JLG 400S Operation And Safety Manual Download

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Summary of Contents for 400S

Page 1: ...n 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 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 2: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 3: ...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 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 4: ...ll 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...

Page 5: ...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 inju...

Page 6: ...VED 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 240 420 2661 Fax 301 74...

Page 7: ...FOREWORD d 31215015 REVISION LOG Original Issue A October 14 2019 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 8: ...NANCE 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 Indic...

Page 9: ...TION 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 ...

Page 10: ...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 S...

Page 11: ...et 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 Cha...

Page 12: ...e 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...

Page 13: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 14: ...ion 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 Indust...

Page 15: ...ey all applicable employer local and governmental regulations as they pertain to your utilization and application of the machine WorkplaceInspection 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 ...

Page 16: ...ery 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 us...

Page 17: ... 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...

Page 18: ...ne 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 ElectrocutionHazards This machine is not insulated and does not provide...

Page 19: ...eir 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 0to50KV 10 3 Over50KVto200KV 15 5 Over200KVto350KV 20 6 Over350KVto500KV 25 8 Over500KVto750KV 35 11 Over750KVto1000KV 45 ...

Page 20: ...NEL 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 exc...

Page 21: ...nes forklift trucks or other appropriate equipment to stabilize machine Do not operate the machine when wind conditions exceed specifications shown in Section 7 2 of this manual or as shown on the capacity placard of the platform billboard Factors affecting wind speed are platform elevation surrounding structures local weather events and approaching storms Wind speed can be significantly greater a...

Page 22: ...tbreeze Windfeltonexposedskin Leavesrustle 3 8 12 3 4 5 4 Gentlebreeze Leavesandsmallertwigsinconstantmotion 4 13 18 5 5 7 9 Moderatebreeze Dustandloosepaperraised Smallbranchesbegintomove 5 19 24 8 0 10 7 Freshbreeze Smallertreessway 6 25 31 10 8 13 8 Strongbreeze Largebranchesinmotion Flagswavingnearhorizontal Umbrellause becomesdifficult 7 32 38 13 9 17 1 NearGale ModerateGale Wholetreesinmotio...

Page 23: ...imit travel speed according to conditions of ground surface congestion visibility slope location of personnel and other factors Be aware of stopping distances in all drive speeds When driv ing in high speed reduce drive speed before stopping Travel grades in low speed only Do not use high speed drive in restricted or close quarters or when driving in reverse Exercise extreme caution at all times t...

Page 24: ... inserted at the appropriate points in this manual and in the Ser vice and Maintenance Manual It is of utmost importance that maintenance personnel pay strict attention to these precautions to avoid possible injury to personnel or damage to the machine or property A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe MaintenanceHaza...

Page 25: ...s batteries or solid tires with items of different weight or specification Do not modify the MEWP in any way to affect stability Refer to the Service and Maintenance Manual for the weights of critical stability items MODIFICATION OR ALTERATION OF A MEWP SHALL BE MADE ONLY WITH PRIOR WRIT TEN PERMISSION FROM THE MANUFACTURER Battery Hazards Always disconnect batteries when servicing electrical comp...

Page 26: ...e machine to recognize a malfunction or potential malfunc tion 7 The safest means to operate the machine where overhead obstructions other moving equipment and obstacles depressions holes and drop offs exist 8 Means to avoid the hazards of unprotected electrical con ductors 9 Selection of the appropriate MEWP and available options for the work to be performed considering specific job require ments...

Page 27: ...owing the manu facturer s operator s manual Prior to users authorization of an operator to use a specific model of MEWP the user shall ensure the operator is familiarized on the follow ing 1 Location of the manual storage compartment and the requirementtoensure the required manual s are present on the MEWP 2 Purpose and function of the machine controls and indicators at the platform and ground con...

Page 28: ...dused Owner Dealer orUser QualifiedJLGMechanic ServiceandMaintenanceManual andapplicableJLGinspectionform AnnualMachineInspection SeeNote Annually nolaterthan13monthsfromthedateofprior inspection Owner Dealer orUser FactoryTrained ServiceTechnician Recommended ServiceandMaintenanceManual andapplicableJLGinspectionform PreventativeMaintenance AtintervalsasspecifiedintheServiceandMaintenance Manual ...

Page 29: ...2 3 4 5 6 7 7 8 9 10 11 Figure 2 1 Basic Nomenclature 1 Platform 2 PlatformConsole 3 SkyGuard 4 FlyBoomSection 5 BaseBoomSection 6 FrontDrive SteerWheels 7 RearDriveWheels 8 Frame 9 Turntable 10 OscillationCylinder 11 GroundConsole T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 30: ... Perform as instructed 6 Battery Charge as required 7 Fuel Combustion Engine Powered Machines Add the proper fuel as necessary 8 Engine Oil Supply Ensure the engine oil level is at the Full mark on the dipstick and the filler cap is secure 9 Hydraulic Oil Check the hydraulic oil level Ensure hydrau lic oil is added as required 10 Accessories Attachments Refer to the Accessories section in this man...

