station

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Station 2. Platform Overload (If equipped) Indicates the platform has been overloaded. (See Figure 3-1. and Figure 3-2.) NOTE: When machine is shut down the Platform/Ground Select switch and Emergency Stop must be positioned to Off. 3.
  • Page 43 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. System Distress Indicator 2. Platform Overload Indicator 3. Engine/Generator Start Button 4. Battery Condition Indicator & Hourmeter 5. Telescope 6. Swing 7. Function Enable 8. Circuit Breakers 9. Emergency Stop 10. Platform/Ground Select 11.
  • Page 44 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. System Distress Indicator 2. Platform Overload Indicator 3. Engine/Generator Start Button 4. Not Used 5. Telescope 6. Swing 7. Function Enable 8. Circuit Breakers 9. Emergency Stop 10. Platform/Ground Select 11. Lower/Mid Lift 12.
  • Page 45 SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Telescope 9. Power/Emergency Stop Switch Provides for extension and retraction of Upper A two-position red mushroom shaped switch Boom when positioned to in or out. furnishes power to Platform/Ground Select switch when pulled out (on). When pushed in (off ), power is shut off to the Platform/Ground Select switch.
  • Page 46 SECTION 3 - MACHINE CONTROLS AND INDICATORS 11. Lower/Mid Boom Lift Provides for raising and lowering of ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF Lower Boom when positioned to Up or THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR Down.

  • Page 47: Platform Station

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 16. Indicator Gauge Platform Station Registers the amount of time the machine has been in use, (See Figure 3-4.) with functions operating. In the event of a fault, the hourme- 1. Posi-Track Control ter also displays the three digit fault code.
  • Page 48 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Posi-Track 6. Drive Orientation Override 10. Jib 14. Lower Boom Lift 2. Platform Leveling Override 7. Drive/Steer 11. Soft Touch/SkyGuard Override 15. Platform Rotate 3. Horn 8. Telescope 12. Jib Swing 16. Function Speed 4.
  • Page 49 SECTION 3 - MACHINE CONTROLS AND INDICATORS 3. Horn 6. Drive Orientation Override A push-type Horn switch supplies electrical When the boom is swung over the rear tires power to an audible warning device when pressed. or further in either direction, the Drive Orien- tation indicator will illuminate when the drive 4.
  • Page 50 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: To operate the Drive joystick, pull up on the lock- ing ring below the handle. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE NOTE: The Drive joystick is spring loaded and will auto- OFF OR NEUTRAL POSITION WHEN RELEASED.
  • Page 51 SECTION 3 - MACHINE CONTROLS AND INDICATORS 11. Soft Touch/SkyGuard Override Switch (If equipped) 12. Jib Swing The machine can be equipped with one of three options. It Push toggle switch right to swing right, push may have Soft Touch, SkyGuard, or both Soft Touch and Sky- left to swing left.
  • Page 52 SECTION 3 - MACHINE CONTROLS AND INDICATORS 15. Platform Rotate NOTE: The Main Boom Lift/Swing joystick is spring loaded and will automatically return to neutral (off) position when released. The PLATFORM ROTATE control switch allows the operator to rotate the basket to the left or 17.
  • Page 53 SECTION 3 - MACHINE CONTROLS AND INDICATORS Table 3-1. Simultaneous Functions If This Function is Selected: These Functions Will Also Work at the Same Time: Drive and Steer Swing Lower Lift** Upper Lift** Telescope Swing Drive and Steer Lower Lift** Upper Lift** Telescope Lower Lift...

