JLG 0300203771 Operation & Maintenance Instructions Manual
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JLG 0300203771 Operation & Maintenance Instructions 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
S/N 0300203771* to Present
S/N 1300007289 to Present
S/N E300000100 to Present
* See inside front cover for exceptions.
3121670
AS/NZS
ANSI
November 5, 2018 - Rev L
®

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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 S/N 0300203771* to Present S/N 1300007289 to Present S/N E300000100 to Present * See inside front cover for exceptions. 3121670...
  • 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 FOREWORD SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death INDICATES A POTENTIALLY HAZARDOUS SITUATION.
  • 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 A - March 12, 2015 Revised B - March 21, 2015 Revised C - April 2, 2015 Revised D - July 30, 2015 Revised E - January 19, 2016 Revised F - June 7, 2016 Revised G - January 23, 2017 Revised...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 1 - SAFETY PRECAUTIONS Function Check........2-8 SkyGuard Function Test.
  • Page 8 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Traveling on a Grade ......4-10 SECTION - 5 - EMERGENCY PROCEDURES STEERING.
  • Page 9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Accessory Ratings ....... . . 6-7 OPERATOR MAINTENANCE .
  • Page 10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This Page Left Blank Intentionally 3121670...
  • Page 11 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE 2-1. Basic Nomenclature........2-4 6-1.
  • Page 12 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE This Page Left Blank Intentionally 3121670...
  • Page 13 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE Minimum Approach Distances (M.A.D.) ....1-6 7-16 Critical Stability Weights ......7-10 Beaufort Scale (For Reference Only).
  • Page 14 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE This Page Left Blank Intentionally viii 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

    • Do not carry materials directly on platform railing unless • Hydraulic cylinders are subject to thermal expansion and con- approved by JLG. traction. This may result in changes to the boom and/or plat- form position while the machine is stationary. Factors •...

  • Page 19: Electrocution Hazards

    SECTION 1 - SAFETY PRECAUTIONS • Before operating the machine, make sure all gates are closed Electrocution Hazards and fastened in their proper position. • This machine is not insulated and does not provide protection from contact or proximity to electrical current. •...
  • Page 20 SECTION 1 - SAFETY PRECAUTIONS Table 1-1. Minimum Approach Distances (M.A.D.) Voltage Range MINIMUM APPROACH DISTANCE (Phase to Phase) in Feet (Meters) 0 to 50 KV 10 (3) Over 50KV to 200 KV 15 (5) Over 200 KV to 350 KV 20 (6) Over 350 KV to 500 KV 25 (8)

  • Page 21: Tipping Hazards

    SECTION 1 - SAFETY PRECAUTIONS • The minimum approach distance may be reduced if insulating Tipping Hazards barriers are installed to prevent contact, and the barriers are • The user must be familiar with the surface before driving. Do rated for the voltage of the line being guarded. These barriers not exceed the allowable sideslope and grade while driving.
  • 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 SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/ Table 1-2. Beaufort Scale (For Reference Only) Wind Speed Beaufort Description Land Conditions Number 0-0.2 Calm Calm. Smoke rises vertically 0.3-1.5 Light air Wind motion visible in smoke 1.6-3.3 Light breeze...

  • Page 24: Crushing And Collision Hazards

    SECTION 1 - SAFETY PRECAUTIONS Crushing and Collision Hazards • Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving and swing operations. • Approved head gear must be worn by all operating and • Under all travel conditions, the operator must limit travel ground personnel.

  • Page 25: Towing, Lifting, And Hauling

    SECTION 1 - SAFETY PRECAUTIONS TOWING, LIFTING, AND HAULING MAINTENANCE • Never allow personnel in platform while towing, lifting, or This sub-section contains general safety precautions which must hauling. be observed during maintenance of this machine. Additional pre- cautions to be observed during machine maintenance are •...
  • Page 26 SECTION 1 - SAFETY PRECAUTIONS • DO NOT use your hand to check for leaks. Use a piece of card- • Do not use machine as a ground for welding. board or paper to search for leaks. Wear gloves to help protect •...

  • Page 27: Battery Hazards

    SECTION 1 - SAFETY PRECAUTIONS Battery Hazards • Always disconnect batteries when servicing electrical compo- BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND nents or when performing welding on the machine. CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION.
  • Page 28 SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-14 3121670...

  • Page 29: Section 2. User Responsibilities, Machine Preparation, And Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.1 PERSONNEL TRAINING 6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, The aerial platform is a personnel handling device; so it is neces- depressions, holes, or drop-offs exist.

  • 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 Preventative Maintenance 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...
  • Page 32 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 1. Platform 2. Platform Console 3. SkyGuard (If Equipped) 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.

  • Page 33: Pre-Start Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection 5. Daily Walk-Around Inspection – Perform as instructed. 6. Battery – Charge as required. The Pre-Start Inspection should include each of the following: 7. Fuel (Combustion Engine Powered Machines) – Add the 1.

