Oshkosh JLG E400A Narrow Operation And Safety Manual Download | Manualshive

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SECTION 1 - SAFETY PRECAUTIONS

3121716

1-1

SECTION 1. SAFETY PRECAUTIONS

1.1

GENERAL

This section outlines the necessary precautions for proper and
safe machine usage and maintenance. It is mandatory that a daily
routine is established based on the content of this manual to pro-
mote proper machine usage. A maintenance program, using the
information provided in this manual and the Service and Mainte-
nance Manual, must also be established by a qualified person and
must be followed to ensure that the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine must not
accept operating responsibility until this manual has been read,
training is accomplished, and operation of the machine has been
completed under the supervision of an experienced and quali-
fied operator.

This section contains the responsibilities of the owner, user, oper-
ator, lessor, and lessee concerning safety, training, inspection,
maintenance, application, and operation. If there are any ques-
tions with regard to safety, training, inspection, maintenance,
application, and operation, please contact JLG Industries, Inc.
(“JLG”).

FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL
COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR
DEATH.

1.2

PRE-OPERATION

Operator Training and Knowledge

• The Operation and Safety Manual must be read and under-

stood in its entirety before operating the machine. For clarifi-
cation, questions, or additional information regarding any
portions of this manual, contact JLG Industries, Inc.

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Summary of Contents for JLG E400A Narrow

Page 1: ...ginal Instructions Keep this manual with the machine at all times AS NZS Boom Lift Models E400A Narrow E400AJP E400AJP Narrow M400AJP M400AJP Narrow S N 0300208530 to Present Seeinsidefrontcoverforexceptions 3121716 November 5 2018 Rev D ...

Page 2: ... carbon monoxide phthalates and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle or equipment in a well ventilated area and wear gloves or wash your hands frequently when servicing For more information go to www P65Warnings ca gov ...

Page 3: ...ners 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 4: ...N ORANGE BACK GROUND INDICATES A POTENTIALLY HAZARDOUS SITUATION IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES THIS DECAL WILL HAVE A YELLOW BACKGROUND IMPORTANT INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY This is the Safety Alert Symbol It is used to alert you...

Page 5: ...E JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PER SONAL PROPERTY OR THE JLG PRODUCT Contact Product Safety and Reliability Department JLG Industries Inc 13224 Fountainhead Plaza Hagerstown MD 21742 USA or Your Local JLG Office See addresses on rear cover In USA Toll Free 877 JLG SAFE 877 554 7233 Outside US...

Page 6: ...FOREWORD d 3121716 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 ...

Page 7: ...Training 2 1 Training Supervision 2 1 Operator Responsibility 2 1 2 2 PREPARATION INSPECTION AND MAINTENANCE 2 2 Pre Start Inspection 2 5 Daily Walk Around Inspection 2 6 Function Check 2 9 SkyGuard Function Test 2 11 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 1 GENERAL 3 1 3 2 CONTROLS AND INDICATORS 3 1 Ground Control Console 3 2 Platform Control Console 3 6 Platform Control Indicator Panel 3 1...

Page 8: ...SkyGuard SkyLine 4 14 SkyGuard SkyEye 4 15 SkyGuard Function Table 4 15 4 13 BOOM SYNCHRONIZING PROCEDURE 4 16 4 14 SHUT DOWN AND PARK 4 16 4 15 MACHINE LIFTING AND TIE DOWN 4 17 Lifting 4 17 Tie Down 4 17 SECTION 5 EMERGENCY PROCEDURES 5 1 GENERAL 5 1 5 2 INCIDENT NOTIFICATION 5 1 5 3 EMERGENCY OPERATION 5 1 Operator Unable to Control Machine 5 1 Platform or Boom Caught Overhead 5 2 5 4 EMERGENCY...

Page 9: ...ns 7 8 7 3 MAINTENANCE AND LUBRICATION 7 11 7 4 BATTERY MAINTENANCE AND CHARGING 7 17 Battery Maintenance Quarterly 7 17 Optional On Board Generator 7 18 Battery Charging On Board Charger 7 18 7 5 TIRES WHEELS 7 19 Tire Inflation 7 19 Tire Damage 7 19 Tire Replacement 7 19 Wheel Replacement 7 20 Wheel Installation 7 20 7 6 SUPPLEMENTAL INFORMATION 7 22 SECTION 8 INSPECTION AND REPAIR LOG ...

Page 10: ...iv 3121716 TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE SECTION PARAGRAPH SUBJECT PAGE This Page Left Blank Intentionally ...

Page 11: ...kward Stability 4 4 4 3 Grade and Side Slopes 4 7 4 4 Traveling on a Grade 4 8 4 5 Lifting Chart 4 18 4 6 Decal Installation Sheet 1 of 6 4 19 4 7 Decal Installation Sheet 2 of 6 4 20 4 8 Decal Installation Sheet 3 of 6 4 21 4 9 Decal Installation Sheet 4 of 6 4 22 4 10 Decal Installation Sheet 5 of 6 4 23 4 11 Decal Installation Sheet 6 of 6 4 24 7 1 Serial Number Locations 7 8 7 2 E450 Maintenan...

Page 12: ...vi 3121716 LIST OF FIGURES FIGURE NUMBER TITLE PAGE FIGURE NUMBER TITLE PAGE This Page Left Blank Intentionally ...

