Jlg M400 Operator Manual User Manual Page 1

ANSI®Operation and Safety ManualOriginal Instructions - Keep this manual with the machine at all times.Boom Lift ModelsE400A NarrowE400AJPE400AJP Nar

TABLE OF CONTENTSiv – JLG Lift – 3121644SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGEThis page intentionally left blank.

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-18 – JLG Lift – 31216446.5 TIRES & WHEELSTire InflationThe air pressure for pneumat

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121644 – JLG Lift – 6-19Wheel ReplacementThe rims installed on each product model have b

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-20 – JLG Lift – 31216442. Tighten nuts in the following sequence:3. The tightening of t

SECTION 7 - INSPECTION AND REPAIR LOG3121644 – JLG Lift – 7-1SECTION 7. INSPECTION AND REPAIR LOGMachine Serial Number ______________________________

SECTION 7 - INSPECTION AND REPAIR LOG7-2 – JLG Lift – 3121644Table 7-1. Inspection and Repair LogDate Comments

TRANSFER OF OWNERSHIPTo Product O wner:If you now own but ARE NOT the original purchaser of the product covered by this manual, we would like to know

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (

SECTION 1 - SAFETY PRECAUTIONS3121644 – JLG Lift – 1-1SECTION 1. SAFETY PRECAUTIONS1.1 GENERALThis section outlines the necessary precautions for pro

SECTION 1 - SAFETY PRECAUTIONS1-2 – JLG Lift – 3121644• An operator must not accept operating responsibilities untiladequate training has been given b

SECTION 1 - SAFETY PRECAUTIONS3121644 – JLG Lift – 1-3Machine Inspection • Do not operate this machine until the inspections and func-tional checks as

SECTION 1 - SAFETY PRECAUTIONS1-4 – JLG Lift – 3121644• Do not carry materials directly on platform railing unlessapproved by JLG.• When two or more p

SECTION 1 - SAFETY PRECAUTIONS3121644 – JLG Lift – 1-5• Before operating the machine, make sure all gates are closedand fastened in their proper posit

SECTION 1 - SAFETY PRECAUTIONS1-6 – JLG Lift – 3121644• Maintain distance from electrical lines, apparatus, or any ener-gized (exposed or insulated) p

SECTION 1 - SAFETY PRECAUTIONS3121644 – JLG Lift – 1-7• The minimum approach distance may be reduced if insulatingbarriers are installed to prevent co

SECTION 1 - SAFETY PRECAUTIONS1-8 – JLG Lift – 3121644• Never exceed the maximum work load as specified on theplatform. Keep all loads within the conf

SECTION 1 - SAFETY PRECAUTIONS3121644 – JLG Lift – 1-9DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/S).Table 1-2. Beaufort Sca

SECTION 1 - SAFETY PRECAUTIONS1-10 – JLG Lift – 3121644Crushing and Collision Hazards• Approved head gear must be worn by all operating andground pers

SECTION 1 - SAFETY PRECAUTIONS3121644 – JLG Lift – 1-111.4 TOWING, LIFTING, AND HAULING• Never allow personnel in platform while towing, lifting, orha

SECTION 1 - SAFETY PRECAUTIONS1-12 – JLG Lift – 3121644• DO NOT use your hand to check for leaks. Use a piece of card-board or paper to search for lea

SECTION 1 - SAFETY PRECAUTIONS3121644 – JLG Lift – 1-13Battery Hazards• Always disconnect batteries when servicing electrical compo-nents or when perf

SECTION 1 - SAFETY PRECAUTIONS1-14 – JLG Lift – 3121644NOTES:

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121644 – JLG Lift – 2-1SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION,

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-2 – JLG Lift – 31216442.2 PREPARATION, INSPECTION, AND MAINTENANCEThe followin

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121644 – JLG Lift – 2-3Table 2-1.Inspection and Maintenance TableType Frequency

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-4 – JLG Lift – 3121644Pre-Start InspectionThe Pre-Start Inspection should incl

