JLG 400SJ Operation And Safety Manual
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JLG 400SJ Operation And Safety Manual

JLG 400SJ Operation And Safety Manual

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Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
400S
460SJ
3121216
ANSI
®
May 25, 2012

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  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Boom Lift Models 400S 460SJ 3121216 ANSI ® May 25, 2012...
  • 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 AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO- DECAL WILL HAVE AN ORANGE BACKGROUND. TECTION OF PROPERTY. – JLG Lift – 3121216...
  • Page 5 THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE- • Accident Reporting • Standards and Regulations Compliance Information TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED • Product Safety JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY- Publications • Questions Regarding...
  • Page 6 Revised - February 8, 2006 Revised - May 24, 2006 Revised - July 31, 2007 Revised - October 8, 2008 Revised - November 5, 2009 Revised - October 6, 2011 Revised - May 25, 2012 – JLG Lift – 3121216...

  • Page 7: Table Of Contents

    Pre-Start Inspection ..... . 2-5 Functional Check ......2-6 3121216 – JLG Lift –...
  • Page 8 Critical Stability Weights ....6-12 Serial Number Location ....6-13 – JLG Lift – 3121216...
  • Page 9 Decal Installation - Sheet 1 of 4 ....4-20 4-9. Decal Installation - Sheet 2 of 4 ....4-21 3121216 – JLG Lift –...
  • Page 10 6-13. Filter Lock Assembly ..... . . 6-37 6-13 Hydraulic Oil ......6-9 – JLG Lift – 3121216...
  • Page 11 6-21 Wheel Torque Chart ..... . . 6-34 Inspection and Repair Log ....7-1 3121216 – JLG Lift –...

  • Page 12: Section - Paragraph, Subject

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This page left blank intentionally. – JLG Lift – 3121216...

  • Page 13: Section 1. Safety Precautions

    If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“ JLG”). • Do not operate this machine until complete training is per- formed by authorized persons.

  • Page 14: Workplace Inspection

    • Do not operate any machine on which safety or instruction placards or decals are missing or illegible. ment unless approved in writing by JLG. • Avoid any buildup of debris on the platform floor. Keep • Do not operate the machine in hazardous environments mud, oil, grease, and other slippery substances from foot- unless approved for that purpose by JLG.

  • Page 15: Operation

    • Do not carry materials directly on platform railing. Contact JLG for approved material handling accessories. • When two or more persons are in the platform, the opera- tor shall be responsible for all machine operations.

  • Page 16: Electrocution Hazards

    • Keep both feet firmly positioned on the platform floor at all times. Never use ladders, boxes, steps, planks, or similar items on platform to provide additional reach. • Never use the boom assembly to enter or leave the plat- form. – JLG Lift – 3121216...

  • Page 17: Minimum Approach Distances (M.a.d.)

    50,000 volts. One foot additional clearance is required for • Allow for machine movement and electrical line swaying. every additional 30,000 volts or less. 3121216 – JLG Lift –...

  • Page 18: Tipping Hazards

    DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE. – JLG Lift – 3121216...

  • Page 19: Crushing And Collision Hazards

    Increase of the area exposed to the wind will decrease stability. • Do not increase the platform size with unauthorized deck • During operation, keep all body parts inside platform rail- extensions or attachments. ing. 3121216 – JLG Lift –...

  • Page 20: Towing, Lifting, And Hauling

    Disconnect power to overhead cranes. • Warn personnel not to work, stand, or walk under a raised boom or platform. Position barricades on floor if neces- sary. – JLG Lift – 3121216...

  • Page 21: Additional Hazards / Safety

    • When performing welding or metal cutting operations, • Charge batteries only in a well ventilated area. precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter. 3121216 – JLG Lift –...

  • Page 22: Beaufort Scale (For Reference Only)

    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. 1-10 – JLG Lift – 3121216...

  • Page 23: Section 2 - User Responsibilities, Machine Preparation, And Inspection

    4. Use of approved fall protection device. or the job site. 5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal- function. 3121216 – JLG Lift –...

  • Page 24: Preparation, Inspection, And Maintenance

    JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED The following table covers the periodic machine inspections THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PROD- and maintenance required by JLG Industries, Inc. Consult UCT MODEL.

