JLG 400S Operation Manual
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JLG 400S Operation Manual

Boom lift
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See also: Service Maintenance Manual
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
400S
460SJ
S/N 0300203771*
to Present
* See inside front cover for exceptions.
ANSI
3121670
®
January 19, 2016

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Summary of Contents for JLG 400S

  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Boom Lift Models 400S 460SJ S/N 0300203771* to Present * See inside front cover for exceptions. ANSI 3121670 ® January 19, 2016...
  • Page 2 This manual also covers the following Serial Numbers. 0300184729 0300203261 0300203580 0300203677 0300200144 0300203262 0300203581 0300203678 0300200145 0300203307 0300203582 0300203679 0300200476 0300203308 0300203583 0300203680 0300200477 0300203351 0300203584 0300203681 0300202446 0300203352 0300203628 0300203724 0300202447 0300203394 0300203629 0300203725 0300202448 0300203395 0300203630 0300203727 0300202449 0300203439 0300203631...
  • Page 3 The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.
  • Page 4 INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI- INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY. RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACK- GROUND. – JLG Lift – 3121670...
  • Page 5 Modifications Product Safety JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE Contact: CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE. Product Safety and Reliability Department JLG Industries, Inc.
  • Page 6 FOREWORD REVISION LOG Original Issue - March 12, 2015 Revised - March 21, 2015 Revised - April 2, 2015 Revised - July 30, 2015 Revised - January 19, 2016 – JLG Lift – 3121670...

  • Page 7: Table Of Contents

    Stability ......... . . 4-2 Operator Responsibility ......2-1 3121670 – JLG Lift –...
  • Page 8 Tie Down......... 4-15 – JLG Lift –...
  • Page 9 PROPANE FUEL SYSTEM PRESSURE RELIEF ... 6-34 SUPPLEMENTAL INFORMATION ..... 6-35 3121670 – JLG Lift –...
  • Page 10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This Page Left Blank Intentionally. – JLG Lift – 3121670...
  • Page 11 3-1. Ground Control Console - 400S ..... . . 3-3 Deutz..........6-11 3-2.
  • Page 12 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE This Page Left Blank Intentionally. – JLG Lift – 3121670...
  • Page 13 Skyguard Function Table ......4-13 Decal Legend - 400S ....... .4-24 Decal Legend - 460SJ.
  • Page 14 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE This Page Left Blank Intentionally. viii – JLG Lift – 3121670...

  • Page 15: Section 1. Safety Precautions

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

  • Page 16: Workplace Inspection

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

  • Page 17: Machine Inspection

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

  • Page 18: Trip And Fall Hazards

    Face the machine when entering or not operate this machine. leaving the platform. Always maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit. – JLG Lift – 3121670...

  • Page 19: Electrocution Hazards

    • Keep both feet firmly positioned 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. 3121670 – JLG Lift –...
  • Page 20 • Allow for machine movement and electrical line swaying. 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less. – JLG Lift – 3121670...

  • Page 21: Tipping Hazards

    • Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces. 3121670 – JLG Lift –...
  • Page 22 Keep all loads within the confines of the platform, gusts, may exceed 28 mph (12.5 m/s). Factors affecting wind unless authorized by JLG. speed are; platform elevation, surrounding structures, local weather events, and approaching storms. Refer to Table 1-2, •...
  • Page 23 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind. 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road. 47-54 20.8-24.4 Strong Gale Light structure damage. 3121670 – JLG Lift –...

  • Page 24: Crushing And Collision Hazards

    • Use the boom functions, not the drive function, to position the boom or platform. Position barricades on floor if necessary. platform close to obstacles. • Always post a lookout when driving in areas where vision is obstructed. 1-10 – JLG Lift – 3121670...

  • Page 25: Towing, Lifting, And Hauling

    • DO NOT attempt to repair or tighten any hydraulic hoses or fit- tings while the machine is powered on or when the hydraulic system is under pressure. • Always relieve hydraulic pressure from all hydraulic circuits before loosening or removing hydraulic components. 3121670 – JLG Lift – 1-11...
  • Page 26 • Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. Ensure adequate support is provided when raising components of the machine. 1-12 – JLG Lift – 3121670...

