Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
400S
400SJ
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September 18, 2014 |
FOREWORD
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 RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACKGROUND.
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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FOREWORD
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED 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.
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Accident Reporting |
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Standards and Regulations |
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Product Safety |
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Compliance Information |
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Questions Regarding |
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Current Owner Updates |
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• Questions Regarding Prod- |
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Questions Regarding |
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For: |
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Product Modifications
uct 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)
Outside USA:
Phone: 240-420-2661
Fax: 301-745-3713
E-mail: ProductSafety@JLG.com
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FOREWORD
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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 |
Revised |
- September 18, 2014 |
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TABLE OF CONTENTS
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 . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-4
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-5
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Crushing and Collision Hazards. . . . . . . . . . . . 1-10
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . .1-11
1.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Maintenance Hazards. . . . . . . . . . . . . . . . . . . . 1-11
Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . 1-13
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
SECTION - PARAGRAPH, SUBJECT |
PAGE |
2.2PREPARATION, INSPECTION,
AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 2-2 Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . 2-5 Functional Check . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Walk-Around inspection . . . . . . . . . . . . . . . . . . . 2-9
2.3OSCILLATING 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
4.2OPERATING 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
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SECTION - PARAGRAPH, SUBJECT |
PAGE |
4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-7 Traveling Forward or Reverse . . . . . . . . . . . . . . 4-9 4.5 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.6 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . 4-10 4.7 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Loading from Ground Level. . . . . . . . . . . . . . . 4-10 Loading From Positions Above Ground Level 4-10 Platform Level Adjustment . . . . . . . . . . . . . . . . 4-11 Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . 4-11 4.8 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Swinging the Boom . . . . . . . . . . . . . . . . . . . . . 4-12 Raising and Lowering the Main Boom . . . . . . 4-12 Telescoping the Main Boom . . . . . . . . . . . . . . 4-12
4.9AUXILIARY POWER - NON ADE EQUIPPED
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MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4-13 |
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Activating from the Platform Control Station . . |
4-13 |
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Activating from the Ground Control Station . . |
4-13 |
4.10 |
AUXILIARY POWER - |
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ADE EQUIPPED MACHINES. . . . . . . . . . . . . . . . |
4-14 |
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Activating from the Platform Control Station . . |
4-14 |
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Activating from the Ground Control Station . . |
4-14 |
4.11 |
SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . |
4-15 |
4.12 |
TIE DOWN AND LIFTING. . . . . . . . . . . . . . . . . . . . |
4-15 |
4.13 |
TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4-19 |
4.14 |
PLACARDS AND DECALS. . . . . . . . . . . . . . . . . . . |
4-20 |
SECTION - PARAGRAPH, SUBJECT |
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Critical Stability Weights . . . . . . . . . . . . . . . . . . 6-13
Serial Number Location . . . . . . . . . . . . . . . . . . 6-14
6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-28
6.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-39
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-39
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-40
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-40
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6.5DRAINING OIL BUILD UP FROM THE PROPANE
REGULATOR (PRIOR TO S/N 0300109274) . . . .6-42 6.6 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-44 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-46
6.8 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-46
SECTION - 7 - INSPECTION AND REPAIR LOG
SECTION - PARAGRAPH, SUBJECT |
PAGE |
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 3-9. Fuel Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 4-1. Position Of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-2 4-2. Position Of Least Forward Stability . . . . . . . . . . . . . . . . . . . 4-3 4-3. Grades and Sideslopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4-4. Machine Tie Down - 400S Models. . . . . . . . . . . . . . . . . . . . 4-16 4-5. Machine Tie Down - 460SJ Models. . . . . . . . . . . . . . . . . . . 4-17 4-6. Lifting and Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 4-7. Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 4-8. Decal Installation - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . 4-21
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4-9. |
Decal Installation - Sheet 2 of 4. . . . . . . . . . . . . . . . . . . |
. . . 4-22 |
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6-13. Operator Maintenance and Lubrication Diagram - |
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4-10. |
Decal Installation - Sheet 3 of 4. . . . . . . . . . . . . . . . . . . |
. . . 4-23 |
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Deutz 2.9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 6-26 |
4-11. |
Decal Installation - Sheet 4 of 4. . . . . . . . . . . . . . . . . . . . |
. . 4-24 |
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6-14. Operator Maintenance and Lubrication Diagram - |
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6-1. |
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . 6-14 |
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GM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . 6-27 |
6-2. |
Engine Operating Temperature Specifications - |
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6-15. Deutz D2011 Engine Dipsticks . . . . . . . . . . . . . . . . . . . |
. . . 6-31 |