  • Page 25: Inspection And Maintenance Table

    O w n e r, D e a l e r, o r Qualified JLG Service and Maintenance Maintenance Maintenance Manual. User Mechanic Manual NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. 3121216 – JLG Lift –...

  • Page 26: Basic Nomenclature

    3. Jib Lift Cylinder (460SJ Only) 4. Level Cylinder 5. Power Track 6. Lift Cylinder 7. Drive Wheels 8. Steer Wheels 9. Ground Control 10. Turntable 11. Base Boom 12. Fly Boom 13. Platform Console Figure 2-1. Basic Nomenclature – JLG Lift – 3121216...

  • Page 27: Pre-Start Inspection

    Figure 2-4. MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION. 5. Battery – Charge as required. 6. Fuel (Combustion Engine Powered Machines) – Add the proper fuel as necessary. 3121216 – JLG Lift –...

  • Page 28: Functional Check

    9. Check boom horizontal limit switches to see that they 4. With the aid of an assistant to monitor the CHASSIS are operable and not damaged. Raise and lower Boom. OUT OF LEVEL indicator light on the platform control Check for smooth operation. – JLG Lift – 3121216...
  • Page 29 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTE: When the boom is raised above horizontal, high drive machine and contact a trained JLG service techni- speed is cut out. cian. 12. Auxiliary Power. 10. Steer left and right; check for proper operation.

  • Page 30: Daily Walk-Around Inspection - Sheet 1 Of 3

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-2. Daily Walk-Around Inspection - Sheet 1 of 3 – JLG Lift – 3121216...

  • Page 31: Walk-Around Inspection

    Cap in place and secure. legible, control markings legible. 3. Rotator - See Inspection Note. Figure 2-3. Daily Walk-Around Inspection - Sheet 2 of 3 3121216 – JLG Lift –...

  • Page 32: Daily Walk-Around Inspection - Sheet 3 Of 3

    22. Battery - Proper electrolyte levels; cables tight, no visi- ble damage or corrosion. 17. Engine Air Filter - Element clean. See Inspection Note. Figure 2-4. Daily Walk-Around Inspection - Sheet 3 of 3 2-10 – JLG Lift – 3121216...

  • Page 33: Oscillating Axle Lockout Test (If Equipped)

    9. Place DRIVE control lever to FORWARD and carefully carefully drive machine up ascension ramp until left drive machine up ascension ramp until right front wheel front wheel is on top of block. is on top of block. 3121216 – JLG Lift – 2-11...
  • Page 34 DRIVE to release cylinders. 13. If lockout cylinders do not function properly, have quali- fied personnel correct the malfunction prior to any fur- ther operation. 2-12 – JLG Lift – 3121216...

  • Page 35: Section 3 - Machine Controls And Indicators

    3121216 – JLG Lift –...

  • Page 36: Ground Controls

    MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN adjust the platform level in situations such as ascend- RELEASED. ing/descending a grade. 3. Articulating Jib Boom. (If Equipped) Provides raising and lowering of the jib when posi- tioned up or down. – JLG Lift – 3121216...

  • Page 37: Ground Control Station - S Models

    4. Power/Emergency Stop 5. Engine Start/Auxiliary Power Engine Start/Auxiliary Power/Function Enable 6. Boom Lift 7. Hourmeter 8. Platform/Ground Select Switch 9. Swing 10. Boom Telescope QUARTZ HOURS 1706946 A Figure 3-1. Ground Control Station - S Models 3121216 – JLG Lift –...

  • Page 38: Ground Control Station - Sj Models

    4. Power/Emergency Stop 5. Engine Start/Auxiliary Power Engine Start/Auxiliary Power/Function Enable 6. Boom Lift 7. Hourmeter 8. Platform/Ground Select Switch 9. Swing 10. Boom Telescope QUARTZ HOURS 1706945 A Figure 3-2. Ground Control Station - SJ Models – JLG Lift – 3121216...
  • Page 39 NOTE: When Power/Emergency Stop switch is in the on position and engine is not running, an alarm will NOTE: Auxiliary power only works if there is no oil pressure, sound, indicating Ignition is on. and is disabled if engine is running. 3121216 – JLG Lift –...
  • Page 40 Provides 360 degrees non-continuous turntable rota- hours and cannot be reset. tion when positioned to the right or left. 10. Main Telescope Control. Provides extension and retraction of the main boom, when positioned to in or out. – JLG Lift – 3121216...

