JLG 400S Use and care manual

ANSI
®
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
AS/NZS
Models
400S
460SJ
PVC 2001
31215015
October 14, 2019 - Rev A
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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.
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FOREWORD
31215015 a
FOREWORD
The Mobile Elevating Work Platform (MEWP) models covered in this manual are designed and tested to meet or exceed var-
ious compliance standards. Please refer to the manufacturer’s nameplate affixed to the subject MEWP for specific standard
compliance information.
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.
Refer to www.JLG.com for Warranty, Product Registration, and other machine-related documentation.
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FOREWORD
b31215015
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 BACK-
GROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACK-
GROUND.
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.
IMPORTANT
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI-
RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION 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
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FOREWORD
31215015 c
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG
INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA-
TION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR
THIS PRODUCT.
IMPORTANT
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.
IMPORTANT
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE
JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY
OR DEATH 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: [phone]
Fax: [phone]
E-mail: [e-mail]
For:
• Accident Reporting
• Product Safety Publica-
tions
• Current Owner Updates
• Questions Regarding
Product Safety
• Standards and Regulations
Compliance Information
• Questions Regarding Special
Product Applications
• Questions Regarding Prod-
uct Modifications
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FOREWORD
d31215015
REVISION LOG
Original Issue A - October 14, 2019
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31215015 i
TABLE OF CONTENTS
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . . 1-11
1.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Maintenance Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION,
AND INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Machine Familiarization. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2
Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
SkyGuard Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED). . . . 2-12
SECTION - 3 - MACHINE CONTROLS AND INDICATORS
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Ground Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . 3-10
Ground Control Console Display Gauge . . . . . . . . . . 3-12
Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-21
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 BOOM OPERATING CHARACTERISTICS AND
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Platform Load Sensing System (LSS). . . . . . . . . . . . . . . . 4-2
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Fuel Reserve / Shut-Off System
(Diesel Engines Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . 4-10
Traveling on a Grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
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ii 31215015
TABLE OF CONTENTS
4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-11
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Raising and Lowering the Main Boom . . . . . . . . . . . . . 4-12
Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-12
4.8 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.9 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
(CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.10 SKYGUARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
SkyGuard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
SkyGuard - SkyLine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
SkyGuard - SkyEye. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
SkyGuard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.11 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Shut Down and Park. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.12 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
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
5.5 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
(CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
SECTION - 6 - ACCESSORIES
6.1 FALL ARREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2 PIPE RACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Capacity Specifications (Australia Only) . . . . . . . . . . . . 6-4
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 SKYGLAZIER™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Capacity Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.4 SKYPOWER™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.5 SKYWELDER™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Welding Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
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31215015 iii
TABLE OF CONTENTS
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . 6-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.6 SOFT TOUCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.7 BOLT-ON EXTERNAL FALL ARREST . . . . . . . . . . . . . . . . . . . 6-11
Inspection Before Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
SECTION - 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTE-
NANCE
7.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.4 TIRES & WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Tire Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
7.5 PROPANE FUEL FILTER REPLACEMENT
(KUBOTA ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
7.6 PROPANE FUEL SYSTEM PRESSURE RELIEF . . . . . . . . . . . 7-33
7.7 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 7-33
SECTION - 8 - INSPECTION AND REPAIR LOG
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31215015 v
LIST OF FIGURES
2-1. Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
3-1. Ground Control Console - 400S. . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2. Ground Control Console - 400S w/MSSO (CE Only) . . . . 3-3
3-3. Ground Control Console - 460SJ . . . . . . . . . . . . . . . . . . . . . . 3-4
3-4. Ground Control Console - 460SJ w/MSSO (CE Only) . . . 3-5
3-5. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . . 3-9
3-6. Splash Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-7. Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-8. Engine Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-9. Ground Control Console Display Gauge . . . . . . . . . . . . . 3-14
3-10. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-11. Platform Control Indicator Panel. . . . . . . . . . . . . . . . . . . . . 3-20
