JLG 400S HC3 Operation & Safety Manual
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JLG 400S HC3 Operation & Safety Manual

JLG 400S HC3 Operation & Safety Manual

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Operation & Safety
Manual
Original Instructions -
Keep this manual with the machine at all times.
400S HC3, 460SJ HC3
PVC 2501
3122342600
January 13, 2025 - Rev A
Copyright ©
ANSI
AS/NZS MOL70
English (en-US)

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  • Page 1 Operation & Safety Manual Original Instructions - Keep this manual with the machine at all times. 400S HC3, 460SJ HC3 PVC 2501 3122342600 January 13, 2025 - Rev A Copyright © ANSI AS/NZS MOL70 English (en-US)
  • Page 2 WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other repro- ductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing.

  • Page 3: Foreword

    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 It may also alert against unsafe practices. This decal will have a yellow background. NOTICE Indicates information or a company policy that relates directly or indirectly to the safety of personnel or protection of property. 3122342600 400S HC3, 460SJ HC3...
  • Page 5 NOTICE JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate.
  • Page 6 Questions Regarding Product Modifications Contact: Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 or Visit www.jlg.com to find your local JLG office. In USA: Toll Free: 877-JLG-SAFE (877-554-7233) Outside USA: Phone: 240-420-2661 Fax: 301-745-3713 E-mail: ProductSafety@JLG.com...

  • Page 7: Revision Log

    REVISION LOG DATE REVISION DESCRIPTION January 13, 2025 Original Issue Other Publications Available Publication Publication Number Service & Maintenance Manual 31223427 Illustrated Parts Manual 31223428 400S HC3, 460SJ HC3 3122342600...
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  • Page 9: Table Of Contents

    SkyGuard® Function Check ..........32 SECTION 3 MACHINE CONTROLS AND INDICATORS......35 General ................35 Controls and Indicators .............35 Ground Control Station .............36 Ground Control Indicator Panel..........42 Platform Control Station ............44 Platform Control Indicator Panel ........48 Beacons ................50 400S HC3, 460SJ HC3 3122342600...
  • Page 10 Section Contents SECTION 4 MACHINE OPERATION............... 53 General ................53 Operating Characteristics and Limitations......53 Stability................54 400S HC3/460SJ HC3 Reach Charts .........56 Engine Operation .............57 Fuel Shutoff System (Reserve) ..........60 Diesel Particulate Filter (If Equipped) .........60 Traveling (Driving) ............61 Traveling (Grade/Side Slope) ..........62 4.10...
  • Page 11 Propane Fuel System Pressure Relief......138 7.17 Radio Frequency (RF) Information ........138 7.18 Supplemental Information Only Applicable to CE/UKCA Machines ............... 140 7.19 EC Declaration of Conformity .......... 142 7.20 UKCA Declaration of Conformity........143 400S HC3, 460SJ HC3 3122342600...
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  • Page 13: Safety Precautions

    Read, understand, and study the Operation and Safety Manual in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc. • Only personnel who have received proper training regarding the inspection, application and operation of MEWPs (including recognizing and avoiding hazards associated with their operation) shall be authorized to operate a MEWP.
  • Page 14 • Check the work area for hazardous locations. Do not operate the machine in hazardous environments unless approved for that purpose by JLG. • Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel.

  • Page 15: Operation

    Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency. • Do not carry materials directly on platform railing unless approved by JLG. • When two or more persons are in the platform, the operator shall be responsible for all machine operations.
  • Page 16 Enter and exit only through gate area. Use extreme caution when entering or leaving platform. Ensure that the platform assembly is fully lowered. Face the platform when entering or leaving the platform. Always maintain “three point 3122342600 400S HC3, 460SJ HC3...
  • Page 17 Over 350 KV to 500 KV 35 (11) Over 500 KV to 750 KV 45 (14) Over 750 KV to 1000 KV Note: This requirement shall apply except where employer, local or governmental regulations are more stringent. 400S HC3, 460SJ HC3 3122342600...
  • Page 18 Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces. • Never exceed the maximum platform capacity as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG. 3122342600 400S HC3, 460SJ HC3...
  • Page 19 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion 13-18 5.5-7.9 Moderate Dust and loose paper raised. Small breeze branches begin to move. 400S HC3, 460SJ HC3 3122342600...

  • Page 20: Crushing And Collision Hazards

    • Be aware of stopping distances in all drive speeds. When driving in high speed, reduce drive speed before stopping. Travel grades in low speed only. 3122342600 400S HC3, 460SJ HC3...

  • Page 21: Towing, Lifting, And Hauling

    • DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the machine is powered on or when the hydraulic system is under pressure. 400S HC3, 460SJ HC3 3122342600...
  • Page 22 Wear gloves to help protect hands from spraying fluid. • Use only replacement parts or components that are approved by JLG. To be considered approved, replacement parts or components must be identical or equivalent to original parts or components.