  • Page 27: Battery Hazards

    • Avoid overfilling the battery fluid level. Add distilled water to terminals. batteries only after the batteries are fully charged. • Always wear hand, eye, and face protection when servicing batteries. Ensure that battery acid does not come in contact with skin or clothing. 3121670 – JLG Lift – 1-13...
  • Page 28 SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-14 – JLG Lift – 3121670...

  • Page 29: Section - 2 - User Responsibilities, Machine Preparation

    4. Use of approved fall protection device. site. 5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunc- tion. 3121670 – JLG Lift –...

  • Page 30: 2.2 Preparation, Inspection, And Maintenance

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.2 PREPARATION, INSPECTION, AND MAINTENANCE JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A The following table covers the periodic machine inspections and PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL maintenance required by JLG Industries, Inc.
  • Page 31 At intervals as specified in the Service and Maintenance Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual Manual. NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. 3121670 – JLG Lift –...

  • Page 32: Pre-Start Inspection

    3. Decals and Placards – Check all for cleanliness and legibil- upon the machine for specific inspection, operation, and ity. Make sure none of the decals and placards are missing. maintenance instructions. Make sure all illegible decals and placards are cleaned or replaced. – JLG Lift – 3121670...

  • Page 33: Function Check

    Drive Orientation Override switch must be used for the drive d. Ensure that all machine functions are disabled when function to operate. the Emergency Stop Button is pushed in. e. Ensure all boom functions stop when the function enable switch is released. 3121670 – JLG Lift –...

  • Page 34: Skyguard Function Test

    SkyGuard sensor depress and hold the SkyGuard Override Switch to allow normal and footswitch are disengaged. use of machine functions until the SkyGuard sensor is disen- gaged. – JLG Lift – 3121670...
  • Page 35 4. Cross Rail (If Equipped) 5. Fly Boom Section 6. Base Boom Section 7. Front Drive/Steer Wheels 8. Rear Drive Wheels 9. Frame 10. Turntable 11. Oscillation Cylinder 12. Ground Console Figure 2-1. Basic Nomenclature 3121670 – JLG Lift –...
  • Page 36 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-2. Daily Walk-Around Inspection - Sheet 1 of 3 – JLG Lift – 3121670...

  • Page 37: General

    Latch and hinges Note. in working condition. 2. Platform & Ground Control Consoles - Switches and levers return to neutral, decals/placards secure and legible, control markings legible. Figure 2-3. Daily Walk-Around Inspection - Sheet 2 of 3 3121670 – JLG Lift –...
  • Page 38 12. Fuel Tank - See Inspection Note. 15. Platform Rotator - See Inspection Note. 13. Hydraulic Reservoir - See Inspection Note. 16. SkyGuard (If Equipped) - See Inspection Note. Figure 2-4. Daily Walk-Around Inspection - Sheet 3 of 3 2-10 – JLG Lift – 3121670...

  • Page 39: Oscillating Axle Lockout Test (If Equipped)

    4. Carefully activate Telescope or Main Boom Lift control and 11. If lockout cylinders do not function properly, have qualified take the boom out of the transport position. personnel correct the malfunction prior to any further oper- ation. 3121670 – JLG Lift – 2-11...
  • Page 40 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTES: 2-12 – JLG Lift – 3121670...

  • Page 41: Section 3 - Machine Controls And Indicators

    3121670 – JLG Lift –...

