Operation and Safety Manual

Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
400S
460SJ
S/N 0300203771* to 0300272360,
S/N 1300007289 to 1300007393,
S/N E300000100 to E300007988
* See inside front cover for exceptions.

ANSI ®
AS/NZS 3121670
December 12, 2019 - Rev M
 This manual also covers the following Serial Numbers.

0300184729 0300203261 0300203580 0300203677

0300200144 0300203262 0300203581 0300203678
0300200145 0300203307 0300203582 0300203679
0300200476 0300203308 0300203583 0300203680
0300200477 0300203351 0300203584 0300203681
0300202446 0300203352 0300203628 0300203724
0300202447 0300203394 0300203629 0300203725
0300202448 0300203395 0300203630 0300203727
0300202449 0300203439 0300203631 0300203728
0300202450 0300203440 0300203632

WARNING
Operating, servicing and maintaining this vehicle or equipment
can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other
reproductive harm. To minimize exposure, avoid breathing
exhaust, do not idle the engine except as necessary, service your
vehicle or equipment in a well-ventilated area and wear gloves
or wash your hands frequently when servicing. For more
information go to www.P65Warnings.ca.gov.
 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.

3121670 a
 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 INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACK- IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES.
GROUND. THIS DECAL WILL HAVE A YELLOW BACKGROUND.

IMPORTANT
INDICATES A POTENTIALLY HA ZARDOUS SITUATION. IF NOT AVOIDED, COULD INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI-
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACK- RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
GROUND.

b 3121670
 FOREWORD

For:
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG • Accident Reporting • Standards and Regulations
INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA- Compliance Information
• Product Safety Publica-
TION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR
tions • Questions Regarding Special
THIS PRODUCT.
Product Applications
• Current Owner Updates
• Questions Regarding Prod-
IMPORTANT • Questions Regarding
uct Modifications
Product Safety
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF
RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE
Contact:
CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.
Product Safety and Reliability Department
JLG Industries, Inc.
IMPORTANT 13224 Fountainhead Plaza
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE Hagerstown, MD 21742
JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY USA
OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PER-
or Your Local JLG Office
SONAL PROPERTY OR THE JLG PRODUCT.
(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: [email protected]

3121670 c
FOREWORD

REVISION LOG

Original Issue A - March 12, 2015

Revised B - March 21, 2015
Revised C - April 2, 2015
Revised D - July 30, 2015
Revised E - January 19, 2016
Revised F - June 7, 2016
Revised G - January 23, 2017
Revised H - June 30, 2017
Revised I - April 3, 2018
Revised J - May 30, 2018
Revised K - June 29, 2018 - Revised Covers, Prop 65
Revised L - November 5, 2018
Revised M - December 12, 2019

d 3121670
 TABLE OF CONTENTS

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

SECTION - 1 - SAFETY PRECAUTIONS Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 SkyGuard Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED). . . . 2-10
Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 SECTION - 3 - MACHINE CONTROLS AND INDICATORS
Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Ground Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . 3-9
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Ground Control Console Display Gauge . . . . . . . . . . 3-13
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10 Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-22
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . . 1-11
1.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 SECTION - 4 - MACHINE OPERATION
Maintenance Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 4.2 BOOM OPERATING CHARACTERISTICS AND
LIMITATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
AND INSPECTION Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 4.3 ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Fuel Reserve / Shut-Off System (Diesel Engines
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2 Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . . . . . . 2-6 Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . . 4-9

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TABLE OF CONTENTS

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

Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 SECTION - 5 - EMERGENCY PROCEDURES
4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 5.2 INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-10 5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Operator Unable to Control Machine. . . . . . . . . . . . . . . 5-1
4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Platform or Boom Caught Overhead . . . . . . . . . . . . . . . 5-2
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 5.4 EMERGENCY TOWING PROCEDURES . . . . . . . . . . . . . . . . . . 5-2
Raising and Lowering the Main Boom . . . . . . . . . . . . . 4-11 5.5 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-11 (CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
4.8 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.9 MACHINE SAFETY SYSTEM OVERRIDE (MSSO) SECTION - 6 - ACCESSORIES
(CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
6.1 FALL ARREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
4.10 SKYGUARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
SkyGuard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
6.2 PIPE RACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
SkyGuard - SkyLine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Capacity Specifications (Australia Only) . . . . . . . . . . . . 6-4
SkyGuard - SkyEye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
SkyGuard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-4
4.11 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Shut Down and Park. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
6.3 SKYGLAZIER™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
4.12 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Capacity Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.4 SKYPOWER™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

ii 3121670
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SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 7.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 7.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
6.5 SKYWELDER™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Welding Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 7.5 PROPANE FUEL FILTER REPLACEMENT (GM ENGINE). . 7-39
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . 6-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 7.6 PROPANE FUEL FILTER REPLACEMENT (KUBOTA
6.6 SOFT TOUCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
6.7 BOLT-ON EXTERNAL FALL ARREST . . . . . . . . . . . . . . . . . . . 6-11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Inspection Before Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
7.7 PROPANE FUEL SYSTEM PRESSURE RELIEF . . . . . . . . . . . 7-42
SECTION - 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTE- 7.8 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 7-42
NANCE
7.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 SECTION - 8 - INSPECTION AND REPAIR LOG
7.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

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TABLE OF CONTENTS

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

This Page Left Blank Intentionally

iv 3121670
 LIST OF FIGURES

FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

2-1. Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 6-1. Bolt-On External Fall Arrest Cable Tension . . . . . . . . . . . 6-13
3-1. Ground Control Console - 400S. . . . . . . . . . . . . . . . . . . . . . . 3-3 6-2. Bolt-On External Fall Arrest System . . . . . . . . . . . . . . . . . . 6-14
3-2. Ground Control Console - 400S w/MSSO (CE Only) . . . . 3-4 7-1. Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
3-3. Ground Control Console - 460SJ . . . . . . . . . . . . . . . . . . . . . . 3-5 7-2. Hydraulic Oil Operation Chart - Sheet 1 of 2. . . . . . . . . . 7-12
3-4. Ground Control Console - 460SJ w/MSSO (CE Only) . . . 3-6 7-3. Hydraulic Oil Operation Chart - Sheet 2 of 2. . . . . . . . . . 7-13
3-5. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . 3-10 7-4. Engine Operating Temperature Specifications -
3-6. Ground Control Indicator Panel - Kubota Engine . . . . . 3-11 Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
3-7. Splash Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 7-5. Engine Operating Temperature Specifications - GM - Sheet
3-8. Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 1 of 27-15
3-9. Engine Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 7-6. Engine Operating Temperature Specifications - GM - Sheet
3-10. Ground Control Console Display Gauge . . . . . . . . . . . . . 3-15 2 of 27-16
3-11. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 7-7. Engine Oil Operation Chart - Kubota. . . . . . . . . . . . . . . . . 7-17
3-12. Platform Control Indicator Panel. . . . . . . . . . . . . . . . . . . . . 3-23 7-8. Operator Maintenance and Lubrication Diagram - Deutz
3-13. Fuel Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 2.9L Engine7-18
4-1. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-5 7-9. Operator Maintenance and Lubrication Diagram - Deutz
4-2. Position of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-6 2011L Engine7-19
4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 7-10. Operator Maintenance and Lubrication Diagram - GM . . .
4-4. Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Engine7-20
4-5. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 7-11. Operator Maintenance and Lubrication Diagram - Kubota
4-6. Decal Location Sheet 1 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Engine7-21
4-7. Decal Location Sheet 2 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 7-12. GM Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
4-8. Decal Location Sheet 3 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 7-13. Kubota Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7-41
4-9. Decal Location Sheet 4 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4-10. Decal Location Sheet 5 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-11. Decal Location Sheet 6 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-12. Decal Location Sheet 7 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

3121670 v
 LIST OF FIGURES
FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

This Page Left Blank Intentionally

vi 3121670
 LIST OF TABLES

TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6 7-16 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
1-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-9 7-17 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3 7-18 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
4-1 Decal Legend - 400S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25 8-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
4-2 Decal Legend - 460SJ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
4-3 Decal Legend - 400S Kubota Engine-Powered
Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33
4-4 Decal Legend - 460SJ Kubota Engine-Powered
Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35
6-1 Available Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 Options/Accessories Relationship Table. . . . . . . . . . . . . . . 6-2
7-1 Operating Specifications - 400S. . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2 Operating Specifications - 460SJ. . . . . . . . . . . . . . . . . . . . . . 7-2
7-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-4 Deutz D2011L03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-5 Deutz D2.9L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-6 GM 3.0L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-7 Kubota WG 2503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-8 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-9 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-10 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-11 Mobil DTE 10 Excel 32 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-12 UCon Hydrolube HP-50/46 . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-13 Mobil EAL 224H Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-14 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-15 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

3121670 vii
 LIST OF TABLES
TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

This Page Left Blank Intentionally

viii 3121670
 SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL
This section outlines the necessary precautions for proper and FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL
safe machine usage and maintenance. It is mandatory that a daily COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR
routine is established based on the content of this manual to pro- DEATH.
mote proper machine usage. A maintenance program, using the
information provided in this manual and the Service and Mainte-
1.2 PRE-OPERATION
nance Manual, must also be established by a qualified person and
must be followed to ensure that the machine is safe to operate. Operator Training and Knowledge
The owner/user/operator/lessor/lessee of the machine must not • The Operation and Safety Manual must be read and under-
accept operating responsibility until this manual has been read, stood in its entirety before operating the machine. For clarifi-
training is accomplished, and operation of the machine has been cation, questions, or additional information regarding any
completed under the supervision of an experienced and quali- portions of this manual, contact JLG Industries, Inc.
fied operator.
This section contains the responsibilities of the owner, user, oper-
ator, lessor, and lessee concerning safety, training, inspection,
maintenance, application, and operation. If there are any ques-
tions with regard to safety, training, inspection, maintenance,
application, and operation, please contact JLG Industries, Inc.
(“JLG”).

3121670 1-1
 SECTION 1 - SAFETY PRECAUTIONS

• An operator must not accept operating responsibilities until Workplace Inspection

adequate training has been given by competent and autho-
rized persons. • Precautions to avoid all hazards in the work area must be
taken by the user before and during operation of the machine.
• Allow only those authorized and qualified personnel to oper-
ate the machine who have demonstrated that they under- • Do not operate or raise the platform from a position on trucks,
stand the safe and proper operation and maintenance of the trailers, railway cars, floating vessels, scaffolds or other equip-
unit. ment unless the application is approved in writing by JLG.
• Read, understand, and obey all DANGERS, WARNINGS, CAU- • Before operation, check work area for overhead hazards such
TIONS, and operating instructions on the machine and in this as electric lines, bridge cranes, and other potential overhead
manual. obstructions.
• Ensure that the machine is to be used in a manner which is • Check operating surfaces for holes, bumps, drop-offs, obstruc-
within the scope of its intended application as determined by tions, debris, concealed holes, and other potential hazards.
JLG. • Check the work area for hazardous locations. Do not operate
• All operating personnel must be familiar with the emergency the machine in hazardous environments unless approved for
controls and emergency operation of the machine as specified that purpose by JLG.
in this manual. • Ensure that the ground conditions are adequate to support
• Read, understand, and obey all applicable employer, local, and the maximum tire load indicated on the tire load decals
governmental regulations as they pertain to your utilization located on the chassis adjacent to each wheel. Do not travel
and application of the machine. on unsupported surfaces.

1-2 3121670
 SECTION 1 - SAFETY PRECAUTIONS

Machine Inspection 1.3 OPERATION

• Do not operate this machine until the inspections and func-
tional checks as specified in Section 2 of this manual have
General
been performed. • Machine operation requires your full attention. Bring the
• Do not operate this machine until it has been serviced and machine to a full stop before using any device, i.e. cell phones,
maintained according to the maintenance and inspection two-way radios, etc. that will distract your attention from
requirements as specified in the machine’s Service and Main- safely operating the machine.
tenance Manual. • Do not use the machine for any purpose other than position-
• Ensure all safety devices are operating properly. Modification ing personnel, their tools, and equipment.
of these devices is a safety violation. • 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
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE occurs, shut down the machine. Remove the unit from service
ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER. and notify the proper authorities.
• Do not operate any machine on which the safety or instruction • Do not remove, modify, or disable any safety devices.
placards or decals are missing or illegible.
• Never slam a control switch or lever through neutral to an
• Check the machine for modifications to original components. opposite direction. Always return switch to neutral and stop
Ensure that any modifications have been approved by JLG. before moving the switch to the next function. Operate con-
• Avoid accumulation of debris on platform floor. Keep mud, oil, trols with slow and even pressure.
grease, and other slippery substances from footwear and plat- • Do not allow personnel to tamper with or operate the
form floor. machine from the ground with personnel in the platform,
except in an emergency.

3121670 1-3
 SECTION 1 - SAFETY PRECAUTIONS

• Do not carry materials directly on platform railing unless • Hydraulic cylinders are subject to thermal expansion and con-
approved by JLG. traction. This may result in changes to the boom and/or plat-
form position while the machine is stationary. Factors
• When two or more persons are in the platform, the operator
affecting thermal movement can include the length of time
shall be responsible for all machine operations.
the machine will remain stationary, hydraulic oil temperature,
• Always ensure that power tools are properly stowed and never ambient air temperature, and boom and platform position.
left hanging by their cord from the platform work area.
• When driving, always position boom over rear axle in line with Trip and Fall Hazards
the direction of travel. Remember, if boom is over the front • During operation, occupants in the platform must wear a full
axle, steer and drive functions will be reversed. body harness with a lanyard attached to an authorized lanyard
• Do not assist a stuck or disabled machine by pushing or pull- anchorage point. Attach only one (1) lanyard per lanyard
ing except by pulling at the chassis tie-down lugs. anchorage point.

• 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 unre-
strained which may become caught or entangled in equip-
ment.
• Persons under the influence of drugs or alcohol or who are • Enter and exit only through gate area. Use extreme caution
subject to seizures, dizziness or loss of physical control must when entering or leaving platform. Ensure that the platform
not operate this machine. 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.

1-4 3121670
 SECTION 1 - SAFETY PRECAUTIONS

• Before operating the machine, make sure all gates are closed Electrocution Hazards
and fastened in their proper position.
• This machine is not insulated and does not provide protection
from contact or proximity to electrical current.

• 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.

3121670 1-5
 SECTION 1 - SAFETY PRECAUTIONS

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

Voltage Range MINIMUM APPROACH DISTANCE

(Phase to Phase) in Feet (Meters)
0 to 50 KV 10 (3)
Over 50KV to 200 KV 15 (5)
Over 200 KV to 350 KV 20 (6)
Over 350 KV to 500 KV 25 (8)
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 distance from electrical lines, apparatus, or any ener-
gized (exposed or insulated) parts according to the Minimum • Maintain a clearance of at least 10 ft. (3m) between any part of
Approach Distance (MAD) as shown in Table 1-1. the machine and its occupants, their tools, and their equip-
• Allow for machine movement and electrical line swaying. ment 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.

1-6 3121670
 SECTION 1 - SAFETY PRECAUTIONS

• The minimum approach distance may be reduced if insulating Tipping Hazards

barriers are installed to prevent contact, and the barriers are
rated for the voltage of the line being guarded. These barriers • The user must be familiar with the surface before driving. Do
shall not be part of (or attached to) the machine. The mini- not exceed the allowable sideslope and grade while driving.
mum 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 require-
ments 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 OTH-
ERWISE.

