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 ModelsE400AE400A NarrowE400AJPE400AJ

TABLE OF CONTENTSiv – JLG Lift – 3121215SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGELIST OF TABLES1-1 Minimum Approach Distance

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-8 – JLG Lift – 3121215Serial Number LocationsFor machine identification, a serial numbe

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121215 – JLG Lift – 6-9Figure 6-2. Operator Maintenance & Lubrication Diagram

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-10 – JLG Lift – 31212156.3 OPERATOR MAINTENANCENOTE: The following numbers correspond t

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121215 – JLG Lift – 6-112. Swing Bearing/Worm Gear TeethLube Point(s) - Grease FittingsC

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-12 – JLG Lift – 31212153. Hydraulic TankLube Point(s) - Fill CapCapacity - 4 Gal. (15.1

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121215 – JLG Lift – 6-135. Wheel Drive HubLube Point(s) - Level/Fill PlugCapacity - 17 o

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-14 – JLG Lift – 31212158. Boom Pivot Pins/BushingCapacity - A/RLube - Lithium Lubricant

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121215 – JLG Lift – 6-156.4 BATTERY MAINTENANCE AND CHARGINGBattery Maintenance, Quarter

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-16 – JLG Lift – 3121215Optional On Board GeneratorEXHAUST GAS HAZARD. RUN THE GENERATOR

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121215 – JLG Lift – 6-176.5 TIRES & WHEELSTire InflationThe air pressure for pneumat

SECTION 1 - SAFETY PRECAUTIONS3121215 – JLG Lift – 1-1SECTION 1. SAFETY PRECAUTIONS1.1 GENERALThis section outlines the necessary precautions for pro

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-18 – JLG Lift – 3121215by JLG. Due to size variations between tire brands, both tires

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121215 – JLG Lift – 6-192. Tighten nuts in the following sequence:3. The tightening of t

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-20 – JLG Lift – 3121215NOTES:

SECTION 7 - INSPECTION AND REPAIR LOG3121215 – JLG Lift – 7-1SECTION 7. INSPECTION AND REPAIR LOGMachine Serial Number ______________________________

SECTION 7 - INSPECTION AND REPAIR LOG7-2 – JLG Lift – 3121215Table 7-1. Inspection and Repair LogDate Comments

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

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

SECTION 1 - SAFETY PRECAUTIONS1-2 – JLG Lift – 3121215• Read, understand, and obey all DANGERS, WARNINGS,CAUTIONS, and operating instructions on the m

SECTION 1 - SAFETY PRECAUTIONS3121215 – JLG Lift – 1-31.3 OPERATION General • Do not use the machine for any purpose other than posi-tioning personnel

SECTION 1 - SAFETY PRECAUTIONS1-4 – JLG Lift – 3121215• Before operating the machine, make sure all gates areclosed and fastened in their proper posit

SECTION 1 - SAFETY PRECAUTIONS3121215 – JLG Lift – 1-5• Maintain distance from electrical lines, apparatus, or anyenergized (exposed or insulated) par

SECTION 1 - SAFETY PRECAUTIONS1-6 – JLG Lift – 3121215• The minimum approach distance may be reduced if insulat-ing barriers are installed to prevent

SECTION 1 - SAFETY PRECAUTIONS3121215 – JLG Lift – 1-7• Do not elevate platform or drive with platform elevatedwhile on a sloping, uneven, or soft sur

SECTION 1 - SAFETY PRECAUTIONS1-8 – JLG Lift – 3121215• Use the boom functions, not the drive function, to positionthe platform close to obstacles. •

SECTION 1 - SAFETY PRECAUTIONS3121215 – JLG Lift – 1-91.5 ADDITIONAL HAZARDS / SAFETY• Do not use machine as a ground for welding.• When performing we

SECTION 1 - SAFETY PRECAUTIONS1-10 – JLG Lift – 3121215DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28MPH (12.5 M/S).Table 1-2. Beaufort Sca

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121215 – JLG Lift – 2-1SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION,

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-2 – JLG Lift – 31212152.2 PREPARATION, INSPECTION, AND MAINTENANCEThe followin

