Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times.
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. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.
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. IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND. INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH.
FOREWORD For: THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETYRELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT. • Accident Reporting • Product Safety Publications • Current Owner Updates • Questions Regarding Product Safety JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC.
FOREWORD REVISION LOG d 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
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT SECTION - 1 - SAFETY PRECAUTIONS 1.1 1.2 1.3 1.4 1.5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Operator Training and Knowledge . . . . . . . . . . . 1-1 Workplace Inspection . . . . . . . . . . . . . . . . . . . . . 1-2 Machine Inspection . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT 4.7 4.8 4.9 4.10 4.11 4.12 4.13 PAGE Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-7 Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-9 Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Jib Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT 6.5 6.6 PAGE SECTION - PARAGRAPH, SUBJECT Battery Charging (On Board Charger) . . . . . . . 6-16 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-17 Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-17 Wheel Replacement . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE LIST OF TABLES 1-1 1-2 2-1 3-1 4-1 4-2 4-3 4-4 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 iv Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5 Beaufort Scale (For Reference Only) . . . . . . . . . . 1-10 Inspection and Maintenance Table . . . . . . . . . . . . . 2-3 Simultaneous Functions. . . . . . . . . . . . . . . . . . . . . 3-11 E400A/E400AJP Decal Legend Prior to S/N 0300142589 . . . . . . . . . . . . . . . . . . .
SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 GENERAL 1.2 This section outlines the necessary precautions for proper and safe machine operation and maintenance. For proper machine use, it is mandatory that a daily routine is established based on the content of this manual. A maintenance program, using the information provided in this manual and the Service and Maintenance Manual, must also be established by a qualified person and followed to ensure the machine is safe to operate.
SECTION 1 - SAFETY PRECAUTIONS • Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine and in this manual. • Use the machine in a manner which is within the scope of its intended application set by JLG. • All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specified in this manual.
SECTION 1 - SAFETY PRECAUTIONS 1.3 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 front axle, steer and drive functions will be reversed. • Do not use the machine for any purpose other than positioning personnel, their tools, and equipment.
SECTION 1 - SAFETY PRECAUTIONS • Before operating the machine, make sure all gates are closed and fastened in their proper position. • Use extreme caution when entering or leaving platform. Be sure that the boom is fully lowered. It may be necessary to telescope out to position the platform closer to the ground for entry/exit. Face the machine, maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand during entry and exit.
SECTION 1 - SAFETY PRECAUTIONS Table 1-1. Minimum Approach Distances (M.A.D.) Voltage Range (Phase to Phase) 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) Over 500 KV to 750 KV 35 (11) Over 750 KV to 1000 KV 45 (14) NOTE: • Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum Approach Distance (MAD) as shown in Table 11.
SECTION 1 - SAFETY PRECAUTIONS • The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier.
SECTION 1 - SAFETY PRECAUTIONS • Do not elevate platform or drive with platform elevated while on a sloping, uneven, or soft surface. • If boom assembly or platform is in a position that one or more wheels are off the ground, all persons must be removed before attempting to stabilize the machine. Use cranes, forklift trucks, or other appropriate equipment to stabilize machine. • Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.
SECTION 1 - SAFETY PRECAUTIONS • Use the boom functions, not the drive function, to position the platform close to obstacles. • Always post a lookout when driving in areas where vision is obstructed. • Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving and swing operations. • 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.
SECTION 1 - SAFETY PRECAUTIONS 1.5 ADDITIONAL HAZARDS / SAFETY • Do not refuel the machine with the engine running. • Battery fluid is highly corrosive. Avoid contact with skin and clothing at all times. • Do not use machine as a ground for welding. • When performing welding or metal cutting operations, precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter. 3121215 – JLG Lift – • Charge batteries only in a well ventilated area.
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) 1-10 Wind Speed Beaufort Number mph m/s 0 0 0-0.2 1 1-3 2 4-7 3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion 4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move. Description Land Conditions Calm Calm. Smoke rises vertically 0.3-1.
