JLG E400A Narrow Operation And Safety Manual
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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 0300208530* to Present
* See inside front cover for exceptions.
AS/NZS
ANSI
3121716
®
November 5, 2018 - Rev D

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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 0300208530* to Present * See inside front cover for exceptions. AS/NZS ANSI 3121716 ®...
  • Page 2 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...
  • Page 3 This manual also covers the following Serial Numbers. 0300200544 0300202223 WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
  • Page 4 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. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.
  • Page 5 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 6 Modifications Product Safety JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE Contact: CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE. Product Safety and Reliability Department JLG Industries, Inc.
  • Page 7 FOREWORD REVISION LOG Original Issue A - July 6, 2015 Revised B - May 30, 2018 Revised C - June 29, 2018 - Revised Covers, Prop 65 Revised D - November 5, 2018 3121716...

  • Page 8: Table Of Contents

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 1 - SAFETY PRECAUTIONS Function Check........2-9 SkyGuard Function Test.
  • Page 9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Loading From Positions Above Ground Level..4-9 SECTION - 5 - EMERGENCY PROCEDURES Platform Level Adjustment ......4-9 GENERAL .
  • Page 10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Torque Specifications ......7-5 Hydraulic Oil .
  • Page 11 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE 2-1. Basic Nomenclature........2-4 3-1.
  • Page 12 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 13 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 14: Section 1 - Safety Precautions

    JLG Industries, Inc. completed under the supervision of an experienced and quali- fied operator.

  • Page 15: Workplace Inspection

    JLG. unit. • Before operation, check work area for overhead hazards such •...

  • Page 16: Machine Inspection

    • Check the machine for modifications to original components. opposite direction. Always return switch to neutral and stop Ensure that any modifications have been approved by JLG. before moving the switch to the next function. Operate con- trols with slow and even pressure.

  • Page 17: Trip And Fall Hazards

    • 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 18: 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 19 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 20: 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 21 Keep all loads within the confines of the platform, gusts, may exceed 28 mph (12.5 m/s). Factors affecting wind unless authorized by JLG. speed are; platform elevation, surrounding structures, local weather events, and approaching storms. Refer to Table 1-2, •...
  • Page 22 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 23: 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 24: 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 25 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 26: 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 27 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...
  • Page 28 SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-14 3121716...

  • 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, or drop-offs exist.

  • Page 30: 2.2 Preparation, Inspection, And Maintenance

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.2 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 required by JLG Industries, Inc.
  • Page 31 Preventative Maintenance At intervals as specified in the Service and Maintenance Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual Manual. NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. 3121716...
  • Page 32 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 33: Pre-Start Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection 5. Daily Walk-Around Inspection – Perform as instructed. 6. Battery – Charge as required. The Pre-Start Inspection should include each of the following: 7. Fuel (Generator Equipped Machines) – Add the proper fuel 1.

  • Page 34: Daily Walk-Around Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Daily Walk-Around Inspection 3121716...
  • Page 35 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, dis- abled or blocked; Bar slides freely. Begin the “Walk-Around Inspection” at Item 1, as noted on the diagram.
  • Page 36 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 11. Swing Motor and Worm Gear - See Note. 18. Boom/Upright - No visible damage; All pins properly secured. Upright in vertical position. If Upright does not rest 12. Hydraulic Pump and Reservoir - Properly secured; no visible on stop with machine in the stowed position, this indicates damage or hydraulic leaks.

  • Page 37: 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 the 3. If tower boom does not rest on stop with machine in the walk-around inspection is complete, in an area free of overhead stowed position, this indicates upright is out of plumb.
  • Page 38 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. Plat- during raising and lowering of boom. form controls should not operate. 8. Check rotator for smooth operation and assure platform will 13.

  • Page 39: Skyguard Function Test

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SkyGuard Function Test 4. Disengage the SkyGuard sensor, release controls, then recy- cle the footswitch. Ensure normal operation is available. NOTE: Refer to Section 4.12 for additional information on SkyGuard NOTE: On machines equipped with SkyLine, reattach magnetic end of operation.
  • Page 40 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...
  • Page 41 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTES: 2-12 3121716...