  • Page 41: Ground Control Indicator Panel

    9. Trans Filter Bypass 5. Engine Malfunction 10. Engine Air Filter Bypass Indicates that engine coolant temperature is abnor- Figure 3-3. Ground Control Indicator Panel (Prior mally high and service is required. to S/N 93233) 3121216 – JLG Lift –...
  • Page 42 4. Engine Oil Temp 10. Not Used gallons of fuel remaining. 5. Engine Malfunction 11. Platform Overload CE Only 6. Low Fuel 12. Drive and Steer Disable Figure 3-4. Ground Control Indicator Panel (S/N 93233 to Present) – JLG Lift – 3121216...
  • Page 43 Indicates that charge pump filter is too restrictive and needs to be replaced. This indicator has an integral temperature sensor (70 degrees F.) so that false sig- nals are not generated when the hydraulic oil is below normal operating temperature. 3121216 – JLG Lift –...

  • Page 44: Platform Station

    ON and the drive motors in maximum displacement. position and the ENGINE START switch is push for- ward. 3-10 – JLG Lift – 3121216...

  • Page 45: Platform Control Console

    2. Platform Leveling Override 6. Fuel Select 10. Jib Lift 14. Footswitch (Not Shown) 3. Horn 7. Lights 11. Platform Rotate 4. Power/Emergency Stop 8. Drive Steer 12. Function Speed Figure 3-5. Platform Control Console 3121216 – JLG Lift – 3-11...

  • Page 46: Platform Control Console - W/Drive Orientation

    8. Drive Steer 12. Function Speed 16. Soft Touch Override 4. Power/Emergency Stop 9. Main Telescope Control 13. Main Lift/Swing 17. Soft Touch Indicator 5. Auxiliary Power Figure 3-6. Platform Control Console - w/Drive Orientation 3-12 – JLG Lift – 3121216...
  • Page 47 NOTE: The main function of auxiliary power is to lower the platform in the event of primary power failure. Deter- mine the reason for primary power failure and have the problem corrected by a certified JLG service technician. 3121216 – JLG Lift –...
  • Page 48 Function Speed knob as well as Allows the operator to rotate the basket to the left or near the proportional controllers to act as a reminder. right when positioned to the desired direction. 3-14 – JLG Lift – 3121216...
  • Page 49 NOTE: These machines have a 7 second delay timer. If func- combination. The handle features a round gate so tion has not been activated within 7 seconds after that maximum speed is reduced when multiple func- depressing the footswitch, recycle footswitch. tions are selected. 3121216 – JLG Lift – 3-15...

  • Page 50: Platform Control Indicator Panel

    All controls are cut out until the override button is BOOM OR RAISING BOOM ABOVE HORIZONTAL. pushed, at which time controls are active in the Creep Mode. 2. Platform Overload (If equipped) Indicates the platform has been overloaded. 3-16 – JLG Lift – 3121216...

  • Page 51: Platform Control Indicator Panel

    4. Fuel Level 10. Creep Speed 5. Enable 10. Creep Speed 5. Enable 11. Drive Orientation 6. Glow Plug Figure 3-7. Platform Control Indicator Panel Figure 3-8. Platform Control Indicator Panel - w/ Drive Orientation 3121216 – JLG Lift – 3-17...
  • Page 52 To enable the controls again, remove your foot from the footswitch and depress the footswitch. 6. Glow Plug Indicator Illuminates when the glow plugs are operating. Wait until the light goes out before cranking engine. 3-18 – JLG Lift – 3121216...
  • Page 53 Creep mode. 10. Creep Speed Indicator Illuminated (Green) 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. 3121216 – JLG Lift – 3-19...
  • Page 54 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTES: 3-20 – JLG Lift – 3121216...

  • Page 55: Section 4 - Machine Operation

    4. Proper tire pressure exists in the tires. operator in the platform be unable to do so. 5. Machine is as originally equipped from JLG. 3121216 – JLG Lift –...