• 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 elevat-
ing platform or driving with the platform in the elevated posi-
tion.
• Before driving on floors, bridges, trucks, and other surfaces,
check allowable capacity of the surfaces.

3121670 1-7
 SECTION 1 - SAFETY PRECAUTIONS

• Never exceed the maximum work load as specified on the • Do not operate the machine when wind conditions, including
platform. Keep all loads within the confines of the platform, gusts, may exceed 28 mph (12.5 m/s). Factors affecting wind
unless authorized by JLG. speed are; platform elevation, surrounding structures, local
weather events, and approaching storms. Refer to Table 1-2,
• Keep the chassis of the machine a minimum of 2 ft. (0.6m)
Beaufort scale (For Reference Only) or use other means to
from holes, bumps, drop-offs, obstructions, debris, concealed
monitor wind conditions.
holes, and other potential hazards at the ground level.
• Wind speed can be significantly greater at height than at
• Do not push or pull any object with the boom.
ground level.
• Never attempt to use the machine as a crane. Do not tie-off
• Wind speed can change rapidly. Always consider approaching
machine to any adjacent structure. Never attach wire, cable, or
weather events, the time required to lower the platform, and
any similar items to platform.
methods to monitor current and potential wind conditions.
• If boom assembly or platform is in a position that one or more
• Do not increase surface area of the platform or the load.
wheels are off the ground, all persons must be removed before
Increased areas exposed to wind will decrease stability.
attempting to stabilize the machine. Use cranes, forklift trucks,
or other appropriate equipment to stabilize machine. • Do not increase the platform size with unauthorized modifica-
tions or attachments.

1-8 3121670
 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 Wind Speed

Description Land Conditions
Number mph m/s
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 rustle
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. Flags waving near horizontal. Umbrella use
becomes difficult.
7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort 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.

3121670 1-9
 SECTION 1 - SAFETY PRECAUTIONS

Crushing and Collision Hazards • Keep non-operating personnel at least 6 ft. (1.8m) away from
machine during all driving and swing operations.
• Approved head gear must be worn by all operating and
• Under all travel conditions, the operator must limit travel
ground personnel.
speed according to conditions of ground surface, congestion,
• Check work area for clearances overhead, on sides, and bot- visibility, slope, location of personnel, and other factors which
tom of platform when lifting or lowering platform, and driving. may cause collision or injury to personnel.
• Be aware of stopping distances in all drive speeds. When driv-
ing 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. Dis-
connect power to overhead cranes.
• During operation, keep all body parts inside platform railing.
• Warn personnel not to work, stand, or walk under a raised
• Use the boom functions, not the drive function, to position the boom or platform. Position barricades on floor if necessary.
platform close to obstacles.
• Always post a lookout when driving in areas where vision is
obstructed.

1-10 3121670
 SECTION 1 - SAFETY PRECAUTIONS

1.4 TOWING, LIFTING, AND HAULING 1.5 MAINTENANCE

• Never allow personnel in platform while towing, lifting, or This sub-section contains general safety precautions which must
hauling. be observed during maintenance of this machine. Additional pre-
cautions to be observed during machine maintenance are
• This machine should not be towed, except in the event of
inserted at the appropriate points in this manual and in the Ser-
emergency, malfunction, power failure, or loading/unloading.
vice and Maintenance Manual. It is of utmost importance that
Refer to the Emergency Procedures section of this manual for
maintenance personnel pay strict attention to these precautions
emergency towing procedures.
to avoid possible injury to personnel or damage to the machine
• Ensure boom is in the stowed position and, if equipped, the or property. A maintenance program must be established by a
turntable locked prior to towing, lifting or hauling. The plat- qualified person and must be followed to ensure that the
form must be completely empty of tools. machine is safe.
• When lifting machine, lift only at designated areas of the
machine. Lift the unit with equipment of adequate capacity. Maintenance Hazards
• Refer to the Machine Operation section of this manual for lift- • Shut off power to all controls and ensure that all moving parts
ing information. 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 fit-
tings 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.

3121670 1-11
 SECTION 1 - SAFETY PRECAUTIONS

• DO NOT use your hand to check for leaks. Use a piece of card- • Do not use machine as a ground for welding.
board or paper to search for leaks. Wear gloves to help protect
• When performing welding or metal cutting operations, pre-
hands from spraying fluid.
cautions 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.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE

• Ensure replacement parts or components are identical or ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
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.

1-12 3121670
 SECTION 1 - SAFETY PRECAUTIONS

Battery Hazards
• Always disconnect batteries when servicing electrical compo- BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND
nents or when performing welding on the machine. CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH
• Do not allow smoking, open flame, or sparks near battery CLEAN WATER AND SEEK MEDICAL ATTENTION.
during charging or servicing. • Charge batteries only in a well ventilated area.
• Do not contact tools or other metal objects across the battery • Avoid overfilling the battery fluid level. Add distilled water to
terminals. batteries only after the batteries are fully charged.
• Always wear hand, eye, and face protection when servicing
batteries. Ensure that battery acid does not come in contact
with skin or clothing.

3121670 1-13
 SECTION 1 - SAFETY PRECAUTIONS

NOTES:

1-14 3121670
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING 6. The safest means to operate the machine where overhead
obstructions, other moving equipment, and obstacles,
The aerial platform is a personnel handling device; so it is neces- depressions, holes, or drop-offs exist.
sary that it be operated and maintained only by trained person-
7. Means to avoid the hazards of unprotected electrical con-
nel.
ductors.
Persons under the influence of drugs or alcohol or who are sub-
8. Specific job requirements or machine application.
ject to seizures, dizziness or loss of physical control must not
operate this machine.
Training Supervision
Operator Training Training must be done under the supervision of a qualified per-
son in an open area free of obstructions until the trainee has
Operator training must cover:
developed the ability to safely control and operate the machine.
1. Use and limitations of the controls in the platform and at the
ground, emergency controls and safety systems. Operator Responsibility
2. Control labels, instructions, and warnings on the machine. The operator must be instructed that he/she has the responsibil-
ity and authority to shut down the machine in case of a malfunc-
3. Rules of the employer and government regulations.
tion or other unsafe condition of either the machine or the job
4. Use of approved fall protection device. site.
5. Enough knowledge of the mechanical operation of the
machine to recognize a malfunction or potential malfunc-
tion.

3121670 2-1
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

The following table covers the periodic machine inspections and JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A
maintenance required by JLG Industries, Inc. Consult local regula- PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL
tions for further requirements for aerial work platforms. The fre- FOR THE SPECIFIC JLG PRODUCT MODEL.
quency of inspections and maintenance must be increased as
necessary when the machine is used in a harsh or hostile environ-
ment, if the machine is used with increased frequency, or if the
machine is used in a severe manner.

2-2 3121670
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1. Inspection and Maintenance Table

Primary Service
Type Frequency Reference
Responsibility Qualification
Pre-Start Inspection Before using each day; or User or Operator User or Operator Operator and Safety Manual
whenever there’s an Operator change.
Pre-Delivery Inspection (See Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Note) and applicable JLG inspection form
Frequent Inspection In service for 3 months or 150 hours, whichever comes first; Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
(See Note) or and applicable JLG inspection form
Out of service for a period of more than 3 months; or
Purchased used.
Annual Machine Inspection Annually, no later than 13 months from the date of prior Owner, Dealer, or User Factory Trained Service and Maintenance Manual
(See Note) inspection. Service Technician and applicable JLG inspection form
(Recommended)
Preventative Maintenance At intervals as specified in the Service and Maintenance Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Manual.
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.

3121670 2-3
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION





OR


 
1. Platform 

2. Platform Console
3. SkyGuard (If Equipped)
4. Cross Rail (If Equipped)
5. Fly Boom Section
6. Base Boom Section
7. Front Drive/Steer Wheels 
8. Rear Drive Wheels
9. Frame 
10. Turntable

11. Oscillation Cylinder
12. Ground Console
  0"$

Figure 2-1. Basic Nomenclature

2-4 3121670
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Pre-Start Inspection 5. Daily Walk-Around Inspection – Perform as instructed.

The Pre-Start Inspection should include each of the following: 6. Battery – Charge as required.

1. Cleanliness – Check all surfaces for leakage (oil, fuel, or bat- 7. Fuel (Combustion Engine Powered Machines) – Add the
tery fluid) or foreign objects. Report any leakage to the proper fuel as necessary.
proper maintenance personnel. 8. Engine Oil Supply – Ensure the engine oil level is at the Full
2. Structure – Inspect the machine structure for dents, dam- mark on the dipstick and the filler cap is secure.
age, weld or parent metal cracks or other discrepancies. 9. Hydraulic Oil – Check the hydraulic oil level. Ensure hydrau-
lic oil is added as required.
10. Accessories/Attachments – Refer to the Accessories section
in this manual or the accessory installed upon the machine
for specific inspection, operation, and maintenance instruc-
tions.
11. Function Check – Once the “Walk-Around” Inspection is
Parent Metal Crack Weld Crack complete, perform a functional check of all systems in an
area free of overhead and ground level obstructions. Refer to
3. Decals and Placards – Check all for cleanliness and legibil- Section 4 for more specific operating instructions.
ity. Make sure none of the decals and placards are missing.
Make sure all illegible decals and placards are cleaned or
replaced.
IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDI-
4. Operation and Safety Manuals – Make sure a copy of the
ATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT
Operation and Safety Manual, AEM Safety Manual (ANSI
OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION.
markets only), and ANSI Manual of Responsibilities (ANSI
markets only) is enclosed in the weather resistant storage
container.

3121670 2-5
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Daily Walk-Around Inspection

   
 







 





  0"$


  


2-6 3121670
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Begin the "Walk-Around Inspection" at Item 1, as noted on the 6. Drive Motor, Brake, and Hub - No evidence of leakage.
diagram. Continue checking each item in sequence for the condi-
7. Hood Assemblies - See Inspection Note.
tions listed in the following checklist.
8. All Hydraulic Cylinders - No visible damage; pivot pins and
hydraulic hoses undamaged, not leaking.
TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF. 9. Turntable Bearing - Evidence of proper lubrication. No evi-
dence of loose bolts or looseness between bearing and
DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.
machine.
INSPECTION NOTE: On all components, make sure there are no 10. Tie Rod Ends and Steering Spindles - See Inspection Note.
loose or missing parts, that they are securely fastened, and no visible
damage, leaks or excessive wear exists in addition to any other crite- 11. Hydraulic Pump - See Inspection Note.
ria mentioned. 12. Fuel Tank - See Inspection Note.
1. Platform Assembly and Gate - Footswitch works properly, 13. Hydraulic Reservoir - See Inspection Note.
not modified, disabled or blocked. Latch and hinges in work-
ing condition. 14. Battery - Batteries have proper electrolyte level; cables
tight; see Inspection Note.
2. Platform & Ground Control Consoles - Switches and levers
return to neutral, decals/placards secure and legible, control 15. Platform Rotator - See Inspection Note.
markings legible. 16. SkyGuard (If Equipped) - See Inspection Note.
3. Boom Sections/Turntable - See Inspection Note.
4. Swing Drive - No evidence of damage.
5. Wheel/Tire Assemblies - Properly secured, no missing lug
nuts. Inspect for worn tread, cuts, tears or other discrepan-
cies. Inspect wheels for damage and corrosion.

3121670 2-7
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Function Check 3. With the platform in the stowed position:

Perform the Function Check as follows: a. Drive the machine on a grade, not to exceed the rated
gradeability, and stop to ensure the brakes hold;
1. From the ground control console with no load in the plat- b. Check that the tilt indicator is illuminated to ensure
form: proper operation.
a. Check that all guards protecting the switches or locks 4. Swing the boom over either of the rear tires and ensure that
are in place; the Drive Orientation indicator illuminates and that the
b. Operate all functions and ensure proper operation; Drive Orientation Override switch must be used for the drive
c. Check auxiliary power and ensure proper operation; function to operate.
d. Ensure that all machine functions are disabled when
the Emergency Stop Button is pushed in.
e. Ensure all boom functions stop when the function
enable switch is released.
2. From the platform control console:
a. Ensure that the control console is firmly secured in the
proper location;
b. Check that all guards protecting the switches or locks
are in place;
c. Operate all functions and ensure proper operation;
d. Ensure that all machine functions are disabled when
the Emergency Stop Button is pushed in.
e. Ensure that all machine functions stop when the
footswitch is released.

2-8 3121670
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SkyGuard Function Test 4. Disengage the SkyGuard sensor, release controls, then recy-
cle the footswitch. Ensure normal operation is available.
NOTE: Refer to Section 4.10 for additional information on SkyGuard
NOTE: On machines equipped with SkyLine, reattach magnetic end of
operation.
the cable to the bracket.
From the Platform Console in an area free from obstructions:
If SkyGuard remains activated after function reversal or cutout,
1. Operate the telescope out function. depress and hold the SkyGuard Override Switch to allow normal
use of machine functions until the sensor is disengaged.
2. Activate the SkyGuard sensor:
a. SkyGuard - Apply approximately 50 lb (222 Nm) of
force to yellow bar.
b. SkyGuard - SkyLine - Press cable to break magnetic
connection between the cable and right bracket.
c. SkyGuard - SkyEye - Put arm or hand in path of sensor
beam.
3. Once the sensor has been activated, verify the following
conditions:
a. Telescope out function stops and telescope in function
operates for a short duration.
b. The horn sounds.
c. If equipped with a SkyGuard beacon, the beacon illumi-
nates.

3121670 2-9
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) 5. Place Drive control lever to Reverse and drive machine off of
block and ramp.
6. Have an assistant check to see that left front or right rear
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM- wheel remains elevated in position off of ground.
PONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. 7. Return boom to stowed position. When boom reaches cen-
ter, stowed position, lockout cylinders should release and
NOTE: Ensure boom is fully retracted, lowered, and centered between allow wheel to rest on ground, it may be necessary to acti-
rear wheels prior to beginning lockout cylinder test. vate Drive to release cylinders.

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

2. From platform control console, start engine. 9. Place Drive control lever to Forward and carefully drive
machine up ascension ramp until right front wheel is on top
3. Place the Drive control lever to the forward position and of block.
carefully drive machine up ascension ramp until left front
wheel is on top of block. 10. Repeat steps 4 thru 7 to check the opposite side of the oscil-
lating axle.
4. Carefully activate Telescope or Main Boom Lift control and
take the boom out of the transport position. 11. If lockout cylinders do not function properly, have qualified
personnel correct the malfunction prior to any further oper-
ation.

2-10 3121670
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL NOTE: The indicator panels use different shaped symbols to alert the
operator to different types of operational situations that could
arise. The meaning of those symbols are explained below.
Indicates a potentially hazardous situation, which if
THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND not corrected, could result in serious injury or death.
OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH This indicator will be red.
GOOD SAFETY PRACTICES.
Indicates an abnormal operating condition, which if
This section provides the necessary information needed to not corrected, may result in machine interruption or
understand control functions. damage. This indicator will be yellow.

3.2 CONTROLS AND INDICATORS Indicates important information regarding the operat-
ing condition, i.e. procedures essential for safe opera-
NOTE: All machines are equipped with control consoles that use sym-
tion. This indicator will be green with the exception of
bols to indicate control functions. On ANSI machines refer to the capacity indicator which will be green or yellow
decal located on the control box guard in front of the control box depending upon platform position.
or by the ground controls for these symbols and the correspond-
ing functions.