  • Page 42: 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 43: Ground Control Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Console High Oil Temperature Low Oil Pressure Engine Overspeed Overvoltage TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR 2. Platform Overload (If equipped) TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED.
  • Page 44 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. System Distress Indicator 2. Platform Overload Indicator (If Equipped) 3. Generator/Engine Start Button 4. Indicator Gauge 5. Charger Status 6. Telescope 7. Machine Safety System Override (MSSO)(If Equipped) 8. Swing 9. Function Enable 10.
  • Page 45 SECTION 3 - MACHINE CONTROLS AND INDICATORS 4. Indicator Gauge 7. Machine Safety System Override (MSSO) (CE Only) Registers the amount of time the machine has been in use, with functions operating. In Provides emergency override of function the event of a fault, the hourmeter also dis- controls that are locked out in the event of plays the three digit fault code.
  • Page 46 SECTION 3 - MACHINE CONTROLS AND INDICATORS 10. Circuit Breakers 13. Lower/Mid Boom Lift The circuit breakers open (pop out) to indicate a short or Provides for raising and lowering of overload somewhere on the machine. Lower Boom when positioned to Up or Down.

  • Page 47: Platform Control Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 16. Jib Swing (If equipped) Platform Control Console The Jib Swing control switch provides swing- (See Figure 3-2.) ing of the jib when positioned left or right. 1. Speed Mode Activating the Speed Mode switch allows the operator to High or Low ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF Speed travel operation.
  • Page 48 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Speed Mode 5. Generator Enable 9. Lights 13. Lower Boom Lift 2. Platform Leveling Override 6. Drive Orientation Override 10. Jib 14. Platform Rotate 3. Horn 7. Drive/Steer 11. Jib Swing 15. 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. Jib Swing (If Equipped) described above and allows the operator to override the sys- tem that has experienced a cutout situation. Push toggle switch right to swing right, push 13. Lower Boom Lift left to swing left.
  • Page 52 SECTION 3 - MACHINE CONTROLS AND INDICATORS 15. Function Speed Control NOTE: To operate the Main Boom Lift/Swing joystick, pull up on the locking ring below the handle. Adjusts speed of Boom and Swing Func- tions. Rotate counterclockwise for slower speed and clockwise for faster speed.
  • 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 3-3., Platform Control Indicator Panel) 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 5. Footswitch Enable 8. SkyGuard 2. Platform Overload 6. Battery Charge 9. Soft Touch 3. System Distress 7. Low Battery 10. Creep Speed 4. Drive Orientation Figure 3-3. Platform Control Indicator Panel 3-14 3121716...
  • 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. Enable Indicator/Footswitch 6. Battery Charge Indicator To operate any function, the footswitch This indicator lights to show the state-of- must be depressed and the function charge of the battery pack.. selected within seven seconds. The enable indicator shows that the controls are enabled.
  • Page 58 SECTION 3 - MACHINE CONTROLS AND INDICATORS 8. SkyGuard (If Equipped) 10. Creep Speed Indicator When illuminated indicates the SkyGuard When the Function Speed Control is sensor has been activated. All controls are turned to the creep position, the indicator cut out until the override button is pushed, acts as a reminder that all functions are set at which time controls will work normally.
  • Page 59 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...
  • Page 60 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTES: 3-18 3121716...

  • Page 61: Section 4 - Machine Operation

    Ground Controls operate Upper and Lower Boom Lift and Swing, 4. Proper tire pressure. and are to be used in an emergency to lower the platform to the 5. Machine is as originally equipped from JLG. ground should the operator in the platform be unable to do so. 3121716...

  • Page 62: 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 63 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 3121716...
  • Page 64 SECTION 4 - MACHINE OPERATION 3121716...

  • Page 65: 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 66: 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 67 SECTION 4 - MACHINE OPERATION Figure 4-3. Grade and Side Slopes 3121716...

  • Page 68: Traveling On A Grade

    SECTION 4 - MACHINE OPERATION 1. Match the black and Traveling on a Grade white direction arrows on both platform con- When traveling a grade, maximum braking and traction are obtained trol panel and the chas- with the boom stowed, in position over the rear (drive) axle, and in sis to determine the line with the direction of travel.

  • Page 69: Steering

    SECTION 4 - MACHINE OPERATION STEERING Platform Level Adjustment Depress footswitch, position thumb switch on 1. Depress footswitch. To raise platform, position Drive/Steer controller to Right for steering right, or Platform/Level control switch Up and hold to Left for steering left. until platform is level.

  • Page 70: Jib Swing

    SECTION 4 - MACHINE OPERATION Jib Swing BOOM 1. Depress footswitch. To rotate Jib and plat- form to the left, Jib Swing control switch is A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE positioned to the Left and held until desired WHICH LIGHTS WHEN THE CHASSIS IS ON A 5 DEGREE OR GREATER position is reached.