Page 31: ... with a lanyard attached to an authorized lanyard anchorage point Attach only one 1 lanyard per lanyard anchorage point IF THE MACHINE DOES NOT OPERATE PROPERLY TURN OFF THE MACHINE IMMEDI ATELY REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 32: ...LITIES MACHINE PREPARATION AND INSPECTION 31215015 2 7 Walk Around Inspection 17 11 5 17 18 7 16 8 9 15 14 10 13 12 9 8 7 4 3 2 1 8 9 20 10 19 9 8 16 6 6 O AC 00172 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 33: ...form Control Console Switches and levers return to neutral when activated and released decals placards secure and legible control markings legible 4 Platform Rotator See Inspection Note 5 Jib Assembly and Jib Rotator If Equipped See Inspec tion Note 6 All Hydraulic Cylinders No visible damage pivot pins and hydraulic hoses undamaged not leaking 7 Boom Sections Uprights Turntable See Inspection Not...

Page 34: ...dles See Inspection Note 17 Counterweight No evidence of damage 18 Engine See Inspection Note 19 Hydraulic Pump See Inspection Note 20 Turntable Bearing Evidence of proper lubrication No evi dence of loose bolts or looseness between bearing and machine T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 35: ...ure that the control console is firmly secured in the proper location b Check that all guards protecting the switches or locks are in place c Ensure that all machine functions are disabled when the Emergency Stop Button is pushed in d Ensure that all machine functions stop when the footswitch is released e Operate all functions and ensure proper operation 3 With the platform in the stowed position...

Page 36: ... in path of sensor beam 3 Once the sensor has been activated verify the following conditions a Telescope out function stops and telescope in function operates for a short duration b The horn sounds c If equipped with a SkyGuard beacon the beacon illumi nates 4 Disengage the SkyGuard sensor release controls then recy cle the footswitch Ensure normal operation is available NOTE On machines equipped ...

Page 37: ...ke the boom out of the transport position 5 Place Drive control lever to Reverse and drive machine off of block and ramp 6 Have an assistant check to see that left front or right rear wheel remains elevated in position off of ground 7 Return boom to stowed position When boom reaches cen ter stowed position lockout cylinders should release and allow wheel to rest on ground it may be necessary to ac...

Page 38: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 39: ...tor to different types of operational situations that could arise The meaning of those symbols are explained below Indicates a potentially hazardous situation which if not corrected could result in serious injury or death This indicator will be red Indicates an abnormal operating condition which if not corrected may result in machine interruption or damage This indicator will be yellow Indicates i...

Page 40: ...9 10 7 Figure 3 1 Ground Control Console 400S 1 IndicatorPanel 2 DisplayGauge 3 EngineStart AuxiliaryPower 4 Platform GroundSelect 5 PlatformLevel 6 PlatformRotate 7 Telescope 8 Power EmergencyStop 9 MainBoomLift 10 Swing T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 41: ... Control Console 400S w MSSO CE Only 1 IndicatorPanel 2 DisplayGauge 3 EngineStart AuxiliaryPower 4 Platform GroundSelect 5 PlatformLevel 6 PlatformRotate 7 Telescope 8 Power EmergencyStop 9 MainBoomLift 10 Swing 11 MachineSafetySystemOverride MSSO T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 42: ...11 Figure 3 3 Ground Control Console 460SJ 1 IndicatorPanel 2 DisplayGauge 3 EngineStart AuxiliaryPower 4 Platform GroundSelect 5 PlatformLevel 6 PlatformRotate 7 JibLift 8 Telescope 9 Power EmergencyStop 10 MainBoomLift 11 Swing T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 43: ...trol Console 460SJ w MSSO CE Only 1 IndicatorPanel 2 DisplayGauge 3 EngineStart AuxiliaryPower 4 Platform GroundSelect 5 PlatformLevel 6 PlatformRotate 7 JibLift 8 Telescope 9 Power EmergencyStop 10 MainBoomLift 11 Swing 12 MachineSafetySystemOverride MSSO T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 44: ...operation 2 Display Gauge Registers the amount of time the machine has been in use with engine running The hourmeter registers up to 16 500 hours and cannot be reset 3 Engine Start Auxiliary Power To start the engine the switch must be held Up until the engine starts To use auxiliary power the switch must be held Down for duration of function use 4 Platform Ground Select Switch The three position ...

Page 45: ...ions such as ascending descending a grade 6 Platform Rotate Provides rotation of the platform 7 Jib Lift If Equipped Provides raising and lowering of the jib 8 Telescope Control Provides extension and retraction of the boom WHEN THE MACHINE IS SHUT DOWN THE POWER EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERIES 9 Power Emergency Stop Switch A two posit...

Page 46: ... of the main boom 11 Swing Provides 360 degrees continuous turntable rotation 12 Machine Safety System Override MSSO CE Only Provides emergency override of function controls that are locked out in the event of Load Sense System activation T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 47: ... Figure 3 5 Ground Control Indicator Panel 1 BatteryChargeIndicator 2 SystemDistress 3 DriveSteerDisable 4 CapacityZoneIndicator 5 Generator 6 GlowPlug 7 FuelLevelIndicator 8 PlatformOverload 9 EngineError 10 EmissionsTemperature T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 48: ...r 2 3 sec onds when the key is positioned to the on position to act as a self test 3 Drive and Steer Disable Indicator If Equipped Indicates the Drive and Steer Disable function has been activated 4 Platform Capacity Zone Indicator Indicates the platform capacity zone for the cur rent position of the platform Restricted capaci ties are permitted at restricted platform positions shorter boom length...