  • Page 23: Long-Term Storage

    • For long-term storage of battery-electric machines, store machines in a cool, dry place away from direct sunlight and heat sources. Avoid storing batteries in a fully discharged or fully charged state. 400S HC3, 460SJ HC3 3122342600...
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  • Page 25: User Responsibilities, Machine Preparation, And Inspection

    Operator Responsibility The operator must be instructed that they have the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site. 400S HC3, 460SJ HC3 3122342600...

  • Page 26: Preparation, Inspection, And Maintenance

    6. Accessories and optional equipment. PREPARATION, INSPECTION, AND MAINTENANCE The following table covers machine inspections and maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for MEWPs. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.
  • Page 27 Mechanic tenance Manual Service & Main- tenance Manual Note: Inspection forms are available from JLG. Use the Service & Maintenance Manual to perform inspections. NOTICE JLG Industries, Inc. recognizes a factory trained service technician as a person who has successfully completed the JLG Service Training School for the specified JLG product model.

  • Page 28: Machine Components

    Report any leakage to the proper maintenance personnel. 2. Structure — Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies. Figure 2. Parent Metal Crack Figure 3. Weld Crack 3122342600 400S HC3, 460SJ HC3...
  • Page 29 Attach only one (1) lanyard per lanyard anchorage point. WARNING If the machine does not operate properly, turn off the machine immediately! Report the problem to the proper maintenance personnel. Do not operate the machine until it is declared safe for operation. 400S HC3, 460SJ HC3 3122342600...

  • Page 30: Walk-Around Inspection

    4. Platform Rotator - See Inspection Note. 5. Jib Assembly and Jib Rotator (If Equipped) - See Inspection Note. 6. All Hydraulic Cylinders - No visible damage; pivot pins and hydraulic hoses undamaged, not leaking. 3122342600 400S HC3, 460SJ HC3...

  • Page 31: Function Check

    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 emergency stop to stop machine. Perform the Function Check as follows: 400S HC3, 460SJ HC3 3122342600...

  • Page 32: Skyguard® Function Check

    From the Platform Control Station in an area free from obstructions: 1. Operate the telescope-out function. 2. Activate the SkyGuard SkyLine® sensor by pressing rod to break connection between the rod and the right bracket. 3122342600 400S HC3, 460SJ HC3...
  • Page 33 If SkyGuard remains activated after function reversal or cutout, press and hold the SkyGuard Override Switch to allow normal use of machine functions until the sensor is deactivated. Refer to the SkyGuard Activation/Deactivation section for additional information. 400S HC3, 460SJ HC3 3122342600...
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  • Page 35: Machine Controls And Indicators

    This indicator will be yellow. Indicates important information regarding the oper- ating condition, i.e. procedures essential for safe op- eration. This indicator will be green with the exception of the capacity indicator which will be yellow. 400S HC3, 460SJ HC3 3122342600...

  • Page 36: Ground Control Station

    Ground Control Station – 400S 1. Indicator Panel 7. Not Used 2. Hourmeter 8. Telescope 3. Engine Start/Auxiliary Power 9. Power/Emergency Stop 4. Platform/Ground Select Switch 10. Main Boom Lift 5. Platform Level 11. Swing 6. Platform Rotate 3122342600 400S HC3, 460SJ HC3...
  • Page 37 Ground Control Station – 460SJ 1. Indicator Panel 7. Jib Lift 2. Hourmeter 8. Telescope 3. Engine Start/Auxiliary Power 9. Power/Emergency Stop 4. Platform/Ground Select Switch 10. Main Boom Lift 5. Platform Level 11. Swing 6. Platform Rotate 400S HC3, 460SJ HC3 3122342600...
  • Page 38 7. Jib Lift 2. Hourmeter 8. Telescope 3. Engine Start/Auxiliary Power 9. Power/Emergency Stop 4. Platform/Ground Select Switch 10. Main Boom Lift 5. Platform Level 11. Swing 6. Platform Rotate 12. Diesel Particulate Filter (DPF) 3122342600 400S HC3, 460SJ HC3...
  • Page 39 The hourmeter registers up to 9,999.9 hours and cannot be reset. Indicator Panel The Indicator Panel contains indicator lights which signal problem conditions or functions ½ operating during machine operation. 400S HC3, 460SJ HC3 3122342600...
  • Page 40 WARNING Only use the platform leveling override function for slight leveling of the platform. Incorrect use could cause the load/occupant to shift or fall. Failure to do so could result in death or serious injury. 3122342600 400S HC3, 460SJ HC3...
  • Page 41 On. NOTICE Always position emergency stop switch to the Off position (pushed in) when machine is not in use. Swing Provides 360 degrees continuous turntable rotation. 400S HC3, 460SJ HC3 3122342600...

