JLG 400SJ, 400S Operation And Safety Manual

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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

ANSI

3121216

May 25, 2012

Page 2

Page 3

FOREWORD

This manual is a very important tool! Keep it with the machine at all times.

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.

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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 AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD DECAL WILL HAVE AN ORANGE BACKGROUND.

RESULT IN SERIOUS INJURY OR DEATH. THIS

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A YELLOW BACKGROUND.

INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.

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THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETYRELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT.

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.

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.

For:

• Accident Reporting

•Product Safety Publications

• Current Owner Updates

• Questions Regarding Product Safety

Contact:

Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 USA

or Your Local JLG Office (See addresses on inside of manual cover)

In USA:

Toll Free: 877-JLG-SAFE (877-554-7233)

FOREWORD

• Standards and Regulations Compliance Information

• Questions Regarding Special Product Applications

• Questions Regarding Product Modifications

Outside USA:

Phone: 240-420-2661 Fax: 301-745-3713 E-mail: ProductSafety@JLG.com

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FOREWORD

REVISION LOG

Original Issue - June 8, 2005

Revised - October 14, 2005

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

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

SECTION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Operator Training and Knowledge . . . . . . . . . . . 1-1

Workplace Inspection. . . . . . . . . . . . . . . . . . . . . 1-2

Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3

Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Crushing and Collision Hazards. . . . . . . . . . . . . 1-7

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-8

1.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9

SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . .2-1

Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Training Supervision. . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . 2-5

Functional Check . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Walk-Around inspection . . . . . . . . . . . . . . . . . . . 2-9

2.3 OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-1

Ground Controls . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Ground Control Indicator Panel . . . . . . . . . . . . . 3-7

Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Platform Control Indicator Panel . . . . . . . . . . . . 3-16

SECTION - 4 - MACHINE OPERATION

4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 OPERATING CHARACTERISTICS AND

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-4

Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . 4-4

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 4-5

4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-5

Traveling Forward or Reverse . . . . . . . . . . . . . . . 4-8

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

4.5 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.6 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . 4-9

4.7 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Loading from Ground Level. . . . . . . . . . . . . . . . 4-9

Loading From Positions Above Ground Level . 4-9

Platform Level Adjustment . . . . . . . . . . . . . . . . 4-10

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.8 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . 4-11

Raising and Lowering the Main Boom . . . . . . 4-11

Telescoping the Main Boom . . . . . . . . . . . . . . 4-11

4.9 AUXILIARY POWER - NON ADE EQUIPPED

MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Activating from the Platform Control Station . . 4-12 Activating from the Ground Control Station . . 4-12

4.10 AUXILIARY POWER - ADE EQUIPPED

MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Activating from the Platform Control Station . . 4-13 Activating from the Ground Control Station . . 4-13

4.11 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . .4-14

4.12 TIE DOWN AND LIFTING . . . . . . . . . . . . . . . . . . . .4-14

4.13 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4.14 PLACARDS AND DECALS . . . . . . . . . . . . . . . . . . .4-19

SECTION - 5 - EMERGENCY PROCEDURES

5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . .5-1

5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . .5-1

Operator Unable to Control Machine . . . . . . . . . 5-1

Platform or Boom Caught Overhead . . . . . . . . . 5-2

5.4 EMERGENCY TOWING PROCEDURES. . . . . . . . .5-2

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Critical Stability Weights . . . . . . . . . . . . . . . . . . 6-12

Serial Number Location . . . . . . . . . . . . . . . . . . 6-13

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-25

6.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-31

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-32

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-32

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-33

6.5 DRAINING OIL BUILD UP FROM THE

PROPANE REGULATOR (PRIOR TO

S/N 0300109274) . . . . . . . . . . . . . . . . . . . . . . . . .6-34

6.6 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-36

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-38

6.8 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-38

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Basic Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-2. Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . 2-8

2-3. Daily Walk-Around Inspection - Sheet 2 of 3 . . . . . 2-9

2-4. Daily Walk-Around Inspection - Sheet 3 of 3 . . . . 2-10

3-1. Ground Control Station - S Models . . . . . . . . . . . . 3-3

3-2. Ground Control Station - SJ Models . . . . . . . . . . . 3-4

3-3. Ground Control Indicator Panel

(Prior to S/N 93233) . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-4. Ground Control Indicator Panel

(S/N 93233 to Present) . . . . . . . . . . . . . . . . . . . . . 3-8

3-5. Platform Control Console . . . . . . . . . . . . . . . . . . . 3-11

3-6. Platform Control Console - w/Drive Orientation . . 3-12

3-7. Platform Control Indicator Panel . . . . . . . . . . . . . 3-17

3-8. Platform Control Indicator Panel - w/Drive

Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

4-1. Position Of Least Backward Stability . . . . . . . . . . . 4-2

4-2. Position Of Least Forward Stability . . . . . . . . . . . . 4-3

4-3. Grades and Sideslopes . . . . . . . . . . . . . . . . . . . . . 4-7

4-4. Machine Tie Down - 400S Models . . . . . . . . . . . . 4-15

4-5. Machine Tie Down - 460SJ Models . . . . . . . . . . . 4-16

4-6. Lifting and Tie Down . . . . . . . . . . . . . . . . . . . . . . . 4-17

4-7. Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . 4-18

4-8. Decal Installation - Sheet 1 of 4 . . . . . . . . . . . . . . 4-20

4-9. Decal Installation - Sheet 2 of 4 . . . . . . . . . . . . . . 4-21

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

4-10. Decal Installation - Sheet 3 of 4. . . . . . . . . . . . . . . 4-22

4-11. Decal Installation - Sheet 4 of 4. . . . . . . . . . . . . . . 4-23

6-1. Serial Number Location. . . . . . . . . . . . . . . . . . . . . 6-13

6-2. Engine Operating Temperature Specifications -

Deutz - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-3. Engine Operating Temperature Specifications -

Deutz - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . 6-15

6-4. Engine Operating Temperature Specifications -

Ford - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-5. Engine Operating Temperature Specifications -

Ford - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . 6-17

6-6. Engine Operating Temperature Specifications -

Caterpillar - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . 6-18

6-7. Engine Operating Temperature Specifications -

Caterpillar - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . 6-19

6-8. Engine Operating Temperature Specifications -

GM - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . 6-20

6-9. Engine Operating Temperature Specifications -

GM - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . 6-21

6-10. Engine Operating Temperature Specifications -

Perkins - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . 6-22

6-11. Engine Operating Temperature Specifications -

Perkins - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . 6-23

6-12. Operator Maintenance and Lubrication Diagram . 6-24

6-13. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-37

LIST OF TABLES

1-1 Minimum Approach Distances (M.A.D.). . . . . . . . . 1-5

1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . 1-10

2-1 Inspection and Maintenance Table . . . . . . . . . . . . 2-3

4-1 Decals - 400S with 500 lb (227 or 230 kg)

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4-2 Decals - 400S with 750 lb (340 kg) Capacity . . . . 4-28

4-3 Decals - 460SJ . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

6-1 Operating Specifications - 400S - Prior to S/N

0300142870 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2 Operating Specifications - 400S - S/N 0300142870 to

Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3 Operating Specifications - 460SJ - Prior to S/N

0300142870 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-4 Operating Specifications - 460SJ - S/N 0300142870 to

Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-5 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-6 Ford LRG-425 (Gas or Dual Fuel) . . . . . . . . . . . . . 6-6

6-7 Deutz F3M1011F/F3M2011F/D2011L03 . . . . . . . . 6-6

6-8 Isuzu 4LE1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-9 Caterpillar 3024/C2.2 . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-10 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-11 Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-12 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-13 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

6-14 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-15 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . 6-10

6-16 Mobil EAL 224H Specs. . . . . . . . . . . . . . . . . . . . . 6-10

6-17 Mobil EAL Envirosyn H Specs . . . . . . . . . . . . . . . 6-11

6-18 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . 6-11

6-19 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . 6-12

6-20 Lubrication Specifications . . . . . . . . . . . . . . . . . . 6-25

6-21 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-34

7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

This page left blank intentionally.

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SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

This section outlines the necessary precautions for proper and safe machine operation and maintenance. For proper machine use, it is mandatory that a daily routine is established based on the content of this manual. A maintenance program, using the information provided in this manual and the Service and Maintenance Manual, must also be established by a qualified person and followed to ensure the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine should not operate the machine until this manual has been read, training is accomplished, and operation of the machine has been completed under the supervision of an experienced and qualified operator.

If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“JLG”).

FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

1.2 PRE-OPERATION

Operator Training and Knowledge

• Read and understand this manual before operating the machine.

• Do not operate this machine until complete training is performed by authorized persons.

• Only authorized and qualified personnel can operate the machine.

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SECTION 1 - SAFETY PRECAUTIONS

• Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine and in this manual.

• Use the machine in a manner which is within the scope of its intended application set by JLG.

• All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specified in this manual.

• Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to operation of the machine.

Workplace Inspection

• The operator is to take safety measures to avoid all hazards in the work area prior to machine operation.

• Do not operate or raise the platform while on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless approved in writing by JLG.

• Do not operate the machine in hazardous environments unless approved for that purpose by JLG.

• Be sure that the ground conditions are able to support the maximum load shown on the decals located on the machine.

Machine Inspection

• Before machine operation, perform inspections and functional checks. Refer to Section 2 of this manual for detailed instructions.

• Do not operate this machine until it has been serviced and maintained according to requirements specified in the Service and Maintenance Manual.

• Be sure the footswitch and all other safety devices are operating properly. Modification of these devices is a safety violation.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER

• Do not operate any machine on which safety or instruction placards or decals are missing or illegible.

• Avoid any buildup of debris on the platform floor. Keep mud, oil, grease, and other slippery substances from footwear and platform floor.

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SECTION 1 - SAFETY PRECAUTIONS

1.3 OPERATION

General

• Do not use the machine for any purpose other than positioning personnel, their tools, and equipment.

• Never operate a machine that is not working properly. If a malfunctions occurs, shut down the machine.

• Never slam a control switch or lever through neutral to an opposite direction. Always return switch to neutral and stop before moving the switch to the next function. Operate controls with slow and even pressure.

• Hydraulic cylinders should never be left fully extended or fully retracted before shutdown or for long periods of time.

• 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. Contact JLG for approved material handling accessories.

• When two or more persons are in the platform, the operator shall be responsible for all machine operations.

• Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area.

• Supplies or tools which extend outside the platform are prohibited unless approved by JLG.

• When driving, always position boom over rear axle in line with the direction of travel. Remember, if boom is over the front axle, steer and drive functions will be reversed.

• Do not assist a stuck or disabled machine by pushing, pulling, or by using boom functions. Only pull the unit from the tie-down lugs on the chassis.

• Do not place boom or platform against any structure to steady the platform or to support the structure.

• Stow boom and shut off all power before leaving machine.

Trip and Fall Hazards

During operation, occupants in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point. Attach only one (1) lanyard per lanyard anchorage point.