Page 49: ...s the platform has been overloaded 9 Engine Error Indicator Indicates an engine error fault requiring service 10 Emissions Temperature Indicator Indicator illuminates when the engine emissions control sensor reaches a high temperature T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 50: ...tem and the engine control system During machine start up with no active DTCs in the control system the splash screen will show for 3 seconds and then switch to main screen If there is an active DTC while powering up the machine the splash screen will show for 3 seconds and then launch the Diagnostics Screen The indicator lamp will light when there is an active DTC in the Fault Log Figure 3 6 Spla...

Page 51: ...gnostics Screen will show SPN Suspect Parameter Number FMI Failure Mode Identifier and Occurrence count information Engine SPN text is not scrollable If there is more than one engine trouble code the operator must exit from the Engine DTC Screen to see other SPN and FMI information DIAGNOSTIC CODES Figure 3 7 Diagnostic Screen Figure 3 8 Engine Diagnostic Screen T o o r d e r g o t o D i s c o u n...

Page 52: ...D INDICATORS 3 14 31215015 h Figure 3 9 Ground Control Console Display Gauge INDICATORLAMP ENGINEHOURS FUELLEVEL NAVIGATEFORWARDARROW NAVIGATIONBUTTONS NAVIGATEBACKARROW T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 53: ...lingOverride 3 FuelSelect IfEquipped 4 Horn 5 Power EmergencyStop 6 Start AuxiliaryPower 7 DriveOrientationOverride 8 Drive Steer 9 Telescope 10 Lights IfEquipped 11 JibLift 12 SoftTouch SkyGuardOverride 13 SoftTouch SkyGuardIndicator 14 PlatformRotate 15 FunctionSpeedControl 16 MainLift SwingController Figure 3 10 Platform Control Console T o o r d e r g o t o D i s c o u n t E q u i p m e n t c ...

Page 54: ...USE COULD CAUSE THE LOAD OCCUPANTS TO SHIFT OR FALL FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY 2 Platform Leveling Override A three position switch allows the operator to adjust the automatic self leveling system This switch is used to adjust platform level in situa tions such as ascending descending a grade 3 Fuel Select Dual Fuel Engine Only If Equipped Moving the switch to the app...

Page 55: ...s 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 plat form controls Move the drive controls in a direction match ing the directional arrows for the intended direction of travel NOTE To operate the Drive joystick pull up on the lock ing ring below t...

Page 56: ...he Soft Touch system to operate again at creep speed allowing the operator to move the platform away from the obstacle that caused the shut down situation 13 Soft Touch SkyGuard Indicator Indicates the Soft Touch bumper is against an object or the SkyGuard sensor has been activated All controls are cut out until the override button is pushed For Soft Touch controls are then active in the Creep Mod...

Page 57: ...ft Swing joystick pull up on the locking ring below the handle NOTE The Main Boom Lift Swing joystick is spring loaded and will automatically return to neutral off position when released 16 Main Lift Swing Controller Provides Main Lift and Swing Push for ward to lift up pull backward to boom down Move right to swing right move left to swing left Moving the joystick activates switches to provide th...

Page 58: ...2 DriveOrientation 3 CapacityZoneIndicator 4 TiltAlarmWarning 5 Generator 6 Creep 7 FootswitchEnable 8 FuelLevelIndicator 9 GlowPlug 10 EmissionsFailure 11 PlatformOverload 12 EngineError 13 EmissionsTemperature Figure 3 11 Platform Control Indicator Panel T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 59: ...rive control is being operated in the proper direction i e controls reversed situations 3 Platform Capacity Zone Indicator Indicates the platform capacity zone for the cur rent position of the platform Restricted capaci ties are permitted at restricted platform positions shorter boom lengths and higher boom angles 4 Tilt Alarm Warning Light and Alarm This red illuminator indicates the chassis is o...

Page 60: ...ontrols are enabled If a function is not selected within seven sec onds or if a seven second lapse between ending one func tion and beginning the next function the enable light will go out and the footswitch must be released and depressed again to enable the controls Releasing the footswitch removes power from all controls and applies the drive brakes TO AVOID SERIOUS INJURY DO NOT REMOVE MODIFY O...

Page 61: ... Engine Error Indicator Indicates an engine error fault requiring service 13 Emissions Temperature Indicator Indicator illuminates when the engine emissions control sensor reaches a high temperature T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 62: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 63: ...round Con trol Station which will override the Platform Control Station Ground Controls operate all functions except drive and steer Except for performing inspections and the Function Check the ground controls are used in an emergency to lower the platform to the ground should the operator in the platform be unable to do so 4 2 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS Capacities Raising boom...

Page 64: ...verload alarm will sound Reduce the weight in the platform to not exceed the rated workload indicated on the capacity decal then the controls will work again Stability Machine stability is based on two 2 conditions which are called FORWARD and BACKWARD stability The machine s position of least FORWARD stability is shown in Figure 4 1 and its position of least BACKWARD stability is shown in Figure ...

Page 65: ... Figure 4 1 Position of Least Forward Stability JIB HORIZONTAL BOOM FULLYEXTENDED MACHINEWILLTIPOVERINTHISDIRECTIONIF OVERLOADEDOROPERATEDBEYONDTHELIMITS OFTHEMAXIMUMOPERATINGSLOPE T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 66: ...ast Backward Stability JIB FULLYELEVATED MAINBOOMFULLYELEVATED ANDFULLYRETRACTED MACHINEWILLTIPOVERINTHISDIRECTIONIF OVERLOADEDOROPERATEDBEYONDTHELIMITS OFTHEMAXIMUMOPERATINGSLOPE PLATFORMROTATED 90DEGREES T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 67: ...NOTE Diesel engines only After turning on ignition operator must wait until glow plug indicator light goes out before cranking engine 1 Turn key of Platform Ground Select switch to Ground 2 Pull the Power Emergency Stop switch to On 3 Push the Engine Start switch until engine starts ALLOW ENGINE TO WARM UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD 4 After engine has had sufficient ti...

