Oshkosh Corporation JLG M400A Operation And Safety Manual
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Oshkosh Corporation JLG M400A 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
E400A Narrow
E400AJP
E400AJP Narrow
M400A
M400A Narrow
M400AJP
M400AJP Narrow
ANSI
3121215
January 7, 2013
®

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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 E400A Narrow E400AJP E400AJP Narrow M400A M400A Narrow M400AJP M400AJP Narrow ANSI 3121215 January 7, 2013 ®...
  • 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 AN IMMINENTLY HAZARDOUS SITUATION.
  • Page 5 FOREWORD For: • Accident Reporting • Standards and Regulations THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE- TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED Compliance Information • Product Safety Publica- JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY- tions •...
  • Page 6 FOREWORD REVISION LOG Original Issue - June 6, 2005 Revised - July 21, 2006 Revised - December 3, 2009 Revised - November 9, 2011 Revised - August 20, 2012 Revised - January 7, 2013 – JLG Lift – 3121215...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 1 - SAFETY PRECAUTIONS General ....... . 2-9 GENERAL .
  • Page 8 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Platform Level Adjustment ....4-7 SECTION - 5 - EMERGENCY PROCEDURES Platform Rotation .
  • Page 9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Battery Charging (On Board Charger) ..6-16 4-3. Grade and Side Slopes ..... 4-8 TIRES &...
  • Page 10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE LIST OF TABLES 6-11 Lubrication Specifications....6-10 6-12 Wheel Torque Chart ..... . . 6-19 Minimum Approach Distances (M.A.D.) .

  • Page 11: Section 1. Safety Precautions

    SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS GENERAL PRE-OPERATION This section outlines the necessary precautions for proper Operator Training and Knowledge and safe machine operation and maintenance. For proper machine use, it is mandatory that a daily routine is estab- •...

  • Page 12: Workplace Inspection

    SECTION 1 - SAFETY PRECAUTIONS Machine Inspection • Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine • Before machine operation, perform inspections and func- and in this manual. tional checks. Refer to Section 2 of this manual for •...

  • Page 13: Operation

    SECTION 1 - SAFETY PRECAUTIONS OPERATION • Supplies or tools which extend outside the platform are prohibited unless approved by JLG. General • When driving, always position boom over rear axle in line with the direction of travel. Remember, if boom is over the •...

  • Page 14: Electrocution Hazards

    SECTION 1 - SAFETY PRECAUTIONS • Before operating the machine, make sure all gates are • Use extreme caution when entering or leaving platform. closed and fastened in their proper position. Be sure that the boom is fully lowered. It may be neces- sary to telescope out to position the platform closer to the ground for entry/exit.

  • Page 15: Minimum Approach Distances (M.a.d.)

    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 16: Tipping Hazards

    SECTION 1 - SAFETY PRECAUTIONS Tipping Hazards • The minimum approach distance may be reduced if insulat- ing barriers are installed to prevent contact, and the barriers • The user must be familiar with the surface before driving. are rated for the voltage of the line being guarded. These Do not exceed the allowable sideslope and grade while barriers shall not be part of (or attached to) the machine.

  • Page 17: Crushing And Collision Hazards

    SECTION 1 - SAFETY PRECAUTIONS • Do not elevate platform or drive with platform elevated • If boom assembly or platform is in a position that one or while on a sloping, uneven, or soft surface. more wheels are off the ground, all persons must be removed before attempting to stabilize the machine.

  • Page 18: Towing, Lifting, And Hauling

    SECTION 1 - SAFETY PRECAUTIONS TOWING, LIFTING, AND HAULING • Use the boom functions, not the drive function, to position the platform close to obstacles. • Never allow personnel in platform while towing, lifting, or • Always post a lookout when driving in areas where vision hauling.

  • Page 19: Additional Hazards / Safety

    SECTION 1 - SAFETY PRECAUTIONS ADDITIONAL HAZARDS / SAFETY • Do not refuel the machine with the engine running. • Battery fluid is highly corrosive. Avoid contact with skin • Do not use machine as a ground for welding. and clothing at all times. •...
  • Page 20 SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/S). 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 21: 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 over- head obstructions, other moving equipment, and obsta- The aerial platform is a personnel handling device; so it is cles, depressions, holes, dropoffs.