  • Page 54: Platform Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Control Indicator Panel 2. Platform Overload (If equipped) Indicates the platform has been overloaded. (See Figure 3-4., Platform Control Indicator Panel w/Drive Orientation) 1. Tilt Alarm Warning Light and Alarm This illuminator indicates that the chassis is on a slope.
  • Page 55 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Tilt 4. Posi-Track 7. Creep 2. Platform Overload 5. Enable 8. Drive Orientation Override 3. System Distress 6. Low Battery 9. Soft Touch Indicator Figure 3-4. Platform Control Indicator Panel w/Drive Orientation 3121644 –...
  • Page 56 SECTION 3 - MACHINE CONTROLS AND INDICATORS 3. System Distress Indicator d. There is some other fault in one of the circuits. If so determine the cause by counting the flash code, a num- The system distress indicator lights to signify ber of flashes followed by a pause followed by another an abnormal condition for the generator number of flashes, and refer to the service manual.
  • Page 57 SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Posi-Track Indicator This indicator lights to show that posi- TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH traction is operating. BY BLOCKING OR ANY OTHER MEANS. FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY OPERATES WITHIN LAST 1/4"...
  • Page 58 SECTION 3 - MACHINE CONTROLS AND INDICATORS 8. Soft Touch Indicator (If Equipped) 9. Creep Speed Indicator When illuminated (Yellow) the Soft Touch When the Function Speed Control is bumper is against an object. All controls turned to the creep position, the indicator are disabled until the override button is acts as a reminder that all functions are set pushed, at which time controls are active in...

  • Page 59: Section 4 - Machine Operation

    SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION DESCRIPTION OPERATING CHARACTERISTICS AND LIMITATIONS This machine is a self-propelled hydraulic personnel lift equipped Capacities with a work platform on the end of an elevating and rotating The boom can be raised above horizontal with or without any boom.

  • Page 60: Stability

    SECTION 4 - MACHINE OPERATION Stability MOTOR OPERATION Machine stability is based on two positions which are called For- Power/Emergency Stop ward and Backward stability. The machines position of least For- ward stability is shown in Figure 4-1., Position of Least Forward The Power/Emergency Stop switch, when pulled Stability, and its position of least Backward stability is shown in out (on), provides battery power for all machine...
  • Page 61 SECTION 4 - MACHINE OPERATION UPPER BOOM FLY BOOM HORIZONTAL FULLY EXTENDED MACHINE WILL "TIP OVER" IN THIS DIRECTION IF OPERATED ON AN OUT-OF-LEVEL SURFACE TOWER AND MID BOOM AT 33 DEGREES Figure 4-1. Position of Least Forward Stability 3121644 –...
  • Page 62 SECTION 4 - MACHINE OPERATION – JLG Lift – 3121644...

  • Page 63: Platform/Ground Select Switch

    SECTION 4 - MACHINE OPERATION Platform/Ground Select Switch TRAVELING (DRIVING) The Platform/Ground Select switch directs NOTE: For units equipped with optional tilt cutout, verify that the drive battery power to the desired control station function is cut out when the boom is elevated and tilt alarm is when the Power/Emergency Stop switch is activated.

  • Page 64: Traveling Forward And Reverse

    SECTION 4 - MACHINE OPERATION USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN DRIV- Traveling Forward and Reverse ING WITH PLATFORM ELEVATED AND WHEN DRIVING WITH ANY PART OF MACHINE WITHIN 6 FEET OF ANY OBSTRUCTION. FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNCTION, OTHER- WISE FUNCTION WILL NOT OPERATE.
  • Page 65 SECTION 4 - MACHINE OPERATION Figure 4-3. Grade and Side Slopes 3121644 – JLG Lift –...

  • Page 66: Steering

    SECTION 4 - MACHINE OPERATION 1. Match the black and PLATFORM white direction arrows on both platform con- Loading From Ground Level trol panel and the chas- sis to determine the 1. Position chassis on a smooth, firm and level surface. direction the machine 2.

  • Page 67: Platform Level Adjustment

    SECTION 4 - MACHINE OPERATION Platform Level Adjustment Jib Swing 1. Depress footswitch. To raise platform, position Platform/Level control switch Up and hold 1. Depress footswitch. To rotate Jib and plat- until platform is level. form to the left, Jib Swing control switch is positioned to the Left and held until desired 2.

  • Page 68: Boom

    SECTION 4 - MACHINE OPERATION BOOM Swinging the Boom To swing boom, with footswitch activated, posi- tion Swing control switch to Right or Left for direc- tion desired. A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE WHICH LIGHTS WHEN THE CHASSIS IS ON A 5 DEGREE OR GREATER SLOPE.

  • Page 69: Generator

    SECTION 4 - MACHINE OPERATION GENERATOR Battery Only Operating Mode The machine will operate in the battery only mode when the fol- The machine is equipped with an engine powered DC generator lowing two conditions apply: connected in parallel to the 48V DC battery bank. Automatic Operating Mode 1.