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, depressions, holes, dropoffs. The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.2 PREPARATION, INSPECTION, AND MAINTENANCE The following table covers the periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Table 2-1.Inspection and Maintenance Table Type Primary Responsibility Frequency Service Qualification Reference Pre-Start Inspection Before using each day; or whenever there’s an Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection (See Note) Before each sale, lease, or rental delivery.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection The Pre-Start Inspection should include each of the following: 1. Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel. 2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies. (Domestic only) is enclosed in the weather resistant storage container. 5.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Function Check A functional check of all systems should be performed, once the walk-around inspection is complete, in an area free of overhead and ground level obstructions. First, using the ground controls, check all functions controlled by the ground controls. Next, using the platform controls, check all functions controlled by the platform controls.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION DO NOT DRIVE ON GRADES WHICH EXCEED THE RATED GRADEABILITY OF THE MACHINE AS INDICATED ON THE SERIAL NUMBER PLATE. DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES. 7. Check that platform self-leveling system functions properly during raising and lowering of boom. 8. Check rotator for smooth operation and assure platform will rotate 75 degrees in both directions from centerline of boom.
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. Frame 12. Steer Wheels 13. Drive Wheels 14. Battery Box 15. Lower Lift Cylinder 16. Lower Link 17. Lower Upright 18. Upper Link 19. Mid Boom 20. Slave Cylinder 21. Footswitch Figure 2-1.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 10 17, 18 10 15 13 14 16 11 12 1 9 8 19 2 6,7 7 5 20 23, 16 3, 4 7 24 7 10 2 21 15 14 22 10 Figure 2-2.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION General Begin the “Walk-Around Inspection” at Item 1, as noted on the diagram. Continue to the right (counterclockwise viewed from top) checking each item in sequence for the conditions listed in the “Walk-Around Inspection Checklist”. TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DURING "WALK-AROUND INSPECTION". 1. Platform and Gate Assembly - Platform mounting pins secure.
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. Inspect for worn tread, cuts, tears or other discrepancies. Inspect wheels for damage and corrosion. 11. Swing Motor and Worm Gear - See Note. 12. Hydraulic Pump and Reservoir - Properly secured; no visible damage or hydraulic leaks.
SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS 3.1 GENERAL Ground Control Station (See Figure 3-1. and Figure 3-2.) THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES. NOTE: When machine is shut down the Platform/Ground Select switch and Emergency Stop must be positioned to OFF.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 2. Platform Overload (If equipped) 5. Telescope Indicates the platform has been overloaded. NOTE: The engine will not start if the batteries are fully charged or if the Generator Enable switch on the platform console is not in the on position. Provides for extension and retraction of Upper Boom when positioned to IN or OUT. 6. Swing The SWING control switch provides 360 degrees noncontinuous turntable rotation.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. System Distress Indicator Platform Overload Indicator Engine/Generator Start Button Battery Condition Indicator & Hourmeter Telescope Swing Circuit Breakers Emergency Stop Platform/Ground Select Lower/Mid Lift Upper Boom Lift Jib Platform Leveling Rotate Figure 3-1.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. System Distress Indicator Platform Overload Indicator Engine/Generator Start Button Battery Condition Indicator & Hourmeter Telescope Swing Circuit Breakers Emergency Stop Platform/Ground Select Lower/Mid Lift Upper Boom Lift Jib Platform Leveling Rotate Function Enable Figure 3-2.