  • Page 22: Preparation, Inspection, And Maintenance

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION PREPARATION, INSPECTION, AND MAINTENANCE JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-QUALIFIED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED The following table covers the periodic machine inspections THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PROD- and maintenance recommended by JLG Industries, Inc.
  • Page 23 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 Before each sale, lease, or rental delivery.

  • Page 24: Pre-Start Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection (Domestic only) is enclosed in the weather resistant storage container. The Pre-Start Inspection should include each of the follow- 5. “Walk-Around” Inspection – Refer to Figure 2-2. thru ing: Figure 2-4.

  • Page 25: Function Check

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Function Check 2. Raise, extend, retract, and lower the Upper Boom. Check for smooth operation. A functional check of all systems should be performed, once 3. If tower boom does not rest on stop with machine in the the walk-around inspection is complete, in an area free of stowed position, this indicates upright is out of plumb.
  • Page 26 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION With footswitch depressed, operate LIFT and hold control. Remove foot from footswitch, motion should stop. If it does not, shut down machine and contact a qualified ser- DO NOT DRIVE ON GRADES WHICH EXCEED THE RATED GRADEABILITY OF THE MACHINE AS INDICATED ON THE SERIAL NUMBER PLATE.

  • Page 27: Basic Nomenclature

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 1. Platform Control Console 2. Platform 3. Upper Boom 4. Telescope Cylinder 5. Master Cylinder 6. Upper Upright 7. Upper Lift Cylinder 8. Mid Lift Cylinder 9. Lower Boom 10. Turntable 11.
  • Page 28 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 17, 18 3, 4 23, 16 Figure 2-2. Daily Walk-Around Inspection - Sheet 1 of 3 – JLG Lift – 3121215...
  • Page 29 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION General 1. Platform and Gate Assembly - Platform mounting pins secure. Footswitch in good working order; not modi- Begin the “Walk-Around Inspection” at Item 1, as noted on fied, disabled or blocked; Bar slides freely. the diagram.
  • Page 30 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 9. Drive Axle and Motor - See Note. 15. Cowling and Latches - See Note. 10. Wheel/Tire Assembly - No loose or missing lug nuts. 16. Battery Charger - See Note. Inspect for worn tread, cuts, tears or other discrepan- 17.

  • Page 31: General

    SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS GENERAL Ground Control Station (See Figure 3-1. and Figure 3-2.) NOTE: When machine is shut down the Platform/Ground Select THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE switch and Emergency Stop must be positioned to OFF.
  • Page 32 SECTION 3 - MACHINE CONTROLS AND INDICATORS 2. Platform Overload (If equipped) 5. Telescope Indicates the platform has been overloaded. Provides for extension and retraction of Upper Boom when positioned to IN or OUT. NOTE: The engine will not start if the batteries are fully charged 6.

  • Page 33: Ground Control Station

    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. Circuit Breakers 8. Emergency Stop 9. Platform/Ground Select 10. Lower/Mid Lift 11.

  • Page 34: Ground Control Station W/ Function Enable

    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. Circuit Breakers 8. Emergency Stop 9. Platform/Ground Select 10. Lower/Mid Lift 11.
  • Page 35 SECTION 3 - MACHINE CONTROLS AND INDICATORS 9. Platform/Ground Select Switch 12. Articulating Jib Boom (If equipped) A three position, key operated switch supplies power to The Articulating Jib Boom control switch provides rais- the platform control console when positioned to PLAT- ing and lowering of the jib when positioned up or down.

  • Page 36: Platform Station

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Station 3. Horn A push-type HORN switch supplies electrical power to (See Figure 3-3.) an audible warning device when pressed. 1. Posi-Track Control 4. Power/Emergency Stop Activating the Posi-Track switch allows the operator to A two-position red mushroom shaped switch furnishes engage positive traction for the time period pre-set in the power to PLATFORM Controls when pulled out (on).