  • Page 71: Swinging The Boom

    SECTION 4 - MACHINE OPERATION Swinging the Boom GENERATOR To swing boom, with footswitch activated, posi- The machine is equipped with an engine powered DC generator tion Swing control switch to Right or Left for direc- connected in parallel to the 48V DC battery bank. tion desired.

  • Page 72: Battery Only Operating Mode

    SECTION 4 - MACHINE OPERATION Battery Only Operating Mode Manual (Charge) Operating Mode The machine will operate in the battery only mode when the fol- The generator will operate in manual mode always when the fol- lowing two conditions apply: lowing three conditions apply.

  • Page 73: Inverter

    SECTION 4 - MACHINE OPERATION INVERTER 4.11 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE ONLY) The inverter converts 48 VDC to 110 VAC to allow operation of power tools from the machine’s batteries. The Machine Safety System Override (MSSO) is used to override function controls for Emergency •...

  • Page 74: 4.12 Skyguard Operation

    SECTION 4 - MACHINE OPERATION 4.12 SKYGUARD OPERATION SkyGuard SkyGuard provides enhanced control panel protection. When the SkyGuard sensor is activated, functions in use at the time of actu- ation will reverse or cutout. The SkyGuard Function Table pro- vides more details on these functions. During activation, the horn will sound and, if equipped with a SkyGuard beacon, the beacon will illuminate until sensor and footswitch are disengaged.

  • Page 75: Skyguard - Skyeye

    SECTION 4 - MACHINE OPERATION SkyGuard - SkyEye Reattach magnetic end of cable to bracket if it becomes discon- nected. Operator passes through path of sensor beam. SkyGuard Function Table Tower Boom Drive Drive Tower Boom Boom Boom Basket Basket Steer Swing Lift...

  • Page 76: 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 77: 4.15 Machine Lifting And Tie Down