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Deutz - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . 6-15 |
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6-16. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . 6-45 |
6-3. |
Engine Operating Temperature Specifications - |
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Deutz - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . 6-16 |
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6-4. |
Engine Operating Temperature Specifications - |
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Ford - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . 6-17 |
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6-5. |
Engine Operating Temperature Specifications - |
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Ford - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . 6-18 |
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6-6. |
Engine Operating Temperature Specifications - |
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Caterpillar - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . |
. . 6-19 |
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6-7. |
Engine Operating Temperature Specifications - |
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Caterpillar - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . |
. . 6-20 |
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6-8. |
Engine Operating Temperature Specifications - |
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GM - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . 6-21 |
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6-9. |
Engine Operating Temperature Specifications - |
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GM - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . 6-22 |
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6-10. |
Engine Operating Temperature Specifications - |
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Perkins - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . 6-23 |
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6-11. |
Engine Operating Temperature Specifications - |
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Perkins - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . 6-24 |
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6-12. |
Operator Maintenance and Lubrication Diagram - |
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All Except Deutz 2.9 and GM . . . . . . . . . . . . . . . . . . . . . |
. . 6-25 |
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LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.). . . . . . . . . 1-6 1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . . 1-9 2-1 Inspection and Maintenance Table . . . . . . . . . . . . 2-3 4-1 Decals - 400S with 500 lb
(227 or 230 kg) Capacity . . . . . . . . . . . . . . . . . . . 4-25 4-2 Decals - 400S with 750 lb (340 kg) Capacity. . . . 4-29 4-3 Decals - 460SJ . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 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 Caterpillar 3024/C2.2 . . . . . . . . . . . . . . . . . . . . . . . 6-6 6-7 Deutz TCD2.9L4 Specifications . . . . . . . . . . . . . . . 6-6 6-8 Deutz F3M1011F/F3M2011F/D2011L03 . . . . . . . . 6-7 6-9 Ford LRG-425 (Gas or Dual Fuel) . . . . . . . . . . . . . 6-7 6-11 Isuzu 4LE1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 6-12 Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 6-10 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 6-13 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
SECTION - PARAGRAPH, SUBJECT |
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6-14 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-15 Mobilfluid 424 Specs. . . . . . . . . . . . . . . . . . . . . . . 6-10
6-16 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . 6-11
6-17 Mobil EAL 224H Specs . . . . . . . . . . . . . . . . . . . . . 6-11
6-18 Mobil EAL Envirosyn H Specs . . . . . . . . . . . . . . . 6-12
6-19 Exxon Univis HVI 26 Specs. . . . . . . . . . . . . . . . . . 6-12
6-20 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . 6-13
6-21 Lubrication Specifications. . . . . . . . . . . . . . . . . . . 6-28
6-22 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-41
7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1
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SECTION 1 - SAFETY PRECAUTIONS
This section outlines the necessary precautions for proper and safe machine usage and maintenance. It is mandatory that a daily routine is established based on the content of this manual to promote proper machine usage. 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 must be followed to ensure that the machine is safe to operate.
The owner/user/operator/lessor/lessee of the machine must not accept operating responsibility 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.
This section contains the responsibilities of the owner, user, operator, lessor, and lessee concerning safety, training, inspection, maintenance, application, and operation. 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.
•The Operation and Safety Manual must be read and understood in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc.
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1-1 |
SECTION 1 - SAFETY PRECAUTIONS
•An operator must not accept operating responsibilities until adequate training has been given by competent and authorized persons.
•Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and maintenance of the unit.
•Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine and in this manual.
•Ensure that the machine is to be used in a manner which is within the scope of its intended application as determined 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 your utilization and application of the machine.
•Precautions to avoid all hazards in the work area must be taken by the user before and during operation of the machine.
•Do not operate or raise the platform from a position on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless the application is approved in writing by JLG.
•Before operation, check work area for overhead hazards such as electric lines, bridge cranes, and other potential overhead obstructions.
•Check operating surfaces for holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards.
•Check the work area for hazardous locations. Do not operate the machine in hazardous environments unless approved for that purpose by JLG.
•Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel. Do not travel on unsupported surfaces.
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– JLG Lift – |
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SECTION 1 - SAFETY PRECAUTIONS
•Do not operate this machine until the inspections and functional checks as specified in Section 2 of this manual have been performed.
•Do not operate this machine until it has been serviced and maintained according to the maintenance and inspection requirements as specified in the machine’s Service and Maintenance Manual.
•Ensure all 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 PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
•Do not operate any machine on which the safety or instruction placards or decals are missing or illegible.
•Check the machine for modifications to original components. Ensure that any modifications have been approved by JLG.