  • Page 56: Stability

    SECTION 4 - MACHINE OPERATION Stability This machine as originally manufactured by JLG Indus- ROTATE PLATFORM tries Inc., when operated within its rated capacity on a 90 DEGREES smooth, firm and level supporting surface, and in accor- dance with the instructions provided on the machine and this manual, provides a stable machine for all platform positions.

  • Page 57: Position Of Least Forward Stability

    SECTION 4 - MACHINE OPERATION TELESCOPE BOOM TELESCOPE BOOM FULLY EXTENDED HORIZONTAL HORIZONTAL FULLY EXTENDED MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT-OF-LEVEL SURFACE Figure 4-2. Position Of Least Forward Stability 3121216 – JLG Lift –...

  • Page 58: Engine Operation

    ENGINE START switch to the upward position until engine starts. ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD. 5. After engine has had sufficient time to warm up, shut engine off. – JLG Lift – 3121216...

  • Page 59: Shutdown Procedure

    3-5 minutes; this allows for further reduction of internal engine temperature. 2. Position POWER/EMERGENCY STOP switch to OFF. 3. Turn key of MASTER switch to OFF position. NOTE: Refer to Engine Manufacturer’s manual for detailed information. 3121216 – JLG Lift –...
  • Page 60 BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWS slope. The machines high drive function will also be cut ON BOTH THE CHASSIS AND THE PLATFORM CONTROLS. MOVE THE back to low drive. DRIVE CONTROLS IN A DIRECTION MATCHING THE DIRECTIONAL ARROWS. – JLG Lift – 3121216...

  • Page 61: Grades And Sideslopes

    SECTION 4 - MACHINE OPERATION LEVEL DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON MANUFACTURER’S NAMEPLATE Figure 4-3. Grades and Sideslopes 3121216 – JLG Lift –...

  • Page 62: Traveling Forward Or Reverse

    5. Prior to stopping the machine, position switches as fol- travel. The indicator light will flash during the 3 second lows: interval until the drive function is selected. Position DRIVE SPEED/TORQUE SELECT switch to LOW. (Backward Position) – JLG Lift – 3121216...

  • Page 63: Steering

    2. If total weight in platform will be less then rated capac- ignition off. ity, proceed with adding weight. 2. Check that brakes hold machine in position. 3. Chock wheels front and rear. 4. Turn off SELECT switch and remove key. 3121216 – JLG Lift –...

  • Page 64: Platform Level Adjustment

    ARD. held until desired position is reached. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF ANY CONTROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE "OFF" POSITION WHEN RELEASED. 4-10 – JLG Lift – 3121216...

  • Page 65: Swinging The Boom

    NOTE: Lift up will not function when the boom is near full elevation and the platform is out of level. To raise or lower the Main Boom, with footswitch acti- vated, position Main Boom Lift lever to UP or DOWN until desired height is reached. 3121216 – JLG Lift – 4-11...

  • Page 66: Auxiliary Power - Non Ade Equipped Machines

    6. Position POWER/EMERGENCY STOP switch to OFF. 1. Position PLATFORM/GROUND SELECT KEY SWITCH to PLATFORM. 2. Position POWER/EMERGENCY STOP switch to ON. 3. Depress and hold footswitch. 4. Operate appropriate control switch, lever or controller for desired function and hold. 4-12 – JLG Lift – 3121216...

  • Page 67: 4.10 Auxiliary Power - Ade Equipped

    1. Position PLATFORM/GROUND SELECT KEY SWITCH 6. Position POWER/EMERGENCY STOP switch to OFF. to PLATFORM. 2. Position POWER/EMERGENCY STOP switch to ON. 3. Depress and hold footswitch. 4. Position AUXILIARY POWER switch to ON and hold. 3121216 – JLG Lift – 4-13...

  • Page 68: 4.11 Shut Down And Park

    1. Drive machine to a protected area. The weight of the machine is stamped on the serial num- ber plate. If the plate is missing or illegible, call JLG Indus- 2. Assure main boom is fully retracted and lowered over tries or weigh the individual unit to find out the Gross rear (Drive) axle;...

