Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times.
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.
FOREWORD SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND. INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY.
FOREWORD For: THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT. • Accident Reporting • Product Safety Publications • Current Owner Updates JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.
FOREWORD REVISION LOG d Original Issue - June 8, 2005 Revised - October 14, 2005 Revised - February 8, 2006 Revised - May 24, 2006 Revised - July 31, 2007 Revised - October 8, 2008 Revised - November 5, 2009 Revised - October 6, 2011 Revised - May 25, 2012 Revised - September 18, 2014 – JLG Lift – 3121216
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT SECTION - 1 - SAFETY PRECAUTIONS 1.1 1.2 1.3 1.4 1.5 2.2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Operator Training and Knowledge . . . . . . . . . . . 1-1 Workplace Inspection . . . . . . . . . . . . . . . . . . . . . 1-2 Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-3 OPERATION . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 ii PAGE TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-7 Traveling Forward or Reverse . . . . . . . . . . . . . . 4-9 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . 4-10 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Loading from Ground Level . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT 6.5 6.6 6.7 6.8 PAGE SECTION - PARAGRAPH, SUBJECT DRAINING OIL BUILD UP FROM THE PROPANE REGULATOR (PRIOR TO S/N 0300109274) . . . .6-42 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-44 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-46 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT 4-9. 4-10. 4-11. 6-1. 6-2. PAGE Decal Installation - Sheet 2 of 4. . . . . . . . . . . . . . . . . . . . . . 4-22 Decal Installation - Sheet 3 of 4. . . . . . . . . . . . . . . . . . . . . . 4-23 Decal Installation - Sheet 4 of 4. . . . . . . . . . . . . . . . . . . . . . 4-24 Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Engine Operating Temperature Specifications Deutz - Sheet 1 of 2 . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT LIST OF TABLES 1-1 1-2 2-1 4-1 4-2 4-3 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-11 6-12 6-10 6-13 3121216 Minimum Approach Distances (M.A.D.). . . . . . . . . 1-6 Beaufort Scale (For Reference Only) . . . . . . . . . . . 1-9 Inspection and Maintenance Table . . . . . . . . . . . . 2-3 Decals - 400S with 500 lb (227 or 230 kg) Capacity . . . . . . . . . . . . . . . . . . . 4-25 Decals - 400S with 750 lb (340 kg) Capacity . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This page intentionally blank.
SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 GENERAL This section outlines the necessary precautions for proper and safe machine usage and maintenance. It is mandatory that a daily routine is established based on the content of this manual to promote proper machine usage.
SECTION 1 - SAFETY PRECAUTIONS • An operator must not accept operating responsibilities until adequate training has been given by competent and authorized persons. • Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and maintenance of the unit. • Precautions to avoid all hazards in the work area must be taken by the user before and during operation of the machine.
SECTION 1 - SAFETY PRECAUTIONS Machine Inspection 1.3 • Do not operate this machine until the inspections and functional checks as specified in Section 2 of this manual have been performed. General • Do not operate this machine until it has been serviced and maintained according to the maintenance and inspection requirements as specified in the machine’s Service and Maintenance Manual. • Ensure all safety devices are operating properly. Modification of these devices is a safety violation.
SECTION 1 - SAFETY PRECAUTIONS • Do not carry materials directly on platform railing unless approved by JLG. • When two or more persons are in the platform, the operator shall be responsible for all machine operations. • Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area. Trip and Fall Hazards • During operation, occupants in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point.
SECTION 1 - SAFETY PRECAUTIONS • Before operating the machine, make sure all gates are closed and fastened in their proper position. Electrocution Hazards • 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.
SECTION 1 - SAFETY PRECAUTIONS Table 1-1. Minimum Approach Distances (M.A.D.) • Allow for machine movement and electrical line swaying.
SECTION 1 - SAFETY PRECAUTIONS • The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier.
SECTION 1 - SAFETY PRECAUTIONS • Never exceed the maximum work load as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG. • Do not operate the machine when wind conditions exceed 28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Reference Only). • Keep the chassis of the machine a minimum of 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards at the ground level.
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) 3121216 Wind Speed Beaufort 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.
SECTION 1 - SAFETY PRECAUTIONS • Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving and swing operations. Crushing and Collision Hazards • Approved head gear must be worn by all operating and ground personnel. • Check work area for clearances overhead, on sides, and bottom of platform when lifting or lowering platform, and driving.
SECTION 1 - SAFETY PRECAUTIONS 1.4 TOWING, LIFTING, AND HAULING 1.5 • Never allow personnel in platform while towing, lifting, or hauling. This sub-section contains general safety precautions which must be observed during maintenance of this machine. Additional precautions to be observed during machine maintenance are inserted at the appropriate points in this manual and in the Service and Maintenance Manual.
SECTION 1 - SAFETY PRECAUTIONS • DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help protect hands from spraying fluid. • Do not use machine as a ground for welding. • When performing welding or metal cutting operations, precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter. • Do not refuel the machine with the engine running. • Use only approved non-flammable cleaning solvents.