Page 13: ... 4 2 M400AJP Decal Legend 4 31 6 1 Available Accessories 6 1 7 1 Operating Specifications 7 1 7 2 Capacities 7 3 7 3 Tire Specifications 7 3 7 4 Dimensional Data 7 4 7 5 Torque Requirements 7 5 7 6 Hydraulic Oil 7 5 7 7 Mobil DTE 10 Excel 15 Specs 7 6 7 8 Mobil EAL Envirosyn H 32 Specs 7 6 7 9 Mobil EAL Envirosyn SHC 32 Specs 7 7 7 10 Critical Stability Weights 7 7 7 11 Lubrication Specifications ...

Page 14: ...viii 3121716 LIST OF TABLES TABLE NUMBER TITLE PAGE TABLE NUMBER TITLE PAGE This Page Left Blank Intentionally ...

Page 15: ...ng is accomplished and operation of the machine has been completed under the supervision of an experienced and quali fied operator This section contains the responsibilities of the owner user oper ator lessor and lessee concerning safety training inspection maintenance application and operation If there are any ques tions with regard to safety training inspection maintenance application and operat...

Page 16: ...mental regulations as they pertain to your utilization and application of the machine Workplace Inspection Precautions to avoid all hazards in the work area must be taken by the user before and during operation of the machine Do not operate or raise the platform from a position on trucks trailers railway cars floating vessels scaffolds or other equip ment unless the application is approved in writ...

Page 17: ...or Keep mud oil grease and other slippery substances from footwear and plat form floor 1 3 OPERATION General Machine operation requires your full attention Bring the machine to a full stop before using any device i e cell phones two way radios etc that will distract your attention from safely operating the machine Do not use the machine for any purpose other than position ing personnel their tools...

Page 18: ... ment Persons under the influence of drugs or alcohol or who are subject to seizures dizziness or loss of physical control must not operate this machine Hydraulic cylinders are subject to thermal expansion and con traction This may result in changes to the boom and or plat form position while the machine is stationary Factors affecting thermal movement can include the length of time the machine wi...

Page 19: ...tioned on the platform floor at all times Never position ladders boxes steps planks or similar items on unit to provide additional reach for any purpose Keep oil mud and slippery substances cleaned from footwear and the platform floor Electrocution Hazards This machine is not insulated and does not provide protection from contact or proximity to electrical current ...

Page 20: ...s occupants their tools and their equip ment from any electrical line or apparatus carrying up to 50 000 volts One foot additional clearance is required for every additional 30 000 volts or less Table 1 1 Minimum Approach Distances M A D Voltage Range Phase to Phase MINIMUM APPROACH DISTANCE in Feet Meters 0to50KV 10 3 Over50KVto200KV 15 5 Over200KVto350KV 20 6 Over350KVto500KV 25 8 Over500KVto750...

Page 21: ...governmental require ments for work practices near energized equipment DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE MAD ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTH ERWISE Tipping Hazards The user must be familiar with the surface before driving Do not exceed the allowable sideslope and grade while driving Do not elevate platform or drive with platform eleva...

Page 22: ...e attempting to stabilize the machine Use cranes forklift trucks or other appropriate equipment to stabilize machine Do not operate the machine when wind conditions including gusts may exceed 28 mph 12 5 m s Factors affecting wind speed are platform elevation surrounding structures local weather events and approaching storms Refer to Table 1 2 Beaufort scale For Reference Only or use other means t...

Page 23: ...ndfeltonexposedskin Leavesrustle 3 8 12 3 4 5 4 Gentlebreeze Leavesandsmallertwigsinconstantmotion 4 13 18 5 5 7 9 Moderatebreeze Dustandloosepaperraised Smallbranchesbegintomove 5 19 24 8 0 10 7 Freshbreeze Smallertreessway 6 25 31 10 8 13 8 Strongbreeze Largebranchesinmotion Flagswavingnearhorizontal Umbrellause becomesdifficult 7 32 38 13 9 17 1 NearGale ModerateGale Wholetreesinmotion Effortne...

Page 24: ...ator must limit travel speed according to conditions of ground surface congestion visibility slope location of personnel and other factors which may cause collision or injury to personnel Be aware of stopping distances in all drive speeds When driv ing in high speed switch to low speed before stopping Travel grades in low speed only Do not use high speed drive in restricted or close quarters or wh...

Page 25: ...during machine maintenance are inserted at the appropriate points in this manual and in the Ser vice and Maintenance Manual It is of utmost importance that maintenance personnel pay strict attention to these precautions to avoid possible injury to personnel or damage to the machine or property A maintenance program must be established by a qualified person and must be followed to ensure that the m...

Page 26: ...chine Do not use machine as a ground for welding When performing welding or metal cutting operations pre cautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter Do not refuel the machine with the engine running Use only approved non flammable cleaning solvents Do not replace items critical to stability such as batteries or solid tires with items of diff...

Page 27: ...across the battery terminals Always wear hand eye and face protection when servicing batteries Ensure that battery acid does not come in contact with skin or clothing BATTERY FLUID IS HIGHLY CORROSIVE AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION Charge batteries only in a well ventilated area Avoid overfilling th...

Page 28: ...SECTION 1 SAFETY PRECAUTIONS 1 14 3121716 NOTES ...

Page 29: ...ployer and government regulations 4 Use of approved fall protection device 5 Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunc tion 6 The safest means to operate the machine where overhead obstructions other moving equipment and obstacles depressions holes or drop offs exist 7 Means to avoid the hazards of unprotected electrical con ductors...

Page 30: ...for further requirements for aerial work platforms The fre quency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environ ment if the machine is used with increased frequency or if the machine is used in a severe manner JLG INDUSTRIES INC RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG S...