  • Page 42: Ground Control Console

    "DOWN" to enable all boom controls. NOTE: The Function Enable switch must be held down in order to operate Main Boom Telescope, Swing, Main Lift, Jib Lift, Platform Level Override, and Platform Rotate functions. – JLG Lift – 3121670...
  • Page 43 Function Enable 4. Platform/Ground Select 5. Platform Level 6. Platform Rotate 7. Not Used 8. Telescope 9. Power/Emergency Stop 10. Main Boom Lift 11. Swing 12. Not Used Figure 3-1. Ground Control Console - 400S 3121670 – JLG Lift –...
  • Page 44 5. Platform Level 6. Platform Rotate 7. Not Used 8. Telescope 9. Power/Emergency Stop 10. Main Boom Lift 11. Swing 12. Machine Safety System Override (MSSO) Figure 3-2. Ground Control Console - 400S w/MSSO (CE Only) – JLG Lift – 3121670...
  • Page 45 Function Enable 4. Platform/Ground Select 5. Platform Level 6. Platform Rotate 7. Jib Lift 8. Telescope 9. Power/Emergency Stop 10. Main Boom Lift 11. Swing 12. Not Used Figure 3-3. Ground Control Console - 460SJ 3121670 – JLG Lift –...
  • Page 46 5. Platform Level 6. Platform Rotate 7. Jib Lift 8. Telescope 9. Power/Emergency Stop 10. Main Boom Lift 11. Swing 12. Machine Safety System Override (MSSO) Figure 3-4. Ground Control Console - 460SJ w/MSSO (CE Only) – JLG Lift – 3121670...
  • Page 47 THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR 7. Jib Lift (If Equipped) FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. Provides raising and lowering of the jib. 3121670 – JLG Lift –...
  • Page 48 SELECT switch when pulled out (on). When pushed in (off ), power is shut off to the PLATFORM/GROUND Provides emergency override of function SELECT switch. controls that are locked out in the event of Load Sense System activation. – JLG Lift – 3121670...

  • Page 49: Ground Control Indicator Panel

    3. Low Engine Oil Pressure Indicator Indicates the glow plugs are operating. After Indicates that engine oil pressure is below nor- turning on ignition, wait until light goes out mal and service is required. before cranking engine. 3121670 – JLG Lift –...
  • Page 50 3. High Engine Coolant Temperature 4. Engine Oil Temperature 5. System Distress 6. Low Fuel 7. Glow Plug 8. Platform Overload (If Equipped) 9. Drive and Steer Disable (If Equipped) Figure 3-5. Ground Control Indicator Panel 3-10 – JLG Lift – 3121670...
  • Page 51 SECTION 3 - MACHINE CONTROLS AND INDICATORS 7. System Distress Indicator 8. Platform Overload Indicator (If Equipped) The light indicates that the JLG Control System Indicates the platform has been overloaded. has detected an abnormal condition and a 9. Drive and Steer Disable Indicator (If Equipped) Diagnostic Trouble Code has been set in the system memory.

  • Page 52: Ground Control Console Display Gauge

    (See Figure 3-9., Ground Control Console Display Gauge) The Display Gauge shows engine hours, fuel level (if applicable), and Diagnostic Trouble Codes (DTCs) from both the JLG Control System and the engine control system. During machine start up, with no active DTCs in the control system, the splash screen will show for 3 seconds and then switch to main screen.
  • Page 53 The Diagnostic Screen will show active and inactive faults from The Engine Diagnostics Screen will show SPN (Suspect Parameter the JLG Control System on the screen. An asterisk (*) will be dis- Number), FMI (Failure Mode Identifier), and Occurrence count played to show active faults.
  • Page 54 SECTION 3 - MACHINE CONTROLS AND INDICATORS INDICATOR LAMP FUEL LEVEL ENGINE HOURS NAVIGATE FORWARD ARROW NAVIGATE BACK ARROW NAVIGATION BUTTONS Figure 3-9. Ground Control Console Display Gauge 3-14 – JLG Lift – 3121670...

