JLG 400SJ Gebrauchs- und Pflegehandbuch

Operation and Safety Manual

ANSI

Original Instructions - Keep this manual with the machine at all times.

Boom Lift Models

400S

460SJ

3121216

May 25, 2012

FOREWORD

3121216 – JLG Lift – a

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

b– JLG Lift – 3121216

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT

AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL

WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT

AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS

DECAL WILL HAVE AN ORANGE BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT

AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY

ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A

YELLOW BACKGROUND.

INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES

DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO-

TECTION OF PROPERTY.

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

FOREWORD

3121216 – JLG Lift – c

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-

TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED

JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-

RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS

PRODUCT.

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE

OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,

INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE

UPDATED AND ACCURATE.

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL

INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN

ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR

WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP-

ERTY OR THE JLG PRODUCT.

Contact:

Product Safety and Reliability Department

JLG Industries, Inc.

13224 Fountainhead Plaza

Hagerstown, MD 21742

USA

or Your Local JLG Office

(See addresses on inside of manual cover)

In USA:

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

Outside USA:

Phone: 240-420-2661

Fax: 301-745-3713

E-mail: Pr[email protected]

For:

• Accident Reporting

•ProductSafety

Publications

• Current Owner Updates

• Questions Regarding

Product Safety

• Standards and Regulations

Compliance Information

• Questions Regarding

Special Product Applica-

tions

• Questions Regarding

Product Modifications

FOREWORD

d– JLG Lift – 3121216

REVISION LOG

Original Issue - June 8, 2005

Revised - October 14, 2005

Revised - February 8, 2006

Revised - May 24, 2006

Revised - July 31, 2007

Revised - October 8, 2008

Revised - November 5, 2009

Revised - October 6, 2011

Revised - May 25, 2012

TABLE OF CONTENTS

3121216 – JLG Lift – i

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

SECTION - 1 - SAFETY PRECAUTIONS

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

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

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

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

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

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

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

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

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

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

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

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

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

SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPA-

RATION, AND INSPECTION

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

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

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

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

2.2 PREPARATION, INSPECTION, AND

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

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

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

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

2.3 OSCILLATING AXLE LOCKOUT TEST

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

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

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

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

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

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

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

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

SECTION - 4 - MACHINE OPERATION

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

4.2 OPERATING CHARACTERISTICS AND

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

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

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

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

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

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

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

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

TABLE OF CONTENTS

ii – JLG Lift – 3121216

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

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

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

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

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

Loading From Positions Above Ground Level . 4-9

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

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

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

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

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

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

4.9 AUXILIARY POWER - NON ADE EQUIPPED

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

Activating from the Platform Control Station . . 4-12

Activating from the Ground Control Station . . 4-12

4.10 AUXILIARY POWER - ADE EQUIPPED

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

Activating from the Platform Control Station . . 4-13

Activating from the Ground Control Station . . 4-13

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

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

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

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

SECTION - 5 - EMERGENCY PROCEDURES

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

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

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

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

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

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

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR

MAINTENANCE

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

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

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

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

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

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

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

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

TABLE OF CONTENTS

3121216 – JLG Lift – iii

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

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

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

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

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

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

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

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

6.5 DRAINING OIL BUILD UP FROM THE

PROPANE REGULATOR (PRIOR TO

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

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

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

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

6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-38

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

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

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

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

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

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

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

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

3-3. Ground Control Indicator Panel

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

3-4. Ground Control Indicator Panel

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

TABLE OF CONTENTS

iv – JLG Lift – 3121216

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

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

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

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

6-2. Engine Operating Temperature Specifications -

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

6-3. Engine Operating Temperature Specifications -

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

6-4. Engine Operating Temperature Specifications -

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

6-5. Engine Operating Temperature Specifications -

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

6-6. Engine Operating Temperature Specifications -

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

6-7. Engine Operating Temperature Specifications -

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

6-8. Engine Operating Temperature Specifications -

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

6-9. Engine Operating Temperature Specifications -

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

6-10. Engine Operating Temperature Specifications -

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

6-11. Engine Operating Temperature Specifications -

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

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

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

LIST OF TABLES

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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