    SECTION 4 - MACHINE OPERATION 4.15 MACHINE LIFTING AND TIE DOWN Tie Down See Figure 4-5. 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 78 SECTION 4 - MACHINE OPERATION Figure 4-5. Lifting Chart 4-18 3121716...
  • Page 79 SECTION 4 - MACHINE OPERATION Figure 4-6. Decal Installation - Sheet 1 of 6 3121716 4-19...
  • Page 80 SECTION 4 - MACHINE OPERATION Figure 4-7. Decal Installation - Sheet 2 of 6 4-20 3121716...
  • Page 81 SECTION 4 - MACHINE OPERATION Figure 4-8. Decal Installation - Sheet 3 of 6 3121716 4-21...
  • Page 82 SECTION 4 - MACHINE OPERATION Figure 4-9. Decal Installation - Sheet 4 of 6 4-22 3121716...
  • Page 83 SECTION 4 - MACHINE OPERATION Figure 4-10. Decal Installation - Sheet 5 of 6 3121716 4-23...
  • Page 84 SECTION 4 - MACHINE OPERATION Figure 4-11. Decal Installation - Sheet 6 of 6 4-24 3121716...
  • Page 85 SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend Eng/ Eng/ Chinese Spa/ Item # ANSI Japanese Korean Lat. Spanish French /Eng Portuguese 1001178364-D 1001178378-E 1001178372-D 1001178374-D 1001190003-C 1001178368-D 1001178366-D 1001178376-D 1001178370-D 1703805 1703938 1703939 1703935 1703936 1703937 1703940 1703798 1705822 1703932...
  • Page 86 SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend Eng/ Eng/ Chinese Spa/ Item # ANSI Japanese Korean Lat. Spanish French /Eng Portuguese 1001178364-D 1001178378-E 1001178372-D 1001178374-D 1001190003-C 1001178368-D 1001178366-D 1001178376-D 1001178370-D 1705828 1703980 1703981 1703983 1703984 1703982 1703985 1705828 1704277 1704277...
  • Page 87 SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend Eng/ Eng/ Chinese Spa/ Item # ANSI Japanese Korean Lat. Spanish French /Eng Portuguese 1001178364-D 1001178378-E 1001178372-D 1001178374-D 1001190003-C 1001178368-D 1001178366-D 1001178376-D 1001178370-D 1701500 1703811 1701500 1701500 1701500 1701500 1701500 1701500 1703811 1701509...
  • Page 88 SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend Eng/ Eng/ Chinese Spa/ Item # ANSI Japanese Korean Lat. Spanish French /Eng Portuguese 1001178364-D 1001178378-E 1001178372-D 1001178374-D 1001190003-C 1001178368-D 1001178366-D 1001178376-D 1001178370-D 1702265 1705977 1702271 1703987 1702265 1702265 1703988 1703991 1705977 1702300...
  • Page 89 SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend Eng/ Eng/ Chinese Spa/ Item # ANSI Japanese Korean Lat. Spanish French /Eng Portuguese 1001178364-D 1001178378-E 1001178372-D 1001178374-D 1001190003-C 1001178368-D 1001178366-D 1001178376-D 1001178370-D 1706950 1706950 1706950 1706950 1001121801 1705978 1001121808 1001121918 1001121805 1001121803...
  • Page 90 SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend Eng/ Eng/ Chinese Spa/ Item # ANSI Japanese Korean Lat. Spanish French /Eng Portuguese 1001178364-D 1001178378-E 1001178372-D 1001178374-D 1001190003-C 1001178368-D 1001178366-D 1001178376-D 1001178370-D 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704885...
  • Page 91 SECTION 4 - MACHINE OPERATION Table 4-2. M400AJP Decal Legend Eng/ Eng/ Spa/ Item # ANSI Japanese Korean Chinese Spanish French Portuguese 1001178362-D 1001178377-E 1001178371-D 1001178373-D 1001178375-D 1001190004-C 1001178367-D 1001178365-D 1001178369-D 1703805 1703805 1703938 1703939 1703935 1703936 1703937 1703940 1703798 1705822 1703932 1703933...
  • Page 92 SECTION 4 - MACHINE OPERATION Table 4-2. M400AJP Decal Legend Eng/ Eng/ Spa/ Item # ANSI Japanese Korean Chinese Spanish French Portuguese 1001178362-D 1001178377-E 1001178371-D 1001178373-D 1001178375-D 1001190004-C 1001178367-D 1001178365-D 1001178369-D 3251243 3251243 3251243 3251243 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691...
  • Page 93 SECTION 4 - MACHINE OPERATION Table 4-2. M400AJP Decal Legend Eng/ Eng/ Spa/ Item # ANSI Japanese Korean Chinese Spanish French Portuguese 1001178362-D 1001178377-E 1001178371-D 1001178373-D 1001178375-D 1001190004-C 1001178367-D 1001178365-D 1001178369-D 1701500 1703811 1701500 1701500 1701500 1701500 1701500 1701500 1703811 1701509 1701509 1701509...
  • Page 94 SECTION 4 - MACHINE OPERATION Table 4-2. M400AJP Decal Legend Eng/ Eng/ Spa/ Item # ANSI Japanese Korean Chinese Spanish French Portuguese 1001178362-D 1001178377-E 1001178371-D 1001178373-D 1001178375-D 1001190004-C 1001178367-D 1001178365-D 1001178369-D 1706950 1706950 1706950 1706950 1706950 1001121801 1705978 1001121808 1001121918 1001121805 1001121803 1001121810...
  • Page 95 SECTION 4 - MACHINE OPERATION Table 4-2. M400AJP Decal Legend Eng/ Eng/ Spa/ Item # ANSI Japanese Korean Chinese Spanish French Portuguese 1001178362-D 1001178377-E 1001178371-D 1001178373-D 1001178375-D 1001190004-C 1001178367-D 1001178365-D 1001178369-D 1702962 1705084 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1001121510...
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  • Page 97 SECTION 4 - MACHINE OPERATION NOTES: 4-36 3121716...

  • Page 98: Section 5 - Emergency Procedures

    BEEN REPAIRED, IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING COR- RECTLY. JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is EMERGENCY OPERATION evident, the factory should be contacted by telephone and pro- vided with all necessary details.

  • Page 99: Platform Or Boom Caught Overhead

    SECTION 5 - EMERGENCY PROCEDURES Platform or Boom Caught Overhead EMERGENCY TOWING PROCEDURES If the platform or boom becomes jammed or snagged in over- Towing this machine is prohibited, unless properly equipped. head structures or equipment, do the following: However, provisions for moving the machine, in case of a mal- function or power failure, have been incorporated.

  • Page 100: Manual Descent System

    If the MSSO functionality is used, the fault indicator will flash 2. Turn manual descent knob counterclockwise and lower the and a fault code is set in the JLG Control System which must be Upper (or main) Boom by pumping the handle until it is reset by a qualified JLG Service Technician.
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  • Page 102 SECTION 5 - EMERGENCY PROCEDURES NOTES: 3121716...

  • Page 103: Section 6 - Accessories

    SECTION 6 - ACCESSORIES SECTION 6. ACCESSORIES Table 6-1. Available Accessories Market Accessory ANSI ANSI Japan China (USA Only) Pipe Racks √ 3121716...