  • Page 42: Ground Control Indicator Panel

    Refer to the capacity decals on the machine for restricted and unrestricted platform capacities. Drive and Steer Disable Indicates the Drive and Steer Disable function has been activated. Emissions Temperature Indicator illuminates when exhaust temperature reaches 1022° F (550° C). 3122342600 400S HC3, 460SJ HC3...
  • Page 43 Indicates the platform has been overloaded. System Distress Indicates the JLG Control System has detected an abnormal condition and a Diagnostic Trouble Code has been set in the system memory. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval.

  • Page 44: Platform Control Station

    To avoid serious injury, do not operate machine if any control levers or toggle switches controlling platform movement do not return to the off or neutral position when released. Note: Lift, Swing, and Drive control levers are spring-loaded and will automatically return to neutral (off) position when released. 3122342600 400S HC3, 460SJ HC3...
  • Page 45 The auxiliary pump functions to provide sufficient oil flow to operate the basic machine functions should the main pump or engine fail. The auxiliary pump will operate main boom lift, main telescope, jib (if equipped) and swing. 400S HC3, 460SJ HC3 3122342600...
  • Page 46 Provides extension and retraction of the main boom. Main Lift / Swing Provides main lift and swing. Push forward to lift up, pull backward to boom down. Move right to swing right, move left to swing left. 3122342600 400S HC3, 460SJ HC3...
  • Page 47 The switch also enables the functions cut out by the SkySense system to operate again at creep speed, allowing the operator to move the platform closer to the obstacle that caused the shutdown situation if desired. 400S HC3, 460SJ HC3 3122342600...

  • Page 48: Platform Control Indicator Panel

    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. Diesel Particulate Filter Icon will illuminate when standstill exhaust system cleaning is required. 3122342600 400S HC3, 460SJ HC3...
  • Page 49 Indicates the level of the fuel in the fuel tank. ½ Glow Plug Indicates the glow plugs are operating. After turning on ignition, wait until light goes out before cranking engine. Platform Overload Indicates the platform has been overloaded. 400S HC3, 460SJ HC3 3122342600...

  • Page 50: Beacons

    System Distress 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. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval.
  • Page 51 The SkyGuard beacon is available in blue or red lamp options. The beacon will flash in conjunction with an audible alarm when the SkyGuard sensor is activated. Refer to the SkyGuard Operation section for more information. 400S HC3, 460SJ HC3 3122342600...
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  • Page 53: Machine Operation

    2. Load is within manufacturer’s rated capacity. 3. All machine systems are functioning properly. 4. Machine is as originally equipped from JLG. 4.2.2 Platform Load Sensing System (LSS) The Platform Load Sensing System (LSS) measures platform load from a sensor in the platform support.

  • Page 54: Stability

    1. Machine will tip over in this direction if overloaded or operated beyond the limits of the maximum operating slope. 2. Platform rotated 90 degrees. 3. Jib fully elevated. 4. Main boom fully retracted and elevated. 3122342600 400S HC3, 460SJ HC3...
  • Page 55 Machine Operation Figure 5. Position of Least Forward Stability 1. Machine will tip over in this direction if overloaded or operated beyond the limits of the maximum operating slope. 2. Jib horizontal. 3. Boom fully extended. 400S HC3, 460SJ HC3 3122342600...

  • Page 56: Hc3/460Sj Hc3 Reach Charts

    Machine Operation 400S HC3/460SJ HC3 REACH CHARTS Figure 6. 400S HC3 Platform Reach Chart 3122342600 400S HC3, 460SJ HC3...

  • Page 57: Engine Operation

    Note: Avoid repeated, low intensity, or periodic machine operation and extended engine idle times in cold weather environments. CAUTION For every 8 hours of low intensity machine operation or extended engine idle time, drive the machine continuously for 15 minutes. 400S HC3, 460SJ HC3 3122342600...

  • Page 58: Starting Procedure

    Machine Operation Note: Contact JLG Customer Service for operation under abnormal conditions. 4.5.1 Starting Procedure Note: Initial starting should always be performed from the Ground Control station. Make sure to perform a ground control function check prior to platform operation.

  • Page 59: Shutdown Procedure

    Remove all load and allow engine to operate at low speed for 3-5 minutes; this allows further reduction of internal engine temperature. Push Power/Emergency Stop switch in. Turn Platform/Ground Select switch to Off. Note: Refer to Engine Manufacturer’s manual for detailed information. 400S HC3, 460SJ HC3 3122342600...