Page 31: ...tInspection SeeNote Inservicefor3monthsor150hours whichevercomesfirst or Outofserviceforaperiodofmorethan3months or Purchasedused Owner Dealer orUser QualifiedJLGMechanic ServiceandMaintenanceManual andapplicableJLGinspectionform AnnualMachineInspection SeeNote Annually nolaterthan13monthsfromthedateofprior inspection Owner Dealer orUser FactoryTrained ServiceTechnician Recommended ServiceandMaint...

Page 32: ...orm 3 UpperBoom 4 TelescopeCylinder inside 5 MasterCylinder 6 UpperUpright 7 UpperLiftCylinder 8 MidLiftCylinder 9 LowerBoom 10 Turntable 11 Frame 12 SteerWheels 13 DriveWheels 14 BatteryBox 15 LowerLiftCylinder 16 LowerLink 17 LowerUpright 18 UpperLink 19 MidBoom 20 SlaveCylinder 21 Footswitch 22 SkyGuard IfEquipped 23 CrossRail IfEquipped or ...

Page 33: ...ontainer 5 Daily Walk Around Inspection Perform as instructed 6 Battery Charge as required 7 Fuel Generator Equipped Machines Add the proper fuel as necessary 8 Engine Oil Supply Generator Equipped Machines Ensure the engine oil level is at the Full mark on the dipstick and the filler cap is secure 9 Hydraulic Oil Check the hydraulic oil level Ensure hydrau lic oil is added as required 10 Accessor...

Page 34: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 6 3121716 Daily Walk Around Inspection 0 0 ...

Page 35: ...g parts that they are securely fastened and that no visible damage exists in addition to any other criteria mentioned 1 Platform and Gate Assembly Platform mounting pins secure Footswitch in good working order not modified dis abled or blocked Bar slides freely 2 Platform Ground Control Console Switches and levers return to neutral and are properly secured decals placards secure and legible contro...

Page 36: ...nd structure 14 Battery Compartment Right Side Batteries have proper electrolyte level cables tight no visible damage or corro sion 15 Cowling and Latches See Note 16 Battery Charger See Note 17 Brake Steer Valve See Note 18 Boom Upright No visible damage All pins properly secured Upright in vertical position If Upright does not rest on stop with machine in the stowed position this indicates uprig...

Page 37: ...ct and lower the Upper Boom Check for smooth operation 3 If tower boom does not rest on stop with machine in the stowed position this indicates upright is out of plumb 4 Telescope boom In and Out several cycles at various degrees of elevation lengths Check for smooth telescope operation 5 Swing turntable to Left and Right a minimum of 45 degrees Check for smooth motion 6 Check the chassis tilt ind...

Page 38: ...JUSTED SO THAT FUNCTIONS WILL OPERATE WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF TRAVEL IF SWITCH OPERATES WITHIN LAST 1 4 6 MM OF TRAVEL TOP OR BOTTOM IT SHOULD BE ADJUSTED FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNCTION CONTROL OTHERWISE THE FUNCTION WILL NOT WORK With footswitch depressed operate LIFT and hold control Remove foot from footswitch motion should stop If it does not...

Page 39: ...kyGuard SkyEye Put arm or hand in path of sensor beam 3 Once the sensor has been activated verify the following conditions a Telescope out function stops and telescope in function operates for a short duration b The horn sounds c If equipped with a SkyGuard beacon the beacon illumi nates 4 Disengage the SkyGuard sensor release controls then recy cle the footswitch Ensure normal operation is availa...

Page 40: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 12 3121716 NOTES ...

Page 41: ... the ground controls for these symbols and the correspond ing functions 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 not corrected could result in serious injury or death This indicator will be red Indica...

Page 42: ...fy an abnormal condition for the genera tor engine high oil temperature or low oil pressure or on electric machines an elec trical system fault NOTE The engine will automatically shut down under the following conditions High Oil Temperature Low Oil Pressure Engine Overspeed Overvoltage 2 Platform Overload If equipped Indicates the platform has been overloaded 3 Generator Engine Start Button If equ...

Page 43: ...mOverloadIndicator IfEquipped 3 Generator EngineStartButton 4 IndicatorGauge 5 ChargerStatus 6 Telescope 7 MachineSafetySystemOverride MSSO IfEquipped 8 Swing 9 FunctionEnable 10 CircuitBreakers 11 Power EmergencyStop 12 Platform GroundSelect 13 Lower MidLift 14 UpperBoomLift 15 Jib 16 JibSwing 17 PlatformLeveling 18 Rotate ...

Page 44: ... visual indicator of the status of the battery charger The red LED indicates Charging Abnormal The yellow LED indicates charging in progress The green LED indicates charging is complete 6 Telescope Provides for extension and retraction of Upper Boom when positioned to in or out 7 Machine Safety System Override MSSO CE Only Provides emergency override of function controls that are locked out in the...

Page 45: ...ey operated switch supplies power to the platform control console when positioned to Platform With the switch key in the Ground posi tion power is shut off to platform and only ground controls are operable NOTE With Platform Ground Select switch in the center position power is shut off to controls at both operating stations 13 Lower Mid Boom Lift Provides for raising and lowering of Lower Boom whe...

Page 46: ...vel in situa tions such as ascending descending a grade 18 Rotate A three position Rotate control switch permits rotation of the platform when positioned to left or right Platform Control Console See Figure 3 2 1 Speed Mode Activating the Speed Mode switch allows the operator to High or Low Speed travel operation ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM ...