  • Page 55: Platform Console

    Moving the switch to the appropriate position selects gasoline or liquid propane fuel. 4. Horn A push-type HORN switch supplies electrical power to an audible warning device when pressed. 3121670 – JLG Lift – 3-15...
  • Page 56 8. Drive Orientation Override 12. Jib Lift (If Equipped) 16. Function Speed Control 4. Horn 9. Drive/Steer 13. Soft Touch/SkyGuard Override (If Equipped) 17. Main Lift/Swing Controller 5. Power/Emergency Stop Figure 3-10. Platform Control Console 3-16 – JLG Lift – 3121670...
  • Page 57 Move the drive controls in a direction match- or engine fail. The auxiliary pump will operate main boom ing the directional arrows for the intended direction of lift, main telescope, jib (if equipped) and swing. travel. 3121670 – JLG Lift – 3-17...
  • Page 58 Push forward to drive forward, pull back to drive in reverse. Steering is accomplished via a thumb-activated rocker switch on the end of the steer handle. 10. Telescope Provides extension and retraction of the main boom. 3-18 – JLG Lift – 3121670...
  • Page 59 This control affects the speed of telescope tor to override the system that has and jib lift (if equipped). Turning the knob experienced a cutout situation. all the way counterclockwise until it clicks puts drive and swing into creep mode. 3121670 – JLG Lift – 3-19...
  • Page 60 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 switches to provide the func- tions selected. 3-20 – JLG Lift – 3121670...

  • Page 61: Platform Control Indicator Panel

    1. AC Generator (If Equipped) NOTE: Refer to the capacity decals on the machine for restricted and unrestricted platform capacities. Indicates the generator is in operation. 2. Platform Overload Indicator (If Equipped) Indicates the platform has been overloaded. 3121670 – JLG Lift – 3-21...
  • Page 62 5. Glow Plug/Wait to Start 8. Creep 2. Platform Overload (If Equipped) 6. Enable/Footswitch 9. System Distress 3. Capacity Indicator 7. Fuel Level 10. Drive Orientation 4. Tilt Figure 3-11. Platform Control Indicator Panel 3-22 – JLG Lift – 3121670...
  • Page 63 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 OR BOTTOM. 3121670 – JLG Lift – 3-23...
  • Page 64 9. System Distress Indicator The light indicates that the JLG Control System has detected an abnormal condition and a Diagnostic Trouble Code has been set in the system memory.

  • Page 65: Section 4 - Machine Operation

    Console. Ground Controls operate all functions except drive and steer 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 3121670 – JLG Lift –...

  • Page 66: Boom Operating Characteristics And Limitations

    2. Load is within manufacturers rated design capacity. Starting Procedure 3. All machine systems are functioning properly. 4. Machine is as originally equipped from JLG. Stability IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED TIME. SHOULD ENGINE FAIL TO START AGAIN, ALLOW STARTER TO “COOL OFF” FOR 2-3 MIN- Machine stability is based on two (2) conditions which are called UTES.
  • Page 67 ANY LOAD. tion, DO NOT OPERATE MACHINE. 4. After engine has had sufficient time to warm up, push in the Power/Emergency Stop switch and shut engine off. 5. Turn Platform/Ground Select switch to Plat- form. 3121670 – JLG Lift –...

  • Page 68: Shutdown Procedure

    2. Push Power/Emergency Stop switch in. 3. Turn Platform/Ground Select switch to Off. Refer to Engine Manufacturer’s manual for detailed information. – JLG Lift – 3121670...
  • Page 69 SECTION 4 - MACHINE OPERATION BOOM HORIZONTAL FULLY EXTENDED MACHINE WILL "TIP OVER" IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT-OF-LEVEL SURFACE Figure 4-1. Position of Least Forward Stability 3121670 – JLG Lift –...
  • Page 70 PLATFORM ROTATED 90 DEGREES MACHINE WILL "TIP OVER" IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN FULLY ELEVATED OUT-OF-LEVEL SURFACE MAIN BOOM FULLY ELEVATED AND FULLY RETRACTED Figure 4-2. Position of Least Backward Stability – JLG Lift – 3121670...

  • Page 71: Traveling (Driving)

    2. Sideslope, which is the angle of the slope the machine can CHASSIS AND THE PLATFORM CONTROLS. MOVE THE DRIVE CONTROLS IN A DIREC- be driven across. TION MATCHING THE DIRECTIONAL ARROWS FOR THE INTENDED DIRECTION OF TRAVEL 3121670 – JLG Lift –...
  • Page 72 SECTION 4 - MACHINE OPERATION Figure 4-3. Grade and Side Slopes – JLG Lift – 3121670...