3121670 3-1
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

2. Display Gauge

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR Registers the amount of time the machine
TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE has been in use, with engine running. The
OFF POSITION WHEN RELEASED. hourmeter registers up to 16,500 hours and
cannot be reset.
Ground Control Console 3. Engine Start/ Auxiliary Power /Function Enable

(See Figure 3-1., Figure 3-2., Figure 3-3., and Figure 3-4. To start the engine, the switch must be held
"UP" until the engine starts.
1. Indicator Panel
To use auxiliary power, the switch must be
held “DOWN” for duration of function use.
The Indicator Panel contains indicator lights that signal
problem conditions or functions operating during machine When the engine is running, the switch must
operation. be held "DOWN" to enable all boom controls.

NOTE: The Function Enable switch must be held down in

order to operate Main Boom Telescope, Swing,
Main Lift, Jib Lift, Platform Level Override, and
Platform Rotate functions.

3-2 3121670
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

4 1. Indicator Panel
3 2. Display Gauge
3. Engine Start/Auxiliary Power/
6 Function Enable
4. Platform/Ground Select
8 5. Platform Level
2 6. Platform Rotate
9 7. Not Used
8. Telescope
10 9. Power/Emergency Stop
10. Main Boom Lift
11. Swing
11 12. Not Used

1
100 1173 643 B

Figure 3-1. Ground Control Console - 400S

3121670 3-3
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Indicator Panel
4
2. Display Gauge
3 3. Engine Start/Auxiliary Power/
6 Function Enable
4. Platform/Ground Select
5. Platform Level
2 8 6. Platform Rotate
7. Not Used
9
8. Telescope
9. Power/Emergency Stop
10
10. Main Boom Lift
11. Swing
11 12. Machine Safety System Override (MSSO)

1 12
10 0118 251 6 A

Figure 3-2. Ground Control Console - 400S w/MSSO (CE Only)

3-4 3121670
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

6
5
4 1. Indicator Panel
3 2. Display Gauge
7
3. Engine Start/Auxiliary Power/
Function Enable
4. Platform/Ground Select
8 5. Platform Level
2 6. Platform Rotate
9 7. Jib Lift
8. Telescope
9. Power/Emergency Stop
10 10. Main Boom Lift
11. Swing
12. Not Used
11

1
100 1172 653 B

Figure 3-3. Ground Control Console - 460SJ

3121670 3-5
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

6
5
4
1. Indicator Panel
3 2. Display Gauge
3. Engine Start/Auxiliary Power/
7
Function Enable
4. Platform/Ground Select
2 8 5. Platform Level
6. Platform Rotate
9
7. Jib Lift
8. Telescope
10 9. Power/Emergency Stop
10. Main Boom Lift
11 11. Swing
12. Machine Safety System Override (MSSO)

1 12
10 01182 515 A

Figure 3-4. Ground Control Console - 460SJ w/MSSO (CE Only)

3-6 3121670
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTE: When the Platform/Ground Select Switch is in the center posi- 5. Platform Leveling Override
tion, power is shut off to the controls at both operating consoles.
Remove the key to prevent the controls from being actuated. A three position switch allows the operator to
adjust the automatic self leveling system. This
4. Platform/Ground Select Switch switch is used to adjust platform level in situa-
tions such as ascending/descending a grade.
The three position, key operated switch sup-
plies power to the platform control console
when positioned to PLATFORM. With the 6. Platform Rotate
switch key turned to the GROUND position
only ground controls are operable. Provides rotation of the platform.

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. 7. Jib Lift (If Equipped)

Provides raising and lowering of the jib.

3121670 3-7
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Telescope Control 10. Main Boom Lift

Provides extension and retraction of the boom. Provides raising/lowering of the main boom
when positioning up or down.

11. Swing

Provides 360 degrees continuous turntable

WHEN THE MACHINE IS SHUT DOWN THE POWER/EMERGENCY STOP SWITCH MUST BE rotation.
POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERIES.

9. Power/Emergency Stop Switch

A two-position red mushroom shaped switch 12. Machine Safety System Override (MSSO) (CE
supplies power to PLATFORM/GROUND Only)
SELECT switch when pulled out (on). When
pushed in (off), power is shut off to the PLATFORM/GROUND Provides emergency override of function
SELECT switch. controls that are locked out in the event of
Load Sense System activation.

3-8 3121670
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

Ground Control Indicator Panel 4. Engine Oil Temperature Indicator (Deutz)

Indicates that the temperature of the engine

(See Figure 3-5., Ground Control Indicator Panel)
oil, which also serves as engine coolant, is
1. Battery Malfunction Indicator abnormally high and service is required.
5. Engine Malfunction/Check Engine Indicator
Indicates a problem in the battery or charging
circuit, and service is required. Indicates that engine oil pressure is below nor-
2. High Engine Temperature Indicator mal or engine coolant temperature is abnor-
mally high and service is required.
Indicates that engine coolant temperature is
abnormally high and service is required.
3. Low Engine Oil Pressure Indicator

Indicates that engine oil pressure is below nor-

mal and service is required.

3121670 3-9
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1 2 3 4 5 6

1. Battery Malfunction
2. Low Engine Oil Pressure
3. High Engine Coolant Temperature
4. Engine Oil Temperature
5. Engine Malfunction/Check Engine
6. Low Fuel
7. Glow Plug
8. Platform Overload (If Equipped)
9. Drive and Steer Disable (If Equipped)

9 8 7

Figure 3-5. Ground Control Indicator Panel

3-10 3121670
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1 2 3 4 5 6

1. Battery Malfunction
2. Not Used
3. Not Used
4. Not Used
5. Engine Malfunction/Check Engine
6. Low Fuel
7. Glow Plug
8. Platform Overload (If Equipped)
9. Drive and Steer Disable (If Equipped)
10. System Distress
9 8 7

Figure 3-6. Ground Control Indicator Panel - Kubota Engine

3121670 3-11
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Low Fuel Level Indicator 8. Platform Overload Indicator (If Equipped)

Indicates the fuel level is low. The Fuel Indicates the platform has been overloaded.
Reserve/Cut-Out System will shut the engine
down (or allow it start and run for an addi- 9. Drive and Steer Disable Indicator (If Equipped)
tional minute, depending upon machine setup) before the
fuel tank is emptied. Indicates the Drive and Steer Disable function
has been activated.
7. Glow Plug Indicator
10. System Distress Indicator
Indicates the glow plugs are operating. After
turning on ignition, wait until light goes out The light indicates that the JLG Control System
before cranking engine. has detected an abnormal condition and a
Diagnostic Trouble Code has been set in the
system memory. Refer to the Service Manual for instructions
concerning the trouble codes and trouble code retrieval.

The system distress indicator light will illuminate for 2-3 sec-
onds when the key is positioned to the on position to act as
a self test.

3-12 3121670
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

Ground Control Console Display Gauge

(See Figure 3-10., Ground Control Console Display Gauge)

The Display Gauge shows engine hours, fuel level (if applicable),
and Diagnostic Trouble Codes (DTCs) from both the JLG Control
System and the engine control system. During machine start up,
with no active DTCs in the control system, the splash screen will
show for 3 seconds and then switch to main screen. If there is an
active DTC while powering up the machine, the splash screen will
show for 3 seconds, and then launch the Diagnostics Screen. The
indicator lamp will light when there is an active DTC in the Fault
Log.

Figure 3-7. Splash Screen

3121670 3-13
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

The Diagnostic Screen will show active and inactive faults from The Engine Diagnostics Screen will show SPN (Suspect Parameter
the JLG Control System on the screen. An asterisk (*) will be dis- Number), FMI (Failure Mode Identifier), and Occurrence count
played to show active faults. information. Engine SPN text is not scrollable. If there is more
than one engine trouble code, the operator must exit from the
Engine DTC Screen to see other SPN and FMI information.

DIAGNOSTIC CODES

Figure 3-8. Diagnostic Screen

Figure 3-9. Engine Diagnostic Screen

3-14 3121670
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

INDICATOR LAMP

ENGINE HOURS FUEL LEVEL

NAVIGATE BACK ARROW NAVIGATE FORWARD ARROW

NAVIGATION BUTTONS

Figure 3-10. Ground Control Console Display Gauge

3121670 3-15
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Console
ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF
(See Figure 3-11., Platform Control Console)
THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR
FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR 2. Platform Leveling Override
TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE
OFF OR NEUTRAL POSITION WHEN RELEASED. A three position switch allows the operator to
adjust the automatic self leveling system. This
1. Drive Speed Switch switch is used to adjust platform level in situa-
tions such as ascending/descending a grade.
The forward position gives maxi- 3. Fuel Select (Dual Fuel Engine Only) (If
mum drive speed. The back posi- Equipped)
tion gives maximum torque for
rough terrain and climbing Moving the switch to the appropriate position
grades. The center position selects gasoline or liquid propane fuel.
allows the machine to be driven
as quietly as possible. 4. Horn

A push-type HORN switch supplies electrical

power to an audible warning device when pressed.

3-16 3121670
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1 2 3 4 5 6 7 8

1001184626 A

1001195947 A

1702566 B 1702565 B

1702567 B

1705170 A

17 16 15 14 13 12 11 10 9

1. Drive Speed/Torque Select 6. Start/Auxiliary Power 10. Telescope 14. Soft Touch/SkyGuard Indicator (If Equipped)
2. Platform Leveling Override 7. Capacity Select 11. Lights (If Equipped) 15. Platform Rotate
3. Fuel Select (If Equipped) 8. Drive Orientation Override 12. Jib Lift (If Equipped) 16. Function Speed Control
4. Horn 9. Drive/Steer 13. Soft Touch/SkyGuard Override (If Equipped) 17. Main Lift/Swing Controller
5. Power/Emergency Stop
Figure 3-11. Platform Control Console

3121670 3-17
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. Power/Emergency Stop Switch 7. Capacity Select

A two-position red mushroom shaped switch This switch allows the operator to select
furnishes power to PLATFORM Controls when between an operating envelope with a 600 lb.
pulled out (on). When pushed in (off ), power is (272 kg for ANSI markets and 270 kg for CE and
shut off to the platform functions. Australia markets) capacity restriction or a 1000
lb. (454 kg for ANSI markets and 450 kg for CE
6. Start/Auxiliary Power
and Australia markets) capacity restriction.
When pushed forward, the switch energizes the
8. Drive Orientation Override
starter motor to start the engine.
When the boom is swung over the rear tires
The Auxiliary Power control switch energizes or further in either direction, the Drive Orien-
the electrically operated hydraulic pump. tation indicator will illuminate when the drive
(Switch must be held ON for duration of auxil- function is selected. Push and release the
iary pump use.) switch, and within 3 seconds move the Drive/Steer control
to activate drive or steer. Before driving, locate the black/
The auxiliary pump functions to provide sufficient oil flow to white orientation arrows on both the chassis and the plat-
operate the basic machine functions should the main pump form controls. Move the drive controls in a direction match-
or engine fail. The auxiliary pump will operate main boom ing the directional arrows for the intended direction of
lift, main telescope, jib (if equipped) and swing. travel.

3-18 3121670
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTE: To operate the Drive joystick, pull up on the lock- 11. Lights (If Equipped)
ing ring below the handle.
This switch operates the chassis lights if
NOTE: The Drive joystick is spring loaded and will auto- the machine is so equipped.
matically return to neutral (off) position when
12. Jib Lift (If Equipped)
released.
Provides for raising or lowering of the jib by
9. Drive/Steer positioning up/down.

Push forward to drive forward,

pull back to drive in reverse.
Steering is accomplished via a
thumb-activated rocker switch on
the end of the steer handle.
10. Telescope

Provides extension and retraction of the main

boom.

3121670 3-19
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

13. Soft Touch/SkyGuard Override Switch (If equipped) 14. Soft Touch/SkyGuard Indicator (If Equipped)

The machine can be equipped with one of three options. It Indicates the Soft Touch bumper is against an object or the
may have Soft Touch, SkyGuard, or both Soft Touch and Sky- SkyGuard sensor has been activated. All controls are cut out
Guard. until the override button is pushed. For Soft Touch, controls
are then active in the Creep Mode or for SkyGuard, controls
If equipped with Soft Touch, the switch
will work normally.
enables the functions that were cut out
by the Soft Touch system to operate
When Soft Touch is active, the indicator will be on continu-
again at creep speed, allowing the
ously and the alarm will sound. When SkyGuard is active, the
operator to move the platform away from the obstacle that
indicator will flash, and the horn will sound continuously.
caused the shutdown situation.
15. Platform Rotate
If equipped with SkyGuard, the switch
enables functions cut out by the Sky-
Provides rotation of the platform when posi-
guard system to be operated again,
tioned to the right or left.
allowing the operator to resume use of
machine functions.
If equipped with both Soft Touch and
16. Function Speed Control
SkyGuard, the switch operates like
described above and allows the opera-
This control affects the speed of telescope
tor to override the system that has
and jib lift (if equipped). Turning the knob
experienced a cutout situation.
all the way counterclockwise until it clicks
puts drive and swing into creep mode.

3-20 3121670
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTE: To operate the Main Boom Lift/Swing joystick,

pull up on the locking ring below the handle.

NOTE: The Main Boom Lift/Swing joystick is spring loaded and will
automatically return to neutral (off) position when released.

17. Main Lift/Swing Controller

Provides main lift and swing. Push for-

ward to lift up, pull backward to boom
down. Move right to swing right, move
left to swing left. Moving the joystick
activates switches to provide the func-
tions selected.

3121670 3-21
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Control Indicator Panel 3. Capacity Indicator

Indicates the maximum platform capacity for

(See Figure 3-12., Platform Control Indicator Panel)
the current position of the platform. Restricted
NOTE: The indicator lights will illuminate for approximately 1 second capacities are permitted at restricted platform
when the key is positioned to the on position to act as a self test. positions (shorter boom lengths and higher
boom angles).
1. AC Generator (If Equipped)
NOTE: Refer to the capacity decals on the machine for restricted and
unrestricted platform capacities.
Indicates the generator is in operation.

2. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded.

3-22 3121670
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. AC Generator (If Equipped) 5. Glow Plug/Wait to Start 8. Creep

2. Platform Overload (If Equipped) 6. Enable/Footswitch 9. System Distress
3. Capacity Indicator 7. Fuel Level 10. Drive Orientation
4. Tilt
Figure 3-12. Platform Control Indicator Panel

3121670 3-23
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

4. Tilt Alarm Warning Light and Alarm 5. Glow Plug/Wait to Start Indicator
Indicates the glow plugs are operating. After
This red illuminator indicates that the chassis is
turning on ignition, wait until light goes out
on a slope. An alarm will also sound when the
before starting engine.
chassis is on an excessive slope and the boom
is out of transport position. If lit when boom is out of trans- 6. Enable Indicator/Footswitch
port position, lower to below horizontal then reposition
machine so that it is level before continuing operation. If the To operate any function, the footswitch must
boom is above horizontal and the machine is on a slope, the be depressed and the function selected within
tilt alarm warning light will illuminate and an alarm will seven seconds. The enable indicator shows
sound and CREEP is automatically activated. that the controls are enabled. If a function is not selected
within seven seconds, or if a seven second lapse between
Tilt Angle Market ending one function and beginning the next function, the
5° All Markets enable light will go out and the footswitch must be released
and depressed again to enable the controls.