  • Page 69: Machine Tie Down - 400S Models

    This prevents the boom from bouncing up and down and pre- venting possible damage while trans- porting. Figure 4-4. Machine Tie Down - 400S Models 3121216 – JLG Lift – 4-15...

  • Page 70: Machine Tie Down - 460Sj Models

    This prevents the boom from bouncing up and down and pre- venting possible damage while transporting. Figure 4-5. Machine Tie Down - 460SJ Models 4-16 – JLG Lift – 3121216...

  • Page 71: Lifting And Tie Down

    SECTION 4 - MACHINE OPERATION Figure 4-6. Lifting and Tie Down 3121216 – JLG Lift – 4-17...

  • Page 72: 4.13 Towing

    1. Retract, lower and position boom over rear drive wheels in line with direction of travel. Figure 4-7. Drive Disconnect Hub 2. Disconnect drive hubs by inverting the disconnect cap. (See Figure 4-7.) After towing the machine, complete the following: 4-18 – JLG Lift – 3121216...

  • Page 73: 4.14 Placards And Decals

    ARE MISSING OR ILLEGIBLE. Replace placards and NOTE: Placards and Decals can be ordered by using part decals if damaged, missing or illegible. numbers located by each placard or decal. 3121216 – JLG Lift – 4-19...

  • Page 74: Decal Installation - Sheet 1 Of 4

    SECTION 4 - MACHINE OPERATION Figure 4-8. Decal Installation - Sheet 1 of 4 4-20 – JLG Lift – 3121216...

  • Page 75: Decal Installation - Sheet 2 Of 4

    SECTION 4 - MACHINE OPERATION Figure 4-9. Decal Installation - Sheet 2 of 4 3121216 – JLG Lift – 4-21...

  • Page 76: Decal Installation - Sheet 3 Of 4

    SECTION 4 - MACHINE OPERATION Figure 4-10. Decal Installation - Sheet 3 of 4 4-22 – JLG Lift – 3121216...

  • Page 77: Decal Installation - Sheet 4 Of 4

    SECTION 4 - MACHINE OPERATION Figure 4-11. Decal Installation - Sheet 4 of 4 3121216 – JLG Lift – 4-23...

  • Page 78: Decals - 400S With 500 Lb (227 Or 230 Kg) Capacity

    1704472 1702868 1704002 1704000 1704001 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1001121800 1705978 1001125330 1001121809 1001121802 1001121807 1001122200 1001121804 1001121813 1705978 1001125338 1001121822 1001121815 1001121820 1001122201 1001121817 3251813 1705084 3251813 3251813 3251813 4-24 – JLG Lift – 3121216...
  • Page 79 1702300 1702300 1702300 1702300 1702300 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1705828 1703985 1703982 1703984 1703980 1703981 1703983 1706126 1706126 1706126 1706126 1706126 1706126 3121216 – JLG Lift – 4-25...
  • Page 80 1701499 1701499 3252672 1707031 3252685 3252684 3252683 3252680 3252681 3252682 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1704726 1704726 1704726 1704726 1704726 1704726 1704726 1704726 4-26 – JLG Lift – 3121216...
  • Page 81 Table 4-1. Decals - 400S with 500 lb (227 or 230 kg) Capacity Portuguese/ English/ Item # ANSI CE/Australian Chinese/ French Japanese Korean Spanish Spanish 0259159-20 0275066-7 0259183-23 0259181-22 0259175-23 0259177-23 0259185-19 0259179-19 1705351 1705905 1705430 1705429 1705426 1705427 1705910 3121216 – JLG Lift – 4-27...