  • Page 60: Fuel Shutoff System (Reserve)

    2 minutes of run time. The operator can repeat this process until there is no more fuel available. NOTICE Contact a qualified JLG mechanic if the machine needs restarted after no more fuel is available. •...

  • Page 61: Traveling (Driving)

    Use extreme caution when driving in reverse and at all times when the platform is elevated. Before driving, locate the black/white orientation arrows on both the chassis and the platform controls. Move the drive controls in a direction matching the directional arrows for the intended direction of travel. 400S HC3, 460SJ HC3 3122342600...

  • Page 62: Traveling Forward And Reverse

    (drive) axle, and in line with the direction of travel. Drive the machine forward when climbing a grade, and in reverse when descending a grade. Do not exceed the machine's maximum rated gradeability. 3122342600 400S HC3, 460SJ HC3...

  • Page 63: Steering

    Figure 9. Grade and Side Slope 4.10 STEERING Press footswitch. Position thumb switch on Drive/Steer controller to Right for steering right, or to Left for steering left. 400S HC3, 460SJ HC3 3122342600...

  • Page 64: Platform

    Machine Operation 4.11 PLATFORM JLG offers multiple platform sizes to accommodate a variety of applications. Refer to the Illustrated Parts Manual for available platforms. Not all platform options may be of adequate size to allow for the maximum number of rated occupants shown on the machine's capacity decal.

  • Page 65: Boom

    When swinging the boom make sure there is ample room for the boom to clear surrounding walls, partitions and equipment. Note: On CE/UKCA market machines, when boom functions are being operated there is an interlock which prevents the use of Drive and Steer functions. 400S HC3, 460SJ HC3 3122342600...

  • Page 66: Telescoping The Main Boom

    Creep Mode puts the functions listed above, as well as the Drive/Steer and Main Lift/Swing functions into the slowest speed setting. 4.14 USB CHARGING PORT The machine is equipped with a USB charging port for the operator. 3122342600 400S HC3, 460SJ HC3...

  • Page 67: Clearsky Smart Fleet

    (if available) restrictions. Refer to the Access Control and Beacons sections of this manual for more information. Visit the ClearSky section of the JLG website for more resources and information about accessing web portal or mobile app data. 4.16 ACCESS CONTROL - CLEARSKY SMART FLEET™...

  • Page 68: Skyguard Activation/Deactivation

    Table 4. SkyGuard Function Table Function Reversal / Cutout Drive Forward R * / C ** Drive Reverse Steer Swing Boom Lift Up 3122342600 400S HC3, 460SJ HC3...

  • Page 69: Shut Down And Park

    4.19 LIFTING AND TIE DOWN See Lifting Chart. 4.19.1 Lifting 1. Refer to the Serial Number Plate, refer to the Specifications section of this manual, or weigh the individual unit to find out the Gross Vehicle Weight. 400S HC3, 460SJ HC3 3122342600...
  • Page 70 4. Ensure the platform is lowered so the wear pad on the bottom rests on the surface of the transportation vehicle 5. Secure through the tie downs on the boom using straps or chains of adequate strength. OAC014470 3122342600 400S HC3, 460SJ HC3...

  • Page 71: Lifting And Tie Down Chart

    4.20 LIFTING AND TIE DOWN CHART Figure 11. 400S/460SJ Lifting Chart 4.21 SAFETY DECAL LOCATIONS Figure 12. 400S HC3/460SJ HC3 Decal Installation - 1 of 5 Figure 13. 400S HC3/460SJ HC3 Decal Installation - 2 of 5 400S HC3, 460SJ HC3...
  • Page 72 Machine Operation Figure 14. 400S HC3/460SJ HC3 Decal Installation - 3 of 5 Figure 15. 400S HC3/460SJ HC3 Decal Installation - 4 of 5 3122342600 400S HC3, 460SJ HC3...
  • Page 73 Machine Operation Figure 16. 400S HC3 /460SJ HC3 Decal Installation - 5 of 5 400S HC3, 460SJ HC3 3122342600...
  • Page 74 Machine Operation 3122342600 400S HC3, 460SJ HC3...
  • Page 75 Machine Operation 400S HC3, 460SJ HC3 3122342600...
  • Page 76 This Page is intentionally left blank...

  • Page 77: Emergency Procedures

    This section explains the steps to be taken in case of an emergency situation during operation. INCIDENT NOTIFICATION JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details.

  • Page 78: Emergency Towing Procedures

    2. Engage the mechanical release on both drive hubs by loosening the cap bolts, completely reversing the cap, and tightening the two bolts on each hub. 3. Connect suitable equipment, remove chocks, and move machine. After moving machine, complete the following procedure: 3122342600 400S HC3, 460SJ HC3...