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SECTION 1 - SAFETY PRECAUTIONS

• Before operating the machine, make sure all gates are closed and fastened in their proper position.

• 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 platform.

• Use extreme caution when entering or leaving platform. Be sure that the boom is fully lowered. It may be necessary to telescope out to position the platform closer to the ground for entry/exit. Face the machine, maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand during entry and exit.

Electrocution Hazards

• This machine is not insulated and does not provide protection from contact or proximity to electrical current.

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SECTION 1 - SAFETY PRECAUTIONS

Table 1-1. Minimum Approach Distances (M.A.D.)

• Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum Approach Distance (MAD) as shown in Table 1-

• Allow for machine movement and electrical line swaying.

Voltage Range

(Phase to Phase)

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)

Over 500 KV to 750 KV 35 (11)

Over 750 KV to 1000 KV 45 (14)

NOTE: This requirement shall apply except where

employer, local or governmental regulations are more stringent.

• Maintain a clearance of at least 10 ft. (3m) between any part of the machine and its occupants, their tools, and their equipment from any electrical line or apparatus carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.

MINIMUM APPROACH DISTANCE

in Feet (Meters)

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Page 18

SECTION 1 - SAFETY PRECAUTIONS

• The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier. This determination shall be made by a qualified person in accordance with the employer, local, or governmental requirements for work practices near energized equipment

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

Tipping Hazards

• The user should be familiar with the surface before driving. Do not exceed the allowable sideslope and grade while driving.

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Page 19

SECTION 1 - SAFETY PRECAUTIONS

• Do not elevate platform or drive with platform elevated while on a sloping, uneven, or soft surface.

• Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.

• Never exceed the maximum platform capacity. Distribute loads evenly on platform floor.

• Do not raise the platform or drive from an elevated position unless the machine is on firm, level and smooth surfaces.

• Keep the chassis of the machine at least 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards on the floor/surface.

• Do not push or pull any object with the boom.

• Never attempt to use the machine as a crane. Do not tieoff machine to any adjacent structure.

• Do not operate the machine when wind conditions exceed 28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Reference Only).

• Do not increase the surface area of the platform or the load. Increase of the area exposed to the wind will decrease stability.

• Do not increase the platform size with unauthorized deck extensions or attachments.

• If boom assembly or platform is in a position that one or more wheels are off the ground, all persons must be removed before attempting to stabilize the machine. Use cranes, forklift trucks, or other appropriate equipment to stabilize machine.

Crushing and Collision Hazards

• Approved head gear must be worn by all operating and ground personnel.

• Check work area for clearances overhead, on sides, and bottom of platform when lifting or lowering platform, and driving.

• During operation, keep all body parts inside platform railing.

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Page 20

SECTION 1 - SAFETY PRECAUTIONS

• Use the boom functions, not the drive function, to position the platform close to obstacles.

• Always post a lookout when driving in areas where vision is obstructed.

• Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving and swing operations.

• Limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors which may cause collision or injury to personnel.

• Be aware of stopping distances in all drive speeds. When driving in high speed, switch to low speed before stopping. Travel grades in low speed only.

• Do not use high speed drive in restricted or close quarters or when driving in reverse.

• Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and persons in the platform.

• Be sure that operators of other overhead and floor level machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes.

• Warn personnel not to work, stand, or walk under a raised boom or platform. Position barricades on floor if necessary.

1.4 TOWING, LIFTING, AND HAULING

• Never allow personnel in platform while towing, lifting, or hauling.

• This machine should not be towed, except in the event of emergency, malfunction, power failure, or loading/unloading. Refer to the Emergency Procedures section of this manual for emergency towing procedures.

• Ensure boom is in the stowed position and the turntable locked prior to towing, lifting or hauling. The platform must be completely empty of tools.

• When lifting machine, lift only at designated areas of the machine. Lift the unit with equipment of adequate capacity.

• Refer to the Machine Operation section of this manual for lifting information.

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SECTION 1 - SAFETY PRECAUTIONS

1.5 ADDITIONAL HAZARDS / SAFETY

• Do not use machine as a ground for welding.

• When performing welding or metal cutting operations, precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter.

• Do not refuel the machine with the engine running.

• Battery fluid is highly corrosive. Avoid contact with skin and clothing at all times.

• Charge batteries only in a well ventilated area.

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SECTION 1 - SAFETY PRECAUTIONS

DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/S).

Table 1-2. Beaufort Scale (For Reference Only)

Beaufort

Number

0 0 0-0.2 Calm Calm. Smoke rises vertically.

1 1-3 0.3-1.5 Light air Wind motion visible in smoke.

2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves r ustle.

3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion.

4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move.

5 19-24 8.0-10.7 Fresh breeze Smaller trees sway.

6 25-31 10.8-13.8 Strong breeze Large branches in motion. Whistling heard in overhead wires.

7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effor t needed to walk against the wind.

8 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road.

9 47-54 20.8-24.4 Strong Gale Light structure damage.

Wind Speed

mph m/s

Description Land Conditions

Umbrella use becomes difficult.

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.

Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical control must not operate this machine.

Operator Training

Operator training must cover:

1. Use and limitations of the controls in the platform and at the ground, emergency controls and safety systems.

2. Control labels, instructions, and warnings on the machine.

3. Rules of the employer and government regulations.

4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation of the

machine to recognize a malfunction or potential malfunction.

6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes, drop-offs.

7. Means to avoid the hazards of unprotected electrical conductors.

8. Specific job requirements or machine application.

Training Supervision

Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has developed the ability to safely control and operate the machine.

Operator Responsibility

The operator must be instructed that he/she has 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.

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

The following table covers the periodic machine inspections and maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms. 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.

JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1.Inspection and Maintenance Table

Type Frequency

Pre-Start Inspection

Pre-Delivery Inspection (See Note)

Frequent Inspection (See Note)

Annual Machine Inspection (See Note)

Preventative Maintenance

Before using each day; or whenever there’s an Operator change.

Before each sale, lease, or rental delivery. O w n e r, D e al e r, o r

In service for 3 months or 150 hours, whichever comes first; or

Out of service for a period of more than 3 months; or

Purchased used.

Annually, no later than 13 months from the date of prior inspection.

At intervals as specified in the Service and Maintenance Manual.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Man-

User

Owner, Dealer, or User

Service

Qualification

Qualified JLG Mechanic

Factory-Trained Service Technician (Recommended)

Qualified JLG Mechanic

Reference

ual

Service and Maintenance Manual and applicable JLG inspection form

Service and Maintenance Manual

NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-1. Basic Nomenclature

1. Platform

2. Jib (460SJ Only)

3. Jib Lift Cylinder (460SJ Only)

4. Level Cylinder

5. Power Track

6. Lif t Cylinder

7. Drive Wheels

8. Steer Wheels

9. Ground Contr ol

10. Turntable

11. Base Boom

12. Fly Boom

13. Platform Console

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Pre-Start Inspection

The Pre-Start Inspection should include each of the following:

1. Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.

2. Decals and Placards – Check all for cleanliness and legibility. Make sure none of the decals and placards are missing. Make sure all illegible decals and placards are cleaned or replaced.

3. Operation and Safety Manuals – Make sure a copy of the Operator and Safety Manual, AEM Safety Manual (ANSI markets only), and ANSI Manual of Responsibilities (ANSI markets only) is enclosed in the weather resistant storage container.

4. “Walk-Around” Inspection – Refer to Figure 2-2. thru Figure 2-4.

5. Battery – Charge as required.

6. Fuel (Combustion Engine Powered Machines) – Add

the proper fuel as necessary.

7. Engine Oil Supply - Ensure the engine oil level is at the Full mark on the dipstick and the filler cap is secure.

8. Hydraulic Oil – Check the hydraulic oil level. Ensure hydraulic oil is added as required.

9. Accessories/Attachments - Reference the Operator and Safety Manual of each attachment or accessory installed upon the machine for specific inspection, operation, and maintenance instructions.

10. Function Check – Once the “Walk-Around” Inspection is complete, perform a functional check of all systems in an area free of overhead and ground level obstructions. Refer to Section 4 for more specific operating instructions.

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.

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Functional Check

First, using the ground controls, check all functions controlled by the ground controls. Next, using the platform controls, check all functions controlled by the platform controls.

1. Telescope boom IN and OUT several cycles at various degrees of elevation lengths. Check for smooth telescope operation.

2. Swing turntable to LEFT and RIGHT a minimum of 45 degrees. Check for smooth motion.

NOTE: Step 3 is only applicable for machines prior to S/N

0300140365.

3. Check the oscillating axle valve (if equipped) under the turntable at the top front of frame. Observe that the valve plunger is depressed when turntable is positioned forward, and centered. Swing the turntable until bracket is past the valve. The plunger should be fully extended.

NOTE: Step 4 is only applicable for machines prior to S/N

61718.

4. With the aid of an assistant to monitor the CHASSIS OUT OF LEVEL indicator light on the platform control

console, manually activate the indicator light by compressing any one of the three tilt indicator mounting springs. If the light does not illuminate, shut down machine and contact a qualified service technician before continuing operation.

NOTE: Step 5 is applicable for machines built from S/N

61718 to present.

5. Check the chassis out of level indicator located on the platform control console by driving, with the machine in level position, up a suitable ramp of at least 5° slope. Check the out of level indicator, with the machine on the ramp. If the light does not illuminate, return the machine to a level surface, shut down the machine, and contact a qualified technician before resuming operation.

6. Check that platform self-leveling system functions properly during raising and lowering of boom.

7. Check rotator for smooth operation and assure platform will rotate 90 degrees in both directions from centerline of boom.

8. Drive forward and reverse; check for proper operation.

9. Check boom horizontal limit switches to see that they

are operable and not damaged. Raise and lower Boom. Check for smooth operation.

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

NOTE: When the boom is raised above horizontal, high drive

speed is cut out.

10. Steer left and right; check for proper operation.

11. Footswitch.

FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL OPERATE WHEN PEDA L IS APPROXIMATELY AT ITS CENTER OF TRAVEL. IF SWITCH OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM, IT SHOULD BE ADJUSTED.

a. Activate hydraulic system, by depressing foot-

switch. Operate Telescope and hold control. Remove foot from footswitch, motion should stop. If it does not, shut down machine and contact a trained JLG service technician.

b. With footswitch depressed, operate Lift and hold

control. Remove foot from footswitch, motion should stop. If it does not, shut down machine and contact a trained JLG service technician.

c. With engine power shut down, depress the foot-

switch. Attempt to start engine. Engine should not attempt to start when footswitch is depressed. If starter engages or engine turns over, shut down

machine and contact a trained JLG service technician.

12. Auxiliary Power.

Operate each function control switch (e.g. Tele, Lift, and Swing) to ensure they function in both directions using auxiliary power.

13. Ground Controls.

Place Ground/Platform Select switch to Ground. Start engine. Platform controls should not operate.