Releasing the footswitch removes power from all controls

and applies the drive brakes.
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.
TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH
BY BLOCKING OR ANY OTHER MEANS.

FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY

OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM.

3-24 3121670
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

7. Fuel Level Indicator 8. Creep Speed Indicator

Indicates the level of fuel in the tank. When the Function Speed Control is turned to
the creep position, the indicator acts as a
reminder that all functions are set to the slow-
est speed. The light will be on continuously if the operator
selects creep speed or if the control system puts the
machine into creep speed. In addition, if the control system
puts one or more individual functions in creep speed, the
indicator flashes when that function is selected.
9. System Distress Indicator

The light indicates that the JLG Control System

has detected an abnormal condition and a
Diagnostic Trouble Code has been set in the
system memory. Refer to the Service Manual for instructions
concerning the trouble codes and trouble code retrieval.
10. Drive Orientation Indicator

When the boom is swung beyond the rear

drive tires or further in either direction, the
Figure 3-13. Fuel Level Indicator 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).

3121670 3-25
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTES:

3-26 3121670
 SECTION 4 - MACHINE OPERATION

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION The primary operator control console is in the platform. From this
control console, the operator can drive and steer the machine in
This machine is a mobile elevating work platform used to posi- both forward and reverse directions. The operator can raise or
tion personnel, along with their necessary tools and materials at lower the boom or swing the boom to the left or right. Standard
work locations. boom swing is 360 degree continuous. The machine has a
Ground Control Console which will override the Platform Control
Console. Ground Controls operate all functions except drive and
steer 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.

3121670 4-1
 SECTION 4 - MACHINE OPERATION

4.2 BOOM OPERATING CHARACTERISTICS AND 4.3 ENGINE OPERATION

LIMITATIONS NOTE: Initial starting should always be per-
formed from the Ground Control con-
Capacities sole.

Raising boom above horizontal with or without any load in plat-

form, is based on the following criteria:
1. Machine is positioned on a smooth, firm and level surface.
2. Load is within manufacturers rated design capacity.
3. All machine systems are functioning properly. Starting Procedure
4. Machine is as originally equipped from JLG.

Stability IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED TIME.
Machine stability is based on two (2) conditions which are called SHOULD ENGINE FAIL TO START AGAIN, ALLOW STARTER TO “COOL OFF” FOR 2-3 MIN-
FORWARD and BACKWARD stability. The machine’s position of UTES. IF ENGINE FAILS AFTER SEVERAL ATTEMPTS, REFER TO ENGINE MAINTENANCE
least FORWARD stability is shown in Figure 4-1., and its position MANUAL.
of least BACKWARD stability is shown in Figure 4-2.
NOTE: Diesel engines only: After turning on ignition,
operator must wait until glow plug indicator light
TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOAD MACHINE OR OPER- goes out before cranking engine.
ATE THE MACHINE ON AN OUT-OF-LEVEL SURFACE.

4-2 3121670
 SECTION 4 - MACHINE OPERATION

1. Turn key of Platform/Ground Select switch to 6. Pull out the Ground Console Power/Emer-
Ground. gency Stop switch to provide power to the
platform controls.

2. Pull the Power/Emergency Stop switch to On. 7. From Platform, pull Power/Emergency Stop
switch out.

3. Push the Engine Start switch until engine starts. 8. Push the Engine Start switch until engine starts.

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

ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING operate. If starter operates with footswitch in the depressed posi-
ANY LOAD. tion, DO NOT OPERATE MACHINE.

4. After engine has had sufficient time to warm

up, push in the Power/Emergency Stop switch
and shut engine off.

5. Turn Platform/Ground Select switch to Plat-

form.

3121670 4-3
 SECTION 4 - MACHINE OPERATION

Shutdown Procedure Fuel Reserve / Shut-Off System (Diesel Engines Only)

The Fuel Shutoff System senses when the fuel level is getting low
and automatically shuts the engine down before the fuel tank is
emptied.
IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN, DETERMINE
THE CAUSE AND CORRECT IT BEFORE RESTARTING THE ENGINE. Depending upon machine setup, the machine will either keep
the engine shut down until the fuel tank is refilled or the operator
1. Remove all load and allow engine to operate at low speed will be able to restart and run the engine for an additional min-
for 3-5 minutes; this allows further reduction of internal ute. After 1 minute, the engine will shut off for a second time and
engine temperature. the machine will return to the engine shutdown mode until the
fuel tank is refilled.
2. Push Power/Emergency Stop switch in.

3. Turn Platform/Ground Select switch to Off.

Refer to Engine Manufacturer’s manual for detailed
information.

4-4 3121670
 SECTION 4 - MACHINE OPERATION

JIB
BOOM HORIZONTAL
FULLY EXTENDED

MACHINE WILL "TIP OVER" IN THIS

DIRECTION IF OVERLOADED OR
OPERATED ON AN
OUT-OF-LEVEL SURFACE

Figure 4-1. Position of Least Forward Stability

3121670 4-5
 SECTION 4 - MACHINE OPERATION
.

MACHINE WILL "TIP OVER" IN THIS

PLATFORM ROTATED
DIRECTION IF OVERLOADED OR
90 DEGREES
OPERATED ON AN
OUT-OF-LEVEL SURFACE
JIB
FULLY ELEVATED

MAIN BOOM FULLY ELEVATED

AND FULLY RETRACTED

Figure 4-2. Position of Least Backward Stability

4-6 3121670
 SECTION 4 - MACHINE OPERATION

4.4 TRAVELING (DRIVING)

See Figure 4-3., Grade and Side Slopes DO NOT DRIVE WITH BOOM OUT OF TRANSPORT MODE EXCEPT ON A SMOOTH, FIRM
AND LEVEL SURFACE.
NOTE: Refer to the Operating Specifications table for Gradeability and
Sideslope ratings. TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ON
GRADES EXCEEDING THOSE SPECIFIED IN THE OPERATING SPECIFICATIONS SECTION
All ratings for Gradeability and Sideslope are based upon the OF THIS MANUAL.
machine’s boom being in the stowed position, fully lowered, and
retracted. DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

Traveling is limited by two factors: USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THE
PLATFORM IS ELEVATED.
1. Gradeability, which is the percent of grade of the incline the
machine can climb.
BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWS ON BOTH THE
2. Sideslope, which is the angle of the slope the machine can CHASSIS AND THE PLATFORM CONTROLS. MOVE THE DRIVE CONTROLS IN A DIREC-
be driven across. TION MATCHING THE DIRECTIONAL ARROWS FOR THE INTENDED DIRECTION OF
TRAVEL

3121670 4-7
 SECTION 4 - MACHINE OPERATION

Figure 4-3. Grade and Side Slopes

4-8 3121670
 SECTION 4 - MACHINE OPERATION

Traveling Forward and Reverse 2. Push and release the Drive Orientation Over-
ride switch. Within 3 seconds, slowly move the
1. At Platform Controls, pull out Emergency Stop Drive control toward the arrow matching the
switch, start the engine, and activate intended direction of machine travel. The indi-
footswitch. cator light will flash during the 3 second inter-
val until the drive function is selected.
2. Position Drive controller to FOR-
WARD or REVERSE as desired.

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 con-
trol console and the
chassis to determine
the direction the
machine will travel.

3121670 4-9
 SECTION 4 - MACHINE OPERATION

Traveling on a Grade 4.5 STEERING

When traveling a grade, maximum braking and traction are obtained Position thumb switch on Drive/Steer controller to
with the boom stowed, in position over the rear (drive) axle, and in Right for steering right, or to Left for steering left.
line with the direction of travel. Drive the machine forward when
climbing a grade, and in reverse when descending a grade. Do not
exceed the machine's maximum rated gradeability.
4.6 PLATFORM
Platform Level Adjustment

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.

To Level Up or Down - Position the Platform/Level

control switch Up or Down and hold until the plat-
form is level.

Figure 4-4. Traveling on a Grade

Platform Rotation
To rotate the platform to the left or right, use the
Platform Rotate control switch to select the direc-
IF THE BOOM IS OVER THE FRONT (STEER) AXLE, DIRECTION OF STEER AND DRIVE tion and hold until desired position is reached.
MOVEMENT WILL BE OPPOSITE FROM THE MOVEMENT OF THE CONTROLS.

4-10 3121670
 SECTION 4 - MACHINE OPERATION

4.7 BOOM
TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL
SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMER-
A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE WHICH LIGHTS GENCY STOP SWITCH TO STOP THE MACHINE.
WHEN THE CHASSIS IS ON AN EXCESSIVE SLOPE. DO NOT SWING OR RAISE BOOM
ABOVE HORIZONTAL WHEN LIGHT IS LIT. Swinging the Boom
DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. TILT
To swing boom, use Swing control switch to select
ALARM INDICATES CHASSIS IS ON AN EXCESSIVE SLOPE (5 DEGREES OR GREATER).
Right or Left direction.
CHASSIS MUST BE LEVEL BEFORE SWINGING, OR RAISING BOOM ABOVE HORIZONTAL
OR DRIVING WITH THE BOOM ELEVATED. Raising and Lowering the Main Boom
TO AVOID TIP OVER IF RED TILT WARNING LIGHT LIGHTS WHEN BOOM IS RAISED
ABOVE HORIZONTAL, LOWER PLATFORM TO GROUND LEVEL. THEN REPOSITION To raise or lower the Main Boom, use Main Boom Lift
MACHINE SO THAT CHASSIS IS LEVEL BEFORE RAISING BOOM. controller to select UP or DOWN movement.

TRAVELING WITH BOOM BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE

SLOPES SPECIFIED IN THE OPERATING SPECIFICATIONS SECTION OF THIS MANUAL.
Telescoping the Main Boom
To extend or retract the main boom, use the Main
Telescope Control Switch to select IN or OUT move-
ment.
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF ANY CONTROL LEVER OR
TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE
‘OFF’ OR NEUTRAL POSITION WHEN RELEASED.

3121670 4-11
 SECTION 4 - MACHINE OPERATION

4.8 FUNCTION SPEED CONTROL 4.9 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE
This control affects the speed of telescope and ONLY)
jib lift. Turning the knob all the way counter-
The Machine Safety System Override (MSSO) is
clockwise until it clicks puts drive, main lift, plat-
used to override function controls for Emergency
form rotate, and swing into creep mode.
Platform Retrieval only. Refer to Section 5.5,
Machine Safety System Override (MSSO)(CE
Only)for operating procedures.

4-12 3121670
 SECTION 4 - MACHINE OPERATION

4.10 SKYGUARD OPERATION SkyGuard

SkyGuard provides enhanced control panel protection. When the
SkyGuard sensor is activated, functions in use at the time of actu-
ation will reverse or cutout. The SkyGuard Function Table pro-
vides more details on these functions.
During activation, the horn will sound and, if equipped with a
SkyGuard beacon, the beacon will illuminate until sensor and
footswitch are disengaged.
If the SkyGuard sensor remains activated after function reversal
0"$
or cutout, depress and hold the SkyGuard Override Switch to
allow normal functions until the sensor is disengaged. Approximately 50 lb (222 Nm) of force is applied to yellow bar.
Consult the following illustrations to determine which type of
SkyGuard the machine has. Regardless of type, SkyGuard func- SkyGuard - SkyLine
tion according to the SkyGuard Function Table does not change.

0"%

Cable is pressed, breaking the magnetic connection between the

cable and right bracket.

3121670 4-13
 SECTION 4 - MACHINE OPERATION

SkyGuard - SkyEye

0"$
0"$
Reattach magnetic end of cable to bracket if it becomes discon-
nected. Operator passes through path of sensor beam.

SkyGuard Function Table

Boom
Drive Drive Boom Boom Boom Basket Basket
Steer Swing Lift Jib Lift
Forward Reverse Lift Up Tele Out Tele In Level Rotate
Down
R * / C ** R C R R R R C C C C
R = Indicates Reversal is Activated
C = Indicates Cutout is Activated
* DOS (Drive Orientation System) Enabled
* * DOS Not Enabled, machine is driving straight without steering, and any other hydraulic function is active

4-14 3121670
 SECTION 4 - MACHINE OPERATION

4.11 SHUT DOWN AND PARK 4.12 LIFTING AND TIE DOWN
(See Figure 4-5.)
Shut Down and Park
The procedures to shut down and park the machine are as fol- Lifting
lows:
1. Refer to the Serial Number Plate, refer to the Specifications
1. Drive machine to a reasonably well protected area. section of this manual, or weigh the individual unit to find
out the Gross Vehicle Weight.
2. Ensure boom is lowered over rear drive axle.
2. Place the boom in the stowed position.
3. Shut down Emergency Stop at Platform Controls.
3. Remove all loose items from the machine.
4. Shut down Emergency Stop at Ground Controls. Position
Platform/Ground Select switch to center OFF. 4. Properly adjust the rigging to prevent damage to the
machine and so the machine remains level.
5. If necessary, cover Platform Controls to protect instruction
placards, warning decals, and operating controls from hos-
tile environment.

3121670 4-15
 SECTION 4 - MACHINE OPERATION

Tie Down

WHEN TRANSPORTING THE MACHINE IN THE STOWED POSITION, THE BOOM MUST BE
FULLY LOWERED INTO THE BOOM REST.

1. Place the boom in the stowed position or storage position.

2. Remove all loose items from the machine.
3. Secure the chassis and the platform using straps or chains of
adequate strength.