  • Page 34: Daily Walk-Around Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Daily Walk-Around Inspection 3121670...
  • Page 35 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Begin the "Walk-Around Inspection" at Item 1, as noted on the 6. Drive Motor, Brake, and Hub - No evidence of leakage. diagram. Continue checking each item in sequence for the condi- 7.

  • Page 36: Function Check

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Function Check 3. With the platform in the stowed position: a. Drive the machine on a grade, not to exceed the rated Perform the Function Check as follows: gradeability, and stop to ensure the brakes hold; 1.

  • Page 37: Skyguard Function Test

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SkyGuard Function Test 4. Disengage the SkyGuard sensor, release controls, then recy- cle the footswitch. Ensure normal operation is available. NOTE: Refer to Section 4.10 for additional information on SkyGuard NOTE: On machines equipped with SkyLine, reattach magnetic end of operation.

  • Page 38: Oscillating Axle Lockout Test (If Equipped)

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) 5. Place Drive control lever to Reverse and drive machine off of block and ramp. 6. Have an assistant check to see that left front or right rear wheel remains elevated in position off of ground.

  • Page 39: Section 3 - Machine Controls And Indicators

    SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS GENERAL NOTE: The indicator panels use different shaped symbols to alert the operator to different types of operational situations that could arise. The meaning of those symbols are explained below. Indicates a potentially hazardous situation, which if THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND not corrected, could result in serious injury or death.

  • Page 40: Ground Control Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 2. Display Gauge Registers the amount of time the machine TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR has been in use, with engine running. The TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE hourmeter registers up to 16,500 hours and OFF POSITION WHEN RELEASED.
  • Page 41 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Indicator Panel 2. Display Gauge 3. Engine Start/Auxiliary Power/ 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.
  • Page 42 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Indicator Panel 2. Display Gauge 3. Engine Start/Auxiliary Power/ 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.
  • Page 43 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Indicator Panel 2. Display Gauge 3. Engine Start/Auxiliary Power/ 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.
  • Page 44 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Indicator Panel 2. Display Gauge 3. Engine Start/Auxiliary Power/ 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.
  • Page 45 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: When the Platform/Ground Select Switch is in the center posi- 5. Platform Leveling Override tion, power is shut off to the controls at both operating consoles. Remove the key to prevent the controls from being actuated. A three position switch allows the operator to adjust the automatic self leveling system.
  • Page 46 SECTION 3 - MACHINE CONTROLS AND INDICATORS 8. Telescope Control 10. Main Boom Lift Provides extension and retraction of the boom. Provides raising/lowering of the main boom when positioning up or down. 11. Swing Provides 360 degrees continuous turntable rotation. WHEN THE MACHINE IS SHUT DOWN THE POWER/EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERIES.

  • Page 47: Ground Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Indicator Panel 4. Engine Oil Temperature Indicator (Deutz) Indicates that the temperature of the engine (See Figure 3-5., Ground Control Indicator Panel) oil, which also serves as engine coolant, is abnormally high and service is required. 1.
  • Page 48 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Battery Malfunction 2. Low Engine Oil Pressure 3. High Engine Coolant Temperature 4. Engine Oil Temperature 5. Engine Malfunction/Check Engine 6. Low Fuel 7. Glow Plug 8. Platform Overload (If Equipped) 9. Drive and Steer Disable (If Equipped) Figure 3-5.
  • Page 49 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Battery Malfunction 2. Not Used 3. Not Used 4. Not Used 5. Engine Malfunction/Check Engine 6. Low Fuel 7. Glow Plug 8. Platform Overload (If Equipped) 9. Drive and Steer Disable (If Equipped) 10.
  • Page 50 7. Glow Plug Indicator 10. System Distress Indicator Indicates the glow plugs are operating. After The light indicates that the JLG Control System turning on ignition, wait until light goes out has detected an abnormal condition and a before cranking engine.

  • Page 51: Ground Control Console Display Gauge

    (See Figure 3-10., 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 52 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 53 SECTION 3 - MACHINE CONTROLS AND INDICATORS INDICATOR LAMP FUEL LEVEL ENGINE HOURS NAVIGATE FORWARD ARROW NAVIGATE BACK ARROW NAVIGATION BUTTONS Figure 3-10. Ground Control Console Display Gauge 3121670 3-15...