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Page 30

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-2. Daily Walk-Around Inspection - Sheet 1 of 3

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Walk-Around inspection

Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram. Continue to the right (counterclockwise viewed from top) checking each item in sequence for the conditions listed in the Walk-Around Inspection Checklist.

TO AVOID INJURY, BE SURE MACHINE POWER IS OFF.

DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.

INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened, and no visible damage, leaks or excessive wear exists in addition to any other criteria mentioned.

1. Platform Assembly and Gate - Footswitch in good working order, not modified, disabled or blocked.

2. Platform & Ground Control Consoles - Switches and levers return to neutral, decals/placards secure and legible, control markings legible.

3. Rotator - See Inspection Note.

4. All Hydraulic Cylinders - No visible damage; pivot pins

and hydraulic hoses undamaged, not leaking.

5. Boom - See Inspection Note.

6. Drive Motor, Brake, and Hub - See Inspection Note.

7. Wheel/Tire Assembly -

No loose or missing lug nuts, proper inflation (pneumatic). Inspect for worn tread, cuts, tears or other discrepancies. Inspect wheels for damage and corrosion.

8. Turntable Bearing - Evidence of proper lubrication; no evidence of loose bolts or looseness between bearing or structure.

9. Swing Drive - See Inspection Note.

10. Hood - See Inspection Note.

11. Control Valve - See Inspection Note.

12. Hydraulic Filter - See Inspection Note.

13. Hydraulic Oil Supply - Recommended oil level sight

gauge. (Check level with cold oil, systems shut down, machine in stowed position) Cap in place and secure.

Figure 2-3. Daily Walk-Around Inspection - Sheet 2 of 3

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Page 32

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

14. Fuel Supply - Filler cap secure, no visible damage to the tank or evidence of leaks.

NOTE: Lockout Valves were used prior to S/N 0300140365.

15. Oscillating Axle, Lockout Valves - See Inspection Note.

16. Tie Rod Ends and Steering Spindles - See Inspection

Note.

17. Engine Air Filter - Element clean. See Inspection Note.

18. Engine Oil Supply - Full mark on dipstick; filler cap

secure.

19. Muffler and Exhaust System - See Inspection Note.

20. Auxiliary Power Pump - See Inspection Note.

21. Hydraulic Pump - See Inspection Note.

22. Battery - Proper electrolyte levels; cables tight, no visi-

ble damage or corrosion.

Figure 2-4. Daily Walk-Around Inspection - Sheet 3 of 3

2-10 – JLG Lift – 3121216

Page 33

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.

NOTE: Ensure boom is fully retracted, lowered, and cen-

tered between drive wheels prior to beginning lockout cylinder test.

1. Place a 6 inches (15.2 cm) high block with ascension ramp in front of left front wheel.

2. From platform control station, start engine

3. Place DRIVE control lever to FORWARD position and

carefully drive machine up ascension ramp until left front wheel is on top of block.

4. Carefully activate SWING control lever and position boom over right side of machine.

5. With boom over right side of machine, 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.

7. Carefully activate SWING control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary activate DRIVE to release cylinders.

8. Place the 6 inches (15.2 cm) high block with ascension ramp in front of right front wheel.

9. Place DRIVE control lever to FORWARD and carefully drive machine up ascension ramp until right front wheel is on top of block.

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

10. With boom over left side, place DRIVE control lever to REVERSE and drive machine off block and ramp.

11. Have an assistant check to see that right front or left rear wheel remains elevated in position off of ground.

12. Carefully activate SWING control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary activate DRIVE to release cylinders.

13. If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation.

2-12 – JLG Lift – 3121216

Page 35

SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.

This section provides the necessary information needed to understand control functions.

3.2 CONTROLS AND INDICATORS

NOTE: All machines are equipped with control panels that use

symbols to indicate control functions. On ANSI machines refer to decal located on the control box guard in front of the control box or by the ground controls for these symbols and the corresponding functions.

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 not corrected, could result in serious injury or death. This indicator will be red.

Indicates an abnormal operating condition, which if not corrected, may result in machine interruption or damage. This indicator will be yellow.

Indicates important information regarding the operating condition, i.e. procedures essential for safe operation. This indicator will be green with the exception of the capacity indicator which will be green or yellow depending upon platform position.

3121216 – JLG Lift – 3-1

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

Ground Controls

See Figure 3-1., Ground Control Station - S Models and Figure 3-2., Ground Control Station - SJ Models

PERFORM PRE-OPERATIONAL CHECKS AND INSPECTIONS FROM THE GROUND CONTROL STATION. WHEN PERSONNEL ARE IN THE PLATFORM, OPERATION OF THE BOOM WILL ONLY BE PERFORMED WITH THE PERMISSION OF THE PLATFORM OCCUPANT(S).

NOTE: Engine Start/Auxiliary Power, Main Lift, Swing, Plat-

form Level, Main Telescope, and Platform Rotator control switches are spring-loaded and will automatically return to neutral (off) when released.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED.

NOTE: If equipped, the Function Enable switch

must be held down in order to operate Telescope, Swing, Lift, Jib Lift, Platform Level Override, and Platform Rotate functions.

1. Platform Rotate.

Permits rotation of the platform when positioned to the left or right.

ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF 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. Platform Leveling Override

A three position switch allows the operator to adjust the automatic self leveling system. This switch is used to adjust the platform level in situations such as ascending/descending a grade.

3. Articulating Jib Boom. (If Equipped)

Provides raising and lowering of the jib when positioned up or down.

3-2 – JLG Lift – 3121216

Page 37

1706946 A

HOURS

QUARTZ

Figure 3-1. Ground Control Station - S Models

1. Platform Rotate

2. Platform Leveling Override

3. Not Used

4. Power/Emergency Stop

5. Engine Star t/Auxiliar y Powe r or E n gi n e S t ar t / A ux i li a r y P o we r /F u nc t io n En a b le

6. Boom Lift

7. Hourmeter

8. Platform/Ground Select Switch

9. Swing

10. Boom Telescope

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3121216 – JLG Lift – 3-3

Page 38

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1706945 A

HOURS

QUARTZ

Figure 3-2. Ground Control Station - SJ Models

1. Platform Rotate

2. Platform Leveling Override

3. Ar ticulating Jib Boom

4. Power/Emergency Stop

5. Engine Start/Auxiliary Power o r E n g i n e S t a r t / A u x i l i a r y P o w e r / F u nc t i o n E n a b l e

6. Boom Lift

7. Hourmeter

8. Platform/Ground Select Switch

9. Swing

10. Boom Telescope

3-4 – JLG Lift – 3121216

Page 39

WHEN THE MACHINE IS SHUT DOWN THE MASTER/EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERY.

4. Power/Emergency Stop Switch.

A two-position red mushroom shaped switch supplies power to PLATFORM/GROUND SELECT switch when pulled out (on). When pushed in (off), power is shut off to the PLATFORM/GROUND SELECT switch.

NOTE: When Power/Emergency Stop switch is in the on

position and engine is not running, an alarm will sound, indicating Ignition is on.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. Engine Start/Auxiliary Power Switch or Engine Start/ Auxiliary Power Switch /Function Enable.

To start the engine, the switch must be held "UP" until the engine starts.

To use auxiliary power, the switch must be held “DOWN” for duration of auxiliary pump use. Aux power can only be used if the engine is not running.

If equipped, the enable switch must be held "DOWN" to enable all boom controls when the engine is running.

NOTE: Auxiliary power only works if there is no oil pressure,

and is disabled if engine is running.

3121216 – JLG Lift – 3-5

Page 40

SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Platform/Ground Select Switch.

WHEN OPERATING THE BOOM ENSURE THERE ARE NO PERSONNEL AROUND OR UNDER PLATFORM.

6. Boom Lift Control.

Provides raising and lowering of the boom when positioned up or down.

7. Hourmeter.

Registers the amount of time the machine has been in use, with the engine running. By connecting into the oil pressure circuit of the engine, only engine run hours are recorded. The hourmeter registers up to 9,999.9 hours and cannot be reset.

Supplies power to the platform control console when positioned to PLATFORM. With the switch in GROUND position, power is shut off to the platform control console, and only the controls on the ground control panel are operable.

NOTE: With the Platform/Ground Select Switch in the center

position, power is shut off to controls at both operating stations. Remove the key to prevent the controls from being actuated.

9. Swing Control.

Provides 360 degrees non-continuous turntable rotation 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.

3-6 – JLG Lift – 3121216

Page 41

Ground Control Indicator Panel

1. Batter y Charging

2. Engine Oil Pressure

3. Engine Coolant Temp

4. Engine Oil Temp

5. Engine Malfunction

6. Low Fuel

7. Glow Plug

8. Hyd. Filter Bypass

9. Trans Filter Bypass

10. Engine Air Filter Bypass

Figure 3-3. Ground Control Indicator Panel (Prior

to S/N 93233)

See Figure 3-3., Ground Control Indicator Panel (Prior to S/N

93233) and Figure 3-4., Ground Control Indicator Panel (S/N 93233 to Present)

1. Battery Charging Indicator.

Indicates a problem in the battery or charging circuit and service is required.

2. Engine Oil Pressure Indicator.

Indicates that engine oil pressure is below normal and service is required.

3. Engine Coolant Temperature (Ford and Isuzu) Indicator.

Indicates that engine coolant temperature is abnormally high and service is required.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3121216 – JLG Lift – 3-7

Page 42

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Battery Charging

2. Engine Oil Pressure

3. Engine Coolant Temp

4. Engine Oil Temp

5. Engine Malfunction

6. Low Fuel

7. Glow Plug

8. Not Used

9. Not Used

10. Not Used

11. Platform Overload CE Only

12. Drive and Steer Disable

Figure 3-4. Ground Control Indicator Panel (S/N 93233 to

Present)

4. Engine Oil Temperature Indicator (Deutz).

Indicates that the temperature of the engine oil, which also serves as engine coolant, is abnormally high and service is required.

5. Engine Malfunction Indicator. (Ford Only, prior to S/N

61718)

If an electrical malfunction occurs, this light will illuminate and stay lit until problem is eliminated. To find the specific malfunction, use the test of the EFI diagnostics

ngine Control Module To show flash code of problem

E area.

6. Low Fuel Level Indicator.

Indicates that the fuel level is 1/8 full or less. When the light first turns on, there are approximately four usable gallons of fuel remaining.

3-8 – JLG Lift – 3121216

Page 43

SECTION 3 - MACHINE CONTROLS AND INDICATORS

7. Glow Plug Wait Indicator. (Diesel)

Indicates the glow plugs are on. The glow plugs are automatically turned on with the ignition circuit and remain on for approximately seven seconds. Start the engine only after the light goes out.

8. Hydraulic Filter Bypass Indicator.

Indicates that the return oil filter is too restrictive and needs to be replaced.

9. Transmission Pump Oil Filter Indicator.

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 signals are not generated when the hydraulic oil is below normal operating temperature.