  • Page 37: Platform Control Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Posi-Track 5. Generator Enable 9. Jib 12. Platform Rotate 2. Platform Leveling Override 6. Lights 10. Jib Swing 13. Function Speed 3. Horn 7. Drive/Steer 11. Lower Boom Lift 14. Main Lift/Swing 4.

  • Page 38: Platform Control Console W/ Drive Orientation

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1702938 1705170 A 1. Posi-Track 5. Generator Enable 9. Jib 13. Function Speed 2. Platform Leveling Override 6. Lights 10. Jib Swing 14. Main Lift/Swing 3. Horn 7. Drive/Steer 11. Lower Boom Lift 15.
  • Page 39 SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Lights (If Equipped) This switch operates control console panel lights and TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON- head lights if the machine is so equipped. TROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION 7.
  • Page 40 SECTION 3 - MACHINE CONTROLS AND INDICATORS 12. Platform Rotate NOTE: Main lift and swing functions may be selected in combina- tion. The handle features a round gate so that maximum The PLATFORM ROTATE control switch allows the oper- speed is reduced when multiple functions are selected. ator to rotate the basket to the left or right when posi- tioned to the desired direction.
  • Page 41 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 Lower Lift** Upper Lift** Telescope Drive and Steer Lower Lift Swing*...

  • Page 42: Platform Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Control Indicator Panel 1. Tilt Alarm Warning Light and Alarm This illuminator indicates that the chassis is on a slope. (See Figure 3-5., Platform Control Indicator Panel) An alarm will also sound when the chassis is on a slope NOTE: The platform control indicator panel uses different shaped and the boom is above horizontal.

  • Page 43: Platform Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1704239 E 1001110226A 1. Tilt 5. Enable 1. Tilt 6. Low Battery 2. Platform Overload 6. Low Battery 2. Platform Overload 7. Creep 3. System Distress 7. Creep 3. System Distress 8. Drive Orientation Override 4.
  • Page 44 SECTION 3 - MACHINE CONTROLS AND INDICATORS 2. Platform Overload (If equipped) c. The batteries are nearly depleted, and should be charged very soon to prevent having the machine Indicates the platform has been overloaded. stop at an inconvenient place. d.
  • Page 45 SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Enable Indicator/Footswitch 6. Low Battery Indicator To operate any function, the footswitch must be Indicates the batteries are low and need to be charged. depressed and the function selected within seven sec- onds.
  • Page 46 SECTION 3 - MACHINE CONTROLS AND INDICATORS 7. Creep Speed Indicator 9. Soft Touch Indicator (If Equipped) When the Function Speed Control is turned to the creep When illuminated (Yellow) the Soft Touch bumper is position, the indicator acts as a reminder that all func- against an object.

  • Page 47: 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 with a work platform on the end of an elevating Capacities and rotating boom. The boom can be raised above horizontal with or without any The primary operator control station is in the platform.

  • Page 48: Stability

    SECTION 4 - MACHINE OPERATION Stability MOTOR OPERATION Machine stability is based on two positions which are called Power/Emergency Stop FORWARD and BACKWARD stability. The machines position of least FORWARD stability is shown in Figure 4-1., Position The Power/Emergency Stop switch, when pulled out (on), of Least Forward Stability, and its position of least BACK- provides battery power for all machine functions.

  • Page 49: Position Of Least Forward Stability

    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 3121215 –...
  • Page 50 SECTION 4 - MACHINE OPERATION – JLG Lift – 3121215...

  • Page 51: Platform/Ground Select Switch

    SECTION 4 - MACHINE OPERATION Platform/Ground Select Switch TRAVELING (DRIVING) The Platform/Ground Select switch directs battery power to NOTE: When lower boom is raised above horizontal, or the upper the desired control station when the POWER/EMERGENCY boom is raised approximately 16 inches (40.6 cm) above STOP switch is pulled out (on).

  • Page 52: Traveling Forward And Reverse

    SECTION 4 - MACHINE OPERATION 3. Position Drive controller to FORWARD or REVERSE as USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL desired. Angle of controller will determine travel speed. TIMES WHEN DRIVING WITH PLATFORM ELEVATED AND WHEN DRIV- ING WITH ANY PART OF MACHINE WITHIN 6 FEET OF ANY OBSTRUC- This machine is equipped with a Drive Orientation Indicator.