Page 68: ...rates with footswitch in the depressed posi tion DO NOT OPERATE MACHINE Shutdown Procedure IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN DETERMINE THE CAUSE AND CORRECT IT BEFORE RESTARTING THE ENGINE 1 Remove all load and allow engine to operate at low speed for 3 5 minutes this allows further reduction of internal engine temperature 2 Push Power Emergency Stop switch in 3 Turn Platform...

Page 69: ... will flash 10 times a second and the engine will react according to machine setup Setup options are as follows Engine One Restart When the engine shuts down the operator will be permitted to cycle power and restart the engine once with approximately 2 minutes of run time After the 2 minute run time is complete or if the engine is shut down by the operator prior to the completion of the 2 minute r...

Page 70: ...SECTION 4 MACHINE OPERATION 4 8 31215015 Figure 4 3 Grade and Side Slopes T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 71: ...DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH FIRM SUR FACE WITHIN THE LIMITS OF THE MAXIMUM OPERATING SLOPE TO AVOID LOSS OF TRAVEL CONTROL OR TIP OVER ON GRADES AND SIDE SLOPES DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED IN THE OPERATING SPECIFICATIONS SECTION OF THIS MANUAL DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES USE EXTREME CAUTION WHEN DRIVING IN REVERSE AN...

Page 72: ...teer in the opposite direction from the movement of the controls If the indicator is illuminated operate the Drive function in the following manner 1 Match the black and white direction arrows on both platform con trol console and the chassis to determine the direction the machine will travel 2 Push and release the Drive Orientation Over ride switch Within 3 seconds slowly move the Drive control t...

Page 73: ...tion thumb switch on Drive Steer controller to Right for steering right or to Left for steering left 4 6 PLATFORM Platform LevelAdjustment ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM INCORRECT USE COULD CAUSE THE LOAD OCCUPANTS TO SHIFT OR FALL FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY To Level Up or Down Position the Platform Level control s...

Page 74: ... CHASSIS IS LEVEL BEFORE RAISING BOOM TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINERY IF ANY CONTROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED REMOVE FOOT FROM FOOTSWITCH OR USE EMER GENCY STOP SWITCH TO STOP THE MACHINE Swing...

Page 75: ...otection When the SkyGuard sensor is activated functions in use at the time of actu ation will reverse or cutout The SkyGuard Function Table pro vides more details on these functions During activation the horn will sound and if equipped with a SkyGuard beacon the beacon will illuminate until sensor and footswitch are disengaged If the SkyGuard sensor remains activated after function reversal or cu...

Page 76: ...llow bar SkyGuard SkyLine Cable is pressed breaking the magnetic connection between the cable and right bracket Reattach magnetic end of cable to bracket if it becomes discon nected SkyGuard SkyEye Operator passes through path of sensor beam 0 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 77: ... Boom Tele Out Boom TeleIn JibLift Basket Level Basket Rotate R C R C R R R R C C C C R IndicatesReversalisActivated C IndicatesCutoutisActivated DOS DriveOrientationSystem Enabled DOSNotEnabled machineisdrivingstraightwithoutsteering andanyotherhydraulicfunctionisactive T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 78: ...XTENDED IT IS THE OPERATOR S RESPONSIBILITY TO ENSURE ALL SAFETY PRECAUTIONS IN SECTION 1 OF THIS MAN UAL ARE FOLLOWED FOR EACH UNIQUE SITUATION 4 12 LIFTING AND TIE DOWN See Figure 4 5 Lifting 1 Refer to the Serial Number Plate refer to the Specifications section of this manual or weigh the individual unit to find out the Gross Vehicle Weight 2 Place the boom in the stowed position 3 Remove all l...

Page 79: ...SECTION 4 MACHINE OPERATION 31215015 4 17 Figure 4 5 Lifting and Tie Down Chart T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 80: ...SECTION 4 MACHINE OPERATION 4 18 31215015 Figure 4 6 Decal Location Sheet 1 of 7 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 81: ...SECTION 4 MACHINE OPERATION 31215015 4 19 Figure 4 7 Decal Location Sheet 2 of 7 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 82: ...SECTION 4 MACHINE OPERATION 4 20 31215015 Figure 4 8 Decal Location Sheet 3 of 7 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 83: ...SECTION 4 MACHINE OPERATION 31215015 4 21 Figure 4 9 Decal Location Sheet 4 of 7 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 84: ...SECTION 4 MACHINE OPERATION 4 22 31215015 Figure 4 10 Decal Location Sheet 5 of 7 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 85: ...SECTION 4 MACHINE OPERATION 31215015 4 23 Figure 4 11 Decal Location Sheet 6 of 7 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 86: ...SECTION 4 MACHINE OPERATION 4 24 31215015 Figure 4 12 Decal Location Sheet 7 of 7 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 87: ...8 1702861 1702861 1702861 1702861 1702861 1702861 1702861 9 1702774 1702774 1702774 1702774 1702774 1702774 1702774 10 1702773 1702773 1702773 1702773 1702773 1702773 1702773 11 1702868 1704001 1704000 1704002 13 1001254665 1001254677 1001254669 1001254675 1001254667 1001254671 1001254673 14 1001254666 1001254678 1001254670 1001254676 1001254668 1001254672 1001254674 15 16 1701504 1701504 1701504 ...