Page 47: ...elingOverride 3 Horn 4 Power EmergencyStop 5 GeneratorEnable 6 DriveOrientationOverride 7 Drive Steer 8 Telescope 9 Lights 10 Jib 11 JibSwing 12 SoftTouch SkyGuardOverride IfEquipped 13 LowerBoomLift 14 PlatformRotate 15 FunctionSpeed 16 MainLift Swing Figure 3 2 Platform Console ...

Page 48: ...erator Enable Control If equipped The Generator Enable control switch when in the off position allows the operator to prevent the generator engine from starting when using the machine indoors When in the on position and the ground Emergency Stop Switch on pulled out the generator is enabled to automat ically start when the batteries need charged 6 Drive Orientation Override When the boom is swung ...

Page 49: ...When lower boom is raised above horizontal or the upper boom is raised approximately 16 inches 40 64 cm above boom rest the high drive function will automatically switch to low drive This also occurs when Function Speed Control is clicked on creep TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRA...

Page 50: ...the obstacle that caused the shutdown situation If equipped with SkyGuard the switch enables functions cut out by the Sky guard system to be operated again allowing the operator to resume use of machine functions If equipped with both Soft Touch and SkyGuard the switch operates like described above and allows the operator to override the sys tem that has experienced a cutout situation 13 Lower Boo...

Page 51: ...erate the Main Boom Lift Swing joystick pull up on the locking ring below the handle NOTE The Main Boom Lift Swing joystick is spring loaded and will automatically return to neutral off position when released 16 Main Lift Swing Controller Provides main lift and swing Push for ward to lift up pull backward to boom down Move right to swing right move left to swing left Moving the joystick activates ...

Page 52: ...ope UpperLift DriveandSteer Swing No Telescope Telescope DriveandSteer Swing LowerLift UpperLift Jib DriveandSteer Swing LowerLift UpperLift Telescope PlatformRotate DriveandSteer No No No No Note Boomfunctionsmaybeslowerwhenselectedwithanotherfunctionthanwhenoperatedindividually duetosharingofoil Thesefunctionsmaymoveveryslowly ornotatall ifthefirstfunctionselected LowerLiftorSwing isbeingoperate...

Page 53: ... retract and lower to below horizontal then reposi tion machine so that it is level before continuing operation If the boom is above horizontal and the machine is on a slope the tilt alarm warning light will illuminate and an alarm will sound and Creep is automatically activated IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITI...

Page 54: ...ROLS AND INDICATORS 3 14 3121716 1 Tilt 2 PlatformOverload 3 SystemDistress 4 DriveOrientation 5 FootswitchEnable 6 BatteryCharge 7 LowBattery 8 SkyGuard 9 SoftTouch 10 CreepSpeed Figure 3 3 Platform Control Indicator Panel ...

Page 55: ...rrain or on steep grades which exceed the rated gradeability of the machine This condition is comparable to stalling the engine by asking it to pro vide more power than it was designed to do c The batteries are nearly depleted and should be charged very soon to prevent having the machine stop at an inconvenient place d There is some other fault in one of the circuits If so determine the cause by c...

Page 56: ...he enable light will go out and the footswitch must be released and depressed again to enable the controls Releasing the footswitch removes power from all controls and applies the drive brakes TO AVOID SERIOUS INJURY DO NOT REMOVE MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY OPERATES WITHIN LAST 1 4 OF TRAVEL TOP...

Page 57: ...ime controls will work normally 9 Soft Touch Indicator If Equipped When illuminated Yellow the Soft Touch bumper is against an object All controls are disabled until the override button is pushed at which time controls are active in the Creep mode 10 Creep Speed Indicator When the Function Speed Control is turned to the creep position the indicator acts as a reminder that all functions are set to ...

Page 58: ...SECTION 3 MACHINE CONTROLS AND INDICATORS 3 18 3121716 NOTES ...

Page 59: ... degree non continuous left and right of the stowed position The machine has a Ground Con trol Station which will override the Platform Control Station Ground Controls operate Upper and Lower Boom Lift and Swing and are to be used in an emergency to lower the platform to the ground should the operator in the platform be unable to do so 4 2 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS Capacities ...

Page 60: ...4 3 MOTOR OPERATION Power Emergency Stop The Power Emergency Stop switch when pulled out on provides battery power for all machine functions The switch should be pushed in off when recharging the batteries or parking the machine overnight NOTE If equipped with the optional on board generator the Emer gency Stop switch must be left on pulled out to allow for auto matic charging of the batteries Wit...

Page 61: ...INE OPERATION 3121716 4 3 Figure 4 1 Position of Least Forward Stability MACHINEWILL TIPOVER INTHIS DIRECTIONIFOPERATEDONAN OUT OF LEVELSURFACE FLYBOOM FULLYEXTENDED UPPERBOOM HORIZONTAL TOWERANDMID BOOMAT 33DEGREES ...

Page 62: ...igure 4 2 Position of Least Backward Stability LOWER BOOM FULLY ELEVATED MID BOOM FULLY ELEVATED UPPER BOOM FULLY ELEVATED AND RETRACTED PLATFORM ROTATED 90 DEGREES MACHINE WILL TIP OVER IN THIS DIRECTION IF OPERATED ON AN OUT OF LEVEL SURFACE ...