  • Page 54: Platform Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Console ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF (See Figure 3-11., Platform Control Console) THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. 2.
  • Page 55 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1001184626 A 1001195947 A 1702566 B 1702565 B 1702567 B 1705170 A 1. Drive Speed/Torque Select 6. Start/Auxiliary Power 10. Telescope 14. Soft Touch/SkyGuard Indicator (If Equipped) 2. Platform Leveling Override 7. Capacity Select 11.
  • Page 56 SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Power/Emergency Stop Switch 7. Capacity Select A two-position red mushroom shaped switch This switch allows the operator to select furnishes power to PLATFORM Controls when between an operating envelope with a 600 lb. pulled out (on).
  • Page 57 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: To operate the Drive joystick, pull up on the lock- 11. Lights (If Equipped) ing ring below the handle. This switch operates the chassis lights if NOTE: The Drive joystick is spring loaded and will auto- the machine is so equipped.
  • Page 58 SECTION 3 - MACHINE CONTROLS AND INDICATORS 13. Soft Touch/SkyGuard Override Switch (If equipped) 14. Soft Touch/SkyGuard Indicator (If Equipped) The machine can be equipped with one of three options. It Indicates the Soft Touch bumper is against an object or the may have Soft Touch, SkyGuard, or both Soft Touch and Sky- SkyGuard sensor has been activated.
  • Page 59 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: To operate the Main Boom Lift/Swing joystick, pull up on the locking ring below the handle. NOTE: The Main Boom Lift/Swing joystick is spring loaded and will automatically return to neutral (off) position when released. 17.

  • Page 60: Platform Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Control Indicator Panel 3. Capacity Indicator Indicates the maximum platform capacity for (See Figure 3-12., Platform Control Indicator Panel) the current position of the platform. Restricted capacities are permitted at restricted platform NOTE: The indicator lights will illuminate for approximately 1 second positions (shorter boom lengths and higher...
  • Page 61 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. AC Generator (If Equipped) 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 3-12.
  • Page 62 SECTION 3 - MACHINE CONTROLS AND INDICATORS 4. Tilt Alarm Warning Light and Alarm 5. Glow Plug/Wait to Start Indicator Indicates the glow plugs are operating. After This red illuminator indicates that the chassis is turning on ignition, wait until light goes out on a slope.
  • Page 63 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 64 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTES: 3-26 3121670...

  • Page 65: Section 4 - Machine Operation

    SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION DESCRIPTION The primary operator control console is in the platform. From this control console, the operator can drive and steer the machine in This machine is a mobile elevating work platform used to posi- both forward and reverse directions.

  • 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 SECTION 4 - MACHINE OPERATION 1. Turn key of Platform/Ground Select switch to 6. Pull out the Ground Console Power/Emer- Ground. gency Stop switch to provide power to the platform controls. 2. Pull the Power/Emergency Stop switch to On. 7. From Platform, pull Power/Emergency Stop switch out.

  • Page 68: Shutdown Procedure

    SECTION 4 - MACHINE OPERATION Shutdown Procedure Fuel Reserve / Shut-Off System (Diesel Engines Only) The Fuel Shutoff System senses when the fuel level is getting low and automatically shuts the engine down before the fuel tank is emptied. IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN, DETERMINE Depending upon machine setup, the machine will either keep THE CAUSE AND CORRECT IT BEFORE RESTARTING THE ENGINE.
  • 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...
  • Page 70 SECTION 4 - MACHINE OPERATION MACHINE WILL "TIP OVER" IN THIS PLATFORM ROTATED DIRECTION IF OVERLOADED OR 90 DEGREES OPERATED ON AN OUT-OF-LEVEL SURFACE FULLY ELEVATED MAIN BOOM FULLY ELEVATED AND FULLY RETRACTED Figure 4-2. Position of Least Backward Stability 3121670...

  • Page 71: Traveling (Driving)

    SECTION 4 - MACHINE OPERATION TRAVELING (DRIVING) DO NOT DRIVE WITH BOOM OUT OF TRANSPORT MODE EXCEPT ON A SMOOTH, FIRM See Figure 4-3., Grade and Side Slopes AND LEVEL SURFACE. NOTE: Refer to the Operating Specifications table for Gradeability and Sideslope ratings.
  • Page 72 SECTION 4 - MACHINE OPERATION Figure 4-3. Grade and Side Slopes 3121670...

  • Page 73: Traveling Forward And Reverse

    SECTION 4 - MACHINE OPERATION Traveling Forward and Reverse 2. Push and release the Drive Orientation Over- ride switch. Within 3 seconds, slowly move the 1. At Platform Controls, pull out Emergency Stop Drive control toward the arrow matching the switch, start the engine, and activate foot- intended direction of machine travel.

  • Page 74: Traveling On A Grade

    SECTION 4 - MACHINE OPERATION Traveling on a Grade STEERING Position thumb switch on Drive/Steer controller to When traveling a grade, maximum braking and traction are obtained Right for steering right, or to Left for steering left. with the boom stowed, in position over the rear (drive) axle, and in line with the direction of travel.

  • Page 75: Boom

    SECTION 4 - MACHINE OPERATION BOOM TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMER- GENCY STOP SWITCH TO STOP THE MACHINE. A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE WHICH LIGHTS WHEN THE CHASSIS IS ON AN EXCESSIVE SLOPE.