Page 88: ... 1705514 35 4420051 4420051 4420051 4420051 4420051 4420051 4420051 37 1702788 38 1701499 1701499 1701499 1701499 1701499 1701499 1701499 39 1001177451 1001177451 1001177451 1001177451 1001177451 1001177451 1001177451 40 1704412 1704412 1704412 1704412 1704412 1704412 1704412 42 1704885 1704885 1704885 1704885 1704885 1704885 1704885 44 1705351 1705426 1705427 1705910 1705429 1705430 1705905 46 54...

Page 89: ...3453 59 1001231801 100 1001232026 1001232026 1001232026 1001232026 1001232026 1001232026 1001232026 101 1704277 1704277 1704277 1704277 1704277 1704277 1704277 Table 4 1 Decal Legend 400S Item ANSI 1001242538 C Japan 1001242561 C Korea 1001242563 C Spanish 1001242565 C French 1001242567 C Chinese 1001242569 C Portuguese Spanish 1001242571 C T o o r d e r g o t o D i s c o u n t E q u i p m e n t c...

Page 90: ...1704473 1704473 1704473 8 1702861 1702861 1702861 1702861 1702861 1702861 1702861 9 1702774 1702774 1702774 1702774 1702774 1702774 1702774 10 1702773 1702773 1702773 1702773 1702773 1702773 1702773 11 1702868 1704001 1704000 1704002 13 1001254750 1001171339 1001254756 1001254752 1001254755 1001254751 1001254753 1001254754 1001171339 14 1001171339 1001171339 15 1001204510 1001204510 16 1701504 170...

Page 91: ...1 4420051 4420051 4420051 4420051 4420051 4420051 4420051 37 1702788 38 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 39 1001177451 1001177451 1001177451 1001177451 1001177451 1001177451 1001177451 1001177451 1001177451 40 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 42 1704885 1704885 1704885 1704885 1704885 1704885 1704885 44 1705351 1705426 1...

Page 92: ...232026 1001232026 1001232026 1001232026 1001232026 1001232026 1001232026 1001232026 101 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 Table 4 2 Decal Legend 460SJ Item ANSI 1001242559 C CE 1001171368 J Japan 1001242562 C Korea 1001242564 C Spanish 1001242566 C French 1001242568 C Chinese 1001242570 C Portuguese Spanish 1001242572 C Australia T o o r d e r g o t o D i s c ...

Page 93: ...may void any warranty consideration on that particular machine FOLLOWING ANY INCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS THEN FROM THE PLATFORM CON TROLS DO NOT LIFT ABOVE 3 M 10 FT UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED IF REQUIRED AND THAT ALL CONTROLS ARE OPERATING COR RECTLY 5 3 EMERGENCYOPERATION Operator Unableto Control Machine...

Page 94: ...sition 6 Inspect the machine for damage If the machine is damaged or does not operate properly turn off the machine immedi ately Report the problem to the proper maintenance per sonnel Do not operate the machine until it is declared safe for operation 5 4 EMERGENCYTOWING PROCEDURES Towing this machine is prohibited However provisions for moving the machine have been incorporated The following proc...

Page 95: ...e locked out from the platform and ground consoles An example of this would be in the case of Load Sense System activation NOTE If the MSSO functionality is used the fault indicator is set with a fault code in the JLG Control System which must be reset by a qualified JLG Service Technician NOTE No functional checks of the MSSO system are necessary The JLG Control system will set a Diagnostic Troub...

Page 96: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 97: ...IES Table 6 1 Available Accessories Accessory Market ANSI USA Only ANSI CSA CE AUS Japan China FallArrestPlatform 36 x72 PipeRacks SkyGlazier SkyPower SkyWelder Bolt OnExternalFallArrest 36 x72 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 98: ...lazier SkyWelder SkyGlazier SkyPower 4 Platform PipeRacks PlatformMeshtoTopRail SoftTouch SkyWelder SkyPower SkyGlazier SkyWelder SkyWelder SkyPower 4 Platform PipeRacks PlatformMeshtoTopRail SoftTouch SkyGlazier SoftTouch SkyPower PipeRacks SkyGlazier SkyWelder Note1 Anynon Sky accessorynotlistedunder INCOMPATIBLEWITH isassumedtobecompatible Note2 Canbeusedonsameunitbutnotsimultaneously T o o r d...

Page 99: ...rness is required with lanyard not to exceed 6 ft 1 8 m in length that limits the maximum arrest force to 900 lb 408 kg for the trans fastener type and 1350 lb 612 kg for the shuttle type fall arrest system Safety Precautions DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE THE PLATFORM USE CAUTION WHEN ENTERING EXITING THE PLATFORM AT ELEVATION 6 2 PIPERACKS Pipe Racks provide a way to store pi...

Page 100: ...e racks are secured to the platform rails Replace torn or frayed tie down straps Operation 1 To prepare racks for loading remove locking pins rotate each rack 90 degrees from stowed to working position then secure with locking pins 2 Loosen and remove tie down straps Place material on racks with weight evenly distributed between both racks 3 Route the tie down straps at each end across loaded mate...