Page 63: ...ES UNSCHEDULED SHUTDOWN DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANY OPERATION 4 4 TRAVELING DRIVING NOTE For units equipped with optional tilt cutout verify that the drive function is cut out when the boom is elevated and tilt alarm is activated NOTE When lower boom is raised above horizontal or the upper boom is raised approximately 16 inches 40 6 cm above boom rest the high drive function wi...

Page 64: ... and Reverse FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNCTION OTHER WISE FUNCTION WILL NOT OPERATE 1 At Platform Controls pull out Emergency Stop switch and activate footswitch 2 Position Drive controller to Forward or Reverse as desired Angle of controller will determine travel speed This machine is equipped with a Drive Orientation Indicator The yellow light on the platform control ...

Page 65: ...SECTION 4 MACHINE OPERATION 3121716 4 7 Figure 4 3 Grade and Side Slopes ...

Page 66: ... light will flash during the 3 second interval until the drive function is selected Traveling on a Grade When traveling a grade maximum braking and traction are obtained with the boom stowed in position over the rear drive axle and in line with the direction of travel Drive the machine forward when climbing a grade and in reverse when descending a grade Do not exceed the machine s maximum rated gr...

Page 67: ...ill be 500 LBS 227 kg for ANSI markets and 230 kg for CE and Australia markets or less proceed with adding weight Platform Level Adjustment 1 Depress footswitch To raise platform position Platform Level control switch Up and hold until platform is level 2 Depress footswitch To lower platform posi tion Platform Level control switch to Down and hold until platform is level ONLY USE THE PLATFORM LEVE...

Page 68: ...ICATOR FOR THE CHASSIS TILT ALARM INDICATES CHASSIS IS ON A SEVERE SLOPE 5 DEGREE OR GREATER CHASSIS MUST BE LEVEL BEFORE SWINGING OR RAISING BOOM ABOVE HORIZONTAL TO AVOID TIP OVER IF RED TILT WARNING LIGHT LIGHTS WHEN BOOM IS RAISED ABOVE HORIZONTAL LOWER PLATFORM TO GROUND LEVEL THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVEL BEFORE RAISING BOOM TRAVELING WITH BOOM BELOW HORIZONTAL IS PERMITTE...

Page 69: ...with footswitch activated position Upper Boom Lift switch to UP or DOWN until desired height is reached 4 8 GENERATOR The machine is equipped with an engine powered DC generator connected in parallel to the 48V DC battery bank Automatic Operating Mode The generator will operate in automatic mode always when the following two conditions apply 1 Ground Control Emergency Stop Switch is pulled out on ...

Page 70: ...Manual Charge Operating Mode The generator will operate in manual mode always when the fol lowing three conditions apply 1 Ground Control Emergency Stop Switch is pulled out on and 2 The switch on the platform control console is in the On or Enable position and 3 The Manual Charge push button is activated Activation of the Manual Charge button will start the engine and initiate the charging cycle ...

Page 71: ... cated overheating It will automatically turn back on when cooled The overload light indicates an output wiring short circuit or a load that is too large for the rating of the inverter 4 10 MACHINE FUNCTION SPEEDS The Function Speed Control affects the speed of boom functions Lower Lift Telescope and Rotate Turn the control clockwise to increase function speed or counterclockwise to decrease func ...

Page 72: ...uminate until sensor and footswitch are disengaged If the SkyGuard sensor remains activated after function reversal or cutout depress and hold the SkyGuard Override Switch to allow normal functions until the sensor is disengaged Consult the following illustrations to determine which type of SkyGuard the machine has Regardless of type SkyGuard func tion according to the SkyGuard Function Table does...

Page 73: ...le 0 0 Drive Forward Drive Reverse Steer Swing Tower Lift Up Tower Lift Down Boom Lift Up Boom Lift Down Boom Tele Out Boom Tele In Jib Lift Jib Swing Basket Level Basket Rotate R C R C R R C R C R C C C C C R IndicatesReversalisActivated C IndicatesCutoutisActivated DOS DriveOrientationSystem Enabled DOSNotEnabled machineisdrivingstraightwithoutsteering andanyotherhydraulicfunctionisactive ...

Page 74: ...vernight batteries should be charged in accordance with instructions in Section 2 to ensure readiness for following workday NOTE Electric machines are equipped with a static strap due to static electricity build ups Strap is located under rear of machine chas sis To shut down and park the machine the procedures are as fol lows 1 Drive machine to a reasonably well protected area 2 Ensure boom is lo...

Page 75: ...hicle Weight 2 Place the boom in the stowed position 3 Remove all loose items from the machine 4 Attach lifting device and equipment only to the designated lifting points 5 Properly adjust the rigging to prevent damage to the machine and so the machine remains level Tie Down 1 Place the boom in the stowed position 2 Remove all loose items from the machine 3 Secure the chassis and the platform usin...

Page 76: ...SECTION 4 MACHINE OPERATION 4 18 3121716 Figure 4 5 Lifting Chart ...

Page 77: ...SECTION 4 MACHINE OPERATION 3121716 4 19 Figure 4 6 Decal Installation Sheet 1 of 6 ...

Page 78: ...SECTION 4 MACHINE OPERATION 4 20 3121716 Figure 4 7 Decal Installation Sheet 2 of 6 ...

Page 79: ...SECTION 4 MACHINE OPERATION 3121716 4 21 Figure 4 8 Decal Installation Sheet 3 of 6 ...

Page 80: ...SECTION 4 MACHINE OPERATION 4 22 3121716 Figure 4 9 Decal Installation Sheet 4 of 6 ...