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121644 – JLG Lift – 2-5Function CheckA functional check of all systems should b

FOREWORD3121644 – JLG Lift – aFOREWORDThis manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to p

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-6 – JLG Lift – 3121644DO NOT DRIVE ON GRADES WHICH EXCEED THE RATED GRADEABILI

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121644 – JLG Lift – 2-7Figure 2-1. Basic Nomenclature1. Plat form Co nt

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-8 – JLG Lift – 3121644Figure 2-2. Daily Walk-Around Inspection - Sheet 1 of 3

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121644 – JLG Lift – 2-9GeneralBegin the “Walk-Around Inspection” at Item 1, as

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-10 – JLG Lift – 31216449. Drive Axle and Motor - See Note.10. Wheel/Tire Assem

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121644 – JLG Lift – 3-1SECTION 3. MACHINE CONTROLS AND INDICATORS3.1 GENERALTHE MANUFACTURER HAS NO DIREC

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-2 – JLG Lift – 3121644Ground Control Station(See Figure 3-1.)NOTE: When machine is shut down the Platform

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121644 – JLG Lift – 3-3Figure 3-1. Ground Control Station1. System Distress Indicator2. Platform Overload

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-4 – JLG Lift – 31216445. Telescope Provides for extension and retraction of UpperBoom when positioned to

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121644 – JLG Lift – 3-511. Lower/Mid Boom LiftProvides for raising and lowering ofLower Boom when position

FOREWORDb – JLG Lift – 3121644SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDSINDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILLRESULT IN S

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-6 – JLG Lift – 3121644Platform Station(See Figure 3-3.)1. Posi-Track ControlActivating the Posi-Track swi

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121644 – JLG Lift – 3-71. Posi-Track2. Platform Leveling Override3. Horn4. Power/Emergency Stop5. Generato

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-8 – JLG Lift – 31216445. Generator Enable ControlThe Generator Enable control switch, when inthe off posi

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121644 – JLG Lift – 3-9TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS ORTOGGLE SWIT

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-10 – JLG Lift – 312164414. Platform Rotate The PLATFORM ROTATE control switch allowsthe operator to rotat

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121644 – JLG Lift – 3-11Table 3-1. Simultaneous FunctionsIf This Function is Selected: These Functions W

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-12 – JLG Lift – 3121644Platform Control Indicator Panel(See Figure 3-3., Platform Control Indicator Panel

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121644 – JLG Lift – 3-131. Tilt2. Platform Overload3. System Distress4. Posi-Track5. Enable6. Low Battery7

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-14 – JLG Lift – 31216443. System Distress IndicatorThe system distress indicator lights to signifyan abno

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121644 – JLG Lift – 3-155. Posi-Track IndicatorThis indicator lights to show that posi-traction is operati

FOREWORD3121644 – JLG Lift – cTHIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLGINDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REP

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-16 – JLG Lift – 31216448. Soft Touch Indicator (If Equipped)When illuminated (Yellow) the Soft Touchbumpe

SECTION 4 - MACHINE OPERATION3121644 – JLG Lift – 4-1SECTION 4. MACHINE OPERATION4.1 DESCRIPTIONThis machine is a self-propelled hydraulic personnel

SECTION 4 - MACHINE OPERATION4-2 – JLG Lift – 3121644StabilityMachine stability is based on two positions which are called For-ward and Backward stabi

SECTION 4 - MACHINE OPERATION3121644 – JLG Lift – 4-3Figure 4-1. Position of Least Forward StabilityMACHINE WILL "TIP OVER" IN THISDIRECTION

SECTION 4 - MACHINE OPERATION4-4 – JLG Lift – 3121644Figure 4-2. Position of Least Backward StabilityLOWER BOOMFULLY ELEVATEDMID BOOMFULLY ELEVATEDUPP

SECTION 4 - MACHINE OPERATION3121644 – JLG Lift – 4-5Platform/Ground Select SwitchThe Platform/Ground Select switch directsbattery power to the desire