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 platform control console when positioned to PLATFORM. With the switch key held in the GROUND position, 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.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Station 3. Horn A push-type HORN switch supplies electrical power to an audible warning device when pressed. (See Figure 3-3.) 1. Posi-Track Control 4. Power/Emergency Stop Activating the Posi-Track switch allows the operator to engage positive traction for the time period pre-set in the controller.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. 2. 3. 4. Posi-Track Platform Leveling Override Horn Power/Emergency Stop 5. 6. 7. 8. Generator Enable 9. Jib 12. Platform Rotate Lights 10. Jib Swing 13. Function Speed Drive/Steer 11. Lower Boom Lift 14. Main Lift/Swing Telescope Figure 3-3.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1 3 2 5 4 1705170 A 1702938 14 1. 2. 3. 4. 13 Posi-Track Platform Leveling Override Horn Power/Emergency Stop 12 5. 6. 7. 8. 11 Generator Enable Lights Drive/Steer Telescope 6 8 Jib Jib Swing Lower Boom Lift Platform Rotate 13. 14. 15. 16. 10 9. 10. 11. 12. 15 16 9 7 Function Speed Main Lift/Swing Drive Orientation Override Soft Touch Override Figure 3-4.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Lights (If Equipped) This switch operates control console panel lights and head lights if the machine is so equipped. 7. Drive/Steer 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 NEUTRAL POSITION WHEN RELEASED. The DRIVE controller provides for driving either forward or backward when positioned to FORWARD or REVERSE.
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: 12. Platform Rotate The PLATFORM ROTATE control switch allows the operator to rotate the basket to the left or right when positioned to the desired direction. 13. Function Speed Control Lower lift will not function when operating upper lift. 15. Drive Orientation Override Adjusts speed of Boom and Swing Functions. Rotate CCW for slower speed and CW for faster speed. To adjust Drive, Swing, and Main Lift to creep, turn knob fully CCW until it clicks.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Table 3-1. Simultaneous Functions.
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. An alarm will also sound when the chassis is on a slope and the boom is above horizontal. If lit when boom is raised or extended, retract and lower to below horizontal then reposition machine so that it is level before continuing operation.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1 2 3 8 4 5 - + + 1001110226A 1704239 E 7 1. 2. 3. 4. Tilt 5. Enable Platform Overload 6. Low Battery System Distress 7. Creep Posi-Track 1. 2. 3. 4. 5. Figure 3-5. Platform Control Indicator Panel 6 9 Tilt Platform Overload System Distress Posi-Track Enable 6. 7. 8. 9. Low Battery Creep Drive Orientation Override Soft Touch Indicator Figure 3-6.
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 stop at an inconvenient place. Indicates the platform has been overloaded. d. There is some other fault in one of the circuits. If so determine the cause by counting the flash code, a number of flashes followed by a pause followed by another number of flashes, and refer to the service manual. 3. System Distress Indicator.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Enable Indicator/Footswitch 6. Low Battery Indicator To operate any function, the footswitch must be depressed and the function selected within seven seconds. The enable indicator shows that the controls are enabled.
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 position, the indicator acts as a reminder that all functions are set to the slowest speed. 8. Drive Orientation Indicator 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.
SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION 4.1 DESCRIPTION 4.2 This machine is a self-propelled hydraulic personnel lift equipped with a work platform on the end of an elevating and rotating boom. Capacities The primary operator control station is in the platform. From this control station, the operator can drive and steer the machine in both forward and reverse directions. The operator can raise or lower the upper or lower boom or swing the boom to the left or right.
SECTION 4 - MACHINE OPERATION Stability 4.3 Machine stability is based on two positions which are called FORWARD and BACKWARD stability. The machines position of least FORWARD stability is shown in Figure 4-1., Position of Least Forward Stability, and its position of least BACKWARD stability is shown in Figure 4-2., Position of Least Backward Stability. MOTOR OPERATION Power/Emergency Stop The Power/Emergency Stop switch, when pulled out (on), provides battery power for all machine functions.
SECTION 4 - MACHINE OPERATION UPPER BOOM HORIZONTAL FLY BOOM 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.
4-4 – JLG Lift – LOWER BOOM FULLY ELEVATED MID BOOM FULLY ELEVATED UPPER BOOM FULLY ELEVATED AND RETRACTED Figure 4-2.
SECTION 4 - MACHINE OPERATION Platform/Ground Select Switch 4.4 The Platform/Ground Select switch directs battery power to the desired control station when the POWER/EMERGENCY STOP switch is pulled out (on). With the switch held in the GROUND position battery power is supplied to the ground control station. When the switch is in the PLATFORM position, battery power is supplied to the platform control station.