Page 81: ...SECTION 4 MACHINE OPERATION 3121716 4 23 Figure 4 10 Decal Installation Sheet 5 of 6 ...

Page 82: ...SECTION 4 MACHINE OPERATION 4 24 3121716 Figure 4 11 Decal Installation Sheet 6 of 6 ...

Page 83: ...703935 1703936 1703937 1703940 3 4 1703798 1705822 1703932 1703933 1703929 1703930 1703931 1703934 1705822 5 1705514 6 1001131269 1700584 7 1706948 1706948 1706948 1706948 1706948 1706948 1706948 1001187083 8 9 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 10 1701642 1701642 1701642 1701642 1701642 1701642 1701642 1701642 1701642 11 1703797 1705921 1703926 1703927 1703923...

Page 84: ... 1001104864 24 1702868 1704001 1704000 1704002 25 1001193949 1001193949 1001193949 1001193949 1001193949 1001193949 1001193949 1001193949 1001193949 26 1001196811 1001196811 1001196811 1001196811 1001196811 27 1704446 1706378 1704417 1704418 1704454 1704452 1704419 1704453 1706378 28 1704431 1704431 1704431 1704431 1704431 1704431 1704431 1704431 1704431 Table 4 1 E400A E400AJP Decal Legend Item A...

Page 85: ...01509 39 1703813 1705670 1704342 1704343 1704339 1704340 1704344 1704341 1705670 40 3252347 41 1703804 1701518 1703950 1703951 1703947 1703948 1703949 1703952 1701518 42 Table 4 1 E400A E400AJP Decal Legend Item ANSI 1001178364 D Aus 1001178378 E Japanese 1001178372 D Korean 1001178374 D Eng Lat Spanish 1001178368 D Eng French 1001178366 D Chinese Eng 1001178376 D Spa Portuguese 1001178370 D CE 10...

Page 86: ...1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 53 1001121814 1705978 1001121821 1001121921 1001121818 1001121816 1001121823 1001121923 1705978 54 55 56 Table 4 1 E400A E400AJP Decal Legend Item ANSI 1001178364 D Aus 1001178378 E Japanese 1001178372 D Korean 1001178374 D Eng Lat Spanish 1001178368 D Eng French 1001178366 D Chinese Eng 1001178376 D Spa Portuguese 1001178370 ...

Page 87: ...121808 1001121918 1001121805 1001121803 1001121810 1001121920 1705978 66 67 68 69 70 Table 4 1 E400A E400AJP Decal Legend Item ANSI 1001178364 D Aus 1001178378 E Japanese 1001178372 D Korean 1001178374 D Eng Lat Spanish 1001178368 D Eng French 1001178366 D Chinese Eng 1001178376 D Spa Portuguese 1001178370 D CE 1001190003 C ...

Page 88: ...85 80 81 1705351 1705426 1705427 1705910 1705429 1705430 1001113680 82 1001189882 1001189882 1001189882 1001189882 1001189882 1001189882 1001189882 1001189882 1001189882 Table 4 1 E400A E400AJP Decal Legend Item ANSI 1001178364 D Aus 1001178378 E Japanese 1001178372 D Korean 1001178374 D Eng Lat Spanish 1001178368 D Eng French 1001178366 D Chinese Eng 1001178376 D Spa Portuguese 1001178370 D CE 10...

Page 89: ...0 1703931 1703934 1705822 5 1705514 6 1001131269 7 1706948 1001126871 1706948 1706948 1706948 1706948 1706948 1706948 1001187083 8 9 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 10 1701642 1701642 1701642 1701642 1701642 1701642 1701642 1701642 1701642 11 1703797 1705921 1703926 1703927 1703923 1703924 1703925 1703928 1705921 12 13 1701644 1701644 1701644 1701644 1701644...

Page 90: ... 1001193949 1001193949 1001193949 1001193949 1001193949 1001173577 1001193949 26 1001196811 1001196811 1001196811 1001196811 27 1704446 1706378 1704417 1704418 1704454 1704452 1704419 1704453 1706378 28 1704431 1704431 1704431 1704431 1704431 1704431 1704431 1704431 1704431 29 30 31 32 33 34 35 Table 4 2 M400AJP Decal Legend Item ANSI 1001178362 D Aus 1001178377 E Japanese 1001178371 D Korean 1001...

Page 91: ...4 45 46 47 1702265 1705977 1702271 1703987 1702265 1702265 1703988 1703991 1705977 48 49 50 1702300 1703814 1702300 1702300 1702300 1702300 1702300 1702300 1703814 51 52 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 53 1001121814 1705978 1001121821 1001121921 1001121818 1001121816 1001121823 1001121923 1705978 Table 4 2 M400AJP Decal Legend Item ANSI 1001178362 D Aus 1001...

Page 92: ...121920 1705978 66 1701502 1701502 1701502 67 1701503 1701503 1701503 68 69 70 1704286 1704286 1001093687 1001093687 1704371 1001093687 1001093687 1001093687 1001093687 71 Table 4 2 M400AJP Decal Legend Item ANSI 1001178362 D Aus 1001178377 E Japanese 1001178371 D Korean 1001178373 D Eng Spanish 1001178367 D Eng French 1001178365 D Chinese 1001178375 D Spa Portuguese 1001178369 D CE 1001190004 C ...