  • Page 79: Clearsky Smart Fleet™ - Locked Out State

    Locked Out state. NOTICE Contact the ClearSky Smart Fleet™ account owner if the machine is in a Locked Out state. 400S HC3, 460SJ HC3 3122342600...
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  • Page 81: Accessories

    96”) Platform Work Lights ✔ ✔ ✔ ✔ ✔ ✔ ✔ Platform Work Surface ✔ ✔ ✔ ✔ ✔ ✔ ✔ SkyGlazier® ✔ ✔ ✔ ✔ SkyPower®- 7.5 kW ✔ ✔ ✔ ✔ ✔ ✔ 400S HC3, 460SJ HC3 3122342600...
  • Page 82 ✔ ✔ ✔ SkySense® Platform ✔ ✔ ✔ ✔ ✔ Bumper Padding SkyWelder® ✔ ✔ ✔ ✔ ✔ ✔ Soft Touch ✔ ✔ ✔ ✔ ✔ Storage Tray ✔ ✔ ✔ ✔ ✔ ✔ ✔ 3122342600 400S HC3, 460SJ HC3...
  • Page 83 Accessories 400S HC3, 460SJ HC3 3122342600...
  • Page 84 Accessories 3122342600 400S HC3, 460SJ HC3...

  • Page 85: Bolt-On External Fall Arrest

    If the external fall arrest system is used to arrest a fall or is otherwise damaged, the entire system must be replaced and the platform fully inspected before returning to service. Refer to the service manual for removal and installation procedures. 400S HC3, 460SJ HC3 3122342600...
  • Page 86 Attachment Ring: No cracks or signs of wear are acceptable. Any signs of corrosion requires replacement. • Attaching Hardware: Inspect all attaching hardware to ensure there are no missing components and hardware is properly tightened. • Platform Rails: No visible damage is acceptable. 3122342600 400S HC3, 460SJ HC3...

  • Page 87: Cable Ladder Carrier

    Accessories CABLE LADDER CARRIER BM000362A Figure 20. Cable Ladder Carrier The Cable Ladder Carrier accessory consists of two vertical brackets mounted to the outside of the platform used to carry a “ladder” style cable tray. 400S HC3, 460SJ HC3 3122342600...

  • Page 88: Fabric Mesh To Mid Or Top Rail

    FALL ARREST PLATFORM Note: See the JLG External Fall Arrest System manual (PN 3128935) for more de- tailed 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 89: Pipe Racks

    Min. Length of Material in Racks: 2.4 m 6.6.2 Safety Precautions WARNING Reduce platform capacity by 100 lb (45.5 kg) when installed. WARNING Weight in racks plus weight in platform must not exceed rated capacity. 400S HC3, 460SJ HC3 3122342600...
  • Page 90 3. Route the tie-down straps at each end across loaded material and tighten. 4. To remove material, loosen and remove tie-down straps, then carefully remove material from racks. Note: Reinstall tie-down straps across any remaining material before continuing machine operations. 3122342600 400S HC3, 460SJ HC3...

  • Page 91: Platform Mesh To Mid Or Top Rail

    Do not operate machine with personnel on this device. WARNING Personnel in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point at all times while in the platform. 400S HC3, 460SJ HC3 3122342600...
  • Page 92 Park the machine on a firm, level surface. Fully retract and lower boom onto the machine’s boom rest stop. Turn the key select switch to off (center) position and push in the power/ emergency stop switch to off (down). Disconnect the battery power from the machine. 3122342600 400S HC3, 460SJ HC3...
  • Page 93 Remove the Do Not Operate tag from the key select switch. Verify proper operation of the machine functions. 10. Return the machine to service. NOTICE Use of the Boom Mid Rail Deck must not block platform entry/exit gate on single entry platforms. 400S HC3, 460SJ HC3 3122342600...
  • Page 94 Note: For machines with a platform hand rail located in front of the mid rail deck hand rail, remove and retain handrail overextension pin (C). Disengage spring pins and remove the handrail (B) from the mid rail deck base. 3122342600 400S HC3, 460SJ HC3...

  • Page 95: Platform Top Rail Extension

    Accessories PLATFORM TOP RAIL EXTENSION BM000017A Figure 27. Platform Top Rail Extension The Platform Top Rail Extension accessory consists of an additional bar extending from all sides of the platform. 400S HC3, 460SJ HC3 3122342600...

  • Page 96: Platform Work Lights

    Accessories 6.10 PLATFORM WORK LIGHTS OAC04000 Figure 28. Platform Work Lights The Platform Work Lights accessory consists of two 12V lights mounted to the platform railing. 3122342600 400S HC3, 460SJ HC3...