SECTION 4 - MACHINE OPERATION 3. Position Drive controller to FORWARD or REVERSE as desired. Angle of controller will determine travel speed. USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN DRIVING WITH PLATFORM ELEVATED AND WHEN DRIVING WITH ANY PART OF MACHINE WITHIN 6 FEET OF ANY OBSTRUCTION. This machine is equipped with a Drive Orientation Indicator.
SECTION 4 - MACHINE OPERATION 4.6 PLATFORM Loading From Positions Above Ground Level Before loading weight to platform above ground level: Loading From Ground Level 1. Position chassis on a smooth, firm and level surface. 1. Determine what the total weight will be after additional weight is loaded (personnel, tools and supplies). 2. If total load (personnel, tools and supplies) is 500 LB.
SECTION 4 - MACHINE OPERATION Figure 4-3.
SECTION 4 - MACHINE OPERATION Platform Level Adjustment Jib Swing 1. Leveling UP. Depress footswitch to raise platform, position PLATFORM/LEVEL control switch UP and hold until platform is level. 2. Leveling DOWN. Depress footswitch to lower platform, position PLATFORM/LEVEL control switch to DOWN and hold until platform is level. 1. Depress footswitch to rotate Jib and platform to the left, JIB SWING control switch is positioned to the LEFT and held until desired position is reached. 2.
SECTION 4 - MACHINE OPERATION 4.7 BOOM WHEN RELEASED. A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE WHICH LIGHTS WHEN THE CHASSIS IS ON A 5 DEGREE OR GREATER SLOPE. DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN LIGHT IS LIT. 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 THE MACHINE. Swinging the Boom DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS.
SECTION 4 - MACHINE OPERATION Raising and Lowering the Upper Boom Battery Only Operating Mode Depress footswitch to raise or lower the Upper Boom, with footswitch activated, position Upper Boom Lift switch to UP or DOWN until desired height is reached. 4.8 The machine will operate in the battery only mode when the following two conditions apply: 1. Ground Control EMS is pulled out, and: GENERATOR 2. The switch on the platform control console is in the Off or Disable position.
SECTION 4 - MACHINE OPERATION mum level. The charging cycle will include finishing phase similar to conventional chargers. 4.9 INVERTER The inverter converts 48 VDC to 110 VAC to allow operation of power tools from the machine’s batteries. 4.10 MACHINE FUNCTION SPEEDS The Function Speed Control affects the speed of boom functions Lower Lift, Telescope, and Rotate. Turn the control CW to increase function speed or CCW to decrease function speed.
SECTION 4 - MACHINE OPERATION 4. Shut down Emergency Stop at Ground Controls. Position Platform/Ground Select switch to center OFF. 5. If necessary, cover Platform Controls to protect instruction placards, warning decals and operating controls from hostile environment. 4.13 MACHINE LIFTING AND TIE DOWN Lifting 1. Check Serial Number Plate, call JLG Industries, or weigh the individual unit to obtain GVW. 4.12 BOOM SYNCHRONIZING PROCEDURE NOTE: 2. Place the boom in the stowed position.
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.
SECTION 4 - MACHINE OPERATION Figure 4-5.
SECTION 4 - MACHINE OPERATION Figure 4-6.
SECTION 4 - MACHINE OPERATION Figure 4-7.
SECTION 4 - MACHINE OPERATION Figure 4-8.
SECTION 4 - MACHINE OPERATION Figure 4-9.
SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend - Prior to S/N 0300142589 4-20 Eng/ Eng/ Lat.
SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend - Prior to S/N 0300142589 3121215 Eng/ Eng/ Lat.
SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend - Prior to S/N 0300142589 4-22 Eng/ Eng/ Lat.
SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend - Prior to S/N 0300142589 3121215 Eng/ Eng/ Lat.
SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend - Prior to S/N 0300142589 4-24 Eng/ Eng/ Lat.
SECTION 4 - MACHINE OPERATION Table 4-1. E400A/E400AJP Decal Legend - Prior to S/N 0300142589 3121215 Eng/ Eng/ Lat.
SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend - S/N 0300142589 to Present 4-26 Eng/ Eng/ Lat.
SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend - S/N 0300142589 to Present 3121215 Eng/ Eng/ Lat.
SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend - S/N 0300142589 to Present 4-28 Eng/ Eng/ Lat.
SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend - S/N 0300142589 to Present 3121215 Eng/ Eng/ Lat.
SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend - S/N 0300142589 to Present 4-30 Eng/ Eng/ Lat.
SECTION 4 - MACHINE OPERATION Table 4-2. E400A/E400AJP Decal Legend - S/N 0300142589 to Present 3121215 Eng/ Eng/ Lat.
SECTION 4 - MACHINE OPERATION Table 4-3.
SECTION 4 - MACHINE OPERATION Table 4-3.
SECTION 4 - MACHINE OPERATION Table 4-3.
SECTION 4 - MACHINE OPERATION Table 4-3.
SECTION 4 - MACHINE OPERATION Table 4-3.
SECTION 4 - MACHINE OPERATION Table 4-4.
SECTION 4 - MACHINE OPERATION Table 4-4.
SECTION 4 - MACHINE OPERATION Table 4-4.
SECTION 4 - MACHINE OPERATION Table 4-4.
SECTION 4 - MACHINE OPERATION Table 4-4.
SECTION 4 - MACHINE OPERATION NOTES: 4-42 – JLG Lift – 3121215
SECTION 5 - EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES 5.1 GENERAL This section explains the steps to be taken in case of an emergency situation while operating. 5.2 INCIDENT NOTIFICATION JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details.
SECTION 5 - EMERGENCY PROCEDURES Platform or Boom Caught Overhead 5.5 If the platform or boom becomes jammed or snagged in overhead structures or equipment, rescue platform occupants prior to freeing the machine. 5.4 EMERGENCY TOWING PROCEDURES Towing this machine is prohibited, unless properly equipped. However, provisions for moving the machine, in case of a malfunction or power failure, have been incorporated.
SECTION 5 - EMERGENCY PROCEDURES is completely lowered. Return manual descent knob to center position and stow handle in bracket provided. 5.6 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. To operate the 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.
SECTION 5 - EMERGENCY PROCEDURES NOTES: 5-4 – JLG Lift – 3121215
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.1 INTRODUCTION 6.2 This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-1. Operating Specifications - Prior to S/N 0300142589 Maximum Tire Load: E/M 400A E/M 400Anarrow E/M400AJP E/M400AJPnarrow Ground Bearing Pressure E/M 400A E/M 400Anarrow E/M400AJP E/M400AJPnarrow Drive Speed: (Above Horz.) E/M400A; E/M400AJP E/M400An; E/M400AJPn Gross Machine Weight E/M400A E400An M400An E400AJP M400AJP E400AJPn M400AJPn 6-2 Table 6-1. Operating Specifications - Prior to S/N 0300142589 Maximum System Voltage 5370 lbs.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-2. Operating Specifications - S/N 0300142589 to Present Horizontal Platform Reach (Up & Over) E/M400A; E/M400An E/M400AJP; E/M400AJPn 21 ft.-2 in. (6.41 m.) 22 ft.-5 in.(6.8 m.) 5 ft.-9 in. (1.75 m.) 4 ft.-11 in. (1.50 m.) Turning Radius (Outside) 10 ft.-4 in. (3.15 m.) Turning Radius (Inside) E/M400A; E/M400AJP E/M400An; E/M400AJPn 2 ft.-0 in. (0.61 m.) 2 ft.- 10 in. (0.86 m.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Capacities Tires Table 6-3. Capacities Generator Fuel Tank Table 6-4. Tire Specifications 4 Gallons (15.1 L) Size Type Pressure Ply Rating Load Range Hydraulic Oil Tank E/M 400A, E/M 400An E/M400AJP, E/M400AJPn 4 gallons. (15.1L) 5 Gallons (19 L) w/ 10% air space IN240/55-17.5 Pneumatic 90 psi (6 Bar) 10 E IN240/55-17.5 Foam-Filled N/A 10 E Hydraulic System (Including Tank) 9 Gallons (34.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Dimensional Data Table 6-5. Dimensional Data Track Width E/M400A; E/M400AJP E/M400An; E/M400AJPn Table 6-5. Dimensional Data Machine Length (stowed) E/M400A; E/M400An E/M400AJP; E/M400AJPn 18 ft. 1 in. (5.50 m) 22.0 ft. (6.7 m) Machine Height (stowed) E/M400A; E/M400AJP E/M400An; E/M400AJPn 6 ft. 7 in. (2.0 m) 6 ft. 5.75 in. (1.31m) Up and Over Platform Height 21 ft. 5 in. (6.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Oil Table 6-8. Mobil DTE 11M Specs Table 6-7. Hydraulic Oil NOTE: Hydraulic System Operating Temperature Range S.A.E. Viscosity Grade +0o to + 180o F(-18o to +83o C 10W +0o to + 210o F(-18o to +99o C 10W-20, 10W30 +50o to + 210o F(+10o to +99o C 20W-20 ISO Viscosity Grade #15 Gravity API 31.9 Pour Point, Max -40°F (-40°C) Flash Point, Min.