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121215 – JLG Lift – 2-3Table 2-1.Inspection and Maintenance TableType Frequency

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-4 – JLG Lift – 3121215Pre-Start InspectionThe Pre-Start Inspection should incl

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121215 – JLG Lift – 2-5Function CheckA functional check of all systems should b

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-6 – JLG Lift – 3121215DO NOT DRIVE ON GRADES WHICH EXCEED THE RATED GRADEABILI

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121215 – JLG Lift – 2-7Figure 2-1. Basic Nomenclature1. Platfor m Control

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-8 – JLG Lift – 31212153, 456,78910111213151019720101023, 162714212215161417, 1

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121215 – JLG Lift – 2-9GeneralBegin the “Walk-Around Inspection” at Item 1, as

FOREWORD3121215 – 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 INSPECTION2-10 – JLG Lift – 31212159. Drive Axle and Motor - See Note.10. Wheel/Tire Assem

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121215 – JLG Lift – 3-1SECTION 3. MACHINE CONTROLS AND INDICATORS3.1 GENERALTHE MANUFACTURER HAS NO DIREC

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-2 – JLG Lift – 31212152. Platform Overload (If equipped)Indicates the platform has been overloaded.NOTE:

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121215 – JLG Lift – 3-3Figure 3-1. Ground Control Station1. System Distress Indicator2. Platform Overload

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-4 – JLG Lift – 3121215Figure 3-2. Ground Control Station w/ Function Enable1. System Distress Indicator2.

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121215 – JLG Lift – 3-59. Platform/Ground Select SwitchA three position, key operated switch supplies powe

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-6 – JLG Lift – 3121215Platform Station(See Figure 3-3.)1. Posi-Track ControlActivating the Posi-Track swi

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121215 – JLG Lift – 3-71. Posi-Track2. Platform Leveling Override3. Horn4. Power/Emergency Stop5. Generato

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-8 – JLG Lift – 312121514 1312 111016 897156543211705170 A17029381. Posi-Track2. Platform Leveling Overrid

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121215 – JLG Lift – 3-96. Lights (If Equipped)This switch operates control console panel lights andhead li

FOREWORDb – JLG Lift – 3121215SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDSINDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOTAVOIDED, WILL RESULT IN S

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-10 – JLG Lift – 312121512. Platform Rotate The PLATFORM ROTATE control switch allows the oper-ator to rot

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121215 – JLG Lift – 3-11Table 3-1. Simultaneous Functions.If This Function is Selected: These Functions

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-12 – JLG Lift – 3121215Platform Control Indicator Panel(See Figure 3-5., Platform Control Indicator Panel

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121215 – JLG Lift – 3-131. Tilt2. Platform Overload3. System Distress4. Posi-Track5. Enable6. Low Battery7

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-14 – JLG Lift – 31212152. Platform Overload (If equipped)Indicates the platform has been overloaded.3. Sy

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121215 – JLG Lift – 3-155. Enable Indicator/FootswitchTo operate any function, the footswitch must bedepre

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-16 – JLG Lift – 31212157. Creep Speed IndicatorWhen the Function Speed Control is turned to the creepposi

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-1SECTION 4. MACHINE OPERATION4.1 DESCRIPTIONThis machine is a self-propelled hydraulic personnel

SECTION 4 - MACHINE OPERATION4-2 – JLG Lift – 3121215StabilityMachine stability is based on two positions which are calledFORWARD and BACKWARD stabili

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-3Figure 4-1. Position of Least Forward StabilityMACHINE WILL "TIP OVER" IN THISDIRECTION

FOREWORD3121215 – JLG Lift – cTHIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZEDJLG RE

SECTION 4 - MACHINE OPERATION4-4 – JLG Lift – 3121215Figure 4-2. Position of Least Backward StabilityLOWER BOOMFULLY ELEVATEDMID BOOMFULLY ELEVATEDUPP

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-5Platform/Ground Select SwitchThe Platform/Ground Select switch directs battery power tothe desire

SECTION 4 - MACHINE OPERATION4-6 – JLG Lift – 3121215USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALLTIMES WHEN DRIVING WITH PLATFORM ELEVATED A