Page 101: ...cure the panel to the platform rail Capacity Specifications Capacity Zone Max Tray Capacity Max Platform Capacity With Max Weight in Tray 500lb 227kg 150lb 68kg 250lb 113kg 550lb 250kg 150lb 68kg 250lb 113kg 600lb 272kg 150lb 68kg 250lb 113kg 750lb 340kg 150lb 68kg 440lb 200kg 1000lb 454kg 250lb 113kg 500lb 227kg Refertothecapacitydecalsinstalledonthemachineforcapac ityzoneinformation Required Pla...

Page 102: ... AREA EXPOSED TO THE WIND WILL DECREASE STABILITY LIMIT PANEL AREA TO 32 SQ FT 3 SQ M Ensure no personnel are beneath platform Do not exit platform over rails or stand on rails Remove tray when not in use Use this option only on approved models Preparationand Inspection Check for cracked welds and damage to tray Ensure tray is properly secured to platform Ensure strap is not torn or frayed Operati...

Page 103: ...nning at the specified speed with the power switch on switch is located on platform A three pole 30 Amp circuit breaker protects the generator from overload Generator Output ANSI Specifications 3 phase 240 V 60 Hz 7 5 kW 1 phase 240 V 120 V 60 Hz 6 kW CE Specifications 3 phase 240 V 7 5 kW 18 3 A 1 0 pf 1 phase 240 V 6 0 kW 26 A 1 0 pf 1 phase 120 V 6 0 kW 50 A 1 0 pf Peak 3 phase 8 5 kW 1 phase 6...

Page 104: ...ing used Do not overload circuit Preparation and Inspection Ensure generator is secure Check condition of belt and wiring Operation Start the engine then turn on the generator See the Miller Generator Technical Manual PN 3121677 for more information 6 5 SKYWELDER SkyWelder is capable of TIG and Stick welding producing 200 Amps at 100 duty cycle or 250 Amps at 50 duty cycle This accessory receives ...

Page 105: ...clamp and stinger stored in the platform Fire extinguisher Welding Mode Input Power Rated Output Welding Amperage Range MaximumOpen CircuitVoltage Amps InputAt Rated LoadOutput 50 60 Hz 230V 460 V 575V kVa kW Stick SMAW TIG GTAW 3 phase 280Ampat31 2V 35 DutyCycle 5 250A 79VDC 32 17 13 15 7 10 200Ampat28V 100 DutyCycle 20 11 8 10 3 6 4 1 phase 200Ampat28V 50 DutyCycle 5 200A 79VDC 35 9 8 6 5 150Amp...

Page 106: ... correct polarity of leads Wear proper welding apparel Use correct rod size and current settings Do not use electrical cords without ground Do not use electrical tools in water Do not weld to the platform Do not ground through the platform Do not use a high frequency arc starter with TIG welder Preparationand Inspection Connect ground clamp to metal being welded Ensure there is a good ground conne...

Page 107: ... all times A full body harness is required with lanyard not to exceed 6 ft 1 8 M in length that limits the maximum arrest force to 900 lb 408 kg External Fall Arrest System capacity is 310 lb 140 kg one 1 person maximum Do not move platform during use of the external fall arrest system DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE OF PLATFORM BE CAREFUL WHEN ENTERING EXITING THE PLATFORM AT E...

Page 108: ... Fittings Brackets Ensure all fittings are tight and there are no signs of fractures Inspect brackets for any damage Cable Inspect cable for proper tension broken strands kinks or any signs of corrosion Attachment Ring No cracks or signs of wear are acceptable Any signs of corrosion requires replacement Attaching Hardware Inspect all attaching hardware to ensure there are no missing components and...

Page 109: ...13 I 8 7 1 2 3 4 6 9 5 Figure 6 2 Bolt On External Fall Arrest System 1 BellevilleWasher 2 Washer 3 HexNut 4 JamNut 5 LHBracket 6 AttachmentRing 7 Cable 8 RHBracket 9 Decal T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 110: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 111: ... and Maintenance Manual Other Publications Available Service and Maintenance Manual 31215016 Illustrated Parts Manual 31215017 7 2 OPERATING SPECIFICATIONS Table 7 1 Operating Specifications 400S MaximumWorkLoad Capacity Unrestricted CE Aus Untrestricted ANSI Restricted CE Aus Restricted ANSI 600lb 270kg 600lb 272kg 1000lb 450kg 1000lb 454kg MaximumOperatingSlope 5 MaximumTravelGrade StowedPositio...

Page 112: ... 400S Table 7 2 Operating Specifications 460SJ MaximumWorkLoad Capacity Unrestricted CEandAus Unrestricted ANSI 600lb 270kg 600lb 272kg MaximumOperatingSlope 5 MaximumTravelGrade StowedPosition Gradeability 45 MaximumTravelGrade StowedPosition SideSlope 5 PlatformHeight 46ft 14 05m HorizontalPlatformReach 39ft 7in 12 07m TurningRadius Outside 15ft 10 5in 4 8m TurningRadius Inside 6ft 6in 2 0m Over...