  • Page 82: Decals - 400S With 750 Lb (340 Kg) Capacity

    1704001 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1001125322 1706382 1001125329 1001125328 1001125327 1001125323 1001125324 1001125325 1001125331 1706382 1001125337 1001125336 1001125335 1001125332 1001125333 1001125334 3251813 1705084 3251813 3251813 3251813 1701502 1701502 1701503 1701503 4-28 – JLG Lift – 3121216...
  • Page 83 1702300 1702300 1702300 1702300 1702300 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1705828 1703985 1703982 1703984 1703980 1703981 1703983 1704829 1704829 1704829 1704829 1704829 1704829 3121216 – JLG Lift – 4-29...
  • Page 84 1701499 1701499 3252672 1707031 3252685 3252684 3252683 3252680 3252681 3252682 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1704726 1704726 1704726 1704726 1704726 1704726 1704726 1704726 4-30 – JLG Lift – 3121216...
  • Page 85 Table 4-2. Decals - 400S with 750 lb (340 kg) Capacity Portuguese/ English/ Item # ANSI CE/Australian Chinese French Japanese Korean Spanish Spanish 0259981-17 0275068-6 0259993-20 0259992-20 0259989-20 0259990-20 0259994-17 0259991-17 1705351 1705905 1705430 1705429 1705426 1705427 1705910 3121216 – JLG Lift – 4-31...

  • Page 86: Decals - 460Sj

    1704473 1702868 1704002 1704000 1704001 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1001121801 1705978 1001121920 1001121812 1001121803 1001121808 1001121918 1001121801 1001121814 1705978 1001121923 1001121825 1001121816 1001121821 1001121921 1001121814 3251813 1705084 3251813 3251813 3251813 4-32 – JLG Lift – 3121216...
  • Page 87 1702300 1702300 1702300 1702300 1702300 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1705828 1703985 1703982 1703984 1703980 1703981 1703983 1704828 1704828 1704828 1704828 1704828 1704828 3121216 – JLG Lift – 4-33...
  • Page 88 1701499 1701499 3252672 1707031 3252685 3252684 3252683 3252680 3252681 3252682 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1704726 1704726 1704726 1704726 1704726 1704726 1704726 1704726 4-34 – JLG Lift – 3121216...
  • Page 89 SECTION 4 - MACHINE OPERATION Table 4-3. Decals - 460SJ Portuguese/ English/ Item # ANSI CE/Australian Chinese French Japanese Korean Spanish Spanish 0259160-16 1001114405-1 0259184-22 0259182-21 0259176-21 0259178-20 0259186-19 0259180-18 1705351 1705905 1705430 1705429 1705426 1702427 1705910 1001112551 3121216 – JLG Lift – 4-35...
  • Page 90 SECTION 4 - MACHINE OPERATION NOTES: 4-36 – JLG Lift – 3121216...

  • Page 91: Section 5 - Emergency Procedures

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

  • Page 92: Platform Or Boom Caught Overhead

    Towing this machine is prohibited, unless properly overhead structures or equipment, rescue platform occu- equipped. However, provisions for moving the machine pants prior to freeing the machine. have been incorporated. For specific procedures, refer to Section 4. – JLG Lift – 3121216...

  • Page 93: Section 6 - General Specifications & Operator Maintenance

    Turning Radius (Inside) 6 ft.-8 in. (2 m.) Prior to S/N 96000..........3120896 Overall Width 6ft.- 6in. (1.98 m) Illustrated Parts Manual (Global) S/N 96000 to Present..........3121236 Tail swing Zero Stowed Height 7ft. 4in. (2.24 m) 3121216 – JLG Lift –...

  • Page 94: Operating Specifications - 400S - S/N 0300142870 To Present

    Overall Width 6ft.- 6in. (1.98 m) Max. Hydraulic System Operating Pressure 4060 psi (280 bar) Tail swing Zero Manual Force 400 N maximum Stowed Height 7ft. 4in. (2.24 m) Maximum Wind Speed 28 mph (12.5 m/s) – JLG Lift – 3121216...

  • Page 95: Operating Specifications - 460Sj - Prior To S/N

    Max. Hydraulic System Operating Pressure 4060 psi (280 bar) Max. Tire Load 7200 lbs. (3266 kg) Manual Force 400 N maximum Ground Bearing Pressure 63 psi (4.4 kg/cm Maximum Wind Speed 28 mph (12.5 m/s) 3121216 – JLG Lift –...

  • Page 96: Operating Specifications - 460Sj - S/N 0300142870 To Present

    6 ft.-8 in. (2 m.) Overall Width 6ft.- 6in. (1.98 m) Tail swing zero Stowed Height 7ft. 4in. (2.24 m) Stowed Length 20ft. 2in. (6.15 m) Wheelbase 7ft. 10in. (2,3 m) Ground Clearance 12in. (30 cm) – JLG Lift – 3121216...