•Avoid accumulation of debris on platform floor. Keep mud, oil, grease, and other slippery substances from footwear and platform floor.
•Machine operation requires your full attention. Bring the machine to a full stop before using any device, i.e. cell phones, two-way radios, etc. that will distract your attention from safely operating the machine.
•Do not use the machine for any purpose other than positioning personnel, their tools, and equipment.
•Before operation, the user must be familiar with the machine capabilities and operating characteristics of all functions.
•Never operate a malfunctioning machine. If a malfunction occurs, shut down the machine. Remove the unit from service and notify the proper authorities.
•Do not remove, modify, or disable any safety devices.
•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.
•Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency.
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1-3 |
SECTION 1 - SAFETY PRECAUTIONS
•Do not carry materials directly on platform railing unless approved by JLG.
•When two or more persons are in the platform, the operator shall be responsible for all machine operations.
•Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area.
•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 or pulling except by pulling at the chassis tie-down lugs.
•Fully lower platform and shut off all power before leaving machine.
•Remove all rings, watches, and jewelry when operating machine. Do not wear loose fitting clothing or long hair unrestrained which may become caught or entangled in equipment.
•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.
•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..
•Enter and exit only through gate area. Use extreme caution when entering or leaving platform. Ensure that the platform assembly is fully lowered. Face the machine when entering or leaving the platform. Always maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit.
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– JLG Lift – |
3121216 |
SECTION 1 - SAFETY PRECAUTIONS
• This machine is not insulated and does not provide protection from contact or proximity to electrical current.
•Keep both feet firmly positioned on the platform floor at all times. Never position ladders, boxes, steps, planks, or similar items on unit to provide additional reach for any purpose.
•Keep oil, mud, and slippery substances cleaned from footwear and the platform floor.
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1-5 |
SECTION 1 - SAFETY PRECAUTIONS
•Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum Approach Distance (MAD) as shown in Table 1-1.
•Allow for machine movement and electrical line swaying.
Table 1-1. Minimum Approach Distances (M.A.D.)
Voltage Range |
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MINIMUM APPROACH DISTANCE |
(Phase to Phase) |
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in Feet (Meters) |
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0to50KV |
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10(3) |
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Over50KVto200KV |
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15(5) |
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Over200KVto350KV |
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20(6) |
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Over350KVto500KV |
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25(8) |
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Over500KVto750KV |
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35(11) |
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Over750KVto1000KV |
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45(14) |
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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.
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– JLG Lift – |
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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.
•The user must be familiar with the surface before driving. Do not exceed the allowable sideslope and grade while driving.
•Do not elevate platform or drive with platform elevated while on or near a sloping, uneven, or soft surface. Ensure machine is positioned on a firm, level and smooth surface before elevating platform or driving with the platform in the elevated position.
•Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.
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1-7 |
SECTION 1 - SAFETY PRECAUTIONS
•Never exceed the maximum work load as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG.
•Keep the chassis of the machine a minimum of 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards at the ground level.
•Do not push or pull any object with the boom.
•Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure. Never attach wire, cable, or any similar items to platform.
•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.
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– JLG Lift – |
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SECTION 1 - SAFETY PRECAUTIONS |
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DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/S). |
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Table 1-2. Beaufort Scale (For Reference Only) |
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Beaufort |
Wind Speed |
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Description |
Land Conditions |
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Number |
mph |
m/s |
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0 |
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0 |
0-0.2 |
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Calm |
Calm.Smokerisesvertically |
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1 |
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1-3 |
0.3-1.5 |
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Lightair |
Windmotionvisibleinsmoke |
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2 |
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4-7 |
1.6-3.3 |
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Lightbreeze |
Windfelt onexposedskin.Leavesrustle |
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3 |
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8-12 |
3.4-5.4 |
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Gentlebreeze |
Leaves andsmallertwigs inconstantmotion |
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4 |
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13-18 |
5.5-7.9 |
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Moderatebreeze |
Dust andloose paperraised.Smallbranches begintomove. |
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5 |
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19-24 |
8.0-10.7 |
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Fresh breeze |
Smallertreessway. |
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6 |
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25-31 |
10.8-13.8 |
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Strongbreeze |
Largebranchesinmotion.Flagswavingnear horizontal.Umbrellause |
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becomesdifficult. |
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7 |
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32-38 |
13.9-17.1 |
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NearGale/ModerateGale |
Whole treesinmotion.Effortneededtowalkagainst thewind. |
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8 |
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39-46 |
17.2-20.7 |
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FreshGale |
Twigsbrokenfromtrees.Cars veer onroad. |
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9 |
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47-54 |
20.8-24.4 |
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StrongGale |
Lightstructuredamage. |
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1-9 |
SECTION 1 - SAFETY PRECAUTIONS
•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.