4-1. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-3
4-2. Position of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-4
4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-4. Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4-5. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-6. Decal Location Sheet 1 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-7. Decal Location Sheet 2 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-8. Decal Location Sheet 3 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
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
6-1. Bolt-On External Fall Arrest Cable Tension . . . . . . . . . . . 6-12
6-2. Bolt-On External Fall Arrest System . . . . . . . . . . . . . . . . . . 6-13
7-1. Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-2. Hydraulic Oil Operation Chart - Sheet 1 of 2 . . . . . . . . . . 7-11
7-3. Hydraulic Oil Operation Chart - Sheet 2 of 2. . . . . . . . . . 7-12
7-4. Engine Operating Temperature Specifications -
Deutz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7-5. Engine Oil Operation Chart - Kubota. . . . . . . . . . . . . . . . . 7-14
7-6. Operator Maintenance and Lubrication Diagram -
Deutz 2.9L Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-7. Operator Maintenance and Lubrication Diagram -
Deutz 2011L Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7-8. Operator Maintenance and Lubrication Diagram -
Kubota Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7-9. Kubota Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7-32
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31215015 vii
LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6
1-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-9
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3
4-1 Decal Legend - 400S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
4-2 Decal Legend - 460SJ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
4-3 Decal Legend - 400S Kubota Engine-Powered
Machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
4-4 Decal Legend - 460SJ Kubota Engine-Powered
Machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-5 Deutz D2.9L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-6 Kubota WG 2503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-7 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-8 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-9 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-10 Mobil DTE 10 Excel 32 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-11 UCon Hydrolube HP-50/46 . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-12 Mobil EAL 224H Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-13 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-14 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-15 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-16 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
7-17 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
8-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
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SECTION 1 - SAFETY PRECAUTIONS
31215015 1-1
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 pro-
mote proper machine usage. A maintenance program, using the
information provided in this manual and the Service and Mainte-
nance Manual, must also be established by a qualified person and
must be followed to ensure that the machine is safe to operate.
The owner/user/operator/lessor/lessee of the machine must not
accept operating responsibility until this manual has been read,
training is accomplished, and operation of the machine has been
completed under the supervision of an experienced and quali-
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”).
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL
COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR
DEATH.
1.2 PRE-OPERATION
Operator Training and Knowledge
• Read, understand, and study the Operation and Safety Manual
in its entirety before operating the machine. For clarification,
questions, or additional information regarding any portions of
this manual, contact JLG Industries, Inc.
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SECTION 1 - SAFETY PRECAUTIONS
1-2 31215015
• Only personnel who have received proper training regarding
the inspection, application and operation of MEWPs (including
recognition and avoiding hazards associated with their opera-
tion) shall be authorized to operate a MEWP.
• Only properly trained personnel who have received unit-spe-
cific familiarization shall operate a MEWP. The user shall deter-
mine if personnel are qualified to operate the MEWP prior to
operation.
• Read, understand, and obey all DANGERS, WARNINGS, CAU-
TIONS, and operating instructions on the machine and in this
manual.
• Ensure that the machine is to be used in a manner which is
within the scope of its intended application as determined by
JLG.
• All operating personnel must have a thorough understanding
of the intended purpose and function of the MEWP controls,
including platform, ground and emergency descent controls.
• Read, understand, and obey all applicable employer, local, and
governmental regulations as they pertain to your utilization
and application of the machine.
Workplace Inspection
• Precautions to avoid all hazards in the work area must be
taken by the user before and during operation of the machine.
• Do not operate or raise the platform from a position on trucks,
trailers, railway cars, floating vessels, scaffolds or other equip-
ment unless the application is approved in writing by JLG.
• Before operation, check work area for overhead hazards such
as electric lines, bridge cranes, and other potential overhead
obstructions.
• Check operating surfaces for holes, bumps, drop-offs, obstruc-
tions, debris, concealed holes, and other potential hazards.
• Check the work area for hazardous locations. Do not operate
the machine in hazardous environments unless approved for
that purpose by JLG.
• Ensure that the ground conditions are adequate to support
the maximum tire load indicated on the tire load decals
located on the chassis adjacent to each wheel. Do not travel
on unsupported surfaces.
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SECTION 1 - SAFETY PRECAUTIONS
31215015 1-3
Machine Inspection
• Do not operate this machine until the inspections and func-
tional checks as specified in Section 2 of this manual have
been performed.
• Do not operate this machine until it has been serviced and
maintained according to the maintenance and inspection
requirements as specified in the machine’s Service and Main-
tenance Manual.
• Ensure all safety devices are operating properly. Modification
of these devices is a safety violation.
MODIFICATION OR ALTERATION OF A MEWP SHALL BE MADE ONLY WITH PRIOR WRIT-
TEN PERMISSION FROM THE MANUFACTURER.