10. Engine Air Filter Indicator.

Indicates the air filter is too restrictive and needs to be replaced.

11. Platform Overload (CE Only)

Indicates the platform has been overloaded.

12. Drive and Steer Disable Indicator (If equipped)

Indicates the Drive and Steer Disable function has been activated.

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Station

See Figure 3-5., Platform Control Console and Figure 3-6., Platform Control Console - w/Drive Orientation

When starting at platform, the Platform/Ground Switch, at the ground control box be selected platform, and the large red Power Stop Button be pulled out at platform and ground control.

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.

1. Drive Speed Switch/Torque Select

The switch has three positions. The forward position gives maximum drive speed. The back position gives maximum torque for rough terrain and climbing grades. The center position allows the machine to be driven as quietly as possible by leaving the engine at mid speed and the drive motors in maximum displacement.

2. Platform Leveling Override

A three position switch allows the operator to adjust the automatic self leveling system. This switch is used to adjust the platform level in situations such as ascending/descending a grade.

3. Horn

Supplies electrical power to an audible warning device when pressed.

4. Power/Emergency Stop

An on-off Power/Emergency Stop switch and a separate Engine Start/Auxiliary Power toggle switch on the platform console supply electrical power to the starter solenoid, when the ignition switch is placed in the ON position and the ENGINE START switch is push forward.

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

8910111213

1. Drive Speed/Torque Select

2. Platform Leveling Override

3. Horn

4. Power/Emergency Stop

5. Auxiliary Power

6. Fuel Select

7. Lights

8. Drive Steer

9. Main Telescope Control

10. Jib Lift

11. Platform Rotate

12. Function Speed

13. Main Lift/Swing

14. Footswitch (Not Shown)

Figure 3-5. Platform Control Console

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

1001107677 A

1705170 A

1702938

1011 17 161213

1. Drive Speed/Torque Select

2. Platform Leveling Override

3. Horn

4. Power/Emergency Stop

5. Auxiliary Power

6. Fuel Select

7. Lights

8. Drive Steer

9. Main Telescope Control

10. Jib Lift

11. Platform Rotate

12. Function Speed

13. Main Lift/Swing

14. Footswitch (Not Shown)

15. Drive Orientation Override

16. Soft Touch Override

17. Soft Touch Indicator

Figure 3-6. Platform Control Console - w/Drive Orientation

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. Auxiliary Power

Energizes the electrically operated pump, when actuated. (Switch must be held ON for duration of auxiliary pump use.)

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 tower boom lift, tower telescope, main boom lift, main telescope and swing.

It should be noted that the functions will operate at a slower than normal rate because of the lower gpm delivered.

WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT THE SAME TIME. SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP MOTOR.

NOTE: The main function of auxiliary power is to lower the

platform in the event of primary power failure. Determine the reason for primary power failure and have the problem corrected by a certified JLG service technician.

6. Fuel Select (Dual Fuel Engine Only) (If Equipped)

Gasoline or liquid propane fuel may be selected by moving the switch to the appropriate position. It is unnecessary to purge the fuel system before switching fuels, so there is no waiting period when switching fuels while the engine is running.

7. Lights (If Equipped)

Operates control console panel lights and head lights if the machine is so equipped. The ignition switch does not have to be on to operate the lights, so care must be taken to avoid draining the battery if left unattended. The master switch and / or the ignition switch at the ground control will turn off power to all lights.

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Drive/Steer.

Provides for driving either forward or backward. Push forward to drive forward, pull back to drive in reverse.

Steering is controlled by a thumb-activated rocker switch on top of the joystick.

NOTE: Both drive and steer functions work in the opposite

direction when the boom is positioned over front of the chassis.

9. Main Telescope Control.

Allows extension and retraction of the main boom when positioned to in or out.

10. Articulating Jib Lift. (460SJ Only)

Push level, toggle switch forward to lift up, pull back to lift down.

11. Platform Rotate.

Allows the operator to rotate the basket to the left or right when positioned to the desired direction.

DO NOT OPERATE MACHINE IF DRIVE SPEED/TORQUE SELECT OR FUNCTION SPEED SWITCHES OPERATE WHEN BOOM IS ABOVE HORIZONTAL.

12. Function Speed.

Provides variable speed control of all boom functions grouped to the right of the knob. For smoothest operation of these functions, use two hands: rotate the knob counterclockwise to the slowest position, select the function switch, and while holding the switch on, rotate the knob to the desired speed. To achieve a smooth stop, rotate the knob ccw to a slow speed prior to letting go of the function switch.

Rotating the knob fully counterclockwise until a click is heard puts all controls, including drive, main lift, and swing into creep speed. This slow speed is used for fine positioning of the platform when close to obstacles. A snail symbol is used to indicate “creep” speed and is shown at the Function Speed knob as well as near the proportional controllers to act as a reminder.

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTE: When boom is positioned above horizontal and any

of the following switches, Drive Speed/torque Select or Function Speed, are positioned to High, high function speeds are automatically cut out and the machine continues to operate at a lower speed.

13. Main Lift/Swing Controller.

The dual axis joystick is provided for main lift and swing. Push forward to lift up, pull backward to lift down. Move right to swing right, move left to swing left. Moving the joystick activates switches to provide the functions selected. Proportional control of these functions can be attained by using the Function Speed knob.

NOTE: Main Lift, Swing, and Drive control levers are spring-

loaded and will automatically return to neutral (off) position when released.

NOTE: Main lift and swing functions may be selected in

combination. The handle features a round gate so that maximum speed is reduced when multiple functions are selected.

14. Footswitch (Not Shown).

This feature makes it necessary to depress the footswitch to allow operation of the platform controls.

TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS.

FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL OPERATE WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF TRAVEL. IF SWITCH OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM, IT SHOULD BE ADJUSTED.

NOTE: For engine starting, the footswitch must be in the

released (up) position. Footswitch must be actuated in order for the platform controls to function.

NOTE: These machines have a 7 second delay timer. If func-

tion has not been activated within 7 seconds after depressing the footswitch, recycle footswitch.

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

15. Drive Orientation Override

When the boom is swung over the rear tires or further in either direction, the Drive Orientation indicator will illuminate when the drive function is selected. Push and release the switch, and within 3 seconds move the Drive/Steer control to activate drive or steer. 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.

16. Soft Touch Override Switch (If equipped)

Enables the functions that were cut out by the Soft Touch system to operate again at creep speed, allowing the operator to move the platform away from the obstacle that caused the shutdown situation.

17. Soft Touch Indicator (If Equipped)

Indicates the Soft Touch bumper is against an object. All controls are cut out until the override button is pushed, at which time controls are active in the Creep Mode.

Platform Control Indicator Panel

(See Figure 3-7., Platform Control Indicator Panel) and Figure 3-

8., Platform Control Indicator Panel - w/Drive Orientation.

1. Tilt Alarm Warning Light and Alarm

This orange illuminator indicates that the chassis is on a slope. An alarm will also sound when the chassis is on a slope and the boom is above horizontal. If lit when boom is raised or extended, retract and lower to below horizontal then reposition machine so that it is level before continuing operation. If the boom is above horizontal and the machine is on a slope, the tilt alarm warning light will illuminate and an alarm will sound and CREEP is automatically activated.

IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL.

2. Platform Overload (If equipped)

Indicates the platform has been overloaded.

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Tilt

2. Platform Overload

3. Capacity

4. Fuel Level

5. Enable

6. Glow Plug

7. Malfunction

8. Generator

9. Sof t Touch

10. Creep Speed

Figure 3-7. Platform Control Indicator Panel

1001107849 B

1. Tilt

2. Platform Overload

3. Capacity

4. Fuel Level

5. Enable

6. Glow Plug

7. Malfunction

8. Generator

9. Not Used

10. Creep Speed

11. Drive Orientation

Figure 3-8. Platform Control Indicator Panel - w/

Drive Orientation

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

3. Capacity Indicator

Indicates the maximum capacity for the current position of the platform.

4. Fuel Indicator

Indicates level of fuel in the tank. When fuel level indicates 1/8 full or less, there is approximately four usable gallons of fuel remaining.

5. Enable Indicator

Indicates that the footswitch is depressed and the platform controls are ready for use. To enable the controls, depress the footswitch and select any function within seven seconds. The controls will then remain active as long as there is not a delay of seven seconds between stopping one function and starting the next one. If the seven second interval is exceeded, the enable light will go out and the controls will not operate. 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.

7. Malfunction Indicator

On machines prior to S/N 61718, the light turns on and an alarm sounds when machine’s power system requires immediate service. Any of the following conditions will turn on light and alarm: low engine oil pressure, high engine coolant temperature, clogged engine air filter, low alternator output, clogged hydraulic oil return filter, or clogged charge pump filter.

On machines from S/N 61718 to present, the light indicates that the Control System has detected a malfunction 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.

The malfunction indicator light will illuminate for 2-3 seconds when the key is positioned to the on position to act as a self test.

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. AC Generator (If Equipped)

When illuminated (Green), indicates the generator is in operation.

9. Soft Touch Indicator (If Equipped)

When illuminated (Yellow), indicates the Soft Touch bumper is against an object. All controls are cut out until the override button is pushed, at which time controls are active in the 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.

11. Drive Orientation Indicator

When the boom is swung beyond the rear drive tires or further in either direction, the Drive Orientation indicator will illuminate when the drive function is selected. This is a signal for the operator to verify that the drive control is being operated in the proper direction (i.e. controls reversed situations).

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTES:

3-20 – JLG Lift – 3121216

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SECTION 4 - MACHINE OPERATION

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION

This machine is a self-propelled hydraulic personnel lift equipped with a work platform on the end of an elevating and rotating boom.

The primary operator control station is in the platform. From this control station, the operator can drive and steer the machine in both forward and reverse directions. The operator can raise or lower the main or tower boom or swing the boom to the left or right. Standard boom swing is 360 degree continuous left and right of the stowed position. The machine has a Ground Control Station which will override the Platform Control Station. Ground Controls operate Boom Lift and Swing, and are to be used in an emergency to lower the platform to the ground should the operator in the platform be unable to do so.

4.2 OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

Raising boom above horizontal and/or extension of boom beyond retracted position with or without any load in platform, is based on the following criteria:

1. Machine is positioned on a smooth, firm and level surface.

2. Load is within manufacturer’s rated design capacity.

3. All machine systems are functioning properly.

4. Proper tire pressure exists in the tires.

5. Machine is as originally equipped from JLG.

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SECTION 4 - MACHINE OPERATION

Figure 4-1. Position Of Least Backward Stability

ROTATE PLATFORM

90 DEGREES

BOOM FULLY

ELEVATED AND

FULLY RETRACTED

MACHINE WILL TIP

OVER IN THIS DIRECTION IF

OVERLOADED OR OPERATED ON

AN OUT-OF-LEVEL

SURFACE

Stability

This machine as originally manufactured by JLG Industries Inc., when operated within its rated capacity on a smooth, firm and level supporting surface, and in accordance with the instructions provided on the machine and this manual, provides a stable machine for all platform positions.