  • Page 70: Manual (Charge) Operating Mode

    SECTION 4 - MACHINE OPERATION Manual (Charge) Operating Mode INVERTER The generator will operate in manual mode always when the fol- The inverter converts 48 VDC to 110 VAC to allow operation of lowing three conditions apply. power tools from the machine’s batteries. 1.

  • Page 71: Machine Safety System Override (Msso)

    SECTION 4 - MACHINE OPERATION 4.11 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE 4.12 SKYGUARD OPERATION ONLY) Skyguard is used to provide enhanced control panel protection. When the SkyGuard sensor is activated, functions that were in The Machine Safety System Override (MSSO) is use at the time of actuation will reverse or cutout.

  • Page 72: 4.13 Boom Synchronizing Procedure

    SECTION 4 - MACHINE OPERATION 4.13 BOOM SYNCHRONIZING PROCEDURE 4.14 SHUT DOWN AND PARK NOTE: If the Lower Boom assembly does not fully lower: NOTE: When parking battery powered units overnight, batteries should be charged in accordance with instructions in Section 2 to 1.

  • Page 73: 4.15 Machine Lifting And Tie Down

    SECTION 4 - MACHINE OPERATION 4.15 MACHINE LIFTING AND TIE DOWN Tie Down See Figure 4-4. 1. Place the boom in the stowed position. 2. Remove all loose items from the machine. Lifting 3. Secure the chassis and the platform using straps or chains of 1.
  • Page 74 SECTION 4 - MACHINE OPERATION Figure 4-4. Lifting Chart 4-16 – JLG Lift – 3121644...
  • Page 75 SECTION 4 - MACHINE OPERATION Figure 4-5. Decal Installation - Sheet 1 of 3 3121644 – JLG Lift – 4-17...
  • Page 76 SECTION 4 - MACHINE OPERATION Figure 4-6. Decal Installation - Sheet 2 of 3 4-18 – JLG Lift – 3121644...
  • Page 77 SECTION 4 - MACHINE OPERATION Figure 4-7. Decal Installation - Sheet 3 of 3 3121644 – JLG Lift – 4-19...
  • Page 78 SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-B 0275070-7 0259536-B 0259538-14 0259497-17 0259495-17 0259540-14 0259499-16 1703805 1703938 1703939 1703935 1703936 1703937 1703940 1703798 1705822...
  • Page 79 SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-B 0275070-7 0259536-B 0259538-14 0259497-17 0259495-17 0259540-14 0259499-16 1705828 1703980 1703981 1703983 1703984 1703982 1703985 1704277 1704277...
  • Page 80 SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-B 0275070-7 0259536-B 0259538-14 0259497-17 0259495-17 0259540-14 0259499-16 1701500 1703811 1701500 1701500 1701500 1701500 1701500 1701500 1701509...
  • Page 81 SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-B 0275070-7 0259536-B 0259538-14 0259497-17 0259495-17 0259540-14 0259499-16 1702265 1705977 1702271 1703987 1702265 1702265 1703988 1703991 1702300...
  • Page 82 SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-B 0275070-7 0259536-B 0259538-14 0259497-17 0259495-17 0259540-14 0259499-16 1706950 1706950 1704252 1706950 1001121801 1705978 1001121808 1001121918 1001121805...
  • Page 83 SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-B 0275070-7 0259536-B 0259538-14 0259497-17 0259495-17 0259540-14 0259499-16 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704830...
  • Page 84 SECTION 4 - MACHINE OPERATION Table 4-3. M400AJP Decal Legend Eng/ Eng/ Spa/ Item # ANSI CE/AusI Japanese Korean Chinese Spanish French Portuguese 0258973-B 0275069-8 0259535-17 0259537-B 0259539-17 0259496-21 0259494-21 0259498-19 1703805 1703938 1703939 1703935 1703936 1703937 1703940 1703798 1705822 1703932 1703933 1703929...
  • Page 85 SECTION 4 - MACHINE OPERATION Table 4-3. M400AJP Decal Legend Eng/ Eng/ Spa/ Item # ANSI CE/AusI Japanese Korean Chinese Spanish French Portuguese 0258973-B 0275069-8 0259535-17 0259537-B 0259539-17 0259496-21 0259494-21 0259498-19 3251243 3251243 3251243 3251243 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691...
  • Page 86 SECTION 4 - MACHINE OPERATION Table 4-3. M400AJP Decal Legend Eng/ Eng/ Spa/ Item # ANSI CE/AusI Japanese Korean Chinese Spanish French Portuguese 0258973-B 0275069-8 0259535-17 0259537-B 0259539-17 0259496-21 0259494-21 0259498-19 1701500 1703811 1701500 1701500 1701500 1701500 1701500 1701500 1701509 1701509 1701509 1701509...
  • Page 87 SECTION 4 - MACHINE OPERATION Table 4-3. M400AJP Decal Legend Eng/ Eng/ Spa/ Item # ANSI CE/AusI Japanese Korean Chinese Spanish French Portuguese 0258973-B 0275069-8 0259535-17 0259537-B 0259539-17 0259496-21 0259494-21 0259498-19 1706950 1706950 1706950 1706950 1001121801 1705978 1001121808 1707058 1001121805 1707055 1001121810 1001121920...
  • Page 88 SECTION 4 - MACHINE OPERATION Table 4-3. M400AJP Decal Legend Eng/ Eng/ Spa/ Item # ANSI CE/AusI Japanese Korean Chinese Spanish French Portuguese 0258973-B 0275069-8 0259535-17 0259537-B 0259539-17 0259496-21 0259494-21 0259498-19 1702962 1705084 1705084 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1001121510...