  • Page 73: Traveling Forward And Reverse

    If the indicator is illuminated, operate the Drive function in the following manner: 1. Match the black and white direction arrows on both platform con- trol console and the chassis to determine the direction the machine will travel. 3121670 – JLG Lift –...

  • Page 74: Traveling On A Grade

    Platform Rotate control switch to select the direc- tion and hold until desired position is reached. IF THE BOOM IS OVER THE FRONT (STEER) AXLE, DIRECTION OF STEER AND DRIVE MOVEMENT WILL BE OPPOSITE FROM THE MOVEMENT OF THE CONTROLS. 4-10 – JLG Lift – 3121670...

  • Page 75: Boom

    Telescope Control Switch to select IN or OUT move- ment. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF ANY CONTROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE ‘OFF’ OR NEUTRAL POSITION WHEN RELEASED. 3121670 – JLG Lift – 4-11...

  • Page 76: Function Speed Control

    Emergency form rotate, and swing into creep mode. Platform Retrieval only. Refer to Section 5.5, Machine Safety System Override (MSSO)(CE Only)for operating procedures. 4-12 – JLG Lift – 3121670...

  • Page 77: 4.10 Skyguard Operation

    C = Indicates Cutout is Activated * Disregard when boom is in line and driving forward with or without steering and no other functions active. Note: When Soft Touch is enabled with SkyGuard all functions are cut out only. 3121670 – JLG Lift – 4-13...

  • Page 78: Shut Down And Park

    4. Properly adjust the rigging to prevent damage to the machine and so the machine remains level. 5. If necessary, cover Platform Controls to protect instruction placards, warning decals, and operating controls from hos- tile environment. 4-14 – JLG Lift – 3121670...