SECTION 4 - MACHINE OPERATION4-6 – JLG Lift – 3121644USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN DRIV-ING WITH PLATFORM ELEVATED

SECTION 4 - MACHINE OPERATION3121644 – JLG Lift – 4-7Figure 4-3. Grade and Side Slopes

SECTION 4 - MACHINE OPERATION4-8 – JLG Lift – 31216441. Match the black and white direction arrows on both platform con-trol panel and the chas-sis to

SECTION 4 - MACHINE OPERATION3121644 – JLG Lift – 4-9Platform Level Adjustment1. Depress footswitch. To raise platform, positionPlatform/Level control

FOREWORDd – JLG Lift – 3121644REVISION LOGOriginal Issue - June 3, 2014

SECTION 4 - MACHINE OPERATION4-10 – JLG Lift – 31216444.7 BOOMA RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLEWHICH LIGHTS WHEN THE CHASSIS

SECTION 4 - MACHINE OPERATION3121644 – JLG Lift – 4-114.8 GENERATORThe machine is equipped with an engine powered DC generatorconnected in parallel to

SECTION 4 - MACHINE OPERATION4-12 – JLG Lift – 3121644Manual (Charge) Operating ModeThe generator will operate in manual mode always when the fol-lowi

SECTION 4 - MACHINE OPERATION3121644 – JLG Lift – 4-134.11 BOOM SYNCHRONIZING PROCEDURENOTE: If the Lower Boom assembly does not fully lower:1. Remove

SECTION 4 - MACHINE OPERATION4-14 – JLG Lift – 31216444.13 MACHINE LIFTING AND TIE DOWNSee Figure 4-4.Lifting1. Refer to the Serial Number Plate, refe

SECTION 4 - MACHINE OPERATION3121644 – JLG Lift – 4-15Figure 4-4. Lifting Chart

SECTION 4 - MACHINE OPERATION4-16 – JLG Lift – 3121644Figure 4-5. Decal Installation - Sheet 1 of 3

SECTION 4 - MACHINE OPERATION3121644 – JLG Lift – 4-17Figure 4-6. Decal Installation - Sheet 2 of 3

SECTION 4 - MACHINE OPERATION4-18 – JLG Lift – 3121644Figure 4-7. Decal Installation - Sheet 3 of 3

SECTION 4 - MACHINE OPERATION3121644 – JLG Lift – 4-19Table 4-1. E400A/E400AJP Decal LegendItem # ANSI0259301-BCE/AusI0275070-7Japanese0259536-BKorean

TABLE OF CONTENTS3121644 – JLG Lift – iSECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGESECTION - 1 - SAFETY PRECAUTIONS1.1 GENERAL

SECTION 4 - MACHINE OPERATION4-20 – JLG Lift – 312164415 - - 1705828 1703980 1703981 1703983 1703984 1703982 170398516 1704277 1704277 1704277 1704277

SECTION 4 - MACHINE OPERATION3121644 – JLG Lift – 4-2129- -- -- -- -- -- -- -- -30- -- -- -- -- -- -- -- -31- -- -- -- -- -- -- -- -32- -- -- -- -- --

SECTION 4 - MACHINE OPERATION4-22 – JLG Lift – 312164443- -- -- -- -- -- -- -- -44- -- -- -- -- -- -- -- -45- -- -- -- -- -- -- -- -46- -- -- -- -- --

SECTION 4 - MACHINE OPERATION3121644 – JLG Lift – 4-2357- -- -- -- -- -- -- -- -58- -- -- -- -- -- -- -- -59- -- -- -- -- -- -- -- -60- -- -- -- -- --

SECTION 4 - MACHINE OPERATION4-24 – JLG Lift – 312164471- -- -- -- -- -- -- -- -72- -- -- -- -- -- -- -- -73- -- -- -- -- -- -- -- -74- -- -- -- -- --