SECTION 1 - SAFETY PRECAUTIONS Battery Hazards • Always disconnect batteries when servicing electrical components or when performing welding on the machine. • Do not allow smoking, open flame, or sparks near battery during charging or servicing. BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION. • Do not contact tools or other metal objects across the battery terminals.
SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-14 – JLG Lift – 3121216
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes, drop-offs. 2.1 PERSONNEL TRAINING The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel. 7. Means to avoid the hazards of unprotected electrical conductors.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.2 PREPARATION, INSPECTION, AND MAINTENANCE The following table covers the periodic machine inspections and maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Table 2-1.Inspection and Maintenance Table Type Frequency Primary Responsibility Service Qualification Reference Pre-Start Inspection Before using each day; or whenever there’s an Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection (See Note) Before each sale, lease, or rental delivery.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 13 12 2 11 3 4 5 6 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Platform Jib (460SJ Only) Jib Lift Cylinder (460SJ Only) Level Cylinder Power Track Lift Cylinder Drive Wheels Steer Wheels Ground Control Turntable Base Boom Fly Boom Platform Console 7 8 Figure 2-1.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 7. Engine Oil Supply - Ensure the engine oil level is at the Full mark on the dipstick and the filler cap is secure. Pre-Start Inspection The Pre-Start Inspection should include each of the following: 8. Hydraulic Oil – Check the hydraulic oil level. Ensure hydraulic oil is added as required. 1. Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTE: Functional Check First, using the ground controls, check all functions controlled by the ground controls. Next, using the platform controls, check all functions controlled by the platform controls. 5. Check the chassis out of level indicator located on the platform control console by driving, with the machine in level position, up a suitable ramp of at least 5° slope.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 11. Footswitch. 12. Auxiliary Power. FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL OPERATE WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF TRAVEL. IF SWITCH OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM, IT SHOULD BE ADJUSTED. a. Activate hydraulic system, by depressing footswitch. Operate Telescope and hold control. Remove foot from footswitch, motion should stop.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-2.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 4. All Hydraulic Cylinders - No visible damage; pivot pins and hydraulic hoses undamaged, not leaking. Walk-Around inspection Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram. Continue to the right (counterclockwise viewed from top) checking each item in sequence for the conditions listed in the Walk-Around Inspection Checklist. 5. Boom - See Inspection Note. 6. Drive Motor, Brake, and Hub - See Inspection Note. 7.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 14. Fuel Supply - Filler cap secure, no visible damage to the tank or evidence of leaks. NOTE: Lockout Valves were used prior to S/N 0300140365. 18. Engine Oil Supply - Full mark on dipstick; filler cap secure. 19. Muffler and Exhaust System - See Inspection Note. 20. Auxiliary Power Pump - See Inspection Note. 15. Oscillating Axle, Lockout Valves - See Inspection Note. 21. Hydraulic Pump - See Inspection Note. 16.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. NOTE: Ensure boom is fully retracted, lowered, and centered between drive wheels prior to beginning lockout cylinder test. 1. Place a 6 inches (15.2 cm) high block with ascension ramp in front of left front wheel. 2.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 10. With boom over left side, place DRIVE control lever to REVERSE and drive machine off block and ramp. 11. Have an assistant check to see that right front or left rear wheel remains elevated in position off of ground. 12. Carefully activate SWING control lever and return boom to stowed position (centered between drive wheels).
SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS 3.1 NOTE: GENERAL THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES. This section provides the necessary information needed to understand control functions. 3.2 CONTROLS AND INDICATORS NOTE: 3121216 All machines are equipped with control panels that use symbols to indicate control functions.