Page 113: ...al 83 3L HydraulicTank 32 5Gal 123L HydraulicSystem IncludingTank 40Gal 151 4L DriveHub 24oz 0 7L DriveBrake 27oz 0 8L EngineCoolant Deutz2 9L Kubota 2 9gal 11 3L 2 25gal 8 5L Table 7 2 Operating Specifications 460SJ Table 7 4 Deutz D2011L03 Fuel Diesel No ofCylinders 3 Bore 3 7in 94mm Stroke 4 4in 112mm Displacement 142cu in 2331cm OilCapacity crankcase cooler totalcapacity 6 3qt 6L 3 7qt 3 5L 10...

Page 114: ...owEngineRPM 1200 MidEngineRPM 1800 Max HighEngineRPM 2500 Table 7 6 Kubota WG 2503 Fuel GasolineorGasoline LPGas BHP Gasoline LP 45 5kW 2700rpm 46Kw 2700rpm Bore 3 46in 88mm Stroke 4 03in 102 4mm Displacement 153cu in 2 5L OilCapacityw filter 2 5gal 9 5L CoolantCapacity engineonly 1 4gal 5 4L Max RPM 2700 FuelConsumption Gasoline InDrive 2 45Gal Hr 9 26L Hr Idle 0 64Gal Hr 2 43L Hr FuelConsumption...

Page 115: ... oil based and pos sesses the same antiwear and rust protection characteristics as mineral oils but will not adversely affect the ground water or the environment when spilled or leaked in small amounts Mobil EAL 224H has a viscosity of 34 cSt at 40 C and viscosity index of 213 The operating temperature range of this oil is 18 C to 83 C Table 7 7 Tires Size Type Pressure Weight 14x17 5 Foam Filled ...

Page 116: ...r rec ommendations Table 7 9 Mobilfluid 424 Specs SAEGrade 10W30 Gravity API 29 0 Density Lb Gal 60 F 7 35 PourPoint Max 46 F 43 C FlashPoint Min 442 F 228 C Viscosity Brookfield cPat 18 C 2700 at40 C 55cSt at100 C 9 3cSt ViscosityIndex 152 Table 7 10 Mobil DTE 10 Excel 32 Specs ISOViscosityGrade 32 SpecificGravity 0 877 PourPoint Max 40 F 40 C FlashPoint Min 330 F 166 C Viscosity at40 C 33cSt at1...

Page 117: ...46cSt 215SUS at65 C 150 F 22cSt 106SUS ViscosityIndex 170 Table 7 12 Mobil EAL 224H Specs Type SyntheticBiodegradable ISOViscosityGrade 32 46 SpecificGravity 922 PourPoint Max 25 F 32 C FlashPoint Min 428 F 220 C OperatingTemp 0to180 F 17to162 C Weight 7 64lb pergal 0 9kgperliter Viscosity at40 C 37cSt at100 C 8 4cSt ViscosityIndex 213 NOTE Must be stored above 32 F 14 C T o o r d e r g o t o D i ...

Page 118: ...atingTemp 0to 180 F 17to 162 C Weight 7 64lb gal 0 9kg L Viscosity at40 C 45cSt at100 C 8 0cSt ViscosityIndex 153 Table 7 14 Exxon Univis HVI 26 Specs SpecificGravity 32 1 PourPoint 76 F 60 C FlashPoint 217 F 103 C Viscosity at40 C 25 8cSt at100 C 9 3cSt ViscosityIndex 376 NOTE Mobil Exxon recommends that this oil be checked on a yearly basis for viscosity T o o r d e r g o t o D i s c o u n t E q...

Page 119: ...al Stability Weights Component lb kg Battery 66 30 Counterweight S 1060 42 4 481 8 19 3 Counterweight SJ 2700 54 1227 3 24 5 Tires SeeTable7 7 Tires PlatformandConsole 36x72 209 95 PlatformandConsole 36x96 240 109 PlatformandConsole FallArrest 287 130 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 120: ...rial number plate is affixed to the left rear side of the frame If the serial number plate is damaged or missing the machine serial num ber is stamped on the left side of the frame SERIAL NUMBER PLATE Figure 7 1 Serial Number Location T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 121: ...SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 31215015 7 11 1001206353 A Figure 7 2 Hydraulic Oil Operation Chart Sheet 1 of 2 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 122: ...9 145 X X X Quintolubric 888 46 50 185 X X X X NOTICE MACHINE OPERATION USING NON JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE HYDRAULIC FLUID OPERATION CHART MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE HYDRAULIC SYSTEM Readily biodegradable classi cation indicates one of the following CO2 Conversion 60 per EPA 560 6 82 003 CO2 Co...

Page 123: ...SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 31215015 7 13 Figure 7 4 Engine Operating Temperature Specifications Deutz T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 124: ...ON USING NON JLG APPROVED ENGINE OIL OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE ENGINE OIL OPERATION CHART MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE Figure 7 5 Engine Oil Operation Chart Kubota T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 125: ...TIONS OPERATOR MAINTENANCE 31215015 7 15 20 2 Only WD 2 2 2 2 4 5 6 3 3 1 7 9 11 12 18 19 16 Figure 7 6 Operator Maintenance and Lubrication Diagram Deutz 2 9L Engine T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 126: ...ICATIONS OPERATOR MAINTENANCE 7 16 31215015 2 2 2 2 4 5 6 3 3 1 7 13 8 18 19 20 2 Only WD Figure 7 7 Operator Maintenance and Lubrication Diagram Deutz 2011L Engine T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 127: ...IONS OPERATOR MAINTENANCE 31215015 7 17 Figure 7 8 Operator Maintenance and Lubrication Diagram Kubota Engine 2 22 2 2 2 4 5 6 3 3 1 7 21 24 11 12 18 19 23 20 2 Only WD T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 128: ...R Lube MPG Interval Every 3 months or 150 hours of operation Comments Fittings in center of bearing Remote Access is optional Apply grease and rotate in 90 degree intervals until bearing is completely lubricated Table 7 16 Lubrication Specifications KEY SPECIFICATIONS MPG MultipurposeGreasehavingaminimumdrippingpointof350 F 177 C Excel lentwaterresistanceandadhesivequalities andbeingofextremepress...