  • Page 76: Function Speed Control

    SECTION 4 - MACHINE OPERATION FUNCTION SPEED CONTROL MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE ONLY) This control affects the speed of telescope and jib lift. Turning the knob all the way counter- The Machine Safety System Override (MSSO) is clockwise until it clicks puts drive, main lift, plat- used to override function controls for Emergency form rotate, and swing into creep mode.

  • Page 77: 4.10 Skyguard Operation

    SECTION 4 - MACHINE OPERATION 4.10 SKYGUARD OPERATION SkyGuard SkyGuard provides enhanced control panel protection. When the SkyGuard sensor is activated, functions in use at the time of actu- ation will reverse or cutout. The SkyGuard Function Table pro- vides more details on these functions. During activation, the horn will sound and, if equipped with a SkyGuard beacon, the beacon will illuminate until sensor and footswitch are disengaged.

  • Page 78: Skyguard - Skyeye

    SECTION 4 - MACHINE OPERATION SkyGuard - SkyEye Reattach magnetic end of cable to bracket if it becomes discon- nected. Operator passes through path of sensor beam. SkyGuard Function Table Boom Drive Drive Boom Boom Boom Basket Basket Steer Swing Lift Jib Lift Forward...

  • Page 79: Shut Down And Park

    SECTION 4 - MACHINE OPERATION 4.11 SHUT DOWN AND PARK 4.12 LIFTING AND TIE DOWN (See Figure 4-5.) Shut Down and Park Lifting The procedures to shut down and park the machine are as fol- lows: 1. Refer to the Serial Number Plate, refer to the Specifications 1.