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: Ground Controls See Figure 3-1., Ground Control Station - S Models and Figure 3-2., Ground Control Station - SJ Models If equipped, the Function Enable switch must be held down in order to operate Telescope, Swing, Lift, Jib Lift, Platform Level Override, and Platform Rotate functions. 1. Platform Rotate PERFORM PRE-OPERATIONAL CHECKS AND INSPECTIONS FROM THE GROUND CONTROL STATION.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. 2. 3. 4. 5. Platform Rotate Platform Leveling Override Not Used Power/Emergency Stop Engine Start/Auxiliary Power or Engine Start/Auxiliary Power/Function Enable 6. Boom Lift 7. Hourmeter 8. Platform/Ground Select Switch 9. Swing 10. Boom Telescope Figure 3-1.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. 2. 3. 4. 5. Platform Rotate Platform Leveling Override Articulating Jib Boom Power/Emergency Stop Engine Start/Auxiliary Power or Engine Start/Auxiliary Power/Function Enable 6. Boom Lift 7. Hourmeter 8. Platform/Ground Select Switch 9. Swing 10. Boom Telescope Figure 3-2.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Engine Start/Auxiliary Power Switch or Engine Start/ Auxiliary Power Switch /Function Enable WHEN THE MACHINE IS SHUT DOWN THE MASTER/EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERY. To start the engine, the switch must be held "UP" until the engine starts. 4. Power/Emergency Stop Switch To use auxiliary power, the switch must be held “DOWN” for duration of auxiliary pump use.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 8. Platform/Ground Select Switch Supplies power to the platform control console when positioned to PLATFORM. With the switch in GROUND position, power is shut off to the platform control console, and only the controls on the ground control panel are operable. WHEN OPERATING THE BOOM ENSURE THERE ARE NO PERSONNEL AROUND OR UNDER PLATFORM. 6. Boom Lift Control Provides raising and lowering of the boom when positioned up or down.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Indicator Panel See Figure 3-3., Ground Control Indicator Panel (Prior to S/N 93233) and Figure 3-4., Ground Control Indicator Panel (S/N 93233 to Present) 1. Battery Charging Indicator Indicates a problem in the battery or charging circuit and service is required. 2. Engine Oil Pressure Indicator Indicates that engine oil pressure is below normal and service is required. 3.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 4. Engine Oil Temperature Indicator (Deutz) Indicates that the temperature of the engine oil, which also serves as engine coolant, is abnormally high and service is required. 5. Engine Malfunction Indicator (Ford Only, prior to S/N 61718) If an electrical malfunction occurs, this light will illuminate and stay lit until problem is eliminated.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 7. Glow Plug Wait Indicator (Diesel) 10. Engine Air Filter Indicator Indicates the glow plugs are on. The glow plugs are automatically turned on with the ignition circuit and remain on for approximately seven seconds. Start the engine only after the light goes out. 8. Hydraulic Filter Bypass Indicator Indicates the air filter is too restrictive and needs to be replaced. 11. Platform Overload (CE Only) Indicates the platform has been overloaded.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Station See Figure 3-5., Platform Control Console and Figure 3-6., Platform Control Console - w/Drive Orientation 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.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1 13 1. 2. 3. 4. 3 2 12 Drive Speed/Torque Select Platform Leveling Override Horn Power/Emergency Stop 11 5. 6. 7. 8. 5 4 10 Auxiliary Power Fuel Select Lights Drive Steer 9. 10. 11. 12. Main Telescope Control Jib Lift Platform Rotate Function Speed 9 6 7 8 13. Main Lift/Swing 14. Footswitch (Not Shown) Figure 3-5.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1 3 2 5 4 6 15 1001107677 A 1705170 A 1702938 13 1. 2. 3. 4. 5. 12 Drive Speed/Torque Select Platform Leveling Override Horn Power/Emergency Stop Auxiliary Power 11 6. 7. 8. 9. 17 16 Fuel Select Lights Drive Steer Main Telescope Control 10. 11. 12. 13. 10 Jib Lift Platform Rotate Function Speed Main Lift/Swing 7 9 14. 15. 16. 17. 8 Footswitch (Not Shown) Drive Orientation Override Soft Touch Override Soft Touch Indicator Figure 3-6.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Auxiliary Power 6. Fuel Select (Dual Fuel Engine Only) (If Equipped) Energizes the electrically operated pump, when actuated. (Switch must be held ON for duration of auxiliary pump use.) The auxiliary pump functions to provide sufficient oil flow to operate the basic machine functions should the main pump or engine fail. The auxiliary pump will operate tower boom lift, tower telescope, main boom lift, main telescope and swing.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 8. Drive/Steer Provides for driving either forward or backward. Push forward to drive forward, pull back to drive in reverse. DO NOT OPERATE MACHINE IF DRIVE SPEED/TORQUE SELECT OR FUNCTION SPEED SWITCHES OPERATE WHEN BOOM IS ABOVE HORIZONTAL. Steering is controlled by a thumb-activated rocker switch on top of the joystick. NOTE: Both drive and steer functions work in the opposite direction when the boom is positioned over front of the chassis. 9.
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: 14. Footswitch (Not Shown) When boom is positioned above horizontal and any of the following switches, Drive Speed/torque Select or Function Speed, are positioned to High, high function speeds are automatically cut out and the machine continues to operate at a lower speed. This feature makes it necessary to depress the footswitch to allow operation of the platform controls. 13.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 15. Drive Orientation Override Platform Control Indicator Panel When the boom is swung over the rear tires or further in either direction, the Drive Orientation indicator will illuminate when the drive function is selected. Push and release the switch, and within 3 seconds move the Drive/Steer control to activate drive or steer. Before driving, locate the black/white orientation arrows on both the chassis and the platform controls.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1 3 2 4 5 1001107849 B 10 1. Tilt 6. Glow Plug 2. Platform Overload 7. Malfunction 8. Generator 3. Capacity 4. Fuel Level 9. Soft Touch 5. Enable 10. Creep Speed Figure 3-7. Platform Control Indicator Panel 3121216 11 8 7 6 1. Tilt 7. Malfunction 2. Platform Overload 8. Generator 3. Capacity 9. Not Used 4. Fuel Level 10. Creep Speed 5. Enable 11. Drive Orientation 6. Glow Plug Figure 3-8.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3. Capacity Indicator 4. Fuel Level Indicator Indicates the maximum capacity for the current position of the platform. NOTE: Refer to Fuel Reserve/Shut-Off System in Section 4 for detailed information. Shows fuel level in tank and provides visual low fuel alarms. FULL TANK 1/4 TANK 3/4 TANK LOW FUEL (FLASHES ONCE PER SECOND) 1/2 TANK EMPTY (FLASHES TEN TIMES PER SECOND) Figure 3-9.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Enable Indicator 7. Malfunction Indicator Indicates that the footswitch is depressed and the platform controls are ready for use. To enable the controls, depress the footswitch and select any function within seven seconds. The controls will then remain active as long as there is not a delay of seven seconds between stopping one function and starting the next one.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 8. AC Generator (If Equipped) 11. Drive Orientation Indicator When illuminated (Green), indicates the generator is in operation. 9. Soft Touch Indicator (If Equipped) When illuminated (Yellow), indicates the Soft Touch bumper is against an object. All controls are cut out until the override button is pushed, at which time controls are active in the Creep mode.
SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION 4.1 DESCRIPTION 4.2 This machine is a self-propelled hydraulic personnel lift equipped with a work platform on the end of an elevating and rotating boom. The primary operator control station is in the platform. From this control station, the operator can drive and steer the machine in both forward and reverse directions. The operator can raise or lower the main or tower boom or swing the boom to the left or right.
SECTION 4 - MACHINE OPERATION Stability This machine as originally manufactured by JLG Industries Inc., when operated within its rated capacity on a smooth, firm and level supporting surface, and in accordance with the instructions provided on the machine and this manual, provides a stable machine for all platform positions. Machine stability is based on two positions which are called FORWARD STABILITY and BACKWARD STABILITY. The machines position of least backward stability is shown in Figure 4-1.
SECTION 4 - MACHINE OPERATION BOOM BOOM HORIZONTAL HORIZONTAL TELESCOPE TELESCOPE FULLY EXTENDED FULLY EXTENDED MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT-OF-LEVEL SURFACE Figure 4-2.
SECTION 4 - MACHINE OPERATION 4.3 ENGINE OPERATION NOTE: Initial starting should always be performed from the Ground Control station. Starting Procedure 1. Check engine oil. If necessary, add oil in accordance with the Engine Manufacturer’s manual. IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED PERIOD. SHOULD ENGINE FAIL TO START ONCE AGAIN, ALLOW STARTER TO "COOL OFF" FOR 2-3 MINUTES. IF ENGINE FAILS AFTER SEVERAL ATTEMPTS, REFER TO ENGINE MAINTENANCE MANUAL. NOTE: 2.
SECTION 4 - MACHINE OPERATION 6. Turn key of SELECT switch to PLATFORM. Shutdown Procedure 7. From Platform position POWER/EMERGENCY STOP switch to ON, then push the ENGINE START switch to the forward position until engine starts. NOTE: Footswitch must be in released (up) position before starter will operate. If starter operates with footswitch in the depressed position, DO NOT OPERATE MACHINE.
SECTION 4 - MACHINE OPERATION Fuel Reserve / Shut-Off System NOTE: Reference the Service and Maintenance Manual along with a qualified JLG Mechanic to verify your machine setup. The Fuel Shutoff System monitors fuel and senses when fuel level is getting low. The JLG Control System automatically shuts the engine down before the fuel tank is emptied unless the machine is set up for Engine Restart.
SECTION 4 - MACHINE OPERATION 4.4 TRAVELING (DRIVING) BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWS ON BOTH THE CHASSIS AND THE PLATFORM CONTROLS. MOVE THE DRIVE CONTROLS IN A DIRECTION MATCHING THE DIRECTIONAL ARROWS. See Figure 4-3., Grades and Sideslopes DO NOT DRIVE WITH BOOM EXTENDED OR ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE. DO NOT DRIVE WITH HOODS RAISED OR UNLATCHED.
SECTION 4 - MACHINE OPERATION PE SIDESLO GRADE LEVEL DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON MANUFACTURER’S NAMEPLATE Figure 4-3.
SECTION 4 - MACHINE OPERATION 6. For traveling up grades, position switches as follows: Position DRIVE SPEED/TORQUE SELECT switch to HIGH. Traveling Forward or Reverse 1. With engine running, depress footswitch and position DRIVE control to FORWARD and hold for the duration of forward travel desired. NOTE: NOTE: When DRIVE or STEER functions are being operated there is an interlock which prevents operation of boom functions. 2.
SECTION 4 - MACHINE OPERATION 4.5 STEERING 4.7 Depress footswitch to steer machine, push on the left side of the switch to steer left, on the right side to steer right. PLATFORM Loading from Ground Level 1. Position chassis on a smooth, firm and level surface. 2. If total load (personnel, tools, and supplies) is less than rated capacity, distribute load uniformly on platform floor, and proceed to work position. BEFORE OPERATING MACHINE, MAKE SURE BOOM IS POSITIONED OVER REAR AXLE.