  • Page 53: Platform

    SECTION 4 - MACHINE OPERATION PLATFORM Loading From Positions Above Ground Level Before loading weight to platform above ground level: Loading From Ground Level 1. Determine what the total weight will be after additional 1. Position chassis on a smooth, firm and level surface. weight is loaded (personnel, tools and supplies).
  • Page 54 SECTION 4 - MACHINE OPERATION Figure 4-3. Grade and Side Slopes – JLG Lift – 3121215...

  • Page 55: Platform Level Adjustment

    SECTION 4 - MACHINE OPERATION Platform Level Adjustment Jib Swing 1. Leveling UP . Depress footswitch to raise platform, posi- tion PLATFORM/LEVEL control switch UP and hold until 1. Depress footswitch to rotate Jib and platform to the left, platform is level. JIB SWING control switch is positioned to the LEFT and held until desired position is reached.

  • Page 56: Boom

    SECTION 4 - MACHINE OPERATION BOOM WHEN RELEASED. TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP SWITCH TO STOP A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE THE MACHINE.

  • Page 57: Raising And Lowering The Upper Boom

    SECTION 4 - MACHINE OPERATION Raising and Lowering the Upper Boom Battery Only Operating Mode Depress footswitch to raise or lower the Upper Boom, with The machine will operate in the battery only mode when the footswitch activated, position Upper Boom Lift switch to UP following two conditions apply: or DOWN until desired height is reached.

  • Page 58: Inverter

    SECTION 4 - MACHINE OPERATION 4.10 MACHINE FUNCTION SPEEDS mum level. The charging cycle will include finishing phase similar to conventional chargers. The Function Speed Control affects the speed of boom func- INVERTER tions Lower Lift, Telescope, and Rotate. Turn the control CW to increase function speed or CCW to decrease function The inverter converts 48 VDC to 110 VAC to allow operation speed.

  • Page 59: 4.12 Boom Synchronizing Procedure

    SECTION 4 - MACHINE OPERATION 4.13 MACHINE LIFTING AND TIE DOWN 4. Shut down Emergency Stop at Ground Controls. Posi- tion Platform/Ground Select switch to center OFF. Lifting 5. If necessary, cover Platform Controls to protect instruc- tion placards, warning decals and operating controls from hostile environment.

  • Page 60: Lifting Chart

    SECTION 4 - MACHINE OPERATION Lifting Instructions: 1. Check Serial Number Plate, call JLG Industries, or weigh the individual unit to obtain GVW. 2. Place the boom in the stowed position. 3. Remove all loose items from the machine. 4. Properly adjust the rigging to prevent damage to the machine and so the machine remains level. Figure 4-4.
  • Page 61 SECTION 4 - MACHINE OPERATION Figure 4-5. Chassis & Platform Tie Down - Sheet 1 of 2 3121215 – JLG Lift – 4-15...
  • Page 62 SECTION 4 - MACHINE OPERATION Figure 4-6. Chassis & Platform Tie Down - Sheet 2 of 2 4-16 – JLG Lift – 3121215...
  • Page 63 SECTION 4 - MACHINE OPERATION Figure 4-7. Decal Installation - Sheet 1 of 3 3121215 – JLG Lift – 4-17...
  • Page 64 SECTION 4 - MACHINE OPERATION Figure 4-8. Decal Installation - Sheet 2 of 3 4-18 – JLG Lift – 3121215...
  • Page 65 SECTION 4 - MACHINE OPERATION Figure 4-9. Decal Installation - Sheet 3 of 3 3121215 – JLG Lift – 4-19...