Machine stability is based on two positions which are called FORWARD STABILITY and BACKWARD STABILITY. The machines position of least backward stability is shown in Figure 4-1., and its position of least forward stability is shown in Figure 4-2.

TO AVOID FORWARD OR BACKWARD UPSET, DO NOT OVERLOAD MACHINE OR OPERATE ON AN OUT-OF-LEVEL SURFACE.

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SECTION 4 - MACHINE OPERATION

TELESCOPE

FULLY EXTENDED

BOOM

HORIZONTAL

Figure 4-2. Position Of Least Forward Stability

BOOM

HORIZONTAL

MACHINE WILL TIP OVER IN

THIS DIRECTION IF OVERLOADED OR

OPERATED ON AN OUT-OF-LEVEL SURFACE

TELESCOPE

FULLY EXTENDED

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SECTION 4 - MACHINE OPERATION

4.3 ENGINE OPERATION

NOTE: Initial starting should always be performed from the

Ground Control station.

Starting Procedure

1. Check engine oil. If necessary, add oil in accordance with the Engine Manufacturer’s manual.

2. Check fuel level. Add fuel if necessary.

3. Check that air cleaner components are in place and

securely fastened.

IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED PERIOD. SHOULD ENGINE FAIL TO START ONCE AGAIN, ALLOW STARTER TO "COOL OFF" FOR 2-3 MINUTES. IF ENGINE FAILS AFTER SEVERAL ATTEMPTS, REFER TO ENGINE MAINTENANCE MANUAL.

NOTE: Machines with diesel engines, after turning on igni-

tion, operator must wait until glow plug indicator light goes out before cranking engine.

4. Turn key of SELECT switch to GROUND. Position POWER/EMERGENCY STOP switch to ON, then push the 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.

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SECTION 4 - MACHINE OPERATION

6. Turn key of SELECT switch to PLATFORM.

7. From Platform position POWER/EMERGENCY STOP

switch to ON, then push the ENGINE START switch to the forward position until engine starts.

NOTE: Footswitch must be in released (up) position before

starter will operate. If starter operates with footswitch in the depressed position, DO NOT OPERATE MACHINE.

Shutdown Procedure

IF AN ENGINE MALFUNCTION NECESSITATES UNSCHEDULED SHUTDOWN, DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANY OPERATION.

1. Remove all load and allow engine to operate at low speed setting for 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.

4.4 TRAVELING (DRIVING)

See Figure 4-3., Grades and Sideslopes

DO NOT DRIVE WITH BOOM EXTENDED OR ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE.

DO NOT DRIVE WITH HOODS RAISED OR UNLATCHED.

TO AVOID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES AND SIDESLOPES, DO NOT DRIVE MACHINE ON GRADES OR SIDESLOPES EXCEEDING THOSE SPECIFIED ON MACHINE INFORMATION PLACARD ON THE LEFT SIDE OF THE FRAME.

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SECTION 4 - MACHINE OPERATION

TRAVEL GRADES WITH DRIVE SPEED/TORQUE SELECT SWITCH IN THE FORWARD POSITION. USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN DRIVING WITH PLATFORM ELEVATED AND ESPECIALLY WHEN DRIVING WITH ANY PART OF MACHINE WITHIN 6 FEET (2 M) OF AN OBSTRUCTION. DO NOT USE DRIVE TO MANEUVER PLATFORM CLOSE TO AN OBSTRUCTION...USE ONE OF THE BOOM FUNCTIONS.

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.

Traveling is limited by two factors:

1. Gradeability, which is the percent of grade of the incline the machine can climb.

2. Sideslope, which is the angle of the slope the machine can be driven across.

When the boom is raised or extended, the machine should not be operated on grades or sideslopes that are greater than that detected by the tilt alarm. The tilt alarm will sound to alert the operator when the machine is on an unsafe slope. The machines high drive function will also be cut back to low drive.

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Page 61

SECTION 4 - MACHINE OPERATION

Figure 4-3. Grades and Sideslopes

DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED

ON MANUFACTURER’S NAMEPLATE

IDE

LEVEL

3121216 – JLG Lift – 4-7

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SECTION 4 - MACHINE OPERATION

Traveling Forward or Reverse

1. With engine running, depress footswitch and position DRIVE control to FORWARD and hold for the duration of forward travel desired.

NOTE: When DRIVE or STEER functions are being operated

there is an interlock which prevents operation of boom functions.

2. Depress footswitch and position DRIVE control to REVERSE and hold for duration of reverse travel desired.

3. Depress footswitch and position STEER control to RIGHT for traveling right and LEFT for traveling left.

4. To obtain maximum travel speed, position the DRIVE controller to FAST and activate the following switches: Position DRIVE SPEED/TORQUE SELECT switch to FAST. (Forward Position)

5. Prior to stopping the machine, position switches as follows: Position DRIVE SPEED/TORQUE SELECT switch to LOW. (Backward Position)

6. For traveling up grades, position switches as follows: Position DRIVE SPEED/TORQUE SELECT switch to HIGH.

NOTE: For smoother operation when driving with fully

extended boom, place DRIVE control to SLOW before stopping.

This machine is equipped with a Drive Orientation Indicator. The yellow light on the platform control console indicates that the boom is swung beyond the rear drive tires and the machine may Drive/Steer in the opposite direction from the movement of the controls. If the indicator is illuminated, operate the Drive function in the following manner:

1. Match the black and white direction arrows on both platform control panel and the chassis to determine the direction the machine will travel.

2. Push and release the Drive Orientation Override switch. Within 3 seconds, slowly move the Drive control toward the arrow matching the intended direction of machine travel. The indicator light will flash during the 3 second interval until the drive function is selected.

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SECTION 4 - MACHINE OPERATION

4.5 STEERING

Depress footswitch to steer machine, push on the left side of the switch to steer left, on the right side to steer right.

BEFORE OPERATING MACHINE, MAKE SURE BOOM IS POSITIONED OVER REAR AXLE. IF BOOM IS OVER FRONT AXLE (STEER WHEELS), STEER AND DRIVE CONTROLS WILL MOVE IN OPPOSITE DIRECTION THAN INDICATED ON MACHINE PLACARDS.

4.6 PARKING AND STOWING

Park and stow machine as follows:

1. Park machine in travel position; boom lowered over rear, all access panels and doors closed and secured, ignition off.

2. Check that brakes hold machine in position.

3. Chock wheels front and rear.

4. Turn off SELECT switch and remove key.

4.7 PLATFORM

Loading from Ground Level

1. Position chassis on a smooth, firm and level surface.

2. If total load (personnel, tools, and supplies) is less than

rated capacity, distribute load uniformly on platform floor, and proceed to work position.

Loading From Positions Above Ground Level

Before loading weight to platform above ground level:

1. Determine what the total rated capacity weight will be after additional weight is loaded (personnel, tools and supplies).

2. If total weight in platform will be less then rated capacity, proceed with adding weight.

3121216 – JLG Lift – 4-9

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SECTION 4 - MACHINE OPERATION

Platform Level Adjustment

This switch is used to adjust the platform level in situations such as ascending/descending a grade. To Level Up or Down - Position the Platform/Level control switch Up or Down and hold until the platform is level.

Platform Rotation

1. Depress footswitch to rotate platform to the left, PLATFORM ROTATE control is positioned to the LEFT and held until desired position is reached.

2. Depress footswitch to rotate platform to the right, PLATFORM ROTATE control is positioned to the RIGHT and held until desired position is reached.

4.8 BOOM

A TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE WHICH LIGHTS WHEN THE CHASSIS IS ON A 5 DEGREE OR GREATER SLOPE. DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN LIGHT IS LIT.

DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. THE TILT ALARM INDICATES THE CHASSIS IS ON A SEVERE SLOPE (5 DEGREE OR GREATER). CHASSIS MUST BE LEVEL BEFORE SWINGING, OR RAISING BOOM ABOVE HORIZONTAL.

TO AVOID MACHINE UPSET IF THE TILT WARNING LIGHT ILLUMINATED WHEN THE BOOM IS RAISED ABOVE HORIZONTAL, LOWER THE PLATFORM TO GROUND LEVEL, THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVEL BEFORE RAISING BOOM.

TRAVELING WITH BOOM BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE SLOPES SPECIFIED ON SERIAL NUMBER PLACARD.

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.

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SECTION 4 - MACHINE OPERATION

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 SWITCH TO STOP MACHINE.

Swinging the Boom

Depress footswitch to swing boom, with footswitch activated, position SWING control switch to RIGHT or LEFT for direction desired.

WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TO CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIPMENT.

Raising and Lowering the Main 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 activated, position Main Boom Lift lever to UP or DOWN until desired height is reached.

Telescoping the Main Boom

To extend or retract the main boom, with the footswitch activated, position the Main Telescope Control Switch to the in or out position and hold until the platform reaches the desired position.

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SECTION 4 - MACHINE OPERATION

4.9 AUXILIARY POWER - NON ADE EQUIPPED MACHINES

WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE 12-VOLT AUXILIARY PUMP MOTOR.)

A toggle type auxiliary power control switch is located on the platform control station and another is located on the ground control station. Operation of either switch turns on the electrically driven auxiliary hydraulic pump. This should be used in case of failure of the main power plant. The auxiliary pump will operate boom lift, telescope and swing. To activate auxiliary power:

Activating from the Platform Control Station

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.

5. Position AUXILIARY POWER switch to ON and hold.

6. Release AUXILIARY POWER switch, selected control

switch, lever or controller, and footswitch.

7. Position POWER/EMERGENCY STOP switch to OFF.

Activating from the Ground Control Station

1. Position PLATFORM/GROUND SELECT KEY SWITCH to GROUND.

2. Position POWER/EMERGENCY STOP switch to ON.

3. Operate appropriate control switch or controller for

desired function and hold.

4. Position AUXILIARY POWER switch to ON and hold.

5. Release AUXILIARY POWER switch, and appropriate

control switch or controller.

6. Position POWER/EMERGENCY STOP switch to OFF.

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SECTION 4 - MACHINE OPERATION

4.10 AUXILIARY POWER - ADE EQUIPPED MACHINES

WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE 12-VOLT AUXILIARY PUMP MOTOR.)

Activating from the Platform Control Station

1. Position PLATFORM/GROUND SELECT KEY SWITCH to PLATFORM.

2. Position POWER/EMERGENCY STOP switch to ON.

3. Depress and hold footswitch.

4. Position AUXILIARY POWER switch to ON and hold.

5. Operate appropriate control switch, lever or controller

for desired function and hold.

6. Release AUXILIARY POWER switch, selected control switch, lever or controller, and footswitch.

7. Position POWER/EMERGENCY STOP switch to OFF.

Activating from the Ground Control Station

1. Position PLATFORM/GROUND SELECT KEY SWITCH to GROUND.

2. Position POWER/EMERGENCY STOP switch to ON.

3. Position AUXILIARY POWER switch to ON and hold.

4. Operate appropriate control switch or controller for

desired function and hold.