4-16 3121670
 SECTION 4 - MACHINE OPERATION

Figure 4-5. Lifting and Tie Down Chart

3121670 4-17
 SECTION 4 - MACHINE OPERATION

46 41
16
2
14

31

33
30
38 21 23 38 21 38 21
32
BOTH SIDES BOTH SIDES BOTH SIDES

Figure 4-6. Decal Location Sheet 1 of 7

4-18 3121670
 SECTION 4 - MACHINE OPERATION

41

45

17 19 28 18 30 57 23

Figure 4-7. Decal Location Sheet 2 of 7

3121670 4-19
 SECTION 4 - MACHINE OPERATION

22
41 41

42 39

15
3

35

4
24

22 21 21 22

Figure 4-8. Decal Location Sheet 3 of 7

4-20 3121670
 SECTION 4 - MACHINE OPERATION

1 48

23
40 37

13

23

Figure 4-9. Decal Location Sheet 4 of 7

3121670 4-21
 SECTION 4 - MACHINE OPERATION

Figure 4-10. Decal Location Sheet 5 of 7

4-22 3121670
 SECTION 4 - MACHINE OPERATION

52

52 48

Figure 4-11. Decal Location Sheet 6 of 7

3121670 4-23
 SECTION 4 - MACHINE OPERATION

47
50

49
53

51

Figure 4-12. Decal Location Sheet 7 of 7

4-24 3121670
 SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend - 400S

Portuguese/
Item # ANSI Japan Korea Spanish French Chinese CE
Spanish
1001171366-E 1001171370-E 1001171372-E 1001171374-E 1001171376-E 1001171378-E 1001171369-I
1001171380-E
1 1703797 1703926 1703927 1703923 1703924 1703925 1703928 1705921
2 1703798 1703932 1703933 1703929 1703930 1703931 1703934 1705822
3 1703805 1703938 1703939 1703935 1703936 1703937 1703940 1705961
4 1703804 1703950 1703951 1703947 1703948 1703949 1703952 1701518
5 1001173262 1001173262 1001173262 1001173262 1001173262 1001173262 1001173262 --
6 1001174313 1001174313 1001174313 1001174313 1001174313 1001174313 1001174313 --
7 -- -- -- -- -- -- -- --
8 -- -- -- -- -- -- -- 1001159323
9 -- -- -- -- -- -- -- --
10 -- -- -- -- -- -- -- 1702773
11 1702868 -- -- 1704001 1704000 -- 1704002 --
12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277
13 1001171335 1001171341 1001171345 1001171349 1001171351 1001171355 1001171359 1001185237
14 1001171336 1001171342 1001171346 1001171350 1001171352 1001171356 1001171360 1001185237
15 3251813 -- -- 3251813 3251813 -- 3251813 1001204510
16 1701504 1701504 1701504 1701504 1701504 17701504 1701504 1701504
17 1702631 1702631 1702631 1702361 1702631 1702631 1702631 1702631

3121670 4-25
 SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend - 400S

Portuguese/
Item # ANSI Japan Korea Spanish French Chinese CE
Spanish
1001171366-E 1001171370-E 1001171372-E 1001171374-E 1001171376-E 1001171378-E 1001171369-I
1001171380-E
18 1001131269 -- -- -- 1001131269 -- -- --
19 1706948 1706948 1706948 1706948 1706948 1706948 1706948 --
20 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509
21 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300
22 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500
23 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529
24 3251243 -- -- 3251243 3251243 -- 3251243 --
25 -- -- -- -- -- -- -- --
26 -- -- -- -- -- -- -- --
27 -- -- -- -- -- -- -- --
28 -- -- -- -- -- -- -- --
29 -- 1703980 1703981 1703983 1703984 1703982 1703985 --
30 -- -- -- -- -- -- -- --
31 -- -- -- -- -- -- -- --
32 -- -- -- -- -- -- -- --
33 -- -- -- -- -- -- -- --
34 1705514 -- -- -- 1705514 -- -- --
35 -- -- -- -- -- -- -- --

4-26 3121670
 SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend - 400S

Portuguese/
Item # ANSI Japan Korea Spanish French Chinese CE
Spanish
1001171366-E 1001171370-E 1001171372-E 1001171374-E 1001171376-E 1001171378-E 1001171369-I
1001171380-E
36 -- -- -- -- -- -- -- --
37 -- -- -- -- -- -- -- --
38 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499
39 -- -- -- -- -- -- -- --
40 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412
41 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691
42 -- -- -- -- -- -- -- --
43 -- -- -- -- -- -- -- --
44 1705351 1705426 1705427 -- 1705429 1705430 1705905 --
45 -- -- -- 1704007 1704006 -- 1704008 --
46 -- -- -- -- -- -- -- 1001197408
47 -- -- -- -- -- -- -- --
48 -- -- -- -- -- -- -- --
49 -- -- -- -- -- -- -- --
50 -- -- -- -- -- -- -- --
51 -- -- -- -- -- -- -- --
52 -- -- -- -- -- -- -- --
53 -- -- -- -- -- -- -- --

3121670 4-27
 SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend - 400S

Portuguese/
Item # ANSI Japan Korea Spanish French Chinese CE
Spanish
1001171366-E 1001171370-E 1001171372-E 1001171374-E 1001171376-E 1001171378-E 1001171369-I
1001171380-E
54 1703953 1703944 1703945 1703941 1703942 1703943 1705903 1701518
55 -- -- -- -- -- -- -- --
56 -- -- -- -- -- -- -- --
57 1001223055 1001224053 1001224048 1001224049 1001223971 1001224050 1001224052 --
58 -- -- -- -- -- -- -- --
59 1001231801 -- -- -- -- -- -- --

4-28 3121670
 SECTION 4 - MACHINE OPERATION

Table 4-2. Decal Legend - 460SJ

Portuguese/
Item # ANSI CE Japan Korea Spanish French Chinese Australia
Spanish
1001171367-E 1001171368-I 1001171371-E 1001171373-E 1001171375-F 1001171377-E 1001171379-E 1001171382-E
1001171381-E
1 1703797 1705921 1703926 1703927 1703923 1703924 1703925 1703928 1705921
2 1703798 1705822 1703932 1703933 1703929 1703930 1703931 1703934 1705822
3 1703805 1705961 1703938 1703939 1703935 1703936 1703937 1703940 1705961
4 1703804 1701518 1703950 1703951 1703947 1703948 1703949 1703952 1701518
5 1001173262 -- 1001173262 1001173262 1001173262 1001173262 1001173262 1001173262 --
6 1001174313 -- 1001174313 1001174313 1001174313 1001174313 1001174313 1001174313 --
7 -- -- -- -- -- -- -- -- --
8 -- 1001159323 -- -- -- -- -- -- --
9 -- -- -- -- -- -- -- -- --
10 -- 1702773 -- -- -- -- -- -- --
11 1702868 -- -- -- 1704001 1704000 -- 1704002 --
12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277
13 1001171337 1001171339 1001171343 1001171347 1001171337 1001171353 1001171357 1001171361 1001171339
14 1001171337 1001171339 1001171343 1001171347 1001171337 1001171353 1001171357 1001171361 1001171339
15 3251813 1001204510 -- -- 3251813 3251813 -- 3251813 1705084
16 1701504 1701504 1701504 1701504 1701504 1701504 17701504 1701504 1701504
17 1702631 1702631 1702631 1702631 1702361 1702631 1702631 1702631 1702631

3121670 4-29
 SECTION 4 - MACHINE OPERATION

Table 4-2. Decal Legend - 460SJ

Portuguese/
Item # ANSI CE Japan Korea Spanish French Chinese Australia
Spanish
1001171367-E 1001171368-I 1001171371-E 1001171373-E 1001171375-F 1001171377-E 1001171379-E 1001171382-E
1001171381-E
18 1001131269 -- -- -- -- 1001131269 -- -- --
19 1706948 -- 1706948 1706948 1706948 1706948 1706948 1706948 --
20 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509
21 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300
22 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500
23 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529
24 3251243 -- -- -- 3251243 3251243 -- 3251243 --
25 -- -- -- -- -- -- -- -- --
26 -- -- -- -- -- -- -- -- --
27 -- -- -- -- -- -- -- -- --
28 -- -- -- -- -- -- -- -- --
29 -- -- 1703980 1703981 1703983 1703984 1703982 1703985 1705828
30 -- -- -- -- -- -- -- -- --
31 -- -- -- -- -- -- -- -- --
32 -- -- -- -- -- -- -- -- --
33 -- -- -- -- -- -- -- -- --
34 1705514 -- -- -- -- 1705514 -- -- --
35 -- -- -- -- -- -- -- -- --

4-30 3121670
 SECTION 4 - MACHINE OPERATION

Table 4-2. Decal Legend - 460SJ

Portuguese/
Item # ANSI CE Japan Korea Spanish French Chinese Australia
Spanish
1001171367-E 1001171368-I 1001171371-E 1001171373-E 1001171375-F 1001171377-E 1001171379-E 1001171382-E
1001171381-E
36 -- -- -- -- -- -- -- -- --
37 -- -- -- -- -- -- -- -- --
38 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499
39 -- -- -- -- -- -- -- -- --
40 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412
41 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691
42 -- -- -- -- -- -- -- -- --
43 -- -- -- -- -- -- -- -- --
44 1705351 -- 1705426 1705427 1705910 1705429 1705430 1705905 --
45 -- -- -- -- 1704007 1704006 -- 1704008 --
46 -- 1001197408 -- -- -- -- -- -- 1001112551
47 -- -- -- -- -- -- -- -- --
48 -- 1001189882 -- -- -- -- -- -- --
49 -- -- -- -- -- -- -- -- --
50 -- -- -- -- -- -- -- -- --
51 -- -- -- -- -- -- -- -- --
52 -- -- -- -- -- -- -- -- --
53 -- -- -- -- -- -- -- -- --

3121670 4-31
 SECTION 4 - MACHINE OPERATION

Table 4-2. Decal Legend - 460SJ

Portuguese/
Item # ANSI CE Japan Korea Spanish French Chinese Australia
Spanish
1001171367-E 1001171368-I 1001171371-E 1001171373-E 1001171375-F 1001171377-E 1001171379-E 1001171382-E
1001171381-E
54 1703953 1701518 1703944 1703945 1703941 1703942 1703943 1705903 1701518
55 -- -- -- -- -- -- -- -- --
56 -- -- -- -- -- -- -- -- --
57 1001223055 -- 1001224053 1001224048 1001224049 1001223971 1001224050 1001224052 --
58 -- -- -- -- -- -- -- -- --
59 1001231801 -- -- -- -- -- -- -- --

4-32 3121670
 SECTION 4 - MACHINE OPERATION

Table 4-3. Decal Legend - 400S Kubota Engine-Powered Machines Table 4-3. Decal Legend - 400S Kubota Engine-Powered Machines

CSA CSA
Item # ANSI Item # ANSI
French French
1001218983-B 1001218983-B
1001218985-B 1001218985-B

1 1703797 1703924 18 1001131269 1001131269

2 1703798 1703930 19 1706948 1706948

3 1703805 1703936 20 1701509 1701509

4 1703804 1703948 21 1702300 1702300

5 1001173262 -- 22 1701500 1701500

6 1001174313 1001174313 23 1701529 1701529

7 -- -- 24 3251243 3251243

8 -- -- 25 -- --

9 -- -- 26 -- --

10 -- -- 27 -- --

11 1702868 1704000 28 -- --

12 1704277 1704277 29 -- 1703984

13 1001171335 1001171351 30 -- --

14 1001171336 1001171352 31 -- --

15 -- -- 32 -- --

16 1701504 1701504 33 -- --

17 1702361 1702361 34 1705514 1705514

35 -- --

3121670 4-33
 SECTION 4 - MACHINE OPERATION

Table 4-3. Decal Legend - 400S Kubota Engine-Powered Machines Table 4-3. Decal Legend - 400S Kubota Engine-Powered Machines

CSA CSA
Item # ANSI Item # ANSI
French French
1001218983-B 1001218983-B
1001218985-B 1001218985-B
36 -- -- 54 1703953 1703942
37 -- -- 55 -- --
38 1701499 1701499 56 -- --
39 -- -- 57 1001223055 1001223971
40 1704412 1704412 58 -- --
41 1705351 -- 59 1001231801 --
42
43 -- --
44 1705351 1705429
45 -- --
46 -- --
47 -- --
48 -- --
49 -- --
50 -- --
51 -- --
52 -- --
53 -- --

4-34 3121670
 SECTION 4 - MACHINE OPERATION

Table 4-4. Decal Legend - 460SJ Kubota Engine-Powered Machines Table 4-4. Decal Legend - 460SJ Kubota Engine-Powered Machines

CSA CSA
Item # ANSI Item # ANSI
French French
1001218984-B 1001218984-B
1001218986-B 1001218986-B

1 1703797 1703924 18 1001131269 1001131269

2 1703798 1703930 19 1706948 1706948

3 1703805 1703936 20 1701509 1701509

4 1703804 1703948 21 1702300 1702300

5 1001173262 1001173262 22 1701500 1701500

6 1001174313 1001174313 23 1701529 1701529

7 -- -- 24 3251243 3251243

8 -- -- 25 -- --

9 -- -- 26 -- --

10 -- -- 27 -- --

11 1702868 1704000 28 -- --

12 1704277 1704277 29 -- 1703984

13 1001171337 1001171353 30 -- --

14 1001171337 1001171353 31 -- --

15 -- -- 32 -- --

16 1701504 1701504 33 -- --

17 1702361 1702361 34 1705514 1705514

35 -- --

3121670 4-35
 SECTION 4 - MACHINE OPERATION

Table 4-4. Decal Legend - 460SJ Kubota Engine-Powered Machines Table 4-4. Decal Legend - 460SJ Kubota Engine-Powered Machines

CSA CSA
Item # ANSI Item # ANSI
French French
1001218984-B 1001218984-B
1001218986-B 1001218986-B
36 -- -- 54 1703953 1703942
37 -- -- 55 -- --
38 1701499 1701499 56 -- --
39 -- -- 57 1001223055 1001223971
40 1704412 1704412 58 -- --
41 1705351 -- 59 1001231801 --
42
43 -- --
44 1705351 1705429
45 -- --
46 -- --
47 -- --
48 -- --
49 -- --
50 -- --
51 -- --
52 -- --
53 -- --

4-36 3121670
 SECTION 5 - EMERGENCY PROCEDURES

SECTION 5. EMERGENCY PROCEDURES

5.1 GENERAL
This section explains the steps to be taken in case of an emer- FOLLOWING ANY INCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALL
gency situation while operating. FUNCTIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CON-
TROLS. DO NOT LIFT ABOVE 3 M (10 FT.) UNTIL YOU ARE SURE THAT ALL DAMAGE HAS
5.2 INCIDENT NOTIFICATION BEEN REPAIRED, IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING COR-
RECTLY.
JLG Industries, Inc. must be notified immediately of any incident
involving a JLG product. Even if no injury or property damage is
evident, the factory should be contacted by telephone and pro-
5.3 EMERGENCY OPERATION
vided with all necessary details.
Operator Unable to Control Machine
• USA: 877-JLG-SAFE (554-7233)
IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO
• EUROPE: (32) 0 89 84 82 20 OPERATE OR CONTROL MACHINE:
• AUSTRALIA: (61) 2 65 811111 1. Other personnel should operate the machine from ground
• E-mail: [email protected] controls only as required.
Failure to notify the manufacturer of an incident involving a JLG 2. Other qualified personnel on the platform may use the plat-
Industries product within 48 hours of such an occurrence may form controls. DO NOT CONTINUE OPERATION IF CONTROLS
void any warranty consideration on that particular machine. DO NOT FUNCTION PROPERLY.
3. Cranes, forklift trucks or other equipment can be used to sta-
bilize motion of the machine.

3121670 5-1
 SECTION 5 - EMERGENCY PROCEDURES

Platform or Boom Caught Overhead 5.4 EMERGENCY TOWING PROCEDURES

If the platform or boom becomes jammed or snagged in overhead Towing this machine is prohibited. However, provisions for moving
structures or equipment, do the following: the machine have been incorporated. The following procedures are
to be used ONLY for emergency movement to a suitable mainte-
1. Shut off the machine. nance area.
2. Rescue all people in the platform before freeing the
machine. Personnel must be out of the platform before
operating any controls on the machine. THE ALLOWABLE TOWING SPEED IS 1.9 MPH (3 KPH). THE MAXIMUM ALLOWABLE
3. Use cranes, forklifts, or other equipment to stabilize motion TOWING DISTANCE IS 0.6 MILES (1 KM).
of the machine to prevent a tip over as required.
1. Chock wheels securely.
4. From the ground controls, use the Auxiliary Power System (if
equipped) to carefully free the platform or boom from the 2. Engage the mechanical release on both drive hubs by loos-
object. ening, completely reversing, and tightening the two bolts on
each hub.
5. Once clear, restart the machine and return the platform to a
safe position. 3. Connect suitable equipment, remove chocks, and move
machine.
6. Inspect the machine for damage. If the machine is damaged
or does not operate properly, turn off the machine immedi-
ately. Report the problem to the proper maintenance per-
sonnel. Do not operate the machine until it is declared safe
for operation.