SECTION 4 - MACHINE OPERATION Platform Level Adjustment 4.8 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. This switch is used to adjust the platform level in situations such as ascending/descending a grade. To Level Up or Down - Position the Platform/Level control switch Up or Down and hold until the platform is level.
SECTION 4 - MACHINE OPERATION Telescoping the Main 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 EMERGENCY STOP SWITCH TO STOP MACHINE. To extend or retract the main boom, with the footswitch activated, position the Main Telescope Control Switch to the in or out position and hold until the platform reaches the desired position.
SECTION 4 - MACHINE OPERATION 4.9 5. Position AUXILIARY POWER switch to ON and hold. AUXILIARY POWER - NON ADE EQUIPPED MACHINES 6. Release AUXILIARY POWER switch, selected control switch, lever or controller, and footswitch. 7. Position POWER/EMERGENCY STOP switch to OFF. WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE 12-VOLT AUXILIARY PUMP MOTOR.
SECTION 4 - MACHINE OPERATION 5. Operate appropriate control switch, lever or controller for desired function and hold. 4.10 AUXILIARY POWER - ADE EQUIPPED MACHINES 6. Release AUXILIARY POWER switch, selected control switch, lever or controller, and footswitch. WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE 12-VOLT AUXILIARY PUMP MOTOR.) 7. Position POWER/EMERGENCY STOP switch to OFF.
SECTION 4 - MACHINE OPERATION 4.11 SHUT DOWN AND PARK 4.12 TIE DOWN AND LIFTING 1. Drive machine to a protected area. The weight of the machine is stamped on the serial number plate. If the plate is missing or illegible, call JLG Industries or weigh the individual unit to find out the Gross Vehicle Weight. 2. Assure main boom is fully retracted and lowered over rear (Drive) axle; all access panels and doors closed and secured.
SECTION 4 - MACHINE OPERATION NOTE: When transporting machine over rough terrain or long distance, the boom needs to be chocked and strapped whenever the base boom is unable to rest on its pad. This prevents the boom from bouncing up and down and preventing possible damage while transporting. Figure 4-4.
SECTION 4 - MACHINE OPERATION NOTE: When transporting machine over rough terrain or long distance, the boom needs to be chocked and strapped whenever the base boom is unable to rest on its pad. This prevents the boom from bouncing up and down and preventing possible damage while transporting. Figure 4-5.
SECTION 4 - MACHINE OPERATION Figure 4-6.
SECTION 4 - MACHINE OPERATION 3. Reconnect drive hubs by inverting the disconnect cap. (See Figure 4-7.) 4.13 TOWING RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH. MAXIMUM TOWING SPEED 5 M.P.H. (8 KM/H.) FOR NO LONGER THAN 30-45 MINUTES. MAXIMUM TOWING GRADE 25%.
SECTION 4 - MACHINE OPERATION Decals are made with a Pressure Sensitive Adhesive on the back with a protective film on the front. Remove the damaged decal and thoroughly clean surface before installing a new decal. Simply peel off the back, and press new decal onto surface and remove the protective film. 4.14 PLACARDS AND DECALS Read and understand all placards and decals. Do not operate any machine on which DANGER, WARNING, CAUTION OR INSTRUCTION PLACARDS OR DECALS ARE MISSING OR ILLEGIBLE.
SECTION 4 - MACHINE OPERATION Figure 4-8.
SECTION 4 - MACHINE OPERATION 7 49 50 400S 46 45 24 35 3 19 20 22 21 45 24 26 35 33 24 25 8 Figure 4-9.
SECTION 4 - MACHINE OPERATION Figure 4-10.
SECTION 4 - MACHINE OPERATION Figure 4-11.
SECTION 4 - MACHINE OPERATION Table 4-1.
SECTION 4 - MACHINE OPERATION Table 4-1.
SECTION 4 - MACHINE OPERATION Table 4-1.
SECTION 4 - MACHINE OPERATION Table 4-1.
SECTION 4 - MACHINE OPERATION Table 4-2.
SECTION 4 - MACHINE OPERATION Table 4-2.
SECTION 4 - MACHINE OPERATION Table 4-2.
SECTION 4 - MACHINE OPERATION Table 4-2.
SECTION 4 - MACHINE OPERATION Table 4-3.
SECTION 4 - MACHINE OPERATION Table 4-3.
SECTION 4 - MACHINE OPERATION Table 4-3.
SECTION 4 - MACHINE OPERATION Table 4-3.
SECTION 5 - EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES 5.1 GENERAL This section explains the steps to be taken in case of an emergency situation while operating. 5.2 INCIDENT NOTIFICATION JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details.