  • Page 79: Tie Down

    FULLY LOWERED INTO THE BOOM REST. 1. Place the boom in the stowed position or storage position. 2. Remove all loose items from the machine. 3. Secure the chassis and the platform using straps or chains of adequate strength. 3121670 – JLG Lift – 4-15...
  • Page 80 SECTION 4 - MACHINE OPERATION Figure 4-5. Lifting and Tie Down Chart 4-16 – JLG Lift – 3121670...
  • Page 81 SECTION 4 - MACHINE OPERATION Figure 4-6. Decal Location Sheet 1 of 7 3121670 – JLG Lift – 4-17...
  • Page 82 SECTION 4 - MACHINE OPERATION Figure 4-7. Decal Location Sheet 2 of 7 4-18 – JLG Lift – 3121670...
  • Page 83 SECTION 4 - MACHINE OPERATION Figure 4-8. Decal Location Sheet 3 of 7 3121670 – JLG Lift – 4-19...
  • Page 84 SECTION 4 - MACHINE OPERATION Figure 4-9. Decal Location Sheet 4 of 7 4-20 – JLG Lift – 3121670...
  • Page 85 SECTION 4 - MACHINE OPERATION Figure 4-10. Decal Location Sheet 5 of 7 3121670 – JLG Lift – 4-21...
  • Page 86 SECTION 4 - MACHINE OPERATION Figure 4-11. Decal Location Sheet 6 of 7 4-22 – JLG Lift – 3121670...
  • Page 87 SECTION 4 - MACHINE OPERATION Figure 4-12. Decal Location Sheet 7 of 7 3121670 – JLG Lift – 4-23...
  • Page 88 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - 400S Portuguese/ Item # ANSI Japan Korea Spanish French Chinese Spanish 1001171366-D 1001171370-D 1001171372-D 1001171374-D 1001171376-D 1001171378-D 1001171369-G 1001171380-D 1703797 1703926 1703927 1703923 1703924 1703925 1703928 1705921 1703798 1703932 1703933...
  • Page 89 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - 400S Portuguese/ Item # ANSI Japan Korea Spanish French Chinese Spanish 1001171366-D 1001171370-D 1001171372-D 1001171374-D 1001171376-D 1001171378-D 1001171369-G 1001171380-D 1001131269 1001131269 1706948 1706948 1706948 1706948 1706948 1706948 1706948 1701509 1701509...
  • Page 90 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - 400S Portuguese/ Item # ANSI Japan Korea Spanish French Chinese Spanish 1001171366-D 1001171370-D 1001171372-D 1001171374-D 1001171376-D 1001171378-D 1001171369-G 1001171380-D 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1704412 1704412 1704412...
  • Page 91 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - 400S Portuguese/ Item # ANSI Japan Korea Spanish French Chinese Spanish 1001171366-D 1001171370-D 1001171372-D 1001171374-D 1001171376-D 1001171378-D 1001171369-G 1001171380-D 1703953 1703944 1703945 1703941 1703942 1703943 1705903 1701518 3121670 – JLG Lift –...
  • Page 92 1001171339 1001171337 1001171339 1001171343 1001171347 1001171337 1001171353 1001171357 1001171361 1001171339 3251813 1001204510 3251813 3251813 3251813 1705084 1701504 1701504 1701504 1701504 1701504 1701504 17701504 1701504 1701504 1702631 1702631 1702631 1702631 1702361 1702631 1702631 1702631 1702631 4-28 – JLG Lift – 3121670...
  • Page 93 1702300 1702300 1702300 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 3251243 3251243 3251243 3251243 1703980 1703981 1703983 1703984 1703982 1703985 1705828 1705514 1705514 3121670 – JLG Lift – 4-29...
  • Page 94 1701499 1701499 1701499 1701499 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1705351 1705426 1705427 1705910 1705429 1705430 1705905 1704007 1704006 1704008 1001112551 1001189882 4-30 – JLG Lift – 3121670...
  • Page 95 Table 4-3. Decal Legend - 460SJ Portuguese/ Item # ANSI Japan Korea Spanish French Chinese Australia Spanish 1001171367-D 1001171368-G 1001171371-D 1001171373-D 1001171375-E 1001171377-D 1001171379-D 1001171382-E 1001171381-D 1703953 1701518 1703944 1703945 1703941 1703942 1703943 1705903 1701518 3121670 – JLG Lift – 4-31...
  • Page 96 SECTION 4 - MACHINE OPERATION NOTES: 4-32 – JLG Lift – 3121670...

  • Page 97: Section 5 - Emergency Procedures

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

  • Page 98: Platform Or Boom Caught Overhead

    1. Chock wheels securely. 2. Engage the mechanical release on both drive hubs by loos- ening, completely reversing, and tightening the two bolts on each hub. 3. Connect suitable equipment, remove chocks, and move machine. – JLG Lift – 3121670...

  • Page 99: Machine Safety System Override

    Sense System activation. NOTE: If the MSSO functionality is used, the fault indicator will flash and a fault code is set in the JLG Control System which must be reset by a qualified JLG Service Technician. NOTE: No functional checks of the MSSO system are necessary. The JLG Control system will set a Diagnostic Trouble Code if the control switch is faulty.
  • Page 100 SECTION 5 - EMERGENCY PROCEDURES NOTES: – JLG Lift – 3121670...

  • Page 101: Section 6 - General Specifications & Operator Maintenance

    SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE INTRODUCTION OPERATING SPECIFICATIONS This section of the manual provides additional necessary infor- Table 6-1. Operating Specifications - 400S mation to the operator for proper operation and maintenance of this machine. Maximum Work Load (Capacity): Unrestricted (CE &...
  • Page 102 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-1. Operating Specifications - 400S Table 6-2. Operating Specifications - 460SJ Wheelbase 7 ft. 9.5 in. (2.37 m) Maximum Work Load (Capacity): Unrestricted (CE and Aus) 600 lb (270 kg) Ground Clearance 12.1 in.

  • Page 103: Capacities

    24 oz. (0.7 L) 90 lbs. (400 N) ANSI 100 lbs. (445 N) Drive Brake 27 oz. (0.8 L) Maximum Wind Speed 28 mph (12.5 m/s) Engine Coolant Deutz 2.9L 2.9 gal. (11.3L) GM 3.0L 2.4 gal. (9.1L) 3121670 – JLG Lift –...