  • Page 66: E400A/E400Ajp Decal Legend

    SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend - Prior to S/N 0300142589 Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-16 0275070-6 0259536-11 0259538-11 0259497-13 0259495-13 0259540-11 0259499-13 1703805 1703938 1703939 1703935...
  • Page 67 SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend - Prior to S/N 0300142589 Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-16 0275070-6 0259536-11 0259538-11 0259497-13 0259495-13 0259540-11 0259499-13 1705828 1703980 1703981 1703983...
  • Page 68 SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend - Prior to S/N 0300142589 Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-16 0275070-6 0259536-11 0259538-11 0259497-13 0259495-13 0259540-11 0259499-13 1701500 1703811 1701500 1701500...
  • Page 69 SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend - Prior to S/N 0300142589 Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-16 0275070-6 0259536-11 0259538-11 0259497-13 0259495-13 0259540-11 0259499-13 1702265 1705977 1702271 1703987...
  • Page 70 SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend - Prior to S/N 0300142589 Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-16 0275070-6 0259536-11 0259538-11 0259497-13 0259495-13 0259540-11 0259499-13 1706950 1706950 1704252 1706950...
  • Page 71 SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend - Prior to S/N 0300142589 Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-16 0275070-6 0259536-11 0259538-11 0259497-13 0259495-13 0259540-11 0259499-13 1704412 1704412 1704412 1704412...

  • Page 72: E400A/E400Ajp Decal Legend - S/N 0300142589 To Present

    SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend - S/N 0300142589 to Present Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-22 0275070-7 0259536-14 0259538-14 0259497-17 0259495-17 0259540-14 0259499-16 1703805 1703938 1703939 1703935...
  • Page 73 SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend - S/N 0300142589 to Present Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-22 0275070-7 0259536-14 0259538-14 0259497-17 0259495-17 0259540-14 0259499-16 1705828 1703980 1703981 1703983...
  • Page 74 SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend - S/N 0300142589 to Present Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-22 0275070-7 0259536-14 0259538-14 0259497-17 0259495-17 0259540-14 0259499-16 1701500 1703811 1701500 1701500...
  • Page 75 SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend - S/N 0300142589 to Present Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-22 0275070-7 0259536-14 0259538-14 0259497-17 0259495-17 0259540-14 0259499-16 1702265 1705977 1702271 1703987...
  • Page 76 SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend - S/N 0300142589 to Present Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-22 0275070-7 0259536-14 0259538-14 0259497-17 0259495-17 0259540-14 0259499-16 1706950 1706950 1704252 1706950...
  • Page 77 SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend - S/N 0300142589 to Present Eng/ Eng/ Chinese Spa/ Item # ANSI CE/AusI Japanese Korean Lat. Spanish CSA French /Eng Portuguese 0259301-22 0275070-7 0259536-14 0259538-14 0259497-17 0259495-17 0259540-14 0259499-16 1704412 1704412 1704412 1704412...

  • Page 78: M400A/M400Aj Decal Legend

    SECTION 4 - MACHINE OPERATION Table 4-3. M400A/M400AJ Decal Legend - Prior to S/N 0300142589 Eng/ Eng/ Spa/ Item # ANSI CE/AusI Japanese Korean Chinese Spanish French Portuguese 0258973-18 0275069-6 0259535-13 0259537-13 0259539-13 0259496-15 0259494-15 0259498-15 1703805 1703938 1703939 1703935 1703936 1703937 1703940...
  • Page 79 SECTION 4 - MACHINE OPERATION Table 4-3. M400A/M400AJ Decal Legend - Prior to S/N 0300142589 Eng/ Eng/ Spa/ Item # ANSI CE/AusI Japanese Korean Chinese Spanish French Portuguese 0258973-18 0275069-6 0259535-13 0259537-13 0259539-13 0259496-15 0259494-15 0259498-15 3251243 3251243 3251243 3251243 1701691 1701691 1701691...
  • Page 80 SECTION 4 - MACHINE OPERATION Table 4-3. M400A/M400AJ Decal Legend - Prior to S/N 0300142589 Eng/ Eng/ Spa/ Item # ANSI CE/AusI Japanese Korean Chinese Spanish French Portuguese 0258973-18 0275069-6 0259535-13 0259537-13 0259539-13 0259496-15 0259494-15 0259498-15 1701500 1703811 1701500 1701500 1701500 1701500 1701500...
  • Page 81 SECTION 4 - MACHINE OPERATION Table 4-3. M400A/M400AJ Decal Legend - Prior to S/N 0300142589 Eng/ Eng/ Spa/ Item # ANSI CE/AusI Japanese Korean Chinese Spanish French Portuguese 0258973-18 0275069-6 0259535-13 0259537-13 0259539-13 0259496-15 0259494-15 0259498-15 1706950 1706950 1706950 1706950 1701645 1705978 1707059...
  • Page 82 SECTION 4 - MACHINE OPERATION Table 4-3. M400A/M400AJ Decal Legend - Prior to S/N 0300142589 Eng/ Eng/ Spa/ Item # ANSI CE/AusI Japanese Korean Chinese Spanish French Portuguese 0258973-18 0275069-6 0259535-13 0259537-13 0259539-13 0259496-15 0259494-15 0259498-15 1702962 1705084 1705084 1704412 1704412 1704412 1704412...