5-2 3121670
 SECTION 5 - EMERGENCY PROCEDURES

After moving machine, complete the following procedure: To operate the MSSO:
1. Position machine on a firm level surface. 1. From the ground control console, place the Platform/
Ground Select switch in the Ground position.
2. Chock wheels securely.
2. Pull out the Power/Emergency Stop control.
3. Disengage the mechanical release on both drive hubs by
loosening, completely reversing, and tightening the two 3. Start the engine or MSSO will function through the Auxiliary
bolts on each hub. Power system.
4. Remove chocks from wheels as desired. 4. Press and hold the MSSO switch and the control switch for
the desired function.
5.5 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE
ONLY)
The Machine Safety System Override (MSSO) is
only to be used to retrieve an operator that is
pinned, trapped, or unable to operate the
machine. The MSSO will override function con-
trols that are locked out from the platform and
ground consoles. An example of this would be in the case of Load
Sense System activation.

NOTE: If the MSSO functionality is used, the fault indicator will flash
and a fault code is set in the JLG Control System which must be
reset by a qualified JLG Service Technician.

NOTE: No functional checks of the MSSO system are necessary. The JLG
Control system will set a Diagnostic Trouble Code if the control
switch is faulty.

3121670 5-3
 SECTION 5 - EMERGENCY PROCEDURES

NOTES:

5-4 3121670
 SECTION 6 - ACCESSORIES

SECTION 6. ACCESSORIES

Table 6-1. Available Accessories

Market
Accessory ANSI
ANSI CSA CE AUS Japan China
(USA Only)
Fall Arrest Platform (36" x 72")   
Pipe Racks      
SkyGlazier™      
SkyPower™      
SkyWelder™     
Bolt-On External Fall Arrest (36" x 72")     

3121670 6-1
 SECTION 6 - ACCESSORIES

Table 6-2. Options/Accessories Relationship Table

COMPATIBLE WITH
ACCESSORY REQUIRED ITEM INCOMPATIBLE WITH INTERCHANGABLE WITH (Note 2)
(Note 1)
Platform MMR**, Platform MTR*,
Pipe Racks SkyPower™ SkyGlazier™, SkyWelder™
Soft Touch
4’Platform, Pipe Racks, Platform
SkyGlazier™ SkyPower™ SkyWelder™
MTR*, Soft Touch,
SkyPower™ SkyGlazier™, SkyWelder™
4’Platform, Pipe Racks, Platform
SkyWelder™ SkyPower™ SkyGlazier™
MTR*, Soft Touch
Pipe Racks, SkyGlazier™,
Soft Touch SkyPower™
SkyWelder™
Note 1: Any non-"Sky" accessory not listed under "INCOMPATIBLE WITH" is assumed to be compatible.
Note 2: Can be used on same unit but not simultaneously.
* Platform MTR = Platform Mesh to Top Rail; ** Platform MMR = Platform Mesh to Mid Rail
4150459 M

6-2 3121670
 SECTION 6 - ACCESSORIES

6.1 FALL ARREST 6.2 PIPE RACKS

NOTE: See the JLG External Fall Arrest System manual (PN 3128935) for
more detailed information.

The external fall arrest system is designed to provide a lanyard

attach point while allowing the operator to access areas outside
the platform. Exit/enter the platform through the gate area only.
The system is designed for use by one person.
Personnel must use fall protection at all times. A full body harness
is required with lanyard not to exceed 6 ft (1.8 m) in length, that
limits the maximum arrest force to 900 lbs (408 kg) for the trans-
fastener type and 1350 lbs (612 kg) for the shuttle type fall arrest
system.

Safety Precautions

DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE THE PLATFORM. USE
CAUTION WHEN ENTERING/EXITING THE PLATFORM AT ELEVATION.

Pipe Racks provide a way to store pipe or conduit inside the plat-
form in order to prevent rail damage and optimize platform util-
ity. This accessory consists of two racks with adjustable straps to
secure the load in place.

3121670 6-3
 SECTION 6 - ACCESSORIES

Capacity Specifications (Australia Only) • Ensure no personnel are beneath the platform.
• Do not exit platform over rails or stand on rails.
Max. Platform Capacity
Max. Capacity in Racks
(With Max. Weight in Racks) • Do not drive machine without material secured
80 kg 184 kg • Return racks to the stowed position when not in use.
Max. Length of Material in Racks: 6.0 m • Use this option only on approved models.
Min. Length of Material in Racks: 2.4 m
Preparation and Inspection
Safety Precautions • Ensure racks are secured to the platform rails.
• Replace torn or frayed tie-down straps.

REDUCE PLATFORM CAPACITY BY 100 LBS (45.5 KG) WHEN INSTALLED.

Operation
1. To prepare racks for loading, remove locking pins, rotate
each rack 90 degrees from stowed to working position, then
secure with locking pins.
WEIGHT IN RACKS PLUS WEIGHT IN PLATFORM MUST NOT EXCEED RATED CAPACITY.
2. Loosen and remove tie-down straps. Place material on racks
with weight evenly distributed between both racks.
3. Route the tie-down straps at each end across loaded mate-
THE MAXIMUM LOAD IN THE RACKS IS 180 LBS (80 KG) EVENLY DISTRIBUTED rial and tighten.
BETWEEN THE TWO RACKS.
4. To remove material, loosen and remove tie-down straps,
then carefully remove material from racks.

THE MAXIMUM LENGTH OF MATERIAL IN RACKS IS 20 FT (6.1 M). NOTE: Reinstall tie-down straps across any remaining material before
continuing machine operations.

6-4 3121670
 SECTION 6 - ACCESSORIES

6.3 SKYGLAZIER™ Capacity Specifications

Max. Platform Capacity
Capacity Zone * Max. Tray Capacity
(With Max. Weight in Tray)

500 lbs 150 lbs 250 lbs

(227 kg) (68 kg) (113 kg)
550 lbs 150 lbs 250 lbs
(250 kg) (68 kg) (113 kg)
600 lbs 150 lbs 250 lbs
(272 kg) (68 kg) (113 kg)
750 lbs 150 lbs 440 lbs
(340 kg) (68 kg) (200 kg)
1000 lbs 250 lbs 500 lbs
(454 kg) (113 kg) (227 kg)
* Refer to the capacity decals installed on the machine for capac-
ity zone information.

Required Platform Type: Side-Entry

Max. Dimensions of Panel: 32 sq.ft. (3 sq.m.)

SkyGlazier™ allows glaziers to position panels efficiently. The gla-
zier package consists of a tray that attaches the bottom of the
platform. The panel rests on the tray and against top-rail of the
platform, which is padded to prevent damage. SkyGlazier™
includes a strap to secure the panel to the platform rail.

3121670 6-5
 SECTION 6 - ACCESSORIES

Safety Precautions Preparation and Inspection

• Check for cracked welds and damage to tray.
• Ensure tray is properly secured to platform.
ENSURE PANEL IS SECURED WITH STRAP.
• Ensure strap is not torn or frayed.

Operation
DO NOT OVERLOAD TRAY OR PLATFORM. TOTAL MACHINE CAPACITY IS REDUCED
1. Load SkyGlazier™ tray with panel.
WHEN TRAY IS INSTALLED.
2. Route the adjustable strap around the panel and tighten
until secure.
3. Position panel to its desired location.
WITH SKYGLAZIER™ INSTALLED, THE ORIGINAL PLATFORM CAPACITY RATINGS ARE
REDUCED AS SPECIFIED IN THE CAPACITY SPECIFICATIONS TABLE. DO NOT EXCEED
NEW PLATFORM CAPACITY RATINGS. REFER TO CAPACITY DECAL LOCATED ON TRAY.

AN INCREASE OF THE AREA EXPOSED TO THE WIND WILL DECREASE STABILITY. LIMIT
PANEL AREA TO 32 SQ FT (3 SQ M).

• Ensure no personnel are beneath platform.

• Do not exit platform over rails or stand on rails.
• Remove tray when not in use.
• Use this option only on approved models.

6-6 3121670
 SECTION 6 - ACCESSORIES

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

Generator Output
ANSI Specifications:
• 3-phase: 240 V, 60 Hz, 7.5 kW
• 1-phase: 240 V/120 V, 60 Hz, 6 kW
CE Specifications:
• 3-phase: 240 V, 7.5 kW, 18.3 A, 1.0-pf
• 1-phase: 240 V, 6.0 kW, 26 A, 1.0-pf
• 1-phase: 120 V, 6.0 kW, 50 A, 1.0-pf
Peak:
• 3-phase: 8.5 kW
• 1-phase: 6.0 kW

Accessory Ratings
The SkyPower™ system supplies AC power to the platform • 3000 rpm (50 Hz)
through an AC receptacle to run tools, lights, cutting, and weld- • 3600 rpm (60 Hz)
ing equipment.

3121670 6-7
 SECTION 6 - ACCESSORIES

Safety Precautions 6.5 SKYWELDER™

DO NOT OVERLOAD PLATFORM.

• Ensure no personnel are beneath platform.

• This factory-installed option is available only on specified
models.
• Keep lanyard attached at all times.
• Do not use electrical tools in water.
• Use correct voltage for tool being used.
• Do not overload circuit.

Preparation and Inspection

• Ensure generator is secure.
• Check condition of belt and wiring.

Operation
Start the engine, then turn on the generator. SkyWelder™ is capable of TIG and Stick welding, producing 200
Amps at 100% duty cycle or 250 Amps at 50% duty cycle. This
See the Miller Generator Technical Manual (PN 3121677) for more accessory receives power from the SkyPower™ system.
information.

6-8 3121670
 SECTION 6 - ACCESSORIES

Accessory Ratings
Welding Amps Input At Rated Load Output (50/60 Hz)
Maximum Open
Welding Mode Input Power Rated Output Amperage
Circuit Voltage 230 V 460 V 575 V kVa kW
Range
280 Amp at 31.2 V,
32 17 13 15.7 10
35% Duty Cycle
3- phase 5-250 A 79 VDC
200 Amp at 28 V,
20 11 8 10.3 6.4
Stick (SMAW) 100% Duty Cycle
TIG (GTAW) 200 Amp at 28 V,
35 ------ ------ 9.8 6.5
50% Duty Cycle
1 -phase 5-200 A 79 VDC
150 Amp at 28 V,
34 ------ ------ 6.9 4.4
100% Duty Cycle

Generator Output Welding Accessories

Engine Speed of 1800 rpm +/- 10%. • 12 ft welding leads with clamp and stinger (stored in the
platform)
ANSI Specifications:
• Fire extinguisher
• 3-phase: 240 V, 60 Hz, 7.5 kW
• 1-phase: 240 V/120 V, 60 Hz, 6 kW
CE Specifications:
• 3-phase: 400 V, 50 Hz, 7.5 kW
• 1-phase: 220 V, 50 Hz, 6 kW

3121670 6-9
 SECTION 6 - ACCESSORIES

Safety Precautions • Use correct rod size and current settings.

• Do not use electrical cords without ground.
• Do not use electrical tools in water.
DO NOT OVERLOAD PLATFORM.
• Do not weld to the platform.
• Do not ground through the platform.
• Do not use a high frequency arc starter with TIG welder.
DE-RATE THE PLATFORM BY 70 LBS (32 KG) WHEN WELDER IS IN THE PLATFORM.
Preparation and Inspection
• Check for cracked welds and damage to welder supports.
• Connect ground clamp to metal being welded.
• Check for proper and secure installation of welder and
bracket. • Ensure there is a good ground connection and observe
proper polarity.
• Ensure no personnel are beneath platform.
• Do not exit platform over rails or stand on rails. Operation
• Use this option only on approved models. Start the engine, turn on the generator, then turn on the welder.
• Keep lanyard attached at all times. See the Miller Welder Owner’s Manual (PN 3128957) for more
• Ensure correct polarity of leads. information.
• Wear proper welding apparel.

6-10 3121670
 SECTION 6 - ACCESSORIES

6.6 SOFT TOUCH 6.7 BOLT-ON EXTERNAL FALL ARREST

A padding kit is mounted to the platform rails and to a frame sus- The bolt-on external fall arrest system is designed to provide a lan-
pended below the platform. Limit switches deactivate platform yard attach point while allowing the operator to access areas outside
functions when the padded framework contacts an adjacent the platform. Exit/Enter the platform through the gate area only. The
structure. A button on the platform console allows override of the system is designed for use by one person.
system.
Personnel must use fall protection at all times. A full body harness is
OVERRIDE BUTTON required with lanyard not to exceed 6 ft. (1.8 M) in length, that limits
OVERRIDE INDICATOR RAIL BUMPER the maximum arrest force to 900 lbs. (408 kg).
LIGHT
External Fall Arrest System capacity is 310 lb (140 kg) - one (1) person
maximum.

Do not move platform during use of the external fall arrest system.

DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE OF PLATFORM. BE

CAREFUL WHEN ENTERING/EXITING THE PLATFORM AT ELEVATION.
LIMIT
SWITCH

LIMIT
SWITCH SUSPENDED FRAME AND RAIL BUMPER

3121670 6-11
 SECTION 6 - ACCESSORIES

Inspection Before Use

IF THE EXTERNAL FALL ARREST SYSTEM IS USED TO ARREST A FALL OR IS OTHERWISE The external fall arrest system must be inspected before each use of
DAMAGED, THE ENTIRE SYSTEM MUST BE REPLACED AND THE PLATFORM FULLY the aerial work platform. Replace components if there are any signs
INSPECTED BEFORE RETURNING TO SERVICE. REFER TO THE SERVICE MANUAL FOR of wear or damage.
REMOVAL AND INSTALLATION PROCEDURES.
Before each use, perform a visual inspection of the following compo-
nents:
THE EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL INSPECTION AND CERTI-
FICATION. THE ANNUAL INSPECTION AND CERTIFICATION MUST BE PERFORMED BY A
QUALIFIED PERSON OTHER THAN THE USER.

6-12 3121670
 SECTION 6 - ACCESSORIES

• Cable: Inspect cable for proper tension, broken strands, kinks, or • Attachment Ring: No cracks or signs of wear are acceptable. Any
any signs of corrosion. signs of corrosion requires replacement.

GAP
GAPSHOWING:
SHOWING:
• Attaching Hardware: Inspect all attaching hardware to ensure
INCORRECT
INCORRECT there are no missing components and hardware is properly tight-
ened.
• Platform Rails: No visible damage is acceptable.

NO GAP:
NO GAP: CORRECT
CORRECT

Figure 6-1. Bolt-On External Fall Arrest Cable Tension

• Fittings & Brackets: Ensure all fittings are tight and there are no
signs of fractures. Inspect brackets for any damage.