•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.
•Under all travel conditions, the operator must 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.
1-10 |
– JLG Lift – |
3121216 |
SECTION 1 - SAFETY PRECAUTIONS
1.4 TOWING, LIFTING, AND HAULING |
1.5 MAINTENANCE |
•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.
This sub-section contains general safety precautions which must be observed during maintenance of this machine. Additional precautions to be observed during machine maintenance are inserted at the appropriate points in this manual and in the Service and Maintenance Manual. It is of utmost importance that maintenance personnel pay strict attention to these precautions to avoid possible injury to personnel or damage to the machine or property. A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe.
•Shut off power to all controls and ensure that all moving parts are secured from inadvertent motion prior to performing any adjustments or repairs.
•Never work under an elevated platform until it has been fully lowered to the full down position, if possible, or otherwise supported and restrained from movement with appropriate safety props, blocking, or overhead supports.
•DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the machine is powered on or when the hydraulic system is under pressure.
•Always relieve hydraulic pressure from all hydraulic circuits before loosening or removing hydraulic components.
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1-11 |
SECTION 1 - SAFETY PRECAUTIONS
•DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help protect hands from spraying fluid.
•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.
•Use only approved non-flammable cleaning solvents.
•Do not replace items critical to stability, such as batteries or solid tires, with items of different weight or specification. Do not modify unit in any way to affect stability.
•Refer to the Service and Maintenance Manual for the weights of critical stability items.
•Ensure replacement parts or components are identical or equivalent to original parts or components.
•Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. Ensure adequate support is provided when raising components of the machine.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
1-12 |
– JLG Lift – |
3121216 |
SECTION 1 - SAFETY PRECAUTIONS
•Always disconnect batteries when servicing electrical components or when performing welding on the machine.
•Do not allow smoking, open flame, or sparks near battery during charging or servicing.
•Do not contact tools or other metal objects across the battery terminals.
•Always wear hand, eye, and face protection when servicing batteries. Ensure that battery acid does not come in contact with skin or clothing.
BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION.
•Charge batteries only in a well ventilated area.
•Avoid overfilling the battery fluid level. Add distilled water to batteries only after the batteries are fully charged.
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1-13 |
SECTION 1 - SAFETY PRECAUTIONS
NOTES:
1-14 |
– JLG Lift – |
3121216 |
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
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.
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.
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.
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.
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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– JLG Lift – |
2-1 |
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
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.
2-2 |
– JLG Lift – |
3121216 |
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Table 2-1.Inspection and Maintenance Table
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Type |
Frequency |
Primary Responsibility |
Service Qualification |
Reference |
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Pre-Start Inspection |
Beforeusing eachday; or |
Useror Operator |
Useror Operator |
OperatorandSafetyManual |
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whenever there’sanOperatorchange. |
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Pre-DeliveryInspection(See |
Beforeeachsale,lease,orrentaldelivery. |
Owner,Dealer,orUser |
QualifiedJLG Mechanic |
ServiceandMaintenanceManual |
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Note) |
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andapplicable JLGinspectionform |
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FrequentInspection |
Inservicefor3monthsor150hours,whichevercomesfirst; |
Owner,Dealer, orUser |
QualifiedJLG Mechanic |
ServiceandMaintenanceManual |
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(See Note) |
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or |
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andapplicable JLGinspectionform |
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Outof servicefora periodofmorethan3months; |
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or |
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Purchasedused. |
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AnnualMachineInspection |
Annually,nolater than13monthsfromthedate ofprior |
Owner,Dealer, orUser |
Factory-Qualified Service |
ServiceandMaintenanceManual |
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(See Note) |
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inspection. |
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Technician |
andapplicable JLGinspectionform |
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(Recommended) |
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Preventative Maintenance |
At intervals asspecifiedintheServiceandMaintenance |
Owner,Dealer, orUser |
QualifiedJLG Mechanic |
ServiceandMaintenanceManual |
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Manual. |
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NOTE: |
Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. |
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3121216 |
– JLG Lift – |
2-3 |
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
1. Platform
2. Jib(460SJOnly)
3. JibLiftCylinder(460SJOnly)
4. LevelCylinder
5. Power Track
6. LiftCylinder
7. DriveWheels
8. SteerWheels
9. GroundControl
10. Turntable
11. BaseBoom
12. FlyBoom
13. PlatformConsole
Figure 2-1. Basic Nomenclature
2-4 |
– JLG Lift – |
3121216 |