  • Page 83: M400A/M400Aj Decal Legend - S/N 0300142589 To Present

    SECTION 4 - MACHINE OPERATION Table 4-4. M400A/M400AJ Decal Legend - S/N 0300142589 to Present Eng/ Eng/ Spa/ Item # ANSI CE/AusI Japanese Korean Chinese Spanish French Portuguese 0258973-23 0275069-8 0259535-17 0259537-17 0259539-17 0259496-21 0259494-21 0259498-19 1703805 1703938 1703939 1703935 1703936 1703937 1703940...
  • Page 84 SECTION 4 - MACHINE OPERATION Table 4-4. M400A/M400AJ Decal Legend - S/N 0300142589 to Present Eng/ Eng/ Spa/ Item # ANSI CE/AusI Japanese Korean Chinese Spanish French Portuguese 0258973-23 0275069-8 0259535-17 0259537-17 0259539-17 0259496-21 0259494-21 0259498-19 3251243 3251243 3251243 3251243 1701691 1701691 1701691...
  • Page 85 SECTION 4 - MACHINE OPERATION Table 4-4. M400A/M400AJ Decal Legend - S/N 0300142589 to Present Eng/ Eng/ Spa/ Item # ANSI CE/AusI Japanese Korean Chinese Spanish French Portuguese 0258973-23 0275069-8 0259535-17 0259537-17 0259539-17 0259496-21 0259494-21 0259498-19 1701500 1703811 1701500 1701500 1701500 1701500 1701500...
  • Page 86 SECTION 4 - MACHINE OPERATION Table 4-4. M400A/M400AJ Decal Legend - S/N 0300142589 to Present Eng/ Eng/ Spa/ Item # ANSI CE/AusI Japanese Korean Chinese Spanish French Portuguese 0258973-23 0275069-8 0259535-17 0259537-17 0259539-17 0259496-21 0259494-21 0259498-19 1706950 1706950 1706950 1706950 1001121801 1705978 1001121808...
  • Page 87 SECTION 4 - MACHINE OPERATION Table 4-4. M400A/M400AJ Decal Legend - S/N 0300142589 to Present Eng/ Eng/ Spa/ Item # ANSI CE/AusI Japanese Korean Chinese Spanish French Portuguese 0258973-23 0275069-8 0259535-17 0259537-17 0259539-17 0259496-21 0259494-21 0259498-19 1702962 1705084 1705084 1704412 1704412 1704412 1704412...
  • Page 88 SECTION 4 - MACHINE OPERATION NOTES: 4-42 – JLG Lift – 3121215...

  • 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 FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE emergency situation while operating. AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CONTROLS.

  • 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 The manual descent system is used, in the event of total power overhead structures or equipment, rescue platform occu- failure, to lower the upper and lower booms using gravity.

  • Page 91: Manual Swing Override

    SECTION 5 - EMERGENCY PROCEDURES is completely lowered. Return manual descent knob to center position and stow handle in bracket provided. MANUAL SWING OVERRIDE The manual swing override is used to manually swing boom and turntable assembly in the event of a total power failure when the platform is positioned over a structure or obstacle.
  • Page 92 SECTION 5 - EMERGENCY PROCEDURES NOTES: – JLG Lift – 3121215...

  • 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 Table 6-1. Operating Specifications - Prior to S/N 0300142589 information to the operator for proper operation and mainte- nance of this machine.