SECTION 4 - MACHINE OPERATION3121644 – JLG Lift – 4-25Table 4-2. M400AJP Decal LegendItem # ANSI0258973-BCE/AusI0275069-8Japanese0259535-17Korean02595

SECTION 4 - MACHINE OPERATION4-26 – JLG Lift – 312164418- -- -- -- -- -- -- -- -19- -- -- -- -- -- -- -- -20 - - - - - - - - 3251243 3251243 3251243 3

SECTION 4 - MACHINE OPERATION3121644 – JLG Lift – 4-2736- -- -- -- -- -- -- -- -37 1701500 1703811 1701500 1701500 1701500 1701500 1701500 170150038 1

SECTION 4 - MACHINE OPERATION4-28 – JLG Lift – 312164454- -- -- -- -- -- -- -- -55- -- -- -- -- -- -- -- -56- -- -- -- -- -- -- -- -57- -- -- -- -- --

SECTION 4 - MACHINE OPERATION3121644 – JLG Lift – 4-2972- -- -- -- -- -- -- -- -731702962- -- -- -- -- -- -- -74- -- -- -- -- -- -- -- -75 - - - - 170

TABLE OF CONTENTSii – JLG Lift – 3121644SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGEPlatform Level Adjustment . . . . . . . .

SECTION 4 - MACHINE OPERATION4-30 – JLG Lift – 3121644NOTES:

SECTION 5 - EMERGENCY PROCEDURES3121644 – JLG Lift – 5-1SECTION 5. EMERGENCY PROCEDURES5.1 GENERALThis section explains the steps to be taken in case

SECTION 5 - EMERGENCY PROCEDURES5-2 – JLG Lift – 3121644Platform or Boom Caught OverheadIf the platform or boom becomes jammed or snagged in over-head

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121644 – JLG Lift – 6-1SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6.1

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-2 – JLG Lift – 3121644Turning Radius (Inside) E/M400AJP E400An; E/M400AJPn2 ft.

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121644 – JLG Lift – 6-3Capacities TiresTable 6-2. CapacitiesGenerator Fuel Tank 4 Gall

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-4 – JLG Lift – 3121644Dimensional DataTorque SpecificationsTable 6-4. Dimensional Dat

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121644 – JLG Lift – 6-5Hydraulic OilNOTE: Hydraulic oils must have anti-wear qualities a

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-6 – JLG Lift – 3121644Critical Stability WeightsDO NOT REPLACE ITEMS CRITICAL TO STABIL

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121644 – JLG Lift – 6-7Serial Number LocationsFor machine identification, a serial numbe

TABLE OF CONTENTS3121644 – JLG Lift – iiiSECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGEWheel Installation . . . . . . . . . . .

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-8 – JLG Lift – 3121644Figure 6-2. E400 Maintenance & Lubrication Diagram

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121644 – JLG Lift – 6-9Figure 6-3. M400 Maintenance & Lubrication Diagram

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-10 – JLG Lift – 31216446.3 MAINTENANCE AND LUBRICATIONNOTE: The following numbers corre

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121644 – JLG Lift – 6-112. Swing Bearing/Worm Gear TeethLube Point(s) - Grease FittingsC

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-12 – JLG Lift – 31216443. Hydraulic Tank Lube Point(s) - Fill CapCapacity - 4 Gal. (15.

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121644 – JLG Lift – 6-134. Hydraulic Return FilterInterval - Change after first 50 hrs.

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-14 – JLG Lift – 31216445. Wheel Drive HubLube Point(s) - Level/Fill PlugCapacity - 17 o

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121644 – JLG Lift – 6-158. Boom Pivot Pins/BushingCapacity - A/RLube - Lithium Lubricant

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-16 – JLG Lift – 31216446.4 BATTERY MAINTENANCE AND CHARGINGBattery Maintenance, Quarter

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121644 – JLG Lift – 6-17Optional On Board GeneratorEXHAUST GAS HAZARD. RUN THE GENERATOR