SECTION 5 - EMERGENCY PROCEDURES Platform or Boom Caught Overhead 5.4 If the platform or boom becomes jammed or snagged in overhead structures or equipment, rescue platform occupants prior to freeing the machine. 5-2 – JLG Lift – EMERGENCY TOWING PROCEDURES Towing this machine is prohibited, unless properly equipped. However, provisions for moving the machine have been incorporated. For specific procedures, refer to Section 4.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.1 INTRODUCTION 6.2 This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-1. Operating Specifications - 400S Prior to S/N 0300142870 Stowed Length 20ft. 2in. (6.15 m) Wheelbase 7ft. 10in. (2,3 m) Ground Clearance 12in. (30 cm) Max. Tire Load (400S-500 lbs. Cap.) Max. Tire Load (400S-750 lbs. Cap.) 6200 lbs. (2812 kg) 8350 lbs. (3788 kg) Ground Bearing Pressure 12x16.5 FF Tires 14x17.5 pneumatic tires 58 psi (4.07 kg/cm2) 45 psi (3.16 kg/cm2) Travel Speed, boom stowed.(2WD/4WD) 4.5 m.p.h. (7.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-2. Operating Specifications - 400S S/N 0300142870 to Present Stowed Length 20ft. 2in. (6.15 m) Wheelbase 7ft. 10in. (2,3 m) Ground Clearance 12in. (30 cm) Max. Tire Load (400S-500 lbs. Cap.) Max. Tire Load (400S-750 lbs. Cap.) 6200 lbs. (2812 kg) 8350 lbs. (3788 kg) Ground Bearing Pressure 12x16.5 FF Tires 14x17.5 pneumatic tires 58 psi (4.07 kg/cm2) 45 psi (3.16 kg/cm2) Travel Speed, boom stowed.(2WD/4WD) 4.5 m.p.h. (7.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-3. Operating Specifications - 460SJ Prior to S/N 0300142870 Travel Speed, boom stowed.(2WD/4WD) Table 6-4. Operating Specifications - 460SJ S/N 0300142870 to Present 4.5 m.p.h. (7.24 kmh) (27-32 sec/ 200ft.) Maximum Work Load (Capacity) - ANSI Unrestricted: 500 lbs. (227 kg.) Travel Speed, boom elevated. (2WD/4WD) 0.75 m.p.h. (1.20 kmh) (46-115 sec/ 50 ft.) Gross Machine Weight Std.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-4. Operating Specifications - 460SJ S/N 0300142870 to Present Capacities Table 6-5. Capacities Max. Tire Load 7200 lb (3266 kg) Ground Bearing Pressure 63 psi (4.4 kg/cm2) Hydraulic Tank 40.0 gal (152 L) 4.5 mph (7.24 kmh) (27-32 sec/ 200ft.) Hydraulic System (Including Tank) 52 gal (196.8 L) 0.75 mph (1.20 kmh) (46-115 sec/ 50 ft.) Engine Oil Capacity Caterpillar Deutz 2.9 Deutz D2011 Ford GM Travel Speed, boom stowed.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Engine NOTE: Table 6-7. Deutz TCD2.9L4 Specifications RPM Tolerances are ± 100. Type Table 6-6. Caterpillar 3024/C2.2 Fuel No. of Cylinders Number of Cylinders Diesel 4 BHP 46.5 hp (34 kW) Bore 3.307 in. (84 mm) Stroke Displacement Oil Capacity Compression Ratio Firing Order Max. RPM 6-6 3.9370 in. (112 mm) Bore Stroke Total Displacement Firing Order Output Liquid Cooled 4 3.6 in. (92 mm) 4.3 in. (110 mm) 178 cu. in.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-9. Ford LRG-425 (Gas or Dual Fuel) Table 6-8. Deutz F3M1011F/F3M2011F/D2011L03 Fuel No. of Cylinders Bore Stroke Displacement BHP at Max. RPM Oil Capacity crankcase cooler total capacity Diesel 3 3.7 in. (94 mm) 4.4 in. (112 mm) 142 cu. in. (2331 cm³) 49 6.3 quarts (6 L) 4.75 quarts (4.5 L) 11 quarts (10.5 L) Type 4 cylinder, 4 stroke, spark ignition Fuel Gasoline or Gasoline/LP Gas Bore 3.4 in. (86.4 mm) Displacement 153 cu. in. (2.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-10. GM 3.0L Fuel No. of Cylinders Table 6-11. Isuzu 4LE1 Gasoline or Gasoline/LP Gas 4 BHP Gasoline LP 83 hp @ 3000 rpm 75 hp @ 3000 rpm Bore 4.0 in. (101.6 mm) Stroke 3.6 in. (91.44 mm) Displacement Oil Capacity w/filter Minimum Oil Pressure at idle Hot Compression Ratio Firing Order Max. RPM Fuel 4 BHP at Max. RPM 1000 Mid RPM 1500 High RPM 2800 181 cu.in. (3.0 L, 2966 cc) 4.5 qt (4.25 L) 6 psi (0.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Tires Table 6-13. Tires Size Type Pressure Weight 12x16.5 Pneumatic 90 psi (6.2 Bar) 128 lbs. (58 kg) 12x16.5 Foam-filled N/A 328 lbs. (149kg) 14x17.5 Pneumatic 90 psi (6 Bar) 128 lbs. (58 kg) 14x17.5 Foam-filled N/A 440 lbs. (200kg) 33/16LLx16.1- Sand Pneumatic 90 psi (2.75 bar) 119.5 lbs. (54 kg) 33/16LLx16.1- Sand Foam Filled N/A 426 lbs. (193 kg) Solid N/A 280 lbs. (127 kg) Pneumatic 20 psi (1.4 bar) 20.7 lbs.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommendations. Hydraulic Oil Table 6-14. Hydraulic Oil NOTE: NOTE: NOTE: 6-10 Hydraulic System Operating Temperature Range S.A.E.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-17. Mobil EAL 224H Specs Table 6-16. UCon Hydrolube HP-5046 Type Synthetic Biodegradable Type Biodegradable Vegetable Oil Specific Gravity 1.082 ISO Viscosity Grade 32/46 Pour Point, Max -58°F (-50°C) Specific Gravity .922 pH 9.1 Pour Point, Max -25°F (-32°C) Flash Point, Min. 428°F (220°C) 340 cSt (1600SUS) Operating Temp.