  • Page 97: Platform Work Surface

    Accessories 6.11 PLATFORM WORK SURFACE BM000276A Figure 29. Platform Work Surface The platform work surface option consists of a corner tray bolted onto the top and mid rails of the platform. 400S HC3, 460SJ HC3 3122342600...

  • Page 98: Skyglazier

    * Refer to the capacity decals installed on the machine for capacity zone information. Required Platform Type: Side-Entry Maximum Dimensions of Panel: 32 sq ft (3 sq m) Maximum Wind Speed: 20 mph (32 kph) 6.12.2 Safety Precautions WARNING Ensure panel is secured with strap. 3122342600 400S HC3, 460SJ HC3...
  • Page 99 Ensure strap is not torn or frayed. 6.12.4 Operation 1. Load SkyGlazier tray with panel. 2. Position panel to its desired location on the tray. 3. Route the adjustable strap around the panel and tighten until secure. 400S HC3, 460SJ HC3 3122342600...

  • Page 100: Skypower® 7.5 Kw And Generator 4 Kw

    1-phase: 240 V / 120 V, 60 Hz, 6 kW (Peak: 6 kW) Generator 4 kW Specifications: • 1-phase: 240 V / 120 V, 60 Hz, 4 kW • 1-phase: 230 V / 115 V, 50 Hz, 4 kW 3122342600 400S HC3, 460SJ HC3...

  • Page 101: Skysense

    SkySense is intended to assist the operator. SkySense may not detect certain objects depending on shape, type of material, or orientation of the object to the sensors. It is the operator’s responsibility to be aware of their surroundings at all times. 400S HC3, 460SJ HC3 3122342600...
  • Page 102 8. Continue to lower the platform. The machine should move in the elevated drive speed mode (SkySense Status LED will remain red). Note: The SkySense system will not stop machine operation while in Creep. 3122342600 400S HC3, 460SJ HC3...
  • Page 103 LED Red: Machine is in SkySense stop zone and all machine functions will cease. • LED Flashing Red: SkySense sensor is obstructed or damaged. Obstructions must be removed and proper function verified. Damaged sensors must be replaced. 400S HC3, 460SJ HC3 3122342600...
  • Page 104 Note: Override is only required to be engaged if the operator desires to move the platform closer to an object that is in or entering the stop zone. 3122342600 400S HC3, 460SJ HC3...
  • Page 105 SkyGuard will function normally. 6.14.6 SkySense Coverage Areas BM000009A BM000010A Figure 32. SkySense Coverage Level Figure 33. SkySense Coverage Level 1 Areas (2– Bar) 2 Areas (3 — Bar) Note: Sensor Cones shown are approximations for reference only. 400S HC3, 460SJ HC3 3122342600...

  • Page 106: Skysense® Platform Bumper Padding

    Accessories 6.15 SKYSENSE® PLATFORM BUMPER PADDING BM001038A Figure 34. Platform Bumper Padding This accessory outfits machines equipped with the SkySense accessory additional padding for the platform. 3122342600 400S HC3, 460SJ HC3...

  • Page 107: Skywelder

    See the Miller Welder Owner’s Manual (PN 31215476) for more information. 6.16.2 Generator Output Engine Speed of 1800 rpm +/- 10%. ANSI Specifications: • 3-phase: 240 V, 60 Hz, 7.5 kW • 1-phase: 240 V/120 V, 60 Hz, 6 kW 400S HC3, 460SJ HC3 3122342600...
  • Page 108 Accessories 3122342600 400S HC3, 460SJ HC3...
  • Page 109 Do not use a high frequency arc starter with TIG welder. 6.16.5 Preparation and Inspection • Connect ground clamp to metal being welded. • Ensure there is a good ground connection and observe proper polarity. 400S HC3, 460SJ HC3 3122342600...

  • Page 110: Soft Touch

    A button on the platform console allows override of the system. BM000011A Figure 36. Soft Touch System 1. Override Indicator Light 2. Override Button 3. Rail Bumper 4. Limit Switch 5. Suspended Frame and Rail Bumper 6. Limit Switch 3122342600 400S HC3, 460SJ HC3...

  • Page 111: General Specifications And Operator Maintenance

    Maximum Work Load (Capacity):* Unrestricted: ANSI, CSA, MOL70, China 660 lb (299 kg) Unrestricted: CE/UKCA, AUS 660 lb (300 kg) Restricted: ANSI, CSA, MOL70, China 750 lb (340 kg) Restricted: CE/UKCA, AUS 750 lb (340 kg) 400S HC3, 460SJ HC3 3122342600...

  • Page 112: Dimensional Data

    400S HC3 8 ft. 1 in. (2.44 m) 460SJ HC3 8 ft. 5 in. (2.45 m) Machine Length (Stowed) 400S HC3 24 ft. 11 in. (7.6 m) 460SJ HC3 29 ft. 8.2 in. (9.1 m) 3122342600 400S HC3, 460SJ HC3...