5. Release AUXILIARY POWER switch, and appropriate control switch or controller.

6. Position POWER/EMERGENCY STOP switch to OFF.

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SECTION 4 - MACHINE OPERATION

4.11 SHUT DOWN AND PARK

1. Drive machine to a protected area.

2. Assure main boom is fully retracted and lowered over

rear (Drive) axle; all access panels and doors closed and secured.

3. Remove all load and allow engine to operate 3-5 minutes at LOW setting to permit reduction of engine internal temperatures.

4. At Ground Controls, turn KEY SELECT switch to (center) OFF. Position, POWER/EMERGENCY STOP switch (down) to OFF. Remove key.

5. Cover Platform Control console to protect instruction placards, warning decals and operating controls from hostile environment.

4.12 TIE DOWN AND LIFTING

The weight of the machine is stamped on the serial number plate. If the plate is missing or illegible, call JLG Industries or weigh the individual unit to find out the Gross Vehicle Weight.

When transporting machine, boom must be in the stowed mode and machine securely tied down to truck or trailer deck. Four tie down eyes are provided in the frame slab, one at each corner of the machine. Lock turntable before traveling long distances or before hauling machine on a truck or trailer.

If it becomes necessary to lift the machine using an overhead or mobile crane, it is very important that the lifting devices are attached only to the designated lifting area. (See Figure 4-6 Lifting and Tie Down Decal)

NOTE: Tie down eyes are provided at the front, center, and

rear in the frame slab. Lifting eyes are located in plate mounted on machine front at boom pivot. (See Figure 4-6 Lifting and Tie Down Decal)

4-14 – JLG Lift – 3121216

Page 69

SECTION 4 - MACHINE OPERATION

Figure 4-4. Machine Tie Down - 400S Models

NOTE: When transporting machine over rough

terrain or long distance, the boom needs to be chocked and strapped whenever the base boom is unable to rest on its pad. This prevents the boom from bouncing up and down and preventing possible damage while transporting.

3121216 – JLG Lift – 4-15

Page 70

SECTION 4 - MACHINE OPERATION

Figure 4-5. Machine Tie Down - 460SJ Models

NOTE: When transporting machine over

rough terrain or long distance, the boom needs to be chocked and strapped whenever the base boom is unable to rest on its pad. This prevents the boom from bouncing up and down and preventing possible damage while transporting.

4-16 – JLG Lift – 3121216

Page 71

SECTION 4 - MACHINE OPERATION

Figure 4-6. Lifting and Tie Down

3121216 – JLG Lift – 4-17

Page 72

SECTION 4 - MACHINE OPERATION

Figure 4-7. Drive Disconnect Hub

4.13 TOWING

RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH.

MAXIMUM TOWING SPEED 5 M.P.H. (8 KM/H.) FOR NO LONGER THAN 30-45 MINUTES.

MAXIMUM TOWING GRADE 25%.

Prior to towing the machine, complete the following:

DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED.

1. Retract, lower and position boom over rear drive wheels in line with direction of travel.

2. Disconnect drive hubs by inverting the disconnect cap. (See Figure 4-7.) After towing the machine, complete the following:

3. Reconnect drive hubs by inverting the disconnect cap. (See Figure 4-7.)

4-18 – JLG Lift – 3121216

Page 73

SECTION 4 - MACHINE OPERATION

4.14 PLACARDS AND DECALS

Read and understand all placards and decals. Do not operate any machine on which DANGER, WARNING, CAUTION OR INSTRUCTION PLACARDS OR DECALS ARE MISSING OR ILLEGIBLE. Replace placards and decals if damaged, missing or illegible.

Decals are made with a Pressure Sensitive Adhesive on the back with a protective film on the front. Remove the damaged decal and thoroughly clean surface before installing a new decal. Simply peel off the back, and press new decal onto surface and remove the protective film.

NOTE: Placards and Decals can be ordered by using part

numbers located by each placard or decal.

3121216 – JLG Lift – 4-19

Page 74

SECTION 4 - MACHINE OPERATION

Figure 4-8. Decal Installation - Sheet 1 of 4

4-20 – JLG Lift – 3121216

Page 75

SECTION 4 - MACHINE OPERATION

Figure 4-9. Decal Installation - Sheet 2 of 4

3121216 – JLG Lift – 4-21

Page 76

SECTION 4 - MACHINE OPERATION

Figure 4-10. Decal Installation - Sheet 3 of 4

4-22 – JLG Lift – 3121216

Page 77

SECTION 4 - MACHINE OPERATION

Figure 4-11. Decal Installation - Sheet 4 of 4

3121216 – JLG Lift – 4-23

Page 78

SECTION 4 - MACHINE OPERATION

Table 4-1. Decals - 400S with 500 lb (227 or 230 kg) Capacity

Item # ANSI

0259159-20

1 1703797 1705921 1703928 1703925 1703924 1703926 1703927 1703923

2 1703798 1705822 1703934 1703931 1703930 1703932 1703933 1703929

3 1703805 1705961 1703940 1703937 1703936 1703938 1703939 1703935

4 1703804 1701518 1703952 1703949 1703948 1703950 1703951 1703947

5 1001108492 - - 1001108492 1001108492 1001108492 1001108492 1001108492 1001108492

6 1706941 - - 1706741 1706941 1706941 1706741 1706941 1706941

7 1704472 1704472 1704472 1704472 1704472 1704472 1704472 1704472

8 - -- -- -- -- -- -- -- -

9 - -- -- -- -- -- -- -- -

10 - -- -- -- -- -- -- -- -

11 1702868 - - 1704002 - - 1704000 - - - - 1704001

12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

13 1001121800 1705978 1001125330 1001121809 1001121802 1001121807 1001122200 1001121804

14 1001121813 1705978 1001125338 1001121822 1001121815 1001121820 1001122201 1001121817

15 3251813 1705084 3251813 - - 3251813 - - - - 3251813

16 - -- -- -- -- -- -- -- -

17 - -- -- -- -- -- -- -- -

CE/Australian

0275066-7

Portuguese/

Spanish

0259185-19

Chinese/

0259183-23

French

0259181-22

Japanese

0259175-23

Korean

0259177-23

English/ Spanish

0259179-19

4-24 – JLG Lift – 3121216

Page 79

SECTION 4 - MACHINE OPERATION

Table 4-1. Decals - 400S with 500 lb (227 or 230 kg) Capacity

Item # ANSI

0259159-20

18 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

19 - - - - 1704008 - - 1704006 - - - - 1704007

20 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

21 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

22 - -- -- -- -- -- -- -- -

23 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

24 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300

25 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500

26 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529

27 - -- -- -- -- -- -- -- -

28 - -- -- -- -- -- -- -- -

29 - -- -- -- -- -- -- -- -

30 - -- -- -- -- -- -- -- -

31 - -- -- -- -- -- -- -- -

32 - -- -- -- -- -- -- -- -

33 - -- -- -- -- -- -- -- -

34 - - 1705828 1703985 1703982 1703984 1703980 1703981 1703983

35 1706126 1706126 - - 1706126 1706126 1706126 1706126 - -

CE/Australian

0275066-7

Portuguese/

Spanish

0259185-19

Chinese/

0259183-23

French

0259181-22

Japanese

0259175-23

Korean

0259177-23

English/ Spanish

0259179-19

3121216 – JLG Lift – 4-25

Page 80

SECTION 4 - MACHINE OPERATION

Table 4-1. Decals - 400S with 500 lb (227 or 230 kg) Capacity

Item # ANSI

0259159-20

36 - -- -- -- -- -- -- -- -

37 - -- -- -- -- -- -- -- -

38 - -- -- -- -- -- -- -- -

39 - -- -- -- -1705514- -- -- -

40 - -- -- -- -- -- -- -- -

41 - -- -- -- -- -- -- -- -

42 - -- -- -- -- -- -N/A- -

43 - -- -- -- -- -- -N/A- -

44 - -- -- -- -- -- -N/A- -

45 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

46 3252672 1707031 3252685 3252684 3252683 3252680 3252681 3252682

47 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

48 - -- -- -- -- -- -- -- -

49 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691

50 1704726 1704726 1704726 1704726 1704726 1704726 1704726 1704726

51 - -- -- -- -- -- -- -- -

52 - -- -- -- -- -- -- -- -

CE/Australian

0275066-7

Portuguese/

Spanish

0259185-19

Chinese/

0259183-23

French

0259181-22

Japanese

0259175-23

Korean

0259177-23

English/ Spanish

0259179-19

4-26 – JLG Lift – 3121216

Page 81

SECTION 4 - MACHINE OPERATION

Table 4-1. Decals - 400S with 500 lb (227 or 230 kg) Capacity

Item # ANSI

0259159-20

53 - -- -- -- -- -- -- -- -

54 1705351 - - 1705905 1705430 1705429 1705426 1705427 1705910

CE/Australian

0275066-7

Portuguese/

Spanish

0259185-19

Chinese/

0259183-23

French

0259181-22

Japanese

0259175-23

Korean

0259177-23

English/ Spanish

0259179-19

3121216 – JLG Lift – 4-27

Page 82

SECTION 4 - MACHINE OPERATION

Table 4-2. Decals - 400S with 750 lb (340 kg) Capacity

Item # ANSI

0259981-17

1 1703797 1705921 1703928 1703925 1703924 1703926 1703927 1703923

2 1703798 1705822 1703934 1703931 1703930 1703932 1703933 1703929

3 1703805 1705961 1703940 1703937 1703936 1703938 1703939 1703935

4 1703804 1701518 1703952 1703949 1703948 1703950 1703951 1703947

5 1001108492 - - 1001108492 1001108492 1001108492 1001108492 1001108492 1001108492

6 1706941 - - 1706941 1706741 1706741 1706941 1706941 1706941

7 1704472 1704472 1704472 1704472 1704472 1704472 1704472 1704472

8 - -- -- -- -- -- -- -- -

9 - -- -- -- -- -- -- -- -

10 - -- -- -- -- -- -- -- -

11 1702868 - - 1704002 - - 1704000 - - - - 1704001

12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

13 1001125322 1706382 1001125329 1001125328 1001125327 1001125323 1001125324 1001125325

14 1001125331 1706382 1001125337 1001125336 1001125335 1001125332 1001125333 1001125334