  • Page 104: Pipe Racks

    SECTION 6 - ACCESSORIES PIPE RACKS Safety Precautions REDUCE PLATFORM CAPACITY BY 100 LBS (45.5 KG) WHEN INSTALLED. WEIGHT IN RACKS PLUS WEIGHT IN PLATFORM MUST NOT EXCEED RATED CAPACITY. THE MAXIMUM LOAD IN THE RACKS IS 180 LBS (80 KG) EVENLY DISTRIBUTED BETWEEN THE TWO RACKS.

  • Page 105: Preparation And Inspection

    SECTION 6 - ACCESSORIES Preparation and Inspection • Ensure racks are secured to the platform rails. • Replace torn or frayed tie-down straps. Operation 1. To prepare racks for loading, remove locking pins, rotate each rack 90 degrees from stowed to working position, then secure with locking pins.
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  • Page 107 SECTION 6 - ACCESSORIES NOTES: 3121716...

  • Page 108: Section 7 - General Specifications & Operator Maintenance

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 7. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE INTRODUCTION OPERATING SPECIFICATIONS This section of the manual provides additional necessary infor- Table 7-1. Operating Specifications mation to the operator for proper operation and maintenance of this machine.
  • Page 109 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-1. Operating Specifications Table 7-1. 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 110: Capacities

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Capacities Tires Table 7-2. Capacities Table 7-3. 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 111: Dimensional Data

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Dimensional Data Table 7-4. Dimensional Data Track Width Table 7-4. 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 112: Torque Specifications

    Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobil DTE 10 is desired, contact JLG Industries for proper recommendations.
  • Page 113 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-8. Mobil EAL Envirosyn H 32 Specs Table 7-7. Mobil DTE 10 Excel 15 Specs Type Synthetic Biodegradable ISO Viscosity Grade ISO Viscosity Grade Pour Point, Max -65°F (-54°C) Density at 15° C .869 Flash Point, Min.

  • Page 114: Critical Stability Weights

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Critical Stability Weights Table 7-9. Mobil EAL Envirosyn SHC 32 Specs Table 7-10. Critical Stability Weights Type Synthetic Biodegradable Component ISO Viscosity Grade Counterweight 3850 1746 Density at 15° C .936 Tire & Wheel (foam-filled) Pour Point, Max -27°F (-33°C) Platform (4ft [1.2 m])

  • Page 115: Serial Number Locations

    SECTION 7 - 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 116 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3121716...
  • Page 117 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 7-10 3121716...

  • Page 118: Maintenance And Lubrication

    Comments - Remote Access (Optional) Mil-Spec Mil-L-2105. Hydraulic Oil. Mobil DTE-10 Open Gear Lube - Tribol Molub-Alloy 936 Open Gear Compound. (JLG Part No. 3020027) Bearing Grease (JLG Part No. 3020029) Mobilith SHA 460. Synthetic Lithium Lubricant, Gredag 741 Grease. (JLG Part No. 3020022) Engine (crankcase) Oil.
  • Page 119 SECTION 7 - 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 120 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3. Hydraulic Tank Lube Point(s) - Fill Cap Capacity - E400An - 4 Gal. (15.1 L); E/M400AJP & E/M400AJPn - 5 Gal. (19 L) Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation.
  • Page 121 SECTION 7 - 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 122 SECTION 7 - 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 123 SECTION 7 - 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 124: Battery Maintenance And Charging

    SECTION 7 - 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 125: Optional On Board Generator

    SECTION 7 - 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 126: Tires & Wheels

    The air pressure for pneumatic tires must be equal to the air pres- sure that is stenciled on the side of the JLG product or rim decal Tire Replacement for safe and proper operational characteristics.

  • Page 127: Wheel Replacement

    SECTION 7 - 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 128 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Tighten nuts in the following sequence: 3. The tightening of the nuts should be done in stages. Follow- ing the recommended sequence, tighten nuts per wheel torque chart. Table 7-12. Wheel Torque Chart TORQUE SEQUENCE 1st Stage 2nd Stage...

  • Page 129: Supplemental Information

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC and is only applicable to CE machines. For electric powered machines, the equivalent continuous A- Weighted sound pressure level at the work platform is less than 70dB(A) For combustion engine powered machines, guaranteed Sound...
  • Page 130 SECTION 8 - INSPECTION AND REPAIR LOG SECTION 8. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 8-1. Inspection and Repair Log Date Comments 3121716...
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