3121670 6-13
 SECTION 6 - ACCESSORIES
I

7
1,2,3,4

5
1. Belleville Washer
2. Washer
6 3. Hex Nut
4. Jam Nut
5. LH Bracket
6. Attachment Ring
7. Cable
8. RH Bracket
9. Decal

Figure 6-2. Bolt-On External Fall Arrest System

6-14 3121670
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

SECTION 7. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7.1 INTRODUCTION 7.2 OPERATING SPECIFICATIONS
This section of the manual provides additional necessary infor- Table 7-1. Operating Specifications - 400S
mation to the operator for proper operation and maintenance of
this machine. Maximum Work Load (Capacity):
The maintenance portion of this section is intended as informa- Unrestricted (CE & Aus) 600 lb (270 kg)
tion to assist the machine operator to perform daily maintenance Untrestricted (ANSI) 600 lb (272 kg)
tasks only, and does not replace the more thorough Preventive Restricted (CE & Aus) 1000 lb (450 kg)
Maintenance and Inspection Schedule included in the Service Restricted (ANSI) 1000 lb (454 kg)
and Maintenance Manual. Maximum Travel Grade, Stowed Position 45%
(Gradeability)
Other Publications Available:
Maximum Travel Grade, Stowed Position 5°
Service and Maintenance Manual .............................................3121671
(Side Slope)
Illustrated Parts Manual ................................................................3121672 Platform Height: 40 ft. 6 in. (12.36 m)
Horizontal Platform Reach: 33 ft. 3 in. (10.13 m)
Turning Radius (Outside) 15 ft. 10.5 in. (4.8 m)
Turning Radius (Inside) 6 ft. 6 in. (2.0 m)
Overall Width 7 ft. 6.8 in. (2.3 m)
Stowed Height 8 ft. 1.4 in. (2.47 m)
Stowed Length 24 ft. 10.1 in. (7.57 m)

3121670 7-1
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 7-1. Operating Specifications - 400S Table 7-2. Operating Specifications - 460SJ
Wheelbase 7 ft. 9.5 in. (2.37 m) Maximum Work Load (Capacity):
Ground Clearance 12.1 in. (0.3 m) Unrestricted (CE and Aus) 600 lb (270 kg)
Unrestricted (ANSI) 600 lb (272 kg)
Max. Tire Load 7200 lbs. (3266 kg)
Maximum Travel Grade, Stowed Position 45%
Ground Bearing Pressure 60 psi (4.19 kg/cm2) (Gradeability)
Travel Speed 4.5 mph (7.2 km/h) Maximum Travel Grade, Stowed Position 5°
Gross Machine Weight 13,425 (6,090 kg) (Side Slope)

Maximum System Voltage 12V Platform Height: 46 ft. (14.05 m)

Max. Hydraulic System Operating Pressure 3000 psi (207 Bar) Horizontal Platform Reach: 39 ft. 7 in. (12.07 m)

Manual Force Turning Radius (Outside) 15 ft. 10.5 in. (4.8 m)

CE 90 lbs. (400 N) Turning Radius (Inside) 6 ft. 6 in. (2.0 m)
ANSI 100 lbs. (445 N)
Overall Width 7 ft. 6.8 in. (2.3 m)
Maximum Wind Speed 28 mph (12.5 m/s)
Stowed Height 8 ft. 1.4 in. (2.47 m)
Stowed Length 29 ft. 2.9 in.(8.91 m)
Wheelbase 7 ft. 9.5 in. (2.37 m)
Ground Clearance 12.1 in. (0.3 m)
Max. Tire Load 7200 lbs. (3266 kg)
Ground Bearing Pressure 60 psi (4.19 kg/cm2)
Travel Speed 4.5 mph (7.2 km/h)

7-2 3121670
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 7-2. Operating Specifications - 460SJ Capacities

Gross Machine Weight 16,370 lbs. (7,425 kg) Table 7-3. Capacities

Maximum System Voltage 12V Fuel Tank 22 gal. (83.3 L)

Max. Hydraulic System Operating Pressure 3000 psi (207 Bar) Hydraulic Tank 32.5 Gal (123 L)

Manual Force Hydraulic System (Including Tank) 40 Gal. (151.4 L)

CE 90 lbs. (400 N) Drive Hub 24 oz. (0.7 L)
ANSI 100 lbs. (445 N) Drive Brake 27 oz. (0.8 L)
Maximum Wind Speed 28 mph (12.5 m/s) Engine Coolant
Deutz 2.9L 2.9 gal. (11.3L)
GM 3.0L 2.4 gal. (9.1L)
Kubota 2.25 gal. (8.5 L)

3121670 7-3
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Engine Data Table 7-5. Deutz D2.9L4

NOTE: RPM Tolerances are ± 100. Type Liquid Cooled

Number of Cylinders 4

Table 7-4. Deutz D2011L03 Bore 3.6 in (92 mm)

Stroke 4.3 in (110 mm)
Fuel Diesel
Total Displacement 178 cu. in (2925 cm³)
No. of Cylinders 3
Firing Order 1-3-4-2
Bore 3.7 in (94 mm)
Output 49 hp (36.5 kW)
Stroke 4.4 in (112 mm)
Oil Capacity 2.4 gal (8.9 L)
Displacement 142 cu. in (2331 cm³)
Coolant Capacity (System) 3.2 gal (12.1 L)
Oil Capacity
Average Fuel Consumption 1.2 gph (4.1 Lph)
crankcase 6.3 qt (6 L)
cooler 3.7 qt (3.5 L) Min. Low Engine RPM 1200
total capacity 10 qt (9.5 L) Mid Engine RPM 1800
Low RPM 1200 Max. High Engine RPM 2500
Mid RPM
Boom Lift, Tele
Swing, Basket Level, Basket 1800
Rotate, Jib Lift 1500
High RPM 2800

7-4 3121670
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 7-6. GM 3.0L Table 7-7. Kubota WG 2503

Fuel Gasoline or Gasoline/LP Gas Fuel Gasoline or Gasoline/LP Gas

No. of Cylinders 4 BHP
BHP Gasoline 45.5 kW @ 2700 rpm
Gasoline 82 hp @ 3000 rpm LP 46 Kw @ 2700 rpm
LP 75 hp @ 3000 rpm Bore 3.46 in (88 mm)
Bore 4.0 in (101.6 mm) Stroke 4.03 in (102.4 mm)
Stroke 3.6 in (91.44 mm) Displacement 153 cu.in(2.5 L)
Displacement 181 cu.in(3.0 L, 2966 cc) Oil Capacity w/filter 2.5 gal (9.5 L)
Oil Capacity w/filter 4.5 qt (4.25 L) Coolant Capacity (engine only) 1.4 gal (5.4 L)
Minimum Oil Pressure Max. RPM 2700
at idle 6 psi (0.4 bar) @ 1000 rpm Fuel Consumption - Gasoline In Drive 2.45 Gal/Hr 9.26 L/Hr --
Hot 18 psi (1.2 bar) @ 2000 rpm
@ Idle 0.64 Gal/Hr 2.43 L/Hr --
Compression Ratio 9.2:1
Fuel Consumption - LP In Drive 2.68 Gal/Hr 10.14 L/Hr 5.88 kg/Hr
Firing Order 1-3-4-2
@ Idle 0.66 Gal/Hr 2.52 L/Hr 1.46 kg/Hr
Max. RPM 2800

3121670 7-5
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Tires
Table 7-8. Tires

Size Type Pressure Weight

12 x 16.5 Pneumatic 90 psi (6 Bar) 128 lbs. (58 kg)
Foam-Filled N/A 328 lbs. (149 kg)
14 x 17.5 Pneumatic 90 psi (6 Bar) 170 lbs. (77.2 kg)
Foam-Filled N/A 440 lbs. (200 kg)
33/16LL x 16.1 Pneumatic 40 psi (3 Bar) 119.5 lbs. (54 kg)
315/55 D20 Foam-Filled N/A 286 lbs. (130 kg)
Solid N/A 286 lbs. (130 kg)

7-6 3121670
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Hydraulic Oil Aside from JLG recommendations, it is not advisable to mix oils of
different brands or types, as they may not contain the same required
Table 7-9. Hydraulic Oil additives or be of comparable viscosities. If use of hydraulic oil other
Hydraulic System S.A.E. Viscosity than Mobilfluid 424 is desired, contact JLG Industries for proper rec-
Operating Temperature Range Grade ommendations.

+0° to + 180° F (-18° to +83° C) 10W Table 7-10. Mobilfluid 424 Specs
+0° to + 210° F (-18° to +99° C) 10W-20, 10W30 SAE Grade 10W30
+50° to + 210° F (+10° to +99° C) 20W-20 Gravity, API 29.0
Density, Lb/Gal. 60°F 7.35
NOTE: Hydraulic oils must have anti-wear qualities at least to API Ser- Pour Point, Max -46°F (-43°C)
vice Classification GL-3, and sufficient chemical stability for
Flash Point, Min. 442°F (228°C)
mobile hydraulic system service. JLG Ind. recommends Mobil-
fluid 424 hydraulic oil, which has an SAE viscosity index of 152. Viscosity
Brookfield, cP at -18°C 2700
NOTE: When temperatures remain consistently below 20° F (-7° C), JLG at 40° C 55 cSt
Industries recommends the use of Mobil DTE-13.
at 100° C 9.3 cSt
NOTE: Machines may be equipped with Mobil EAL224H biodegradable Viscosity Index 152
and non-toxic hydraulic oil. This is Vegetable oil based and pos-
sesses the same antiwear and rust protection characteristics as
mineral oils, but will not adversely affect the ground water or the
environment when spilled or leaked in small amounts. Mobil EAL-
224H has a viscosity of 34 cSt at 40° C. and viscosity index of 213.
The operating temperature range of this oil is -18° C to +83° C.

3121670 7-7
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 7-11. Mobil DTE 10 Excel 32 Specs Table 7-12. UCon Hydrolube HP-50/46

ISO Viscosity Grade #32 Type Synthetic Biodegradable

Specific Gravity 0.877 Specific Gravity 1.082
Pour Point, Max -40°F (-40°C) Pour Point, Max -58°F (-50°C)
Flash Point, Min. 330°F (166°C)
pH 9.1
Viscosity
Viscosity
at 40° C 33cSt
at 0° C (32° F) 340 cSt (1600SUS)
at 100° C 6.6 cSt
at 40° C (104° F) 46 cSt (215SUS)
at 100° F 169 SUS
at 65° C (150° F) 22 cSt (106SUS)
at 210° F 48 SUS
Viscosity Index 170
cp at -20° F 6,200
Viscosity Index 140

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Table 7-13. Mobil EAL 224H Specs Table 7-14. Mobil EAL H 46 Specs

Type Synthetic Biodegradable Type Synthetic Biodegradable

ISO Viscosity Grade 32/46 ISO Viscosity Grade 46
Specific Gravity .922 Specific Gravity .910
Pour Point, Max -25°F (-32°C)
Pour Point -44°F (-42°C)
Flash Point, Min. 428°F (220°C)
Flash Point 500°F (260°C)
Operating Temp. 0 to 180°F (-17 to 162°C)
Operating Temp. 0 to 180°F (-17 to 162°C)
Weight 7.64 lb. per gal.
(0.9 kg per liter) 7.64 lb/gal
Weight
Viscosity (0.9 kg/L)
at 40° C 37 cSt Viscosity
at 100° C 8.4 cSt at 40° C 45 cSt
Viscosity Index 213 at 100° C 8.0 cSt
NOTE: Must be stored above 32°F (14°C) Viscosity Index 153

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Critical Stability Weights

Table 7-15. Exxon Univis HVI 26 Specs

Specific Gravity 32.1 Table 7-16. Critical Stability Weights

Pour Point -76°F (-60°C) Component lb kg
Flash Point 217°F (103°C) Battery 66 30
Viscosity Counterweight (S) 1060 ± 42.4 481.8 ± 19.3
at 40° C 25.8 cSt Counterweight (SJ) 2700 ± 54 1227.3 ± 24.5
at 100° C 9.3 cSt Tires See Table 7-8, Tires
Viscosity Index 376 Platform and Console - 36 x 72 209 95
NOTE: Mobil/Exxon recommends that this oil be checked on a Platform and Console - 36 x 96 240 109
yearly basis for viscosity.
Platform and Console - Fall Arrest 287 130

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Serial Number Location

A serial number plate is affixed to the left rear side of the frame. If the
serial number plate is damaged or missing, the machine serial num-
ber is stamped on the left side of the frame.

SERIAL NUMBER PLATE

Figure 7-1. Serial Number Location

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

1001206353 A

Figure 7-2. Hydraulic Oil Operation Chart - Sheet 1 of 2

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Fluid Properties Base Classi?cation

Fire Resistant***
Biodegradeable*
Viscosity @ 40° C
(CsT, Typical)

Vegetable Oils

Polyol Esters

Readilly
Mineral Oils

Synthetic

Non-toxic**
Description

Virtually
Visc Index

Synthetic
Mobilfluid 424 55 145 X
Mobil DTE 10 Excel 32 32 141 X
UNIVIS HVI 26 26 376 X
Mobil EAL 224 H 36 212 X X X
Mobil Envirosyn H 46 49 145 X X X
Quintolubric 888-46 50 185 X X X X
* Readily biodegradable classi?cation indicates
NOTICE:
one of the following:
MACHINE OPERATION USING NON-JLG APPROVED
CO2 Conversion>60% per EPA 560/6-82-003
HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF
CO2 Conversion>80% per CEC-L-33-A-93
** Virtually Non-toxic classi?cation indicates THE TEMPERATURE BOUNDARIES OUTLINED IN
THE "HYDRAULIC FLUID OPERATION CHART" MAY
an LC50>5000 ppm per OECD 203
RESULT IN PREMATURE WEAR OR DAMAGE TO
*** Fire Resistant classi?cation indicates
COMPONENTS OF THE HYDRAULIC SYSTEM.
Factory Mutual Research Corp. (FMRC) Approval
1001206353 A

Figure 7-3. Hydraulic Oil Operation Chart - Sheet 2 of 2

3121670 7-13
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 7-4. Engine Operating Temperature Specifications - Deutz

7-14 3121670
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

AMBIENT AIR
TEMPERATURE

120 F(49 C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110 F(43 C)
100 F(38 C)
90 F(32 C)
80 F(27 C)
70 F(21 C)
ENGINE 60 F(16 C)
SPECIFICATIONS
50 F(10 C)
40 F(4 C)
ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. 30 F(-1 C)
NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
20 F(-7 C)
ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE 10 F(-12 C)
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
0 F(-18 C)

ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS, -10 F(-23 C)
A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C)
(IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
-30 F(-34 C)
-40 F(-40 C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

Figure 7-5. Engine Operating Temperature Specifications - GM - Sheet 1 of 2

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

EXTENDED DRIVING WITH

HYDRAULIC OIL TANK
TEMPERATURES OF 180°F
(82° C) OR ABOVE.
180° F(82° C)
(HYD. OIL TANK TEMP.)
IF EITHER OR BOTH CONDITIONS
EXIST JLG HIGHLY RECOMMENDS
AMBIENT AIR THE ADDITION OF A HYDRAULIC
TEMPERATURE OIL COOLER (CONSULT JLG SERVICE

120° F (49° C) PROLONGED OPERATION IN

NO OPERATION ABOVE THIS
110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100° F(38° C) OR ABOVE.
100° F (38° C)
MOBIL 424 10W-30

90° F (32° C)
80° F (27° C)
70° F (21° C) EXXON UNIVIS HVI 26
60° F (16° C)
50° F (10° C)
HYDRAULIC
MOBIL DTE 13

SPECIFICATIONS
40° F (4° C)
30° F (-1° C)
20° F (-7° C)
10° F (-12° C)
DO NOT START UP HYDRAULIC SYSTEM
0° F (-18° C)
WITHOUT HEATING AIDS WITH MOBILE 424
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE NOTE:
-20° F (-29° C)
DO NOT START UP HYDRAULIC SYSTEM 1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
-30° F (-34° C) WITHOUT HEATING AIDS AND COLD WEATHER CONSISTENTLY WITHIN SHOWN LIMITS
HYDRAULIC OIL BELOW THIS TEMPERATURE
-40° F (-40° C)
NO OPERATION BELOW THIS 2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
AMBIENT TEMPERATURE

4150548-E
Figure 7-6. Engine Operating Temperature Specifications - GM - Sheet 2 of 2

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

NOTICE:

MACHINE OPERATION USING NON-JLG APPROVED

ENGINE OIL OR OPERATION OUTSIDE OF
THE TEMPERATURE BOUNDARIES OUTLINED IN
THE "ENGINE OIL OPERATION CHART" MAY
RESULT IN PREMATURE WEAR OR DAMAGE TO
COMPONENTS OF THE ENGINE.