15 3251813 1705084 3251813 - - 3251813 - - - - 3251813

16 - -- -- -1701502- -- -- -1701502

17 - -- -- -1701503- -- -- -1701503

CE/Australian

0275068-6

Portuguese/

Spanish

0259994-17

Chinese

0259993-20

French

0259992-20

Japanese

0259989-20

Korean

0259990-20

English/ Spanish

0259991-17

4-28 – JLG Lift – 3121216

Page 83

SECTION 4 - MACHINE OPERATION

Table 4-2. Decals - 400S with 750 lb (340 kg) Capacity

Item # ANSI

0259981-17

18 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

19 - - - - 1704008 - - 1704006 - - - - 1704007

20 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

21 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

22 - -- -- -- -- -N/A- -- -

23 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

24 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300

25 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500

26 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529

27 - -- -- -- -- -- -- -- -

28 - -- -- -- -- -- -- -- -

29 - -- -- -- -- -- -- -- -

30 - -- -- -- -- -- -- -- -

31 - -- -- -- -- -- -- -- -

32 - -- -- -- -- -- -- -- -

33 - -- -- -- -- -- -- -- -

34 - - 1705828 1703985 1703982 1703984 1703980 1703981 1703983

35 1704829 1704829 - - 1704829 1704829 1704829 1704829 - -

CE/Australian

0275068-6

Portuguese/

Spanish

0259994-17

Chinese

0259993-20

French

0259992-20

Japanese

0259989-20

Korean

0259990-20

English/ Spanish

0259991-17

3121216 – JLG Lift – 4-29

Page 84

SECTION 4 - MACHINE OPERATION

Table 4-2. Decals - 400S with 750 lb (340 kg) Capacity

Item # ANSI

0259981-17

36 - -- -- -- -- -- -- -- -

37 - -- -- -- -- -- -- -- -

38 - -- -- -- -- -- -- -- -

39 - -- -- -- -1705514- -- -- -

40 - -- -- -- -- -- -- -- -

41 - -- -- -- -- -- -- -- -

42 - -- -- -- -- -- -- -- -

43 - -- -- -- -- -- -- -- -

44 - -- -- -- -- -- -- -- -

45 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

46 3252672 1707031 3252685 3252684 3252683 3252680 3252681 3252682

47 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

48 - -- -- -- -- -- -- -- -

49 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691

50 1704726 1704726 1704726 1704726 1704726 1704726 1704726 1704726

51 - -- -- -- -- -- -- -- -

52 - -- -- -- -- -- -- -- -

CE/Australian

0275068-6

Portuguese/

Spanish

0259994-17

Chinese

0259993-20

French

0259992-20

Japanese

0259989-20

Korean

0259990-20

English/ Spanish

0259991-17

4-30 – JLG Lift – 3121216

Page 85

SECTION 4 - MACHINE OPERATION

Table 4-2. Decals - 400S with 750 lb (340 kg) Capacity

Item # ANSI

0259981-17

53 - -- -- -- -- -- -- -- -

54 1705351 - - 1705905 1705430 1705429 1705426 1705427 1705910

CE/Australian

0275068-6

Portuguese/

Spanish

0259994-17

Chinese

0259993-20

French

0259992-20

Japanese

0259989-20

Korean

0259990-20

English/ Spanish

0259991-17

3121216 – JLG Lift – 4-31

Page 86

SECTION 4 - MACHINE OPERATION

Table 4-3. Decals - 460SJ

Item # ANSI

0259160-16

1 1703797 1705921 1703928 1703925 1703924 1703926 1703927 1703923

2 1703798 1705822 1703934 1703931 1703930 1703932 1703933 1703929

3 1703805 1705961 1703940 1703937 1703936 1703938 1703939 1703935

4 1703804 1701518 1703952 1703949 1703948 1703950 1703951 1703947

5 1706708 - - 1706941 1001108492 1001108492 1001108492 1001108492 1001108492

6 1706941 - - 1706709 1706941 1706941 1706941 1706941 1706941

7 1704473 1704473 1704473 1704473 1704473 1704473 1704473 1704473

8 - -- -- -- -- -- -- -- -

9 - -- -- -- -- -- -- -- -

10 - -- -- -- -- -- -- -- -

11 1702868 - - 1704002 - - 1704000 - - - - 1704001

12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

13 1001121801 1705978 1001121920 1001121812 1001121803 1001121808 1001121918 1001121801

14 1001121814 1705978 1001121923 1001121825 1001121816 1001121821 1001121921 1001121814

15 3251813 1705084 3251813 - - 3251813 - - - - 3251813

16 - -- -- -- -- -- -- -- -

17 - -- -- -- -- -- -- -- -

CE/Australian

1001114405-1

Portuguese/

Spanish

0259186-19

Chinese

0259184-22

French

0259182-21

Japanese

0259176-21

Korean

0259178-20

English/ Spanish

0259180-18

4-32 – JLG Lift – 3121216

Page 87

Table 4-3. Decals - 460SJ

SECTION 4 - MACHINE OPERATION

Item # ANSI

0259160-16

18 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

19 - - - - 1704008 - - 1704006 - - - - 1704007

20 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

21 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

22 - -- -- -- -- -- -- -- -

23 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

24 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300

25 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500

26 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529

27 - -- -- -- -- -- -- -- -

28 - -- -- -- -- -- -- -- -

29 - -- -- -- -- -- -- -- -

30 - -- -- -- -- -- -- -- -

31 - -- -- -- -- -- -- -- -

32 - -- -- -- -- -- -- -- -

33 - -- -- -- -- -- -- -- -

34 - - 1705828 1703985 1703982 1703984 1703980 1703981 1703983

35 1704828 1704828 - - 1704828 1704828 1704828 1704828 - -

CE/Australian

1001114405-1

Portuguese/

Spanish

0259186-19

Chinese

0259184-22

French

0259182-21

Japanese

0259176-21

Korean

0259178-20

English/ Spanish

0259180-18

3121216 – JLG Lift – 4-33

Page 88

SECTION 4 - MACHINE OPERATION

Table 4-3. Decals - 460SJ

Item # ANSI

0259160-16

36 - -- -- -- -- -- -- -- -

37 - -- -- -- -- -- -- -- -

38 - -- -- -- -- -- -- -- -

39 - -- -- -- -1705514- -- -- -

40 - -- -- -- -- -- -- -- -

41 - -- -- -- -- -- -- -- -

42 - -- -- -- -- -- -- -- -

43 - -- -- -- -- -- -- -- -

44 - -- -- -- -- -- -- -- -

45 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

46 3252672 1707031 3252685 3252684 3252683 3252680 3252681 3252682

47 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

48 - -- -- -- -- -- -- -- -

49 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691

50 1704726 1704726 1704726 1704726 1704726 1704726 1704726 1704726

51 - -- -- -- -- -- -- -- -

52 - -- -- -- -- -- -- -- -

53 - -- -- -- -- -- -- -- -

CE/Australian

1001114405-1

Portuguese/

Spanish

0259186-19

Chinese

0259184-22

French

0259182-21

Japanese

0259176-21

Korean

0259178-20

English/ Spanish

0259180-18

4-34 – JLG Lift – 3121216

Page 89

Table 4-3. Decals - 460SJ

SECTION 4 - MACHINE OPERATION

Item # ANSI

0259160-16

54 1705351 - - 1705905 1705430 1705429 1705426 1702427 1705910

55 - - 1001112551 - - - - - - - - - - - -

CE/Australian

1001114405-1

Portuguese/

Spanish

0259186-19

Chinese

0259184-22

French

0259182-21

Japanese

0259176-21

Korean

0259178-20

English/ Spanish

0259180-18

3121216 – JLG Lift – 4-35

Page 90

SECTION 4 - MACHINE OPERATION

NOTES:

4-36 – JLG Lift – 3121216

Page 91

5.1 GENERAL

SECTION 5 - EMERGENCY PROCEDURES

SECTION 5. EMERGENCY PROCEDURES

This section explains the steps to be taken in case of an emergency situation while operating.

5.2 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.

In USA: JLG Phone: 877-JLG-SAFE (554-7233) (8am till 4:45pm EST)

Outside USA: 240-420-2661

E-mail:

ProductSafety@JLG.com

Failure to notify the manufacturer of an incident involving a JLG Industries product within 48 hours of such an occurrence may void any warranty consideration on that particular machine.

FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CONTROLS. DO NOT LIFT ABOVE 10 FT. (3 M) UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED, IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING CORRECTLY.

5.3 EMERGENCY OPERATION

Operator Unable to Control Machine

IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO OPERATE OR CONTROL MACHINE:

1. Other personnel should operate the machine from ground controls only as required.

2. Other qualified personnel on the platform may use the platform controls. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY.

3. Cranes, forklift trucks or other equipment can be used to remove platform occupants and stabilize motion of the machine.

3121216 – JLG Lift – 5-1

Page 92

SECTION 5 - EMERGENCY PROCEDURES

Platform or Boom Caught Overhead

If the platform or boom becomes jammed or snagged in overhead structures or equipment, rescue platform occupants prior to freeing the machine.

5.4 EMERGENCY TOWING PROCEDURES

Towing this machine is prohibited, unless properly equipped. However, provisions for moving the machine have been incorporated. For specific procedures, refer to Section 4.

5-2 – JLG Lift – 3121216

Page 93

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 INTRODUCTION

This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine.

The maintenance portion of this section is intended as information to assist the machine operator to perform daily maintenance tasks only, and does not replace the more thorough Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual.

Other Publications Available:

Service and Maintenance Manual (ANSI, CSA) ....... 3120788

Service and Maintenance Manual (CE, AUS)........... 3120895

Illustrated Parts Manual (ANSI, CSA)

Prior to S/N 96000.................................................. 3120789

Illustrated Parts Manual (CE, AUS)

Prior to S/N 96000.................................................. 3120896

Illustrated Parts Manual (Global)

S/N 96000 to Present............................................. 3121236

6.2 OPERATING SPECIFICATIONS

Table 6-1. Operating Specifications - 400S - Prior to S/N

0300142870

Maximum Work Load (Capacity): U nr e s tr i ct e d: R es t ri c t ed : O pt i o na l :

Maximum Travel Grade, Stowed Position (Gradeability) see Figure 4-3.

Maximum Travel Grade, Stowed Position (Side Slope) see Figure 4-3.

Maximum Vertical Platform Height: 40 ft. (12 m)

Maximum Horizontal Platform Reach: 34 ft. (10 m.)

Turning Radius (Outside) 16 ft. (5 m.)

Turning Radius (Inside) 6 ft.-8 in. (2 m.)

Overall Width 6ft.- 6in. (1.9 8 m)

Tail swing Zero

Stowed Height 7ft. 4in. (2.24 m)

standard 500 lbs. (230 kg.) 1000 lbs. (450 kg)

750 lbs. (340 kg)

2 W/D-30% 4 W/D-45%

3121216 – JLG Lift – 6-1

Page 94

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-1. Operating Specifications - 400S - Prior to S/N

0300142870

Stowed Length 20ft. 2in. (6.15 m)

Wheelbase 7ft. 10in. (2,3 m)

Ground Clearance 12in. (30 cm)

Max. Tire Load (400S-500 lbs. Cap.) Max. Tire Load (400S-750 lbs. Cap.)