  • Page 80: Tie Down

    SECTION 4 - MACHINE OPERATION Tie Down WHEN TRANSPORTING THE MACHINE IN THE STOWED POSITION, THE BOOM MUST BE 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.
  • Page 81 SECTION 4 - MACHINE OPERATION Figure 4-5. Lifting and Tie Down Chart 3121670 4-17...
  • Page 82 SECTION 4 - MACHINE OPERATION 38 21 38 21 38 21 BOTH SIDES BOTH SIDES BOTH SIDES Figure 4-6. Decal Location Sheet 1 of 7 4-18 3121670...
  • Page 83 SECTION 4 - MACHINE OPERATION Figure 4-7. Decal Location Sheet 2 of 7 3121670 4-19...
  • Page 84 SECTION 4 - MACHINE OPERATION Figure 4-8. Decal Location Sheet 3 of 7 4-20 3121670...
  • Page 85 SECTION 4 - MACHINE OPERATION Figure 4-9. Decal Location Sheet 4 of 7 3121670 4-21...
  • Page 86 SECTION 4 - MACHINE OPERATION 25 26 27 43 BOTH SIDES BOTH SIDES Figure 4-10. Decal Location Sheet 5 of 7 4-22 3121670...
  • Page 87 SECTION 4 - MACHINE OPERATION Figure 4-11. Decal Location Sheet 6 of 7 3121670 4-23...
  • Page 88 SECTION 4 - MACHINE OPERATION Figure 4-12. Decal Location Sheet 7 of 7 4-24 3121670...
  • Page 89 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend - 400S Portuguese/ Item # ANSI Japan Korea Spanish French Chinese Spanish 1001171366-E 1001171370-E 1001171372-E 1001171374-E 1001171376-E 1001171378-E 1001171369-I 1001171380-E 1703797 1703926 1703927 1703923 1703924 1703925 1703928 1705921 1703798 1703932 1703933 1703929 1703930 1703931...
  • Page 90 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend - 400S Portuguese/ Item # ANSI Japan Korea Spanish French Chinese Spanish 1001171366-E 1001171370-E 1001171372-E 1001171374-E 1001171376-E 1001171378-E 1001171369-I 1001171380-E 1001131269 1001131269 1706948 1706948 1706948 1706948 1706948 1706948 1706948 1701509 1701509 1701509 1701509 1701509...
  • Page 91 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend - 400S Portuguese/ Item # ANSI Japan Korea Spanish French Chinese Spanish 1001171366-E 1001171370-E 1001171372-E 1001171374-E 1001171376-E 1001171378-E 1001171369-I 1001171380-E 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1704412 1704412 1704412 1704412 1704412 1704412...
  • Page 92 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend - 400S Portuguese/ Item # ANSI Japan Korea Spanish French Chinese Spanish 1001171366-E 1001171370-E 1001171372-E 1001171374-E 1001171376-E 1001171378-E 1001171369-I 1001171380-E 1703953 1703944 1703945 1703941 1703942 1703943 1705903 1701518 1001223055 1001224053 1001224048 1001224049 1001223971 1001224050...
  • Page 93 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - 460SJ Portuguese/ Item # ANSI Japan Korea Spanish French Chinese Australia Spanish 1001171367-E 1001171368-I 1001171371-E 1001171373-E 1001171375-F 1001171377-E 1001171379-E 1001171382-E 1001171381-E 1703797 1705921 1703926 1703927 1703923 1703924 1703925 1703928 1705921 1703798 1705822 1703932...
  • Page 94 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - 460SJ Portuguese/ Item # ANSI Japan Korea Spanish French Chinese Australia Spanish 1001171367-E 1001171368-I 1001171371-E 1001171373-E 1001171375-F 1001171377-E 1001171379-E 1001171382-E 1001171381-E 1001131269 1001131269 1706948 1706948 1706948 1706948 1706948 1706948 1706948 1701509 1701509 1701509...
  • Page 95 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - 460SJ Portuguese/ Item # ANSI Japan Korea Spanish French Chinese Australia Spanish 1001171367-E 1001171368-I 1001171371-E 1001171373-E 1001171375-F 1001171377-E 1001171379-E 1001171382-E 1001171381-E 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1704412 1704412 1704412...
  • Page 96 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - 460SJ Portuguese/ Item # ANSI Japan Korea Spanish French Chinese Australia Spanish 1001171367-E 1001171368-I 1001171371-E 1001171373-E 1001171375-F 1001171377-E 1001171379-E 1001171382-E 1001171381-E 1703953 1701518 1703944 1703945 1703941 1703942 1703943 1705903 1701518 1001223055 1001224053 1001224048...
  • Page 97 SECTION 4 - MACHINE OPERATION Table 4-3. Decal Legend - 400S Kubota Engine-Powered Machines Table 4-3. Decal Legend - 400S Kubota Engine-Powered Machines Item # ANSI Item # ANSI French French 1001218983-B 1001218983-B 1001218985-B 1001218985-B 1001131269 1001131269 1703797 1703924 1706948 1706948 1703798 1703930...
  • Page 98 SECTION 4 - MACHINE OPERATION Table 4-3. Decal Legend - 400S Kubota Engine-Powered Machines Table 4-3. Decal Legend - 400S Kubota Engine-Powered Machines Item # ANSI Item # ANSI French French 1001218983-B 1001218983-B 1001218985-B 1001218985-B 1703953 1703942 1701499 1701499 1001223055 1001223971 1704412 1704412...
  • Page 99 SECTION 4 - MACHINE OPERATION Table 4-4. Decal Legend - 460SJ Kubota Engine-Powered Machines Table 4-4. Decal Legend - 460SJ Kubota Engine-Powered Machines Item # ANSI Item # ANSI French French 1001218984-B 1001218984-B 1001218986-B 1001218986-B 1001131269 1001131269 1703797 1703924 1706948 1706948 1703798 1703930...
  • Page 100 SECTION 4 - MACHINE OPERATION Table 4-4. Decal Legend - 460SJ Kubota Engine-Powered Machines Table 4-4. Decal Legend - 460SJ Kubota Engine-Powered Machines Item # ANSI Item # ANSI French French 1001218984-B 1001218984-B 1001218986-B 1001218986-B 1703953 1703942 1701499 1701499 1001223055 1001223971 1704412 1704412...

  • Page 101: 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 102: Platform Or Boom Caught Overhead

    SECTION 5 - EMERGENCY PROCEDURES Platform or Boom Caught Overhead EMERGENCY TOWING PROCEDURES If the platform or boom becomes jammed or snagged in overhead Towing this machine is prohibited. However, provisions for moving structures or equipment, do the following: the machine have been incorporated. The following procedures are to be used ONLY for emergency movement to a suitable mainte- 1.

  • Page 103: Machine Safety System Override (Msso)(Ce Only)

    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 104 SECTION 5 - EMERGENCY PROCEDURES NOTES: 3121670...

  • Page 105: Section 6 - Accessories

    SECTION 6 - ACCESSORIES SECTION 6. ACCESSORIES Table 6-1. Available Accessories Market Accessory ANSI ANSI Japan China (USA Only) Fall Arrest Platform (36" x 72") √ √ √ Pipe Racks √ √ √ √ √ √ SkyGlazier™ √ √ √ √...
  • Page 106 SECTION 6 - ACCESSORIES Table 6-2. Options/Accessories Relationship Table COMPATIBLE WITH ACCESSORY REQUIRED ITEM INCOMPATIBLE WITH INTERCHANGABLE WITH (Note 2) (Note 1) Platform MMR**, Platform MTR*, Pipe Racks SkyPower™ SkyGlazier™, SkyWelder™ Soft Touch 4’ Platform, Pipe Racks, Platform SkyGlazier™ SkyPower™ SkyWelder™...