Page 129: ... L 1 2 Full Lube EPGL Interval Check level every 3 months or 150 hrs of opera tion change every 2 years or 1200 hours of operation 3 Drive Brake Lube Point s Fill Plug Capacity 2 7 oz 89 mL Lube DTE 10 Excel 32 Interval Change as necessary O ILLE V E LC H E C K A N DF ILL T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 130: ...r 300 hours thereafter or whenever Charge Filter is replaced 5 Hydraulic Tank Breather Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter Comments Remove wing nut and cover to replace Under cer tain conditions it may be necessary to replace on a more frequent basis T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 131: ... 1200 hours of operation Comments On new machines those recently overhauled or after changing hydraulic oil operate all systems a minimum of two complete cycles and recheck oil level in reservoir 7 Hydraulic Charge Filter Interval Change after first 50 hours and every 6 months or 300 hours thereafter or as indicated by Condition Indicator T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o...

Page 132: ...ck level daily change every 500 hours or six months whichever comes first Adjust final oil level by mark on dipstick 9 Oil Change w Filter Deutz 2 9 L4 Lube Point s Fill Cap Spin on Element Capacity 2 4 gal 8 9 L Lube EO Interval Every Year or 600 hours of operation Comments Check level daily Change in accordance with engine manual T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 133: ...Filter Deutz D2 9 Lube Point s Replaceable Element Interval Drain water daily Every year or 600 hours of operation 11 Fuel Filter Deutz D2 9 Lube Point s Replaceable Element Interval Every year or 600 hours of operation T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 134: ... Fuel Filter Deutz D2011 Lube Point s Replaceable Element Interval Every year or 500 hours of operation 13 Fuel Filter Gasoline Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 135: ... or 150 hours of operation Comments Replace filter Refer to Section 15 Radiator Coolant Deutz 2 9 Lube Point s Fill Cap Capacity 2 9 Gallon 11 3 L Lube Anti Freeze Interval Check level daily change every 1000 hours or 2 years whichever comes first T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 136: ... as indicated by the condition indicator Comments Check Dust Valve daily 17 Swing Drive Hub Lube Point Level Fill Plug Capacity 40 oz 1 2 L Lube 90w80 Gear Oil Interval Check level every 3 months or 150 hours of opera tion change after first 50 hours and every 2 years or 1200 hours of operation thereafter T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 137: ...PERATOR MAINTENANCE 31215015 7 27 18 Wheel Bearings Lube Point s Repack Capacity A R Lube MPG Interval Every 2 years or 1200 hours of operation 19 Oil Change w Filter Kubota T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 138: ...s Check level daily Change in accordance with engine manual 20 Fuel Filter Kubota Lube Point s Replaceable Component Interval Every year or 600 hours of operation 21 Engine Coolant Kubota Lube Point s Fill Cap Capacity 2 25 gal 8 5 L Lube Anti Freeze Interval Check level daily change every 1000 hours or two years whichever comes first T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 139: ... product from service immediately and arrangements must be made for replacement of the tire or tire assembly a smooth even cut through the cord plies which exceeds 3 inches 7 5 cm in total length any tears or rips ragged edges in the cord plies which exceeds 1 inch 2 5 cm in any direction any punctures which exceed 1 inch in diameter any damage to the bead area cords of the tire If a tire is damag...

Page 140: ...me axle should be the same Wheel Replacement 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 recommen dations may result in an unsafe condition regarding stability Wheel Installation It is ext...

Page 141: ...uts should be done in stages Follow ing the recommended sequence tighten nuts per wheel torque chart 4 Wheel nuts should be torqued after first 50 hours of opera tion and after each wheel removal Check torque every 3 months or 150 hours of operation Table 7 17 Wheel Torque Chart TORQUE SEQUENCE 1stStage 2ndStage 3rdStage 40ft lbs 55Nm 100ft lbs 130Nm 170ft lbs 230Nm T o o r d e r g o t o D i s c o...

Page 142: ...nnect the negative battery cable 3 Slowly loosen the bowl retaining nut and remove the nut and filter housing from the Electric lock off assembly 4 Remove the filter from the housing 5 Remove and discard the housing seal 6 Remove and discard the retaining nut seal OUTLET FILTER BOWL GASKET FILTER SEAL BOWL RETAINING NUT Figure 7 9 Kubota Filter Lock Assembly T o o r d e r g o t o D i s c o u n t E...

Page 143: ...gnition switch OFF RESIDUAL VAPOR PRESSUREWILL BE PRESENT IN THE FUEL SYSTEM ENSURE THE WORK AREA ISWELL VENTILATED BEFORE DISCONNECTING ANY FUEL LINE 7 7 SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006 42 EC and is only applicable to CE machines For electric powered machines the equivalent continuous A Wei...

Page 144: ...T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 145: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