Ground Bearing Pressure 12x16.5 FF Tires 14x17.5 pneumatic tires

6200 lbs. (2812 kg) 8350 lbs. (3788 kg)

58 psi (4.07 kg/cm 45 psi (3.16 kg/cm

)

Travel Speed, boom stowed.(2WD/4WD) 4.5 m.p.h. (7.24 kmh)

(27-32 sec/ 200ft.)

Travel Speed, boom elevated. (2WD/4WD) 0.75 m.p.h. (1.20 kmh)

(46-115 sec/ 50 ft.)

Gross Machine Weight Std. 2wd Machine (Platform Empty, Pneumatic Tires) 500 lb. (230 kg) Capacity 750 lb. (340 kg) Capacity

12,525 lbs. (5681kg)

13,525 lbs. (6135 kg)

Maximum System Voltage 12 VDC

Max. Hydraulic System Operating Pressure 4060 psi (280 bar)

Manual Force 400 N maximum

Maximum Wind Speed 28 mph (12.5 m/s)

Table 6-2. Operating Specifications - 400S - S/N 0300142870 to

Present

Maximum Work Load (Capacity) - ANSI U nr e s tr i ct e d: R es t ri c t ed : O pt i o na l :

standard 500 lbs. (227 kg.) 1000 lbs. (454 kg)

750 lbs. (340 kg)

Maximum Work Load (Capacity) - CE &

A us tr a li a

U nr e s tr i ct e d: R es t ri c t ed : O pt i o na l :

Maximum Travel Grade, Stowed Position (Gradeability) see Figure 4-3.

Maximum Travel Grade, Stowed Position

standard 500 lbs. (230 kg.) 1000 lbs. (450 kg)

750 lbs. (340 kg)

2 W/D-30% 4 W/D-45%

(Side Slope) see Figure 4-3.

Maximum Vertical Platform Height: 40 ft. (12 m)

Maximum Horizontal Platform Reach: 34 ft. (10 m.)

Turning Radius (Outside) 16 ft. (5 m.)

Turning Radius (Inside) 6 ft.-8 in. (2 m.)

Overall Width 6ft.- 6i n. (1.98 m)

Tail swing Zero

Stowed Height 7ft. 4in. (2.24 m)

6-2 – JLG Lift – 3121216

Page 95

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-2. Operating Specifications - 400S - S/N 0300142870 to

Present

Stowed Length 20ft. 2in. (6.15 m)

Wheelbase 7ft. 10in. (2,3 m)

Ground Clearance 12in. (30 cm)

Max. Tire Load (400S-500 lbs. Cap.) Max. Tire Load (400S-750 lbs. Cap.)

Ground Bearing Pressure 12x16.5 FF Tires 14x17.5 pneumatic tires

6200 lbs. (2812 kg) 8350 lbs. (3788 kg)

58 psi (4.07 kg/cm 45 psi (3.16 kg/cm

)

Travel Speed, boom stowed.(2WD/4WD) 4.5 m.p.h. (7.24 kmh)

(27-32 sec/ 200ft.)

Travel Speed, boom elevated. (2WD/4WD) 0.75 m.p.h. (1.20 kmh)

(46-115 sec/ 50 ft.)

Gross Machine Weight Std. 2wd Machine (Platform Empty, Pneumatic Tires) 500 lb. (227 or 230 kg) Capacity 750 lb. (340 kg) Capacity

12,525 lbs. (5681kg) 13,525 lbs. (6135 kg)

Maximum System Voltage 12 VDC

Max. Hydraulic System Operating Pressure 4060 psi (280 bar)

Manual Force 400 N maximum

Maximum Wind Speed 28 mph (12.5 m/s)

Table 6-3. Operating Specifications - 460SJ - Prior to S/N

0300142870

Maximum Work Load (Capac ity): U n re s tr i c te d : 5 0 0 lb s . ( 2 30 k g .)

Maximum Travel Grade, Stowed Position (Gradeability) see Figure 4-3.

Maximum Travel Grade, Stowed Position

2 W/D - 30% 4 W/D - 45%

(Side Slope) see Figure 4-3.

Maximum Vertical Platform Height: 46 ft. (14 m.)

Maximum Horizontal Platform Reach: 40 ft. (12 m.)

Turning Radius (Outside) 16 ft. (5 m.)

Turning Radius (Inside) 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 7f t. 10in. (2,3 m)

Ground Clearance 12in. (30 cm)

Max. Tire Load 7200 lbs. (3266 kg)

Ground Bearing Pressure

63 psi (4.4 kg/cm

)

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Page 96

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-3. Operating Specifications - 460SJ - Prior to S/N

0300142870

Travel Speed, boom stowed.(2WD/4WD) 4.5 m.p.h. (7.24 kmh)

(27-32 sec/ 200ft.)

Travel Speed, boom elevated. (2WD/4WD) 0.75 m.p.h. (1.20 kmh)

(46-115 sec/ 50 ft.)

Gross Machine Weight Std. 2wd Machine (Platform Empty, Pneumatic Tires)

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)

7192 kg (15,855 lb.)

Table 6-4. Operating Specifications - 460SJ - S/N 0300142870

to Present

Maximum Work Load (Capac ity) - ANSI U n re s tr i c te d : 5 0 0 lb s . ( 2 27 k g .)

Maximum Work Load (Capac ity) - CE &

Australia

U n re s tr i c te d : 5 0 0 lb s . ( 2 30 k g .)

Maximum Travel Grade, Stowed Position (Gradeability) see Figure 4-3.

Maximum Travel Grade, Stowed Position (Side Slope) see Figure 4-3.

Maximum Vertical Platform Height: 46 ft. (14 m.)

Maximum Horizontal Platform Reach: 40 ft. (12 m.)

Turning Radius (Outside) 16 ft. (5 m.)

Turning Radius (Inside) 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 7f t. 10in. (2,3 m)

Ground Clearance 12in. (30 cm)

2 W/D - 30% 4 W/D - 45%

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SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-4. Operating Specifications - 460SJ - S/N 0300142870

to Present

Max. Tire Load 7200 lbs. (3266 kg)

Ground Bearing Pressure

Travel Speed, boom stowed.(2WD/4WD) 4.5 m.p.h. (7.24 kmh)

Travel Speed, boom elevated. (2WD/4WD) 0.75 m.p.h. (1.20 kmh)

Gross Machine Weight Std. 2wd Machine (Platform Empty, Pneumatic Tires)

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)

63 psi (4.4 kg/cm

(27-32 sec/ 200ft.)

(46-115 sec/ 50 ft.)

7192 kg (15,855 lb.)

)

Capacities

Table 6-5. Capacities

Fuel Tank 26 gallons (98.4 liters)

Hydraulic Tank 40.0 gallons (152 liters)

Hydraulic System (Including Tank) 52 gallons (196.8 liters)

Drive Hub 17 ounces (0.5 liters)

Engine Oil Capacity F or d D eu t z C a te r pi l la r G M

4.5 Quar ts (4.25 L) w/Filter

6.3 qts. (6 L) w/Filter

3.8 quar ts (3.6 L) crankcase only

4.5 qts. (4.25 L) w/Filter

3121216 – JLG Lift – 6-5

Page 98

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Engine

NOTE: RPM Tolerances are ± 100.

Table 6-6. Ford LRG-425 (Gas or Dual Fuel)

Type 4 cylinder, 4 stroke, spark ignition

Fuel Gasoline or Gasoline/LP Gas

Bore 3 in. (96 mm)

Stroke 3.4 in. (86.4 mm)

Displacement 153 cu. in. (2.5 L)

Firing Order 1-3-4-2

BHP at Max. RPM 82

Oil Capacity 4.5 quar ts (4.26 L)

Low RPM 1000

Mid RPM 1800

High RPM 3000

Fuel Consumption: Gasoline I nt e r mi t te n t Continuous

Fuel Consumption: LPG I nt e r mi t te n t Continuous

6 gal. hr.

5 gal. hr.

26 lbs. hr. 23 lbs. hr.

Table 6-6. Ford LRG-425 (Gas or Dual Fuel)

Spark Plug AWSF-52-C

Spark Plug Gap 0.044 in. (1.117 mm)

Table 6-7. Deutz F3M1011F/F3M2011F/D2011L03

Fuel Diesel

No. of Cylinders 3

Bore 3.7 in. (94 mm)

Stroke 4.4 in. (112 mm)

Displacement 142 cu. in. ( 2331 cm³)

BHP at Max. RPM 49

Oil Capacity c ra n k ca s e c oo l e r t ot a l ca p ac i ty

Low RPM 1200

Mid RPM 1800

High RPM 2800

6.3 quar ts (6 L)

4.75 quarts (4.5 L) 11 quarts (10.5 L)

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SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-8. Isuzu 4LE1

Fuel Diesel

No. of Cylinders 4

BHP at Max. RPM 45

Low RPM 1000

Mid RPM 1500

High RPM 2800

Table 6-9. Caterpillar 3024/C2.2

Fuel Diesel

No. of Cylinders 4

BHP 46.5 hp (34 kW)

Bore 3.307 in. (84 mm)

Stroke 3.9370 in. (112 mm)

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

Table 6-10. GM 3.0L

Fuel Gasoline or Gasoline/LP Gas

No. of Cylinders 4

BHP G as o l in e L P

Bore 4.0 in. (101.6 mm)

Stroke 3.6 in. (91.44 mm)

Displacement 181 cu.in. (3.0 L, 2966 cc)

Oil Capacity w/filter 4.5 qts. (4.25 L)

Minimum Oil Pressure a t i d l e H ot

Compression Ratio 9.2:1

Firing Order 1-3-4-2

Max. RPM 2800

18 psi (1.2 Bar) @ 2000 rpm

83 hp @ 3000 rpm 75 hp @ 3000 rpm

6 psi (0.4 Bar) @ 1000 rpm

3121216 – JLG Lift – 6-7

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SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-11. Perkins 404D-22

Fuel Diesel

No. of Cylinders 4

BHP 50 HP (37.3 kW)

Bore 3.3 in. (84 mm)

Stroke 3.9 in. (100 mm)

Firing Order 1-3-4-2

Displacement 135 cu.in. (2.2 L)

Oil Capacity w/filter 10 qt. (9.4 L)

Compression Ratio 23.3:1

Tires

Table 6-12. Tires

Size Ty pe Pressure Weight

12x16.5 Pneumatic 90 psi (6.2 Bar) 128 lbs. (58 kg)

12x16.5 Foam-filled N/A 328 lbs. (149kg)

14x17.5 Pneumatic 90 psi (6 Bar) 128 lbs. (58 kg)

14x17.5 Foam-filled N/A 440 lbs. (200kg)

33/16LLx16.1- Sand Pneumatic 90 psi (2.75 bar) 119.5 lbs. (54 kg)

33/16LLx16.1- Sand Foam Filled N/A 426 lbs. (193 kg)

33x6x11 Solid N/A 280 lbs. (127 kg)

Semitrack Tires

24x12x 12 Pneumatic 20 psi (1.4 bar) 20.7 lbs. (9.38 kg)

6-8 – JLG Lift – 3121216