  • Page 107: Fall Arrest

    FALL ARREST PIPE RACKS NOTE: See the JLG External Fall Arrest System manual (PN 3128935) for more detailed information. The external fall arrest system is designed to provide a lanyard attach point while allowing the operator to access areas outside the platform.

  • Page 108: Capacity Specifications (Australia Only)

    SECTION 6 - ACCESSORIES Capacity Specifications (Australia Only) • Ensure no personnel are beneath the platform. • Do not exit platform over rails or stand on rails. Max. Platform Capacity Max. Capacity in Racks • Do not drive machine without material secured (With Max.

  • Page 109: Skyglazier

    SECTION 6 - ACCESSORIES SKYGLAZIER™ Capacity Specifications Max. Platform Capacity Capacity Zone * Max. Tray Capacity (With Max. Weight in Tray) 500 lbs 150 lbs 250 lbs (227 kg) (68 kg) (113 kg) 550 lbs 150 lbs 250 lbs (250 kg) (68 kg) (113 kg) 600 lbs...

  • Page 110: Safety Precautions

    SECTION 6 - ACCESSORIES Safety Precautions Preparation and Inspection • Check for cracked welds and damage to tray. • Ensure tray is properly secured to platform. ENSURE PANEL IS SECURED WITH STRAP. • Ensure strap is not torn or frayed. Operation DO NOT OVERLOAD TRAY OR PLATFORM.

  • Page 111: Skypower

    SECTION 6 - ACCESSORIES SKYPOWER™ All power regulation components are located in a watertight box connected by cable to the generator. The generator supplies power when running at the specified speed with the power switch on (switch is located on platform). A three-pole, 30 Amp circuit breaker protects the generator from overload.

  • Page 112: Safety Precautions

    SECTION 6 - ACCESSORIES Safety Precautions SKYWELDER™ DO NOT OVERLOAD PLATFORM. • Ensure no personnel are beneath platform. • This factory-installed option is available only on specified models. • Keep lanyard attached at all times. • Do not use electrical tools in water. •...

  • Page 113: Accessory Ratings

    SECTION 6 - ACCESSORIES Accessory Ratings Welding Amps Input At Rated Load Output (50/60 Hz) Maximum Open Welding Mode Input Power Rated Output Amperage Circuit Voltage 230 V 460 V 575 V Range 280 Amp at 31.2 V, 15.7 35% Duty Cycle 3- phase 5-250 A 79 VDC...

  • Page 114: Safety Precautions

    SECTION 6 - ACCESSORIES Safety Precautions • Use correct rod size and current settings. • Do not use electrical cords without ground. • Do not use electrical tools in water. DO NOT OVERLOAD PLATFORM. • Do not weld to the platform. •...

  • Page 115: Soft Touch

    SECTION 6 - ACCESSORIES SOFT TOUCH BOLT-ON EXTERNAL FALL ARREST A padding kit is mounted to the platform rails and to a frame sus- The bolt-on external fall arrest system is designed to provide a lan- pended below the platform. Limit switches deactivate platform yard attach point while allowing the operator to access areas outside functions when the padded framework contacts an adjacent the platform.

  • Page 116: Inspection Before Use

    SECTION 6 - ACCESSORIES Inspection Before Use The external fall arrest system must be inspected before each use of IF THE EXTERNAL FALL ARREST SYSTEM IS USED TO ARREST A FALL OR IS OTHERWISE the aerial work platform. Replace components if there are any signs DAMAGED, THE ENTIRE SYSTEM MUST BE REPLACED AND THE PLATFORM FULLY of wear or damage.
  • Page 117 SECTION 6 - ACCESSORIES • Cable: Inspect cable for proper tension, broken strands, kinks, or • Attachment Ring: No cracks or signs of wear are acceptable. Any any signs of corrosion. signs of corrosion requires replacement. • Attaching Hardware: Inspect all attaching hardware to ensure GAP SHOWING: GAP SHOWING: there are no missing components and hardware is properly tight-...
  • Page 118 SECTION 6 - ACCESSORIES 1,2,3,4 1. Belleville Washer 2. Washer 3. Hex Nut 4. Jam Nut 5. LH Bracket 6. Attachment Ring 7. Cable 8. RH Bracket 9. Decal Figure 6-2. Bolt-On External Fall Arrest System 6-14 3121670...

  • Page 119: Section 7 - General Specifications & Operator Maintenance

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 7. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE INTRODUCTION OPERATING SPECIFICATIONS This section of the manual provides additional necessary infor- Table 7-1. Operating Specifications - 400S mation to the operator for proper operation and maintenance of this machine.
  • Page 120 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-1. Operating Specifications - 400S Table 7-2. 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 121: Capacities

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-2. Operating Specifications - 460SJ Capacities Table 7-3. Capacities Gross Machine Weight 16,370 lbs. (7,425 kg) Maximum System Voltage Fuel Tank 22 gal. (83.3 L) Hydraulic Tank 32.5 Gal (123 L) Max.