Page 93: ...04885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 80 81 1705351 1705351 1705426 1705427 1705910 1705429 1705430 1001113680 82 1001189882 1001189882 1001189882 1001189882 1001189882 1001189882 1001189882 1001189882 1001189882 Table 4 2 M400AJP Decal Legend Item ANSI 1001178362 D Aus 1001178377 E Japanese 1001178371 D Korean 1001178373 D Eng Spanish 1001178367 D Eng French 1001178365 D C...

Page 94: ...SECTION 4 MACHINE OPERATION 4 36 3121716 NOTES ...

Page 95: ... an occurrence may void any warranty consideration on that particular machine FOLLOWING ANY ACCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS THEN FROM THE PLATFORM CON TROLS DO NOT LIFT ABOVE 3 M 10 FT UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED IF REQUIRED AND THAT ALL CONTROLS ARE OPERATING COR RECTLY 5 3 EMERGENCY OPERATION Operator Unable t...

Page 96: ...ine for damage If the machine is damaged or does not operate properly turn off the machine immedi ately Report the problem to the proper maintenance per sonnel Do not operate the machine until it is declared safe for operation 5 4 EMERGENCY TOWING PROCEDURES Towing this machine is prohibited unless properly equipped However provisions for moving the machine in case of a mal function or power failu...

Page 97: ...e manual swing override proceed as follows 1 Using a 7 8 inch socket and ratchet wrench locate nut on swing worm gear on left side of machine 2 Install wrench on nut and ratchet in the direction desired 5 7 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 functi...

Page 98: ...SECTION 5 EMERGENCY PROCEDURES 5 4 3121716 NOTES ...

Page 99: ...SECTION 6 ACCESSORIES 3121716 6 1 SECTION 6 ACCESSORIES Table 6 1 Available Accessories Accessory Market ANSI USA Only ANSI CSA CE AUS Japan China PipeRacks ...

Page 100: ...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 THE MAXIMUM LENGTH OF MATERIAL IN RACKS IS 20 FT 6 1 M Ensure no personnel are beneath the platform Do not exit platform over rails or stand on rails Do not drive machine without material s...

Page 101: ...om stowed to working position then secure with locking pins 2 Loosen and remove tie down straps Place material on racks with weight evenly distributed between both racks 3 Route the tie down straps at each end across loaded mate rial and tighten 4 To remove material loosen and remove tie down straps then carefully remove material from racks NOTE Reinstall tie down straps across any remaining mater...

Page 102: ...SECTION 6 ACCESSORIES 6 4 3121716 NOTES ...

Page 103: ...tion Schedule included in the Service and Maintenance Manual Other Publications Available Service and Maintenance Manual 3121717 Illustrated Parts Manual 3121718 7 2 OPERATING SPECIFICATIONS Table 7 1 Operating Specifications MaximumWorkLoad Capacity ANSIMarkets Unrestricted 500lb 227kg MaximumWorkLoad Capacity CE AustraliaMarkets Unrestricted 500lb 230kg MaximumTravelGrade StowedPosition Gradeabi...

Page 104: ...si 5 2kg cm2 185psi 13 0kg cm2 DriveSpeed AboveHorz E M400AJP E400An E M400AJPn 42 44sec 200ft 50 53sec 50ft 45 50sec 200ft 55 68sec 50ft GrossMachineWeight E400An E400AJP M400AJP E400AJPn M400AJPn 13100lb 5942kg 13700lb 6214kg 13930lb 6319kg 14900lb 6759kg 15130lb 6863kg MaximumSystemVoltage 48VDC Table 7 1 Operating Specifications BatteryLifeperCharge 7hourscontinuous BatteryRechargeTime Charger...

Page 105: ... 10 airspace HydraulicSystem IncludingTank 9Gallons 34 1L TorqueHub Drive 17ounces 0 50L Torquehubsshouldbeonehalffulloflubricant Table 7 3 Tire Specifications Size Type Pressure Ply Rating Load Range IN240 55 17 5 Pneumatic 90psi 6Bar 10 E IN240 55 17 5 Foam Filled N A 10 E LT215 8R16 Pneumatic 95psi 6 5Bar 10 E 26x7x20 Non Marking N A N A N A 25x7x12 Non Marking N A N A N A 22x6x17 5 Non Marking...

Page 106: ...t 5in 6 55m HorizontalReach MaximumUpand Over E400An E M400AJP E M400AJPn 21ft 2in 6 41m 22ft 5in 6 83m MachineWidth E M400AJP E400An E M400AJPn 5ft 9in 1 75m 4ft 11in 1 50m WheelBase 6ft 7 0in 2 00m WorkingHeight 46ft 0in 14 02m PlatformHeight 40ft 0in 12 19m TrackWidth E M400AJP E400An E M400AJPn 5ft 0in 1 51m 4ft 3 75in 1 31m TailSwing AnyPosition E M400AJP E M400AJPnarrow E400Anarrow 0 4in 10c...

Page 107: ...e 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 Table 7 5 Torque Requirements Description Torque Value Interval Hours WheelLugs 170ft lbs 230Nm 150 SwingBearing Loctite 190ft lbs 260Nm 50 600 Check swing bearing bolts for security after first 50 hours of operation and every 600 hours t...

Page 108: ...F 182 C Viscosity at40 C 15 8cSt at100 C 4 07cSt at100 F 15 8cSt at212 F 4 07cSt ViscosityIndex 168 Density Kg l 15 C 0 8375 Density lb in3 60 F 0 0302 Table 7 8 Mobil EAL Envirosyn H 32 Specs Type SyntheticBiodegradable ISOViscosityGrade 32 Densityat15 C 869 PourPoint Max 38 F 39 C FlashPoint Min 514 F 268 C Viscosity at40 C 33 1cSt at100 C 6 36cSt ViscosityIndex 147 ...