  • Page 97: Capacities

    (Platform Empty, Pneumatic Tires) 4.5 qts. (4.25 L) w/Filter Maximum System Voltage 12 VDC Max. Hydraulic System Operating Pressure 4060 psi (280 bar) Maximum Manual Force 400 N Maximum Wind Speed 28 mph (12.5 m/s) 3121216 – JLG Lift –...

  • Page 98: Engine

    11 quarts (10.5 L) High RPM 3000 Low RPM 1200 Fuel Consumption: Gasoline Mid RPM 1800 Intermittent 6 gal. hr. High RPM 2800 Continuous 5 gal. hr. Fuel Consumption: LPG Intermittent 26 lbs. hr. Continuous 23 lbs. hr. – JLG Lift – 3121216...

  • Page 99: Isuzu 4Le1

    3.307 in. (84 mm) Firing Order 1-3-4-2 Stroke 3.9370 in. (112 mm) Max. RPM 2800 Displacement 134.3 cu. in. (2.2L) Oil Capacity 3.8 quarts (3.6 L) crankcase only Compression Ratio 19:1 Firing Order 1-3-4-2 Max. RPM 2800 3121216 – JLG Lift –...

  • Page 100: Tires

    Oil Capacity w/filter 10 qt. (9.4 L) 33/16LLx16.1- Sand Foam Filled 426 lbs. (193 kg) Compression Ratio 23.3:1 33x6x11 Solid 280 lbs. (127 kg) Semitrack Tires 24x12x 12 Pneumatic 20 psi (1.4 bar) 20.7 lbs. (9.38 kg) – JLG Lift – 3121216...

  • Page 101: 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 Table 6-13. Hydraulic Oil required additives or be of comparable viscosities. If use of...

  • Page 102: Ucon Hydrolube Hp-5046

    (0.9 kg per liter) at 65° C (150° F) 22 cSt (106SUS) Viscosity Viscosity Index at 40° C 37 cSt at 100° C 8.4 cSt Viscosity Index NOTE: Must be stored above 32°F (0°C) 6-10 – JLG Lift – 3121216...

  • Page 103: Mobil Eal Envirosyn H Specs

    Viscosity at 100° C 9.3 cSt at 40° C 33.1 cSt Viscosity Index at 100° C 6.36 cSt NOTE: Mobil/Exxon recommends that this oil be checked on a yearly basis for viscosity. Viscosity Index 3121216 – JLG Lift – 6-11...

  • Page 104: Critical Stability Weights

    12 x16.5 F/F Tire & Wheel 12 x 21.5 (NHS)pneu.Tire & Wheel 12 x 21.5 (NHS)F/F Tire & Wheel 14 x16.1 Sand pneu. Tire & Wheel 91.5 14 x16.1 Sand F/F Tire & Wheel 6-12 – JLG Lift – 3121216...

  • Page 105: 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 number is stamped on the left side of the frame. Figure 6-1. Serial Number Location 3121216 – JLG Lift – 6-13...

  • Page 106: Engine Operating Temperature Specifications

    ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10°F(-23°C) GRADE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY FUEL AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20°F(-29°C) WITH PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR KEROSENE -30F°(-34°C)

  • Page 107: Engine Operating Temperature Specifications

    IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS AMBIENT AIR THE ADDITION OF A HYDRAULIC TEMPERATURE OIL COOLER (CONSULT JLG SERVICE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS N O T E : AMBIENT AIR TEMPERATURES 110°...

  • Page 108: Engine Operating Temperature Specifications

    WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. 0 F(-18 C) -10 F(-23 C) 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 109: Engine Operating Temperature Specifications

    IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS AMBIENT AIR TEMPERATURE THE ADDITION OF A HYDRAULIC OIL COOLER (CONSULT JLG SERVICE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS AMBIENT AIR TEMPERATURES 110° F (43° C) AMBIENT TEMPERATURE OF 100°...

  • Page 110: Engine Operating Temperature Specifications

    0°F(-18°C) ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10°F(-23°C) WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20°F(-29°C) PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND -30° F(-34 C) °...