1001120075-A

Figure 7-7. Engine Oil Operation Chart - Kubota

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 7-8. Operator Maintenance and Lubrication Diagram - Deutz 2.9L Engine

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 7-9. Operator Maintenance and Lubrication Diagram - Deutz 2011L Engine

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 7-10. Operator Maintenance and Lubrication Diagram - GM Engine

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 7-11. Operator Maintenance and Lubrication Diagram - Kubota Engine

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7.3 OPERATOR MAINTENANCE NOTE: It is recommended as a good practice to replace all filters at the
same time.
NOTE: The following numbers correspond to those in Figure 7-8., Oper-
ator Maintenance and Lubrication Diagram - Deutz 2.9L Engine. 1. Swing Bearing - Internal Ball Bearing

Table 7-17. Lubrication Specifications Lube Point(s) - 2 Grease Fittings

Capacity - A/R
KEY SPECIFICATIONS Lube - MPG
Interval - Every 3 months or 150 hours of operation
MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excel-
Comments - Fittings in center of bearing: Remote Access is
lent water resistance and adhesive qualities, and being of extreme pressure type.
optional: Apply grease and rotate in 90 degree intervals
(Timken OK 40 pounds minimum.)
until bearing is completely lubricated
EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or MIL-
Spec MIL-L-2105
HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424.
EO Engine (crankcase). Gas (5W30)- API SN, -Arctic ACEA AI/BI, A5/B5 - API SM, SL, SJ,
EC, CF, CD - ILSAC GF-4. Diesel (15W40, 5W30 Arctic) - API CJ-4.
OGL Open Gear Lubricant - Mobiltac 375 or equivalent.

LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDI-

TIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE
ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED
ACCORDINGLY.

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2. Wheel Drive Hub 3. Drive Brake

OIL LEVEL CHECK

ANDFILL

Lube Point(s) - Level/Fill Plug

Capacity - 24 oz. (0.8 L)(1/2 Full)
Lube - EPGL
Interval - Check level every 3 months or 150 hrs of opera-
Lube Point(s) - Fill Plug
tion; change every 2 years or 1200 hours of operation
Capacity - 2.7 oz. (89 mL)
Lube - DTE-10 Excel 32
Interval - Change as necessary

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

4. Hydraulic Return Filter 5. Hydraulic Tank Breather

Interval - Change after first 50 hours and every 6 months or

300 hours thereafter or whenever Charge Filter is replaced Interval - Change after first 50 hrs. and every 6 months or 300
hrs. thereafter.
Comments - Remove wing nut and cover to replace. Under cer-
tain conditions, it may be necessary to replace on a more
frequent basis.

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6. Hydraulic Tank - Prior to S/N 0300220610 Hydraulic Tank - S/N 0300220610 to 0300272360

Lube Point(s) - Fill Cap

Capacity - 32.5 gal tank (123 L) 40.0 gal system (151 L) Lube Point(s) - Fill Cap
Lube - HO Capacity - 15 Gal. (57 L) to Full Level
Interval - Check Level daily; Change every 2 years or 1200 Lube - HO
hours of operation Interval - Check Level daily; Change every 2 years or 1200
hours of operation.
Comments - On new machines, those recently overhauled, or
after changing hydraulic oil, operate all systems a minimum
of two complete cycles and recheck oil level in reservoir.

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7. Hydraulic Charge Filter 8. Oil Change w/Filter - Deutz D2011

Interval - Change after first 50 hours and every 6 months or

300 hours thereafter or as indicated by Condition Indicator

Lube Point(s) - Fill Cap/Spin-on Element

Capacity - 10 Quarts (9.5 L) w/Filter
Lube - EO
Interval - Check level daily; change every 500 hours or six
months, whichever comes first. Adjust final oil level by mark
on dipstick.

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

9. Oil Change w/Filter - Deutz 2.9 L4

Lube Point(s) - Fill Cap/Spin-on Element

Capacity - 2.4 gal (8.9 L)
Lube - EO
Interval - Every Year or 600 hours of operation
Comments - Check level daily/Change in accordance with
engine manual

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

10. Oil Change w/Filter - GM

Lube Point(s) - Fill Cap/Spin-on Element

Capacity - 4.5 qt (4.25 L) w/filter
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance with
engine manual

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

11. Fuel Pre-Filter - Deutz D2.9 12. Fuel Filter - Deutz D2.9

Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element

Interval - Drain water daily; Every year or 600 hours of Interval - Every year or 600 hours of operation
operation

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

13. Fuel Filter - Deutz D2011 14. Fuel Filter (Gasoline) - GM

Lube Point(s) - Replaceable Element

Interval - Every 6 months or 300 hours of operation

Lube Point(s) - Replaceable Element

Interval - Every year or 500 hours of operation

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

15. Fuel Filter (Propane) - GM Engine 16. Radiator Coolant Deutz 2.9

Interval - 3 Months or 150 hours of operation

Comments - Replace filter. Refer to Section 7.5, Propane
Fuel Filter Replacement (GM Engine)

Lube Point(s) - Fill Cap

Capacity - 2.9 Gallon (11.3 L)
Lube - Anti-Freeze
Interval - Check level daily; change every 1000 hours or 2 years,
whichever comes first

3121670 7-31
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

17. Radiator Coolant -GM 18. Air Filter

Lube Point(s) - Fill Cap
Capacity - 2.4Gallon (9.1 L)
Lube - Anti-Freeze
Interval - Check level daily; change every 1000 hours or 2 years,
whichever comes first

Lube Point(s) - Replaceable Element

Interval - Every 6 months or 300 hours of operation or as
indicated by the condition indicator
Comments - Check Dust Valve daily

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

19. Swing Drive Hub 20. Wheel Bearings

Lube Point(s) - Repack

Capacity - A/R
Lube - MPG
Interval - Every 2 years or 1200 hours of operation
Lube Point - Level/Fill Plug
Capacity - 40 oz. (1.2 L)
Lube - 90w80 Gear Oil
Interval - Check level every 3 months or 150 hours of opera-
tion; change after first 50 hours and every 2 years or 1200
hours of operation thereafter

3121670 7-33
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

21. Oil Change w/Filter - Kubota

Lube Point(s) - Fill Cap/Spin-on Element

Capacity - 2.5 gal. (9.5 L) w/filter
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance with
engine manual

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

22. Fuel Filter - Kubota 24. Fuel Filter (Propane) - Kubota

Lube Point(s) - Replaceable Component

Interval - Every year or 600 hours of operation Interval - Every year or 1000 hours of operation
23. Engine Coolant - Kubota Comments - Replace filter. Refer to Section 7.6, Propane
Fuel Filter Replacement (Kubota Engine)
Lube Point(s) - Fill Cap
Capacity - 2.25 gal. (8.5 L)
Lube - Anti-Freeze
Interval - Check level daily; change every 1000 hours or two
years, whichever comes first.

3121670 7-35
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7.4 TIRES & WHEELS If a tire is damaged but is within the above noted criteria, the tire
must be inspected on a daily basis to insure the damage has not
propagated beyond the allowable criteria.
Tire Inflation
The air pressure for pneumatic tires must be equal to the air pres- Tire Replacement
sure that is stenciled on the side of the JLG product or rim decal
for safe and proper operational characteristics. JLG recommends a replacement tire be the same size, ply and brand
as originally installed on the machine. Please refer to the JLG Parts
Tire Damage Manual for the part number of the approved tires for a particular
machine model. If not using a JLG approved replacement tire, we
For pneumatic tires, JLG Industries, Inc. recommends that when any recommend that replacement tires have the following characteris-
cut, rip, or tear is discovered that exposes sidewall or tread area cords tics:
in the tire, measures must be taken to remove the JLG product from
service immediately. Arrangements must be made for replacement • Equal or greater ply/load rating and size of original
of the tire or tire assembly. • Tire tread contact width equal or greater than original
For polyurethane foam filled tires, JLG Industries, Inc. recommends that • Wheel diameter, width, and offset dimensions equal to the
when any of the following are discovered, measures must be taken to original
remove the JLG product from service immediately and arrangements • Approved for the application by the tire manufacturer
must be made for replacement of the tire or tire assembly. (including inflation pressure and maximum tire load)
• a smooth, even cut through the cord plies which exceeds 3 Unless specifically approved by JLG Industries Inc. do not replace a
inches (7.5 cm) in total length foam filled or ballast filled tire assembly with a pneumatic tire. When
• any tears or rips (ragged edges) in the cord plies which selecting and installing a replacement tire, ensure that all tires are
exceeds 1 inch (2.5 cm) in any direction inflated to the pressure recommended by JLG. Due to size variations
between tire brands, both tires on the same axle should be the same.
• any punctures which exceed 1 inch in diameter
• any damage to the bead area cords of the tire

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Wheel Replacement Wheel Installation

The rims installed on each product model have been designed for It is extremely important to apply and maintain proper wheel
stability requirements which consist of track width, tire pressure, and mounting torque.
load capacity. Size changes such as rim width, center piece location,
larger or smaller diameter, etc., without written factory recommen-
dations, may result in an unsafe condition regarding stability. WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PRE-
VENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF
WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE
OF THE WHEEL.

Tighten the lug nuts to the proper torque to prevent wheels from
coming loose. Use a torque wrench to tighten the fasteners. If you do
not have a torque wrench, tighten the fasteners with a lug wrench,
then immediately have a service garage or dealer tighten the lug
nuts to the proper torque. Over-tightening will result in breaking the
studs or permanently deforming the mounting stud holes in the
wheels. The proper procedure for attaching wheels is as follows:
1. Start all nuts by hand to prevent cross threading. DO NOT
use a lubricant on threads or nuts.

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

2. Tighten nuts in the following sequence: 3. The tightening of the nuts should be done in stages. Follow-
ing the recommended sequence, tighten nuts per wheel
torque chart.
Table 7-18. Wheel Torque Chart

TORQUE SEQUENCE
1st Stage 2nd Stage 3rd Stage
40 ft. lbs. 100 ft. lbs. 170 ft. lbs.
(55 Nm) (130 Nm) (230 Nm)

4. Wheel nuts should be torqued after first 50 hours of opera-

tion and after each wheel removal. Check torque every 3
months or 150 hours of operation.

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7.5 PROPANE FUEL FILTER REPLACEMENT (GM ENGINE) Installation

Removal
BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING
1. Relieve the propane fuel system pressure. Refer to Propane
NEW SEAL
Fuel System Pressure Relief.
2. Disconnect the negative battery cable. 1. Install the mounting plate to lock off O-ring seal.

3. Slowly loosen the Filter housing and remove it. 2. Install the retaining bolt seal (if equipped).

4. Pull the filter housing from the Electric lock off assembly. 3. Install the housing seal.

5. Remove the filter from the housing. 4. Drop the magnet into the bottom of the filter housing.

6. Locate Filter magnet and remove it. 5. Install the filter into the housing.

7. Remove and discard the housing seal. 6. If equipped, install the retaining bolt into the filter housing.

8. Remove and discard the retaining bolt seal. 7. Install the filter up to the bottom of the electric lock off.

9. Remove and discard mounting plate to lock off O-ring seal. 8. Tighten the filter to 106 in lbs (12 Nm).
9. Open manual shut-off valve. Start the vehicle and leak check
the propane fuel system at each serviced fitting. Refer to
Propane Fuel System Leak Test.

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7.6 PROPANE FUEL FILTER REPLACEMENT (KUBOTA

ENGINE)

Removal
1. Relieve the propane fuel system pressure. Refer to Propane
Fuel System Pressure Relief.
2. Disconnect the negative battery cable.
3. Slowly loosen the bowl retaining nut and remove the nut
and filter housing from the Electric lock off assembly.
4. Remove the filter from the housing.
5. Remove and discard the housing seal.
6. Remove and discard the retaining nut seal.
1. Electric Lock Off Solenoid 6. Seal 10. Filter
2. Mounting Plate 7. Electrical Connector 11. Fuel Inlet
3. Housing Seal 8. Fuel Outlet 12. Retaining Bolt
4. Filter Magnet 9. O-ring 13. Ring
5. Filter Housing
Figure 7-12. GM Filter Lock Assembly

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Installation
1. If equipped, install the filter bowl gasket.
2. Install the filter into the housing.

OUTLET
3. Install the filter bowl up to the bottom of the electric lock off.
FILTER BOWL 4. Tighten the filter bowl retainer nut.
GASKET
5. Open manual shut-off valve. Start the vehicle and leak check
FILTER the propane fuel system at each serviced fitting.

BOWL
RETAINING NUT SEAL

Figure 7-13. Kubota Filter Lock Assembly

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7.7 PROPANE FUEL SYSTEM PRESSURE RELIEF 7.8 SUPPLEMENTAL INFORMATION

The following information is provided in accordance with the
requirements of the European Machinery Directive 2006/42/EC
THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO MIN- and is only applicable to CE machines.
IMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM
For electric powered machines, the equivalent continuous A-
PRESSURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE FUEL SYSTEM COM-
Weighted sound pressure level at the work platform is less than
PONENTS.
70dB(A)
To relieve propane fuel system pressure: For combustion engine powered machines, guaranteed Sound
Power Level (LWA) per European Directive 2000/14/EC (Noise
1. Close the manual shut-off valve on the propane fuel tank.
Emission in the Environment by Equipment for Use Outdoors)
2. Start and run the vehicle until the engine stalls. based on test methods in accordance with Annex III, Part B,
Method 1 and 0 of the directive, is 104 dB.
3. Turn the ignition switch OFF.
The vibration total value to which the hand-arm system is sub-
jected does not exceed 2,5 m/s2. The highest root mean square
RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM. ENSURE THE WORK value of weighted acceleration to which the whole body is sub-
AREA IS WELL VENTILATED BEFORE DISCONNECTING ANY FUEL LINE. jected does not exceed 0,5 m/s2.

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 SECTION 8 - INSPECTION AND REPAIR LOG

SECTION 8. INSPECTION AND REPAIR LOG

Machine Serial Number _______________________________________

Table 8-1. Inspection and Repair Log

Date Comments

3121670 8-1
 SECTION 8 - INSPECTION AND REPAIR LOG

Table 8-1. Inspection and Repair Log

Date Comments

8-2 3121670
 Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533 USA
(717) 485-5161 (Corporate)
(877) 554-5438 (Customer Support)
(717) 485-6417

Visit our website for JLG Worldwide Locations

www.jlg.com