  • Page 122: Engine Data

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Engine Data Table 7-5. Deutz D2.9L4 Type Liquid Cooled NOTE: RPM Tolerances are ± 100. Number of Cylinders Bore 3.6 in (92 mm) Table 7-4. Deutz D2011L03 Stroke 4.3 in (110 mm) Fuel Diesel Total Displacement...
  • Page 123 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-6. GM 3.0L Table 7-7. Kubota WG 2503 Fuel Gasoline or Gasoline/LP Gas Fuel Gasoline or Gasoline/LP Gas No. of Cylinders Gasoline 45.5 kW @ 2700 rpm 46 Kw @ 2700 rpm Gasoline 82 hp @ 3000 rpm 75 hp @ 3000 rpm...

  • Page 124: Tires

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Tires Table 7-8. Tires Size Type Pressure Weight 12 x 16.5 Pneumatic 90 psi (6 Bar) 128 lbs. (58 kg) Foam-Filled 328 lbs. (149 kg) 14 x 17.5 Pneumatic 90 psi (6 Bar) 170 lbs.

  • Page 125: Hydraulic Oil

    SECTION 7 - 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 7-9. Hydraulic Oil additives or be of comparable viscosities. If use of hydraulic oil other...
  • Page 126 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-11. Mobil DTE 10 Excel 32 Specs Table 7-12. UCon Hydrolube HP-50/46 ISO Viscosity Grade Type Synthetic Biodegradable Specific Gravity 0.877 Specific Gravity 1.082 Pour Point, Max -40°F (-40°C) Pour Point, Max -58°F (-50°C) Flash Point, Min.
  • Page 127 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-14. Mobil EAL H 46 Specs Table 7-13. Mobil EAL 224H Specs Type Synthetic Biodegradable Type Synthetic Biodegradable ISO Viscosity Grade 32/46 ISO Viscosity Grade Specific Gravity .922 Specific Gravity .910 Pour Point, Max -25°F (-32°C) Pour Point...

  • Page 128: Critical Stability Weights

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Critical Stability Weights Table 7-15. Exxon Univis HVI 26 Specs Table 7-16. Critical Stability Weights Specific Gravity 32.1 Pour Point -76°F (-60°C) Component Flash Point 217°F (103°C) Battery Viscosity Counterweight (S) 1060 ± 42.4 481.8 ±...

  • Page 129: Serial Number Location

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 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. SERIAL NUMBER PLATE Figure 7-1.
  • Page 130 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 1001206353 A Figure 7-2. Hydraulic Oil Operation Chart - Sheet 1 of 2 7-12 3121670...
  • Page 131 Mobil Envirosyn H 46 Quintolubric 888-46 Readily biodegradable classi?cation indicates NOTICE: one of the following: MACHINE OPERATION USING NON-JLG APPROVED CO2 Conversion>60% per EPA 560/6-82-003 HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF CO2 Conversion>80% per CEC-L-33-A-93 THE TEMPERATURE BOUNDARIES OUTLINED IN Virtually Non-toxic classi?cation indicates THE "HYDRAULIC FLUID OPERATION CHART"...
  • Page 132 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 7-4. Engine Operating Temperature Specifications - Deutz 7-14 3121670...
  • Page 133 -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 134 (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 135 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE NOTICE: MACHINE OPERATION USING NON-JLG APPROVED ENGINE OIL OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE "ENGINE OIL OPERATION CHART" MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE.
  • Page 136 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE S/N 0300220610 to Present 2WD Only Figure 7-8. Operator Maintenance and Lubrication Diagram - Deutz 2.9L Engine 7-18 3121670...
  • Page 137 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE S/N 0300220610 to Present 2WD Only Figure 7-9. Operator Maintenance and Lubrication Diagram - Deutz 2011L Engine 3121670 7-19...
  • Page 138 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE S/N 0300220610 to Present 2WD Only Figure 7-10. Operator Maintenance and Lubrication Diagram - GM Engine 7-20 3121670...
  • Page 139 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE S/N 0300220610 to Present 2WD Only Figure 7-11. Operator Maintenance and Lubrication Diagram - Kubota Engine 3121670 7-21...