  • Page 113: Engine Data

    General Specifications and Operator Maintenance Table 10. Dimensional Data (continued) Machine Width 7 ft. 6.5 in. (2.3 m) Turning Radius Outside — 400S HC3 15 ft. 8.6 in. (4.79 m) Outside — 460SJ HC3 16 ft. 11 in. (5.1 m) Inside — 400S HC3 6 ft.
  • Page 114 Gasoline or Gasoline/LP Gas Type Liquid Cooled Number of Cylinders Displacement 153 cu.in (2.5 L) Oil Capacity with Filter 2.5 gal (9.5 L) Coolant Capacity (Engine only) 1.4 gal (5.4 L) Max. RPM 2700 RPM Fuel Consumption 3122342600 400S HC3, 460SJ HC3...

  • Page 115: Major Component Weights

    481.8 ± 19.3 Counterweight (SJ) 2700 ± 54 1227.3 ± 24.5 Tires See Table — Tires. Platform and Console - 36 x 72 Platform and Console - 36 x 96 Platform and Console - Fall Arrest 400S HC3, 460SJ HC3 3122342600...

  • Page 116: Hydraulic Oil Specifications

    GL-3 and sufficient chemical stability for mobile hydraulic system service. JLG Industries recommends standard UTTO. Note: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities.
  • Page 117 CO2 Conversion > 60% per EPA 560/6-82-003 CO2 Conversion > 80% per CEC-L-33-A-93 † Virtually Non-toxic classification indicates a LC50 > 5000 ppm per OECD 203 ‡ Fire Resistant classification indicates Factory Mutual Research Corp. (FMRC) Approval 400S HC3, 460SJ HC3 3122342600...

  • Page 118: Hydraulic Oil Operating Temperature Specifications

    (Consult JLG Service). Operation in this temperature range should include the use of hydraulic system heating aids (Consult JLG Service). The addition of a hydraulic oil cooler is not recommended for operation in this temperature range. ENGINE OIL OPERATING TEMPERATURE...

  • Page 119: Deutz D2011 Engine Oil Operating Temperature Specifications

    General Specifications and Operator Maintenance DEUTZ D2011 ENGINE OIL OPERATING TEMPERATURE SPECIFICATIONS DEUTZ (T4F/STAGE V) ENGINE OIL OPERATING TEMPERATURE SPECIFICATIONS 400S HC3, 460SJ HC3 3122342600...

  • Page 120: Kubota Engine Oil Operating Temperature Specifications

    General Specifications and Operator Maintenance KUBOTA ENGINE OIL OPERATING TEMPERATURE SPECIFICATIONS 3122342600 400S HC3, 460SJ HC3...

  • Page 121: Operator Maintenance And Lubrication Diagrams

    General Specifications and Operator Maintenance 7.10 OPERATOR MAINTENANCE AND LUBRICATION DIAGRAMS 7.10.1 Deutz D2011 L03 Engine (T4i) 7.10.2 Deutz D2.9L Engine (T4F/Stage V) 400S HC3, 460SJ HC3 3122342600...

  • Page 122: Kubota Engine

    Lubrication intervals are based on machine operation under normal conditions. For machines used in multi-shift operations and/or exposed to hostile environments or conditions, lubrication frequencies must be increased accordingly. Note: It is recommended as a good practice to replace all filters at the same time. 3122342600 400S HC3, 460SJ HC3...
  • Page 123 Capacity - 24 oz. (0.8 L)(1/2 Full) Lube - EPGL Interval - Check level every 3 months or 150 hours of operation; change every 2 years or 1200 hours of operation 1. Oil Level Check And Fill 400S HC3, 460SJ HC3 3122342600...
  • Page 124 Lube - DTE-10 Excel 32 Interval - Change as necessary 4. Hydraulic Return Filter Interval - Change after first 50 hours and every 6 months or 300 hours thereafter or whenever Charge Filter is replaced 3122342600 400S HC3, 460SJ HC3...
  • Page 125 Interval - Check Level daily; Change every 2 years or 1200 hours of operation. Comments - On new machines, those recently overhauled, or after changing hydraulic oil, operate all systems a minimum of two complete cycles and recheck oil level in reservoir. 400S HC3, 460SJ HC3 3122342600...
  • Page 126 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 10 Quarts (9.5 L) with Filter Lube - EO Interval - Check level daily; change every 500 hours or six months, whichever comes first. Adjust final oil level by mark on dipstick. 3122342600 400S HC3, 460SJ HC3...
  • Page 127 Comments - Check level daily/Change in accordance with engine manual 10. Not shown 11. Fuel Pre-Filter - Deutz D2.9 Lube Point(s) - Replaceable Element Interval - Drain water daily; Every year or 600 hours of operation 400S HC3, 460SJ HC3 3122342600...
  • Page 128 13. Fuel Filter - Deutz D2011 Lube Point(s) - Replaceable Element Interval - Every year or 500 hours of operation 14. Fuel Filter (Gasoline) Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation 3122342600 400S HC3, 460SJ HC3...
  • Page 129 16. Radiator Coolant Deutz 2.9 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 17. Not shown 400S HC3, 460SJ HC3 3122342600...
  • Page 130 Capacity - 40 oz. (1.2 L) Lube - 90w80 Gear Oil Interval - Check level every 3 months or 150 hours of operation; change after first 50 hours and every 2 years or 1200 hours of operation thereafter 3122342600 400S HC3, 460SJ HC3...
  • Page 131 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 2.5 gal. (9.5 L) with filter Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual 400S HC3, 460SJ HC3 3122342600...