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-74.6 PLATFORMLoading From Ground Level1. Position chassis on a smooth, firm and level surface.2. I

SECTION 4 - MACHINE OPERATION4-8 – JLG Lift – 3121215Figure 4-3. Grade and Side Slopes

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-9Platform Level Adjustment1. Leveling UP. Depress footswitch to raise platform, posi-tion PLATFORM

SECTION 4 - MACHINE OPERATION4-10 – JLG Lift – 31212154.7 BOOMA RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLEWHICH LIGHTS WHEN THE CHASSIS

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-11Raising and Lowering the Upper BoomDepress footswitch to raise or lower the Upper Boom, withfoot

SECTION 4 - MACHINE OPERATION4-12 – JLG Lift – 3121215mum level. The charging cycle will include finishing phasesimilar to conventional chargers.4.9 I

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-134. Shut down Emergency Stop at Ground Controls. Posi-tion Platform/Ground Select switch to cente

FOREWORDd – JLG Lift – 3121215REVISION LOGOriginal Issue - June 6, 2005Revised - July 21, 2006Revised - December 3, 2009Revised - November 9, 2011

SECTION 4 - MACHINE OPERATION4-14 – JLG Lift – 3121215Figure 4-4. Lifting ChartLifting Instructions:1. Check Serial Number Plate, call JLG Industrie

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-15Figure 4-5. Chassis & Platform Tie Down - Sheet 1 of 2

SECTION 4 - MACHINE OPERATION4-16 – JLG Lift – 3121215Figure 4-6. Chassis & Platform Tie Down - Sheet 2 of 2

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-17Figure 4-7. Decal Installation - Sheet 1 of 3

SECTION 4 - MACHINE OPERATION4-18 – JLG Lift – 3121215Figure 4-8. Decal Installation - Sheet 2 of 3

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-19Figure 4-9. Decal Installation - Sheet 3 of 3

SECTION 4 - MACHINE OPERATION4-20 – JLG Lift – 3121215Table 4-1. E400A/E400AJP Decal Legend - Prior to S/N 0300142589Item # ANSI0259301-16CE/AusI02750

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-2115 - - 1705828 1703980 1703981 1703983 1703984 1703982 170398516 1704277 1704277 1704277 1704277

SECTION 4 - MACHINE OPERATION4-22 – JLG Lift – 312121529- -- -- -- -- -- -- -- -30- -- -- -- -- -- -- -- -31- -- -- -- -- -- -- -- -32- -- -- -- -- --

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-2343- -- -- -- -- -- -- -- -44- -- -- -- -- -- -- -- -45- -- -- -- -- -- -- -- -46- -- -- -- -- --

TABLE OF CONTENTS3121215 – JLG Lift – iSECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGESECTION - 1 - SAFETY PRECAUTIONS1.1 GENERAL

SECTION 4 - MACHINE OPERATION4-24 – JLG Lift – 312121557- -- -- -- -- -- -- -- -58- -- -- -- -- -- -- -- -59- -- -- -- -- -- -- -- -60- -- -- -- -- --

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-2571- -- -- -- -- -- -- -- -72- -- -- -- -- -- -- -- -73- -- -- -- -- -- -- -- -74- -- -- -- -- --

SECTION 4 - MACHINE OPERATION4-26 – JLG Lift – 3121215Table 4-2. E400A/E400AJP Decal Legend - S/N 0300142589 to PresentItem # ANSI0259301-22CE/AusI027

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-2715 - - 1705828 1703980 1703981 1703983 1703984 1703982 170398516 1704277 1704277 1704277 1704277

SECTION 4 - MACHINE OPERATION4-28 – JLG Lift – 312121529- -- -- -- -- -- -- -- -30- -- -- -- -- -- -- -- -31- -- -- -- -- -- -- -- -32- -- -- -- -- --

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-2943- -- -- -- -- -- -- -- -44- -- -- -- -- -- -- -- -45- -- -- -- -- -- -- -- -46- -- -- -- -- --

SECTION 4 - MACHINE OPERATION4-30 – JLG Lift – 312121557- -- -- -- -- -- -- -- -58- -- -- -- -- -- -- -- -59- -- -- -- -- -- -- -- -60- -- -- -- -- --