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-18. Mobil EAL Envirosyn H Specs Table 6-19. Exxon Univis HVI 26 Specs Type Synthetic Biodegradable Specific Gravity 32.1 ISO Viscosity Grade 32 Pour Point -76°F (-60°C) Specific Gravity .950 Flash Point Pour Point, Max -59°F (-51°C) Flash Point, Min. 514°F (268°C) Viscosity 6-12 at 40° C 33.1 cSt at 100° C 6.36 cSt Viscosity Index 147 217°F (103°C) Viscosity NOTE: – JLG Lift – at 40° C 25.8 cSt at 100° C 9.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Critical Stability Weights Table 6-20. Critical Stability Weights Component LB KG Ford Engine 339 154 Deutz Engine 441 200 8 ft Platform (x 30") 205 93 6 ft. Platform (x 30") 160 73 5 ft. Platform (x 30") 145 66 4ft. Platform (x 30") 130 59 8 ft. Platform (x 36") 230 105 Bolt-on T/T Cwt. (SJ) 487 221 12 x16.5 pneu.Tire & Wheel 128 58 12 x16.5 F/F Tire & Wheel 440 200 12 x 21.5 (NHS)pneu.Tire & Wheel 55 97 12 x 21.
SECTION 6 - 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 number is stamped on the left side of the frame. 400S xxxxx SERIAL NUMBER PLATE SERIAL NUMBER STAMPED ON FRAME Figure 6-1.
SECTION 6 - 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) ENGINE SPECIFICATIONS SUMMER GRADE FUEL 80°F(27°C) 70°F(21°C) 60°F(16°C) 50°F(10°C) 40°F(4°C) 30°F(-1°C) ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
SECTION 6 - 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.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 120 F(49 C) 110 F(43 C) 100 F(38 C) 90 F(32 C) 80 F(27 C) ENGINE SPECIFICATIONS ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
SECTION 6 - 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.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 120°F(49°C) 110°F(43°C) 100°F(38°C) 90°F(32°C) 80°F(27°C) 70°F(21°C) ENGINE SPECIFICATIONS 60°F(16°C) 50°F(10°C) 40°F(4°C) 30°F(-1°C) 20°F(-7°C) ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
SECTION 6 - 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 THE ADDITION OF A HYDRAULIC OIL COOLER (CONSULT JLG SERVICE AMBIENT AIR TEMPERATURE 120° F (49° C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110° F (43° C) 100° F (38° C) PROLONGED OPERATION IN AMBIENT AIR TEMPERATURES OF 100° F (38° C) OR ABOVE.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 120 F(49 C) 110 F(43 C) 100 F(38 C) 90 F(32 C) 80 F(27 C) ENGINE SPECIFICATIONS ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
SECTION 6 - 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.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 120°F(49°C) 110°F(43°C) 100°F(38°C) 90°F(32°C) 80°F(27°C) 70°F(21°C) ENGINE SPECIFICATIONS 60°F(16°C) 50°F(10°C) 40°F(4°C) 30°F(-1°C) 20°F(-7°C) ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
SECTION 6 - 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 THE ADDITION OF A HYDRAULIC OIL COOLER (CONSULT JLG SERVICE AMBIENT AIR TEMPERATURE 120° F (49° C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110° F (43° C) 100° F (38° C) PROLONGED OPERATION IN AMBIENT AIR TEMPERATURES OF 100° F (38° C) OR ABOVE.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3 11 20 *CAT and Perkins air filters located under right front side of engine. 27* 5 12,19 18 8,9,13,14,15,24,25 NOTE: Item #2 Not Shown 1 4 7 6 Figure 6-12. Operator Maintenance and Lubrication Diagram - All Except Deutz 2.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3 28 10 5 1 4 NOTE: 7 6 Item #2 Not Shown Figure 6-13. Operator Maintenance and Lubrication Diagram - Deutz 2.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3 12 22,23 27 5 NOTE: Item #2 Not Shown 1 4 7 6 21 Figure 6-14.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.3 NOTE: OPERATOR MAINTENANCE NOTE: The following numbers correspond to those in Figure 6-12., Operator Maintenance and Lubrication Diagram - All Except Deutz 2.9 and GM. Table 6-21. Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3. Wheel Drive Hub 5. Hydraulic Charge Filter Lube Point(s) - Level/Fill Plug Capacity - 17 oz (0.5 L) - 1/2 Full Lube - EPGL Interval - Check level every 3 months or 150 hours of operation; change every 2 years or 1200 hours of operation 4. Hydraulic Return Filter Interval - Change after first 50 hours and every 6 months or 300 hours thereafter or as indicated by Condition Indicator 6.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 7. Suction Strainers 9. Oil Change w/Filter - Deutz D2011 Lube Point(s) - 2 Interval - Every 2 years or 1200 hours of operation, remove and clean at time of hydraulic oil change 8. Oil Change w/Filter - Caterpillar Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7026855) Capacity - 10 qt (9.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE MINIMUM LEVEL, OIL HOT MINIMUM OIL LEVEL MAXIMUM LEVEL, OIL HOT MINIMUM LEVEL, OIL COLD MAXIMUM LEVEL, OIL COLD MAXIMUM OIL LEVEL NOTE: Hot oil checks should be made a period of 5 minutes after the engine has been shut down. Figure 6-15.