Operation and Safety Manual - Genfor

1 Operation and Safety Manual ANSI Original Instructions - Keep this Manual with the machine at all Lift Models400S460SJ3121216 November 5, 2009 FOREWORD3121216 JLG Lift aFOREWORDThis 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 andoperating procedures essential for the safe and proper machine Operation for its intended to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changeswithout prior notification. Contact JLG Industries, Inc. for updated JLG Lift 3121216 Safety ALERT SYMBOLS AND Safety SIGNAL WORDSINDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOTAVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECALWILL HAVE A RED A POTENTIALLY HAZARDOUS SITUATION.

2 IF NOTAVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THISDECAL WILL HAVE AN ORANGE A POTENTIALLY HAZARDOUS SITUATION. IF NOTAVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAYALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE AYELLOW is the Safety Alert Symbol. It is used to alert you to the potential personalinjury hazards. Obey all Safety messages that follow this symbol to avoid possibleinjury or deathFOREWORD3121216 JLG Lift cTHIS PRODUCT MUST COMPLY WITH ALL Safety RELATED BULLE-TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZEDJLG REPRESENTATIVE FOR INFORMATION REGARDING Safety -RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THISPRODUCT. JLG INDUSTRIES, INC. SENDS Safety RELATED BULLETINS TO THEOWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,INC. TO ENSURE THAT THE CURRENT OWNER RECORDS AREUPDATED AND INDUSTRIES, INC.

3 MUST BE NOTIFIED IMMEDIATELY IN ALLINSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN ANACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL ORWHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP-ERTY OR THE JLG PRODUCT. Contact:Product Safety and Reliability DepartmentJLG Industries, Fountainhead PlazaHagerstown, MD 21742or Your Local JLG Office(See addresses on inside of Manual cover)In USA:Toll Free: 877-JLG-SAFE (877-554-7233)Outside USA:Phone: 240-420-2661 Fax: 301-745-3713E-mail: Accident Reporting Product Safety Publications Current Owner Updates Questions Regarding Product Safety Standards and Regulations Compliance Information Questions Regarding Special Product Applica-tions Questions Regarding Product ModificationsFOREWORDd JLG Lift 3121216 REVISION LOGO riginal 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 TABLE OF CONTENTS3121216 JLG Lift iSECTION - PARAGRAPH, SUBJECTPAGESECTION - PARAGRAPH, SUBJECTPAGESECTION - 1 - Safety GENERAL.

4 PRE- Operation ..1-1 Operator Training and Knowledge .. 1-1 Workplace Inspection .. 1-2 Machine Inspection .. Operation ..1-3 General .. 1-3 Trip and Fall Hazards .. 1-3 Electrocution Hazards .. 1-4 Tipping Hazards .. 1-6 Crushing and Collision Hazards.. TOWING, LIFTING, AND HAULING .. HAZARDS / Safety ..1-9 SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND TRAINING ..2-1 Operator Training .. 2-1 Training Supervision .. 2-1 Operator Responsibility .. , INSPECTION, AND MAINTENANCE ..2-2 Pre-Start Inspection .. 2-5 Functional Check .. 2-6 Walk-Around inspection .. AXLE LOCKOUT TEST (IF EQUIPPED) .. 2-11 SECTION - 3 - MACHINE CONTROLS AND .. AND INDICATORS .. 3-1 Ground Controls .. 3-2 Ground Control Indicator Panel .. 3-7 Platform Station .. 3-10 Platform Control Indicator Panel.

5 3-16 SECTION - 4 - MACHINE .. CHARACTERISTICS AND LIMITATIONS .. 4-1 Capacities .. 4-1 Stability .. Operation .. 4-4 Starting Procedure .. 4-4 Shutdown Procedure .. (DRIVING) .. 4-5 Traveling Forward or Reverse .. 4-8 TABLE OF CONTENTSii JLG Lift 3121216 SECTION - PARAGRAPH, SUBJECTPAGESECTION - PARAGRAPH, STEERING .. AND STOWING .. PLATFORM .. 4-9 Loading from Ground Level .. 4-9 Loading From Positions Above Ground Level . 4-9 Platform Level Adjustment .. 4-10 Platform Rotation .. 4-10 Swinging the Boom .. 4-11 Raising and Lowering the Main Boom .. 4-11 Telescoping the Main Boom .. POWER - NON ADE EQUIPPED MA-CHINES .. 4-12 Activating from the Platform Control Station .. 4-12 Activating from the Ground Control Station .. AUXILIARY POWER - ADE EQUIPPED MACHINES.