  • Page 94: Operating Specifications - S/N 0300142589

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-1. Operating Specifications - Prior to S/N 0300142589 Table 6-1. Operating Specifications - Prior to S/N 0300142589 Maximum Tire Load: Maximum System Voltage 48 VDC E/M 400A 5370 lbs. (2436 kg) Battery Life per Charge 7 hours continuous E/M 400Anarrow...
  • Page 95 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-2. Operating Specifications - S/N 0300142589 to Table 6-2. Operating Specifications - S/N 0300142589 to Present Present Horizontal Platform Reach (Up & Over) Drive Speed: (Above Horz.) E/M400A; E/M400An 21 ft.-2 in. (6.41 m.) E/M400A;...

  • Page 96: Capacities

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Capacities Tires Table 6-3. Capacities Table 6-4. Tire Specifications Generator Fuel Tank 4 Gallons (15.1 L) Load Size Type Pressure Rating Range Hydraulic Oil Tank E/M 400A, E/M 400An 4 gallons. (15.1L) Pneumatic 90 psi (6 Bar) IN240/55-17.5...

  • Page 97: Dimensional Data

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Dimensional Data Table 6-5. Dimensional Data Track Width Table 6-5. Dimensional Data E/M400A; E/M400AJP 5 ft. 0 in. (1.51 m) E/M400An; E/M400AJPn 4 ft. 3.75 in.(1.31 m) Machine Length (stowed) E/M400A; E/M400An 18 ft.

  • Page 98: Hydraulic Oil

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Oil Table 6-8. Mobil DTE 11M Specs ISO Viscosity Grade Table 6-7. Hydraulic Oil Gravity API 31.9 Hydraulic System Operating S.A.E. Viscosity -40°F (-40°C) Pour Point, Max Temperature Range Grade 330°F (166°C) Flash Point, Min.

  • Page 99: Critical Stability Weights

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Critical Stability Weights Table 6-9. Mobil EAL H Series Specs Type Synthetic Biodegradable Table 6-10. Critical Stability Weights ISO Viscosity Grade Specific Gravity .950 Component Pour Point -59°F (-51°C) Counterweight 1746 3850 Flash Point 514°F (268°C) Tire &...

  • Page 100: Serial Number Locations

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Serial Number Locations stamped on top of 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 101 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3121215 – JLG Lift –...

  • Page 102: Operator Maintenance

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE OPERATOR MAINTENANCE LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION NOTE: The following numbers correspond to those in Figure 6- UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT 2., Operator Maintenance & Lubrication Diagram. OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CON- DITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORD- Table 6-11.
  • Page 103 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Swing Bearing/Worm Gear Teeth DO NOT OVERGREASE BEARINGS. OVERGREASING BEARINGS WILL RESULT IN BLOWING 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 4. Hydraulic Return Filter Lube Point(s) - Fill Cap Capacity - 4 Gal. (15.1 L) Lube - HO Interval - Check Level daily; Change every 2 years or 1200 Interval - Change after first 50 hrs.
  • Page 105 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 opera- Interval - Every 2 years or 1200 hours of operation tion;...
  • Page 106 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 107: Battery Maintenance And Charging

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE BATTERY MAINTENANCE AND CHARGING 3. Remove battery cables from each battery post one at a time, negative first. Clean cables with acid neutralizing solution (e.g. baking soda and water or ammonia) and Battery Maintenance, Quarterly wire brush.

  • Page 108: Optional On Board Generator

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Optional On Board Generator Battery Charging (On Board Charger) 1. For maximum battery life: a. Avoid completely discharging the batteries. EXHAUST GAS HAZARD. RUN THE GENERATOR IN A WELL VENTI- b. Fully charge the batteries each day the machine is LATED AREA ONLY.

  • Page 109: 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 110: Wheel Replacement

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Installation by JLG. Due to size variations between tire brands, both tires on the same axle should be the same. It is extremely important to apply and maintain proper wheel Wheel Replacement mounting torque.

  • Page 111: 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 operation 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/...
  • Page 112 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE NOTES: 6-20 – JLG Lift – 3121215...

  • 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 3121215 – JLG Lift –...

  • Page 114: Inspection And Repair Log

    SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log Date Comments – JLG Lift – 3121215...
  • Page 118 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 3121215 (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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