  • Page 89: Section 5 - Emergency Procedures

    SECTION 5 - EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES GENERAL This section explains the steps to be taken in case of an emer- FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALL gency situation while operating. FUNCTIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CON- TROLS.

  • Page 90: Platform Or Boom Caught Overhead

    SECTION 5 - EMERGENCY PROCEDURES Platform or Boom Caught Overhead MANUAL DESCENT SYSTEM If the platform or boom becomes jammed or snagged in over- The manual descent system is used, in the event of total power fail- head structures or equipment, rescue platform occupants prior to ure, to lower the upper and lower booms using gravity.

  • Page 91: Machine Safety System Override (Msso)

    SECTION 5 - EMERGENCY PROCEDURES MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE ONLY) The Machine Safety System Override (MSSO) is only to be used to retrieve an operator that is pinned, trapped, or unable to operate the machine and function controls are locked out from the platform due to a platform overload sit- uation.
  • Page 92 SECTION 5 - EMERGENCY PROCEDURES NOTES: – JLG Lift – 3121644...

  • Page 93: Section 6 - General Specifications & Operator Maintenance

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE INTRODUCTION OPERATING SPECIFICATIONS This section of the manual provides additional necessary infor- Table 6-1. Operating Specifications mation to the operator for proper operation and maintenance of this machine.
  • Page 94 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-1. Operating Specifications Table 6-1. Operating Specifications Turning Radius (Inside) Battery Life per Charge 7 hours continuous E/M400AJP 2 ft.-0 in. (0.61 m.) Battery Recharge Time E400An; E/M400AJPn 2 ft.- 10 in. (0.86 m.) Charger 17 hours from full discharge Maximum Tire Load:...

  • Page 95: Capacities

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Capacities Tires Table 6-2. Capacities Table 6-3. Tire Specifications Generator Fuel Tank 4 Gallons (15.1 L) Size Type Pressure Load Range Rating Hydraulic Oil Tank E400An 4 gallons. (15.1L) IN240/55-17.5 Pneumatic 90 psi (6 Bar) E/M400AJP, E/M400AJPn 5 Gallons (19 L) w/ 10% air space...

  • Page 96: Dimensional Data

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Dimensional Data Table 6-4. Dimensional Data Track Width Table 6-4. Dimensional Data E/M400AJP 5 ft. 0 in. (1.51 m) E400An; E/M400AJPn 4 ft. 3.75 in.(1.31 m) Machine Length (stowed) E400An 18 ft. 1 in. (5.50 m) Tail Swing (Any Position) E/M400AJP;...

  • Page 97: Hydraulic Oil

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Oil Table 6-7. Mobil DTE 11M Specs ISO Viscosity Grade Table 6-6. Hydraulic Oil Gravity API 31.9 Hydraulic System Operating Pour Point, Max -40°F (-40°C) S.A.E. Viscosity Temperature Range Grade Flash Point, Min. 330°F (166°C) Viscosity to + 180...