  • Page 140: Operator Maintenance

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE OPERATOR MAINTENANCE NOTE: It is recommended as a good practice to replace all filters at the same time. NOTE: The following numbers correspond to those in Figure 7-8., Oper- 1. Swing Bearing - Internal Ball Bearing ator Maintenance and Lubrication Diagram - Deutz 2.9L Engine.
  • Page 141 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Wheel Drive Hub 3. Drive Brake O IL LE V E L C H E C K A N D F ILL Lube Point(s) - Level/Fill Plug Capacity - 24 oz. (0.8 L)(1/2 Full) Lube - EPGL Interval - Check level every 3 months or 150 hrs of opera- Lube Point(s) - Fill Plug...
  • Page 142 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4. Hydraulic Return Filter 5. Hydraulic Tank Breather Interval - Change after first 50 hours and every 6 months or Interval - Change after first 50 hrs. and every 6 months or 300 300 hours thereafter or whenever Charge Filter is replaced hrs.
  • Page 143 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6. Hydraulic Tank - Prior to S/N 0300220610 Hydraulic Tank - S/N 0300220610 to Present Lube Point(s) - Fill Cap Lube Point(s) - Fill Cap Capacity - 32.5 gal tank (123 L) 40.0 gal system (151 L) Capacity - 15 Gal.
  • Page 144 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 7. Hydraulic Charge Filter 8. Oil Change w/Filter - Deutz D2011 Interval - Change after first 50 hours and every 6 months or 300 hours thereafter or as indicated by Condition Indicator Lube Point(s) - Fill Cap/Spin-on Element Capacity - 10 Quarts (9.5 L) w/Filter Lube - EO...
  • Page 145 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 9. Oil Change w/Filter - Deutz 2.9 L4 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 2.4 gal (8.9 L) Lube - EO Interval - Every Year or 600 hours of operation Comments - Check level daily/Change in accordance with engine manual 3121670...
  • Page 146 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 10. Oil Change w/Filter - GM 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 7-28 3121670...
  • Page 147 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 11. Fuel Pre-Filter - Deutz D2.9 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...
  • Page 148 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 14. Fuel Filter (Gasoline) - GM 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 7-30 3121670...
  • Page 149 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 15. Fuel Filter (Propane) - GM Engine 16. Radiator Coolant Deutz 2.9 Interval - 3 Months or 150 hours of operation Comments - Replace filter. Refer to Section 7.5, Propane Fuel Filter Replacement (GM Engine) Lube Point(s) - Fill Cap Capacity - 2.9 Gallon (11.3 L) Lube - Anti-Freeze...
  • Page 150 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 17. Radiator Coolant -GM 18. Air Filter Lube Point(s) - Fill Cap Capacity - 2.4Gallon (9.1 L) Lube - Anti-Freeze 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...
  • Page 151 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 19. Swing Drive Hub 20. Wheel Bearings Lube Point(s) - Repack Capacity - A/R Lube - MPG Interval - Every 2 years or 1200 hours of operation Lube Point - Level/Fill Plug Capacity - 40 oz.
  • Page 152 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 21. Oil Change w/Filter - Kubota Lube Point(s) - Fill Cap/Spin-on Element Capacity - 2.5 gal. (9.5 L) w/filter Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual 7-34 3121670...
  • Page 153 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 22. Fuel Filter - Kubota 24. Fuel Filter (Propane) - Kubota Lube Point(s) - Replaceable Component Interval - Every year or 600 hours of operation Interval - Every year or 1000 hours of operation Comments - Replace filter.

  • Page 154: 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 155: Wheel Replacement

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Replacement Wheel Installation It is extremely important to apply and maintain proper wheel The rims installed on each product model have been designed for mounting torque. stability requirements which consist of track width, tire pressure, and load capacity.
  • Page 156 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Tighten nuts in the following sequence: 3. The tightening of the nuts should be done in stages. Follow- ing the recommended sequence, tighten nuts per wheel torque chart. Table 7-18. Wheel Torque Chart TORQUE SEQUENCE 1st Stage 2nd Stage...

  • Page 157: Propane Fuel Filter Replacement (Gm Engine)

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE PROPANE FUEL FILTER REPLACEMENT (GM ENGINE) Installation Removal BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING 1. Relieve the propane fuel system pressure. Refer to Propane NEW SEAL Fuel System Pressure Relief.

  • Page 158: Propane Fuel Filter Replacement (Kubota Engine)

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE PROPANE FUEL FILTER REPLACEMENT (KUBOTA ENGINE) Removal 1. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief. 2. Disconnect the negative battery cable. 3. Slowly loosen the bowl retaining nut and remove the nut and filter housing from the Electric lock off assembly.

  • Page 159: Installation

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Installation 1. If equipped, install the filter bowl gasket. 2. Install the filter into the housing. 3. Install the filter bowl up to the bottom of the electric lock off. OUTLET FILTER BOWL 4.

  • Page 160: Propane Fuel System Pressure Relief

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE PROPANE FUEL SYSTEM PRESSURE RELIEF SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO MIN- and is only applicable to CE machines.

  • Page 161: Section 8 - Inspection And Repair Log

    SECTION 8 - INSPECTION AND REPAIR LOG SECTION 8. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 8-1. Inspection and Repair Log Date Comments 3121670...
  • Page 162 SECTION 8 - INSPECTION AND REPAIR LOG Table 8-1. Inspection and Repair Log Date Comments 3121670...
  • Page 164 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations www.jlg.com...

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