6 4-13 Activating from the Platform Control Station .. 4-13 Activating from the Ground Control Station .. SHUT DOWN AND PARK .. TIE DOWN AND LIFTING .. TOWING .. PLACARDS AND DECALS ..4-19 SECTION - 5 - EMERGENCY .. NOTIFICATION .. Operation ..5-1 Operator Unable to Control Machine .. 5-1 Platform or Boom Caught Overhead .. EMERGENCY TOWING PROCEDURES ..5-2 SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR .. SPECIFICATIONS ..6-1 Capacities .. 6-3 Engine.. 6-4 Tires .. 6-6 Hydraulic Oil .. 6-7 Critical Stability Weights .. 6-10 Serial Number Location .. 6-11 TABLE OF CONTENTS3121216 JLG Lift iiiSECTION - PARAGRAPH, SUBJECTPAGESECTION - PARAGRAPH, MAINTENANCE .. TIRES & WHEELS ..6-30 Tire Inflation .. 6-30 Tire Damage .. 6-30 Tire Replacement .. 6-31 Wheel Replacement .. 6-31 Wheel Installation.

7 OIL BUILD UP FROM THE PROPANE REG-ULATOR .. FUEL FILTER REPLACEMENT..6-35 Removal .. 6-35 Installation.. FUEL SYSTEM PRESSURE RELIEF .. SUPPLEMENTAL INFORMATION ..6-37 SECTION - 7 - INSPECTION AND REPAIR LOGLIST OF Nomenclature.. Walk-Around Inspection - Sheet 1 of 3 .. Walk-Around Inspection - Sheet 2 of 3 .. Walk-Around Inspection - Sheet 3 of 3 .. Control Station - S Models .. Control Station - SJ Models .. Control Indicator Panel (Prior to S/N 93233) .. Control Indicator Panel (S/N 93233 to Present) .. Control Console .. Control Console - w/Drive Orientation .. Control Indicator Panel .. Control Indicator Panel - w/Drive Orientation .. Of Least Backward Stability .. Of Least Forward Stability .. and Sideslopes .. Tie Down - 400S Models .. Tie Down - 460SJ Models.

8 And Tie Down .. Disconnect Hub .. Installation - Sheet 1 of 4 .. Installation - Sheet 2 of 4 .. 4-214-10. Decal Installation - Sheet 3 of 4 .. 4-224-11. Decal Installation - Sheet 4 of 4 .. Number Location .. Operating Temperature Specifications - Deutz - Sheet 1 of 2 .. Operating Temperature Specifications - Deutz - Sheet 2 of 2 .. Operating Temperature Specifications - Ford - Sheet 1 of 2 .. 6-15 TABLE OF CONTENTSiv JLG Lift 3121216 SECTION - PARAGRAPH, SUBJECTPAGESECTION - PARAGRAPH, Operating Temperature Specifications - Ford - Sheet 2 of 2 .. Operating Temperature Specifications - Caterpillar - Sheet 1 of 2 .. Operating Temperature Specifications - Caterpillar - Sheet 2 of 2 .. Operating Temperature Specifications - GM - Sheet 1 of 2 .. Operating Temperature Specifications - GM - Sheet 2 of 2.

9 6-206-10. Engine Operating Temperature Specifications - Perkins - Sheet 1 of 2.. 6-216-11. Engine Operating Temperature Specifications - Perkins - Sheet 2 of 2.. 6-226-12. Operator Maintenance and Lubrication Diagram . 6-236-13. Filter Lock Assembly .. 6-36 LIST OF TABLES1-1 Minimum Approach Distances ( ) .. 1-51-2 Beaufort Scale (For Reference Only) .. 1-102-1 Inspection and Maintenance Table .. 2-34-1 Decals - 400S with 500 lb (230 kg) Capacity .. 4-244-2 Decals - 400S with 750 lb (340 kg) Capacity .. 4-284-3 Decals - 460SJ .. 4-326-1 Operating Specifications - 400S .. 6-16-2 Operating Specifications - 460SJ.. 6-26-3 Capacities .. 6-36-4 Ford LRG-425 (Gas or Dual Fuel) .. 6-46-5 Deutz F3M1011F/F3M2011F/D2011L03 .. 6-46-6 Isuzu 4LE1 .. 6-56-7 Caterpillar 3024 .. 6-56-8GM .. 6-56-9 Perkins 404D-22.

10 6-66-10 Tires .. 6-66-11 Hydraulic Oil .. 6-76-12 Mobilfluid 424 Specs .. 6-76-13 UCon Hydrolube HP-5046 .. 6-86-14 Mobil EAL 224H Specs.. 6-86-15 Mobil EAL Envirosyn H Specs .. 6-96-16 Exxon Univis HVI 26 Specs .. 6-96-17 Critical Stability Weights.. 6-106-18 Lubrication Specifications .. 6-246-19 Wheel Torque Chart .. 6-337-1 Inspection and Repair Log .. 7-1 SECTION 1 - Safety PRECAUTIONS3121216 JLG Lift 1-1 SECTION 1. Safety section outlines the necessary precautions for properand safe machine Operation and maintenance. For propermachine use, it is mandatory that a daily routine is estab-lished based on the content of this Manual . A maintenanceprogram, using the information provided in this Manual andthe Service and Maintenance Manual , must also be estab-lished by a qualified person and followed to ensure themachine is safe to owner/user/operator/lessor/lessee of the machineshould not operate the machine until this Manual has beenread, training is accomplished, and Operation of the machinehas been completed under the supervision of an experi-enced and qualified operator.