  • Page 98: Critical Stability Weights

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Critical Stability Weights Table 6-8. Mobil EAL H Series Specs Type Synthetic Biodegradable Table 6-9. Critical Stability Weights ISO Viscosity Grade Component Specific Gravity .950 Pour Point -59°F (-51°C) Counterweight 1746 3850 Flash Point 514°F (268°C) Tire &...

  • Page 99: Serial Number Locations

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Serial Number Locations the end of the upper boom, mid boom, and lower boom at the left rear of the booms. For machine identification, a serial number plate is affixed to the left rear of frame, in front of left rear wheel.
  • Page 100 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE – JLG Lift – 3121644...
  • Page 101 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3121644 – JLG Lift –...

  • Page 102: Maintenance And Lubrication

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE MAINTENANCE AND LUBRICATION LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL NOTE: The following numbers correspond to those in Figure 6-2., E400 CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED Maintenance &...
  • Page 103 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Swing Bearing/Worm Gear Teeth DO NOT OVERGREASE BEARINGS. OVERGREASING BEARINGS WILL RESULT IN BLOW- ING OUTER SEAL IN HOUSING. Lube Point(s) - Grease Fittings Capacity - Spray On Lube - OG or Mobiltac375NC Interval - A/R Comments - If necessary install grease fittings into worm gear housing and grease bearings.
  • Page 104 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3. Hydraulic Tank Lube Point(s) - Fill Cap Capacity - 4 Gal. (15.1 L) Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation. Comments - On new machines, those recently overhauled, or after changing hydraulic oil, operate all systems a minimum of two complete cycles and recheck oil level in reservoir.
  • Page 105 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4. Hydraulic Return Filter E400 Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter. Comments - Under certain conditions, it may be necessary to replace the hydraulic filter on a more frequent basis. A com- mon symptom of a dirty filter is sluggishness experienced in hydraulic functions.
  • Page 106 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 5. Wheel Drive Hub 6. Wheel Bearings Lube Point(s) - Level/Fill Plug Lube Point(s) - Repack Capacity - 17 oz. (1/2 Full) Capacity - A/R Lube - EPGL Lube - MPG Interval - Check level every 3 months or 150 hrs of operation; Interval - Every 2 years or 1200 hours of operation change every 2 years or 1200 hours of operation 7.
  • Page 107 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 8. Boom Pivot Pins/Bushing Capacity - A/R Lube - Lithium Lubricant Interval - Every 2 years or 1200 hours of operation Comments - At boom pivot pins/bushing replacement; Coat I.D. of bushings prior to installing pivot pins. 9.

  • Page 108: Battery Maintenance And Charging

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE BATTERY MAINTENANCE AND CHARGING (e.g. baking soda and water or ammonia) and wire brush. Replace cables and/or cable clamp bolts as required. Battery Maintenance, Quarterly 4. Clean battery post with wire brush then re-connect cable to post.

  • Page 109: Optional On Board Generator

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Optional On Board Generator Battery Charging (On Board Charger) For maximum battery life: a. Avoid completely discharging the batteries. EXHAUST GAS HAZARD. RUN THE GENERATOR IN A WELL VENTILATED AREA ONLY. b. Fully charge the batteries each day the machine is used. c.

  • Page 110: Tires & Wheels

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE TIRES & WHEELS • any damage to the bead area cords of the tire If a tire is damaged but is within the above noted criteria, the tire Tire Inflation must be inspected on a daily basis to insure the damage has not propagated beyond the allowable criteria.

  • Page 111: Wheel Replacement

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Replacement Wheel Installation It is extremely important to apply and maintain proper wheel The rims installed on each product model have been designed for mounting torque. stability requirements which consist of track width, tire pressure, and load capacity.

  • Page 112: Supplemental Information

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Tighten nuts in the following sequence: 4. Wheel nuts should be torqued after first 50 hours of opera- tion and after each wheel removal. Check torque every 3 months or 150 hours of operation. SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC...

  • Page 113: Section 7 - Inspection And Repair Log

    SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 7-1. Inspection and Repair Log Date Comments 3121644 – JLG Lift –...
  • Page 114 SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log Date Comments – JLG Lift – 3121644...
  • Page 118 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I.

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