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 10. Oil Change w/Filter - Deutz 2.9 L4 11. Oil Change w/Filter - Ford 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 6-32 – JLG Lift – Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7014501) Capacity - 4.5 qt (4.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 12. Oil Change w/Filter - GM 13. Oil Change w/Filter - Isuzu Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7022111) Capacity - 6 qt (5.6L) engine; 6.5 qt (6.1 L) w/cooler Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual 14. Oil Change w/Filter - Perkins Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7027965) Capacity - 4.5 qt (4.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 16. Fuel Pre-Filter - Deutz D2.9 17. Fuel Filter - Deutz D2.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 18. Fuel Strainer - Deutz D2011 19.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 20. Fuel Filter - Ford 22. Fuel Filter (Propane) - GM Engine Interval - 3 Months or 150 hours of operation Comments - Replace filter. Refer to Section 6.6, Propane Fuel Filter Replacement Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation 21.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 23. Electronic Pressure Regulator (LP only) 26. Radiator Coolant Deutz 2.9 Interval - 3 Months or 150 hours of operation Comments - Drain oil build up. Refer to Section 6.5, DRAINING OIL BUILD UP FROM THE PROPANE REGULATOR (Prior to S/N 0300109274) 24. Fuel Filter - Isuzu Lube Point(s) - Fill Cap Capacity - 3.2Gallon (12.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 27. Air Filter 28. Air Filter - Deutz D2.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.4 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. TIRES & WHEELS Tire Inflation The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Replacement Wheel Installation The rims installed on each product model have been designed for stability requirements which consist of track width, tire pressure, and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in an unsafe condition regarding stability. It is extremely important to apply and maintain proper wheel mounting torque.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Tighten nuts in the following sequence: 3. The tightening of the nuts should be done in stages. Following the recommended sequence, tighten nuts per wheel torque chart. Table 6-22. Wheel Torque Chart TORQUE SEQUENCE 1st Stage 2nd Stage 3rd Stage 40 ft. lbs. (55 Nm) 100 ft. lbs. (130 Nm) 170 ft. lbs. (255 Nm) 4. Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.5 4. Push in the Emergency Switch once the engine stops. DRAINING OIL BUILD UP FROM THE PROPANE REGULATOR (PRIOR TO S/N 0300109274) 5. Disconnect the electrical connection to the LPG fuel temperature sensor in the auxiliary fuel port of the EPR. During the course of normal operation oils may build inside the primary and secondary chambers of the propane pressure regulator.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6. Remove the retainer clip for the LPG fuel temperature sensor and remove the sensor from the regulator body. NOTE: Have a small container ready to collect oil that will drain freely from the regulator at this point. 7. Once all of the oil has been drained, reinstall the LPG fuel temperature sensor and reconnect the electrical connector. 8. Open the fuel tank manual valve. 9. Start the engine and verify all connections are secure. 10.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.6 PROPANE FUEL FILTER REPLACEMENT Installation Removal 1. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief. BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING NEW SEAL 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.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 1 7 8 2 1 7 8 9 13 3 10 9 3 4 10 OR 4 5 11 5 6 11 12 1. 2. 3. 4. 5. Electric Lock Off Solenoid Mounting Plate Housing Seal Filter Magnet Filter Housing 6. 7. 8. 9. Seal Electrical Connector Fuel Outlet O-ring 10. 11. 12. 13. Filter Fuel Inlet Retaining Bolt Ring Figure 6-16.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF 6.8 THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRESSURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE FUEL SYSTEM COMPONENTS.
SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 7-1.
SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1.
TRANSFER OF OWNERSHIP Title:____________________________________________________________________ Name: ___________________________________________________________________________ Who in your organization should we notify? Country: _____________________________ Telephone: (_______) ________________________ _________________________________________________________________________________ Address: _________________________________________________________________________ Current Owner: __________________
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 3121216 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 JLG Latino Americana Ltda. Rua Eng.