  • Page 104: Engine Data

    10 qt (9.5 L) Mid Engine RPM 1800 Low RPM 1200 Max. High Engine RPM 2500 Mid RPM Boom Lift, Tele Swing, Basket Level, Basket 1800 Rotate, Jib Lift 1500 High RPM 2800 – JLG Lift – 3121670...

  • Page 105: Tires

    286 lbs. (130 kg) Minimum Oil Pressure Solid 286 lbs. (130 kg) at idle 6 psi (0.4 bar) @ 1000 rpm 18 psi (1.2 bar) @ 2000 rpm Compression Ratio 9.2:1 Firing Order 1-3-4-2 Max. RPM 2800 3121670 – JLG Lift –...

  • Page 106: Hydraulic Oil

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Oil Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required Table 6-8. Hydraulic Oil additives or be of comparable viscosities. If use of hydraulic oil other...
  • Page 107 40° C (104° F) 46 cSt (215SUS) at 100° F 169 SUS at 65° C (150° F) 22 cSt (106SUS) at 210° F 48 SUS Viscosity Index cp at -20° F 6,200 Viscosity Index 3121670 – JLG Lift –...
  • Page 108 (0.9 kg/L) Viscosity Viscosity at 40° C 37 cSt at 40° C 45 cSt at 100° C 8.4 cSt at 100° C 8.0 cSt Viscosity Index Viscosity Index NOTE: Must be stored above 32°F (14°C) – JLG Lift – 3121670...

  • Page 109: Critical Stability Weights

    Viscosity Index Platform and Console - 36 x 72 NOTE: Mobil/Exxon recommends that this oil be checked on a Platform and Console - 36 x 96 yearly basis for viscosity. Platform and Console - Fall Arrest 3121670 – JLG Lift –...

  • Page 110: Serial Number Location

    A serial number plate is affixed to the left rear side of the frame. If the serial number plate is damaged or missing, the machine serial num- ber is stamped on the left side of the frame. Figure 6-1. Serial Number Location 6-10 – JLG Lift – 3121670...
  • Page 111 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-2. Engine Operating Temperature Specifications - Deutz 3121670 – JLG Lift – 6-11...
  • Page 112 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-3. Hydraulic Oil Operation Chart - Sheet 1 of 2 6-12 – JLG Lift – 3121670...
  • Page 113 ** Virtually Non-toxic classification indicates an LC50 > 5000 ppm per OECD 203 *** Fire Resistant classification indicates Factory Mutual Research Corp. (FMRC) Approval 4150740 B Figure 6-4. Hydraulic Oil Operation Chart - Sheet 2 of 2 3121670 – JLG Lift – 6-13...
  • Page 114 -10 F(-23 C) ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C) (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
  • Page 115 (HYD. OIL TANK TEMP.) IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC AMBIENT AIR OIL COOLER (CONSULT JLG SERVICE TEMPERATURE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS AMBIENT AIR TEMPERATURES 110°...
  • Page 116 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-7. Operator Maintenance and Lubrication Diagram - Deutz 2.9L Engine 6-16 – JLG Lift – 3121670...
  • Page 117 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-8. Operator Maintenance and Lubrication Diagram - Deutz 2011L Engine 3121670 – JLG Lift – 6-17...
  • Page 118 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-9. Operator Maintenance and Lubrication Diagram - GM Engine 6-18 – JLG Lift – 3121670...