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-9. Mobil EAL H Series Specs Type Synthetic Biodegradable ISO Viscosity Grade 32 Specific Gravity .950 Pour Point -59°F (-51°C) Flash Point 514°F (268°C) Weight 7.64 lb. per gal. (0.9 kg per liter) Critical Stability Weights Table 6-10. Critical Stability Weights Component 33.1 cSt at 100° C 6.36 cSt Viscosity Index 147 LB. 1746 3850 Tire & Wheel (foam-filled) 94 207 Platform (4ft [1.2 m]) 41 90 Platform (5 ft. [1.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Serial Number Locations For machine identification, a serial number plate is affixed to the left rear of frame, 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 6-2.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.3 OPERATOR MAINTENANCE NOTE: The following numbers correspond to those in Figure 62., Operator Maintenance & Lubrication Diagram. Table 6-11. Lubrication Specifications. KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 degrees F. Excellent water resistance and adhesive qualities; and being of extreme pressure type (Timken OK 40 pounds minimum).
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. NOTE: OG will allow better cycle times than Mobiltac375NC, however Mobiltac375NC must be used in dusty environments.
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 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. 6-12 – JLG Lift – Interval - Change after first 50 hrs. and every 6 months or 300 hrs.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 5. Wheel Drive Hub 6. Wheel Bearings Lube Point(s) - Level/Fill Plug Capacity - 17 oz. (1/2 Full) Lube - EPGL Interval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation Lube Point(s) - Repack Capacity - A/R Lube - MPG Interval - Every 2 years or 1200 hours of operation 7.
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. 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.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.4 BATTERY MAINTENANCE AND CHARGING Battery Maintenance, Quarterly 1. Open battery compartment cover to allow access to battery terminals and 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. Replace cables and/or cable clamp bolts as required. 4.
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 VENTILATED AREA ONLY. b. Fully charge the batteries each day the machine is used. c. Charge the batteries at available times between charging.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.5 TIRES & WHEELS • any damage to the bead area cords of the tire Tire Inflation The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics. Tire Damage For pneumatic tires, JLG Industries, Inc.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE by JLG. Due to size variations between tire brands, both tires on the same axle should be the same. Wheel Replacement The rims installed on each product model have been designed for stability requirements which consist of track width, tire pressure, and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in an unsafe condition regarding stability.
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. 6.6 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.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE NOTES: 6-20 – JLG Lift – 3121215
SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 7-1.
SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1.
TRANSFER OF OWNERSHIP Title:____________________________________________________________________ Name: ___________________________________________________________________ Who in your organization should we notify? Country: _________________________ Telephone: (_______) ____________________ _________________________________________________________________________ Address: _________________________________________________________________ Current Owner: __________________________________________________
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 3121215 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +55 19 3295 0407 +61 2 65 811111 +55 19 3295 1025 +44 (0)161 654 1000 +49 (0)421 69 350 20 +49 (0)421 69 350 45 JLG France SAS Z.I.