• Do not operate any machine on which the safety or instruction
placards or decals are missing or illegible.
• Check the machine for modifications to original components.
Ensure that any modifications have been approved by JLG.
• Avoid accumulation of debris on platform floor. Keep mud, oil,
grease, and other slippery substances from footwear and plat-
form floor.
1.3 OPERATION
General
• Machine operation requires your full attention. Bring the
machine to a full stop before using any device, i.e. cell phones,
two-way radios, etc. that will distract your attention from
safely operating the machine.
• Do not use the machine for any purpose other than position-
ing personnel, their tools, and equipment.
• Before operation, the user must be familiar with the machine
capabilities and operating characteristics of all functions.
• Never operate a malfunctioning machine. If a malfunction
occurs, shut down the machine. Remove the unit from service
and notify the proper authorities.
• Do not remove, modify, or disable any safety devices.
• Never slam a control switch or lever through neutral to an
opposite direction. Always return switch to neutral and stop
before moving the switch to the next function. Operate con-
trols with slow and even pressure.
• Do not allow personnel to tamper with or operate the
machine from the ground with personnel in the platform,
except in an emergency.
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SECTION 1 - SAFETY PRECAUTIONS
1-4 31215015
• Do not carry materials directly on platform railing unless
approved by JLG.
• When two or more persons are in the platform, the operator
shall be responsible for all machine operations.
• Always ensure that power tools are properly stowed and never
left hanging by their cord from the platform work area.
• When driving, always position boom over rear axle in line with
the direction of travel. Remember, if boom is over the front
axle, steer and drive functions will be reversed.
• Do not assist a stuck or disabled machine by pushing or pull-
ing except by pulling at the chassis tie-down lugs.
• Fully lower platform and shut off all power before leaving
machine.
• Remove all rings, watches, and jewelry when operating
machine. Do not wear loose fitting clothing or long hair unre-
strained which may become caught or entangled in equip-
ment.
• Persons under the influence of drugs or alcohol or who are
subject to seizures, dizziness or loss of physical control must
not operate this machine.
• Hydraulic cylinders are subject to thermal expansion and con-
traction. This may result in changes to the platform position
while the machine is stationary. Factors affecting thermal
movement can include the length of time the machine will
remain stationary, hydraulic oil temperature, ambient air tem-
perature, and platform position.
Trip and Fall Hazards
• Prior to operation, ensure all gates are closed and fastened in
their proper position.
• During operation, occupants in the platform must wear a full
body harness with a lanyard attached to an authorized lanyard
anchorage point. Attach only one (1) lanyard per lanyard
anchorage point.
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SECTION 1 - SAFETY PRECAUTIONS
31215015 1-5
• Enter and exit only through gate area. Use extreme caution
when entering or leaving platform. Ensure that the platform
assembly is fully lowered. Face the platform when entering or
leaving the platform. Always maintain three points of contact
with the machine, using two hands and one foot or two feet
and one hand at all times during entry and exit.
• 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.
Electrocution Hazards
• This machine is not insulated and does not provide protection
from contact or proximity to electrical current.
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SECTION 1 - SAFETY PRECAUTIONS
1-6 31215015
• Maintain distance from electrical lines, apparatus, or any ener-
gized (exposed or insulated) parts according to the Minimum
Approach Distance (MAD) as shown in Table 1-1.
• Allow for machine movement and electrical line swaying.
• Maintain a clearance of at least 10 ft. (3m) between any part of
the machine and its occupants, their tools, and their equip-
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.
Table 1-1. Minimum Approach Distances (M.A.D.)
Voltage Range
(Phase to Phase)
MINIMUM APPROACH DISTANCE
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.
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SECTION 1 - SAFETY PRECAUTIONS
31215015 1-7
• 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 mini-
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.
Tipping Hazards
• Ensure that the ground conditions are adequate to support
the maximum tire load indicated on the tire load decals
located on the chassis adjacent to each wheel. Do not travel
on unsupported surfaces.
• The user must be familiar with the operating surface before
driving. Do not exceed the allowable sideslope and grade
while driving.
• Do not elevate platform or drive with platform elevated while
on or near a sloping, uneven, or soft surface. Ensure machine is
positioned on a smooth, firm surface within the limits of the
maximum operating slope before elevating platform or driv-
ing with the platform in the elevated position.
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