  • Page 119: Operator Maintenance

    Open Gear Lubricant - Mobiltac 375 or equivalent. LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDI- TIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY. 3121670 – JLG Lift – 6-19...
  • Page 120 Interval - Check level every 3 months or 150 hrs of opera- Lube Point(s) - Fill Plug tion; change every 2 years or 1200 hours of operation Capacity - 27 oz. (0.8 L) Lube - DTE-13M Interval - Change as necessary 6-20 – JLG Lift – 3121670...
  • Page 121 300 hours thereafter or whenever Charge Filter is replaced hrs. thereafter. Comments - Remove wing nut and cover to replace. Under cer- tain conditions, it may be necessary to replace on a more frequent basis. 3121670 – JLG Lift – 6-21...
  • Page 122 Capacity - 32.5 gal tank (123 L) 40.0 gal system (151 L) 300 hours thereafter or as indicated by Condition Indicator Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation 6-22 – JLG Lift – 3121670...
  • Page 123 Lube - EO Comments - Check level daily/Change in accordance with Interval - Check level daily; change every 500 hours or six engine manual months, whichever comes first. Adjust final oil level by mark on dipstick. 3121670 – JLG Lift – 6-23...
  • Page 124 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 4.5 qt (4.25 L) w/filter Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual 6-24 – JLG Lift – 3121670...
  • Page 125 12. Fuel Filter - Deutz D2.9 Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Drain water daily; Every year or 600 hours of Interval - Every year or 600 hours of operation operation 3121670 – JLG Lift – 6-25...
  • Page 126 13. Fuel Filter - Deutz D2011 Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation Lube Point(s) - Replaceable Element Interval - Every year or 500 hours of operation 6-26 – JLG Lift – 3121670...
  • Page 127 Comments - Replace filter. Refer to Section 6.5, Propane Fuel Filter Replacement Lube Point(s) - Fill Cap Capacity - 2.9 Gallon (11.3 L) Lube - Anti-Freeze Interval - Check level daily; change every 1000 hours or 2 years, whichever comes first 3121670 – JLG Lift – 6-27...
  • Page 128 Interval - Check level daily; change every 1000 hours or 2 years, whichever comes first Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator Comments - Check Dust Valve daily 6-28 – JLG Lift – 3121670...
  • Page 129 Capacity - 40 oz. (1.2 L) Lube - 90w80 Gear Oil Interval - Check level every 3 months or 150 hours of opera- tion; change after first 50 hours and every 2 years or 1200 hours of operation thereafter 3121670 – JLG Lift – 6-29...

  • Page 130: Tires & Wheels

    Tire Replacement The air pressure for pneumatic tires must be equal to the air pres- sure that is stenciled on the side of the JLG product or rim decal JLG recommends a replacement tire be the same size, ply and brand for safe and proper operational characteristics.

  • Page 131: Wheel Replacement

    The proper procedure for attaching wheels is as follows: 1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts. 3121670 – JLG Lift – 6-31...
  • Page 132 (55 Nm) (130 Nm) (230 Nm) 4. Wheel nuts should be torqued after first 50 hours of opera- tion and after each wheel removal. Check torque every 3 months or 150 hours of operation. 6-32 – JLG Lift – 3121670...

  • Page 133: Propane Fuel Filter Replacement

    9. Remove and discard mounting plate to lock off O-ring seal. 9. Open manual shut-off valve. Start the vehicle and leak check the propane fuel system at each serviced fitting. Refer to Propane Fuel System Leak Test. 3121670 – JLG Lift – 6-33...

  • Page 134: Propane Fuel System Pressure Relief

    11. Fuel Inlet AREA IS WELL VENTILATED BEFORE DISCONNECTING ANY FUEL LINE. 3. Housing Seal 8. Fuel Outlet 12. Retaining Bolt 4. Filter Magnet 9. O-ring 13. Ring 5. Filter Housing Figure 6-10. Filter Lock Assembly 6-34 – JLG Lift – 3121670...

  • Page 135: Supplemental Information

    The vibration total value to which the hand-arm system is sub- jected does not exceed 2,5 m/s . The highest root mean square value of weighted acceleration to which the whole body is sub- jected does not exceed 0,5 m/s 3121670 – JLG Lift – 6-35...
  • Page 136 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE NOTES: 6-36 – JLG Lift – 3121670...
  • Page 137 SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 7-1. Inspection and Repair Log Date Comments 3121670 – JLG Lift –...
  • Page 138 SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log Date Comments – JLG Lift – 3121670...
  • Page 140 JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu...

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