Page 109: ...ODIFY UNIT IN ANY WAY TO AFFECT STABILITY Table 7 9 Mobil EAL Envirosyn SHC 32 Specs Type SyntheticBiodegradable ISOViscosityGrade 32 Densityat15 C 936 PourPoint Max 27 F 33 C FlashPoint Min 540 F 282 C Viscosity at40 C 33 1cSt at100 C 6 2cSt ViscosityIndex 152 Table 7 10 Critical Stability Weights Component LB KG Counterweight 3850 1746 Tire Wheel foam filled 207 94 Platform 4ft 1 2m 90 41 Platfo...

Page 110: ...ame in front of left rear wheel If the serial number plate is damaged or missing the machine serial number is stamped on the top left side of the frame and the top left side of the turntable In addition the serial number is stamped on top of the end of the upper boom mid boom and lower boom at the left rear of the booms Figure 7 1 Serial Number Locations SERIALNUMBERPLATE ...

Page 111: ...SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 3121716 7 9 Figure 7 2 E450 Maintenance Lubrication Diagram ...

Page 112: ...SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 7 10 3121716 Figure 7 3 M450 Maintenance Lubrication Diagram ...

Page 113: ...s of operation Comments Remote Access Optional Table 7 11 Lubrication Specifications KEY SPECIFICATIONS MPG MultipurposeGreasehavingaminimumdrippingpointof350degreesF Excellentwaterresistanceandadhesivequalities andbeingofextreme pressuretype TimkenOK40poundsminimum EPGL ExtremePressureGearLube oil meetingAPIServiceClassificationGL 5or Mil SpecMil L 2105 HO HydraulicOil MobilDTE 10 OG OpenGearLube...

Page 114: ...l A R Comments If necessary install grease fittings into worm gear housing and grease bearings NOTE OG will allow better cycle times than Mobiltac375NC however Mobiltac375NC must be used in dusty environments If the swing function becomes noisy and or rough lubricate the bearing teeth DO NOT OVERGREASE BEARINGS OVERGREASING BEARINGS WILL RESULT IN BLOW ING OUTER SEAL IN HOUSING ...

Page 115: ... 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 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 E400 M400 ...

Page 116: ... Filter 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 E400 ...

Page 117: ...nths or 150 hrs of operation change every 2 years or 1200 hours of operation 6 Wheel Bearings Lube Point s Repack Capacity A R Lube MPG Interval Every 2 years or 1200 hours of operation 7 Spindles Bushing Capacity A R Lube Lithium Lubricant Interval Every 2 years or 1200 hours of operation Comments At Spindle Bushing Replacement Coat I D of bushings prior to installing king pins ...

Page 118: ...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 Engine Lube Point s Fill Cap Capacity Refer to Engine Manual Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accordance with engine manual ...

Page 119: ... Remove all vent caps and inspect electrolyte level of each cell Electrolyte level should be to the ring approximately one inch from top of battery Fill batteries with distilled water only Replace and secure all vent caps 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 wire brush Repla...

Page 120: ...peed Generator Overvoltage TO AVOID INJURY FROM AN EXPLOSION DO NOT SMOKE OR ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVICING ALWAYS WEAR EYE AND HAND PROTEC TION WHEN SERVICING BATTERIES Battery Charging On Board Charger 1 For maximum battery life a Avoid completely discharging the batteries b Fully charge the batteries each day the machine is used c Charge the batteries at available times b...

Page 121: ...punctures which exceed 1 inch in diameter any damage to the bead area cords of the tire If a tire is damaged but is within the above noted criteria the tire must be inspected on a daily basis to insure the damage has not propagated beyond the allowable criteria Tire Replacement JLG recommends a replacement tire be the same size ply and brand as originally installed on the machine Please refer to t...

Page 122: ...AINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS BROKEN STUDS AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL Tighten the lug nuts to the proper torque to prevent wheels from coming loose Use a torque wrench to tighten the fasteners If you do not have a torque wrench tighten the fasteners with a lug wrench then imme...

Page 123: ...ne in stages Follow ing the recommended sequence tighten nuts per wheel torque chart 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 Table 7 12 Wheel Torque Chart TORQUE SEQUENCE 1stStage 2ndStage 3rdStage 40ft lbs 55Nm 100ft lbs 130Nm 170ft lbs 255Nm ...

Page 124: ...re level at the work platform is less than 70dB A For combustion engine powered machines guaranteed Sound Power Level LWA per European Directive 2000 14 EC Noise Emission in the Environment by Equipment for Use Outdoors based on test methods in accordance with Annex III Part B Method 1 and 0 of the directive is 104 dB The vibration total value to which the hand arm system is sub jected does not ex...

Page 125: ...SECTION 8 INSPECTION AND REPAIR LOG 3121716 8 1 SECTION 8 INSPECTION AND REPAIR LOG MachineSerialNumber_______________________________________ Table 8 1 Inspection and Repair Log Date Comments ...

Page 126: ...SECTION 8 INSPECTION AND REPAIR LOG 8 2 3121716 Table 8 1 Inspection and Repair Log Date Comments ...

Page 127: ......

Page 128: ...CorporateOffice JLGIndustries Inc 1JLGDrive McConnellsburg PA17233 9533USA 717 485 5161 Corporate 877 554 5438 CustomerSupport 717 485 6417 Visit our website for JLG Worldwide Locations www jlg com ...

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