  • Page 132: Tires And Wheels

    7.12.1 Tire Damage For polyurethane foam filled tires, JLG Industries, Inc. recommends that when any of the following are discovered, measures must be taken to remove the JLG product from service immediately and arrangements must be made for replacement of the tire or tire assembly.
  • Page 133 JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for a particular machine model. If not using a JLG approved...

  • Page 134: Oscillating Axle Lockout Test (If Equipped)

    1. Place a 6 in (15.2 cm) high block with ascension ramp in front of left front wheel. 2. From platform control station, start engine 3. Place the Drive control lever to the forward position and carefully drive machine up ascension ramp until left front wheel is on top of block. 3122342600 400S HC3, 460SJ HC3...
  • Page 135 Drive to release cylinders. 13. If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation. 400S HC3, 460SJ HC3 3122342600...

  • Page 136: Propane Fuel Filter Replacement

    8. If equipped, remove and discard the retaining bolt seal. 9. Remove and discard mounting plate to lock off O-ring seal. 7.14.2 Installation NOTICE Be sure to reinstall the filter magnet into the housing before installing new seal 3122342600 400S HC3, 460SJ HC3...

  • Page 137: Propane Fuel Filter Replacement (Kubota Engine)

    3. Slowly loosen the bowl retaining nut and remove the nut and filter housing from the Electric lock off assembly. 4. Remove the filter from the housing. 5. Remove and discard the housing seal. 6. Remove and discard the retaining nut seal. 400S HC3, 460SJ HC3 3122342600...

  • Page 138: Propane Fuel System Pressure Relief

    Sky Smart Fleet telematics must be received by countries that are certified to have ClearSky Smart Fleet. For a full listing of ClearSky Smart Fleet certified countries, please refer to the ClearSky webpage on the JLG website. 3122342600 400S HC3, 460SJ HC3...
  • Page 139 Consequently, a person within 20 cm (8 inches) of a CS550 that is connected to machine battery power could expose that person to RF energy in excess of what has been established by the ISED RF exposure guidelines. 400S HC3, 460SJ HC3 3122342600...

  • Page 140: Supplemental Information Only Applicable To Ce/Ukca Machines

    JLG Industries, Inc. declares that the radio equipment ClearSky Smart Fleet CS550 Connectivity Module complies with Directive 2014/53/EU. Full details can be found on the declaration of conformity. The CS550 is intended to be mounted on JLG machines and has integrated beacon functionality. Additionally, it provides telematics data via WiFi or Cell, and provides local diagnostic data exchange with a mobile device connected via WiFi and BLE.
  • Page 141 General Specifications and Operator Maintenance 400S HC3, 460SJ HC3 3122342600...

  • Page 142: Ec Declaration Of Conformity

    EN 61000-6-2:2005 • EN 60204-1:2018 • EN 280–1:2022 • EN ISO 12100:2010 JLG Industries, Inc. hereby declares that the above mentioned machine conforms with the requirements of: • 2006/42/EC — Machinery Directive • 2014/30/EU — EMC Directive • 2014/53/EU — RED Directive (If fitted with optional equipment) •...

  • Page 143: Ukca Declaration Of Conformity

    EN 60204-1:2018 • EN 280–1:2022 • EN ISO 12100:2010 JLG Industries, Inc. hereby declares that the above mentioned machine conforms with the requirements of: • 2008 No. 1597 - Supply of Machinery (Safety) Regulations 2008 • 2016 No. 1091 - Electromagnetic Compatibility Regulations 2016 •...
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  • Page 145 Inspection, Maintenance and Repair Log Serial Number ___________________________________ Any additional required certificates can be attached to the rear cover of this manual or stored in the manual box. Date Comments...
  • Page 146 Inspection, Maintenance and Repair Log...
  • Page 148 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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