  • Page 111: Engine Operating Temperature Specifications

    (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 112: Engine Operating Temperature Specifications

    -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 113: Engine Operating Temperature Specifications

    (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 114: Engine Operating Temperature Specifications

    0°F(-18°C) ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10°F(-23°C) WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20°F(-29°C) PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND -30° F(-34 C) °...

  • Page 115: Engine Operating Temperature Specifications

    (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: Operator Maintenance And Lubrication Diagram

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 14,15,16,17,18,19 21, 22 8,9,10,11,12,13 NOTE: Item #2 Not Shown Figure 6-12. Operator Maintenance and Lubrication Diagram 6-24 – JLG Lift – 3121216...

  • Page 117: Operator Maintenance

    Lube Point(s) - Repack OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CON- Capacity - A/R DITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORD- Lube - MPG INGLY. Interval - Every 2 years or 1200 hours of operation 3121216 – JLG Lift – 6-25...
  • Page 118 Capacity - 40.0 gal. tank (151L) 52.0 gal. system (196.8L) or 300 hrs. thereafter or whenever Charge Filter is replaced. Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation. 6-26 – JLG Lift – 3121216...
  • Page 119 Interval - Every 2 years or 1200 hours of operation, remove and clean at time of hydraulic oil change. 8. Oil Change w/Filter - Ford Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7016331) Capacity - 6.3 qt. (5.9 L) engine only...
  • Page 120 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 10. Oil Change w/Filter - Isuzu 12. Oil Change w/Filter - GM Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7022111) Capacity - 6 qt. (5.6L) engine; 6.5 qt. (6.1L) w/cooler Lube - EO...
  • Page 121 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 13. Oil Change w/Filter - Perkins 15. Fuel Filter - Deutz Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7026855) Capacity - 10 qt. (9.4 L) Lube - EO Interval - Every Year or 500 hours of operation Comments - Check level daily/Change in accordance with engine manual.
  • Page 122 DRAINING OIL BUILD UP FROM THE PROPANE REG- ULATOR (Prior to S/N 0300109274) Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator 6-30 – JLG Lift – 3121216...

  • Page 123: Tires & Wheels

    22. Fuel Filter (Propane) - GM Engine 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.

  • Page 124: Tire Replacement

    Please refer to the The rims installed on each product model have been designed JLG Parts Manual for the part number of the approved tires for a for stability requirements which consist of track width, tire pres- particular machine model.

  • Page 125: Wheel Installation

    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. 3121216 – JLG Lift – 6-33...

  • Page 126: Draining Oil Build Up From The Propane Regulator (Prior To S/N 0300109274)

    1. Move the equipment to a well ventilated area. Ensure there are no external ignition sources. 2. Start the engine and bring to operating temperature. 3. With the engine running, close the manual tank valve and run the engine out of fuel. 6-34 – JLG Lift – 3121216...
  • Page 127 8. Open the fuel tank manual valve. 9. Start the engine and verify all connections are secure. 10. Dispose of any drained oil per local regulations in a safe and proper fashion. 3121216 – JLG Lift – 6-35...

  • Page 128: Propane Fuel Filter Replacement

    8. Tighten the filter to 106 in lbs (12 Nm). 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. 6-36 – JLG Lift – 3121216...

  • Page 129: Jlg Lift

    10. Filter 2. Mounting Plate 7. Electrical Connector 11. Fuel Inlet 3. Housing Seal 8. Fuel Outlet 12. Retaining Bolt 4. Filter Magnet 9. O-ring 13. Ring 5. Filter Housing Figure 6-13. Filter Lock Assembly 3121216 – JLG Lift – 6-37...

  • Page 130: Propane Fuel System Pressure Relief

    0,5 m/s RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYS- TEM. ENSURE THE WORK AREA IS WELL VENTILATED BEFORE DIS- CONNECTING ANY FUEL LINE. 6-38 – JLG Lift – 3121216...

  • Page 131: Section 7 - Inspection And Repair Log

    SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 7-1. Inspection and Repair Log Date Comments 3121216 – JLG Lift –...
  • Page 132 SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log Date Comments – JLG Lift – 3121216...
  • Page 136 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 3121216 (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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