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-3171- -- -- -- -- -- -- -- -72- -- -- -- -- -- -- -- -73- -- -- -- -- -- -- -- -74- -- -- -- -- --

SECTION 4 - MACHINE OPERATION4-32 – JLG Lift – 3121215Table 4-3. M400A/M400AJ Decal Legend - Prior to S/N 0300142589Item # ANSI0258973-18CE/AusI027506

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-3318- -- -- -- -- -- -- -- -19- -- -- -- -- -- -- -- -20 - - - - - - - - 3251243 3251243 3251243 3

TABLE OF CONTENTSii – JLG Lift – 3121215SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGEPlatform Level Adjustment . . . . . . . . .

SECTION 4 - MACHINE OPERATION4-34 – JLG Lift – 312121536- -- -- -- -- -- -- -- -37 1701500 1703811 1701500 1701500 1701500 1701500 1701500 170150038 1

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-3554- -- -- -- -- -- -- -- -55- -- -- -- -- -- -- -- -56- -- -- -- -- -- -- -- -57- -- -- -- -- --

SECTION 4 - MACHINE OPERATION4-36 – JLG Lift – 312121572- -- -- -- -- -- -- -- -731702962- -- -- -- -- -- -- -74- -- -- -- -- -- -- -- -75 - - - - 170

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-37Table 4-4. M400A/M400AJ Decal Legend - S/N 0300142589 to PresentItem # ANSI0258973-23CE/AusI0275

SECTION 4 - MACHINE OPERATION4-38 – JLG Lift – 312121518- -- -- -- -- -- -- -- -19- -- -- -- -- -- -- -- -20 - - - - - - - - 3251243 3251243 3251243 3

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-3936- -- -- -- -- -- -- -- -37 1701500 1703811 1701500 1701500 1701500 1701500 1701500 170150038 1

SECTION 4 - MACHINE OPERATION4-40 – JLG Lift – 312121554- -- -- -- -- -- -- -- -55- -- -- -- -- -- -- -- -56- -- -- -- -- -- -- -- -57- -- -- -- -- --

SECTION 4 - MACHINE OPERATION3121215 – JLG Lift – 4-4172- -- -- -- -- -- -- -- -731702962- -- -- -- -- -- -- -74- -- -- -- -- -- -- -- -75 - - - - 170

SECTION 4 - MACHINE OPERATION4-42 – JLG Lift – 3121215NOTES:

SECTION 5 - EMERGENCY PROCEDURES3121215 – JLG Lift – 5-1SECTION 5. EMERGENCY PROCEDURES5.1 GENERALThis section explains the steps to be taken in case

TABLE OF CONTENTS3121215 – JLG Lift – iiiSECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGEBattery Charging (On Board Charger) . . .

SECTION 5 - EMERGENCY PROCEDURES5-2 – JLG Lift – 3121215Platform or Boom Caught OverheadIf the platform or boom becomes jammed or snagged inoverhead s

SECTION 5 - EMERGENCY PROCEDURES3121215 – JLG Lift – 5-3is completely lowered. Return manual descent knob tocenter position and stow handle in brack

SECTION 5 - EMERGENCY PROCEDURES5-4 – JLG Lift – 3121215NOTES:

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121215 – JLG Lift – 6-1SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6.1

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-2 – JLG Lift – 3121215Maximum Tire Load: E/M 400A E/M 400Anarrow E /M400 A

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121215 – JLG Lift – 6-3Horizontal Platform Reach (Up & Over) E /M400 A; E/ M400

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-4 – JLG Lift – 3121215Capacities TiresTable 6-3. CapacitiesGenerator Fuel Tank 4 Gall

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121215 – JLG Lift – 6-5Dimensional DataTorque SpecificationsTable 6-5. Dimensional Dat

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-6 – JLG Lift – 3121215Hydraulic OilNOTE: Hydraulic oils must have anti-wear qualities a

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121215 – JLG Lift – 6-7Critical Stability WeightsDO NOT REPLACE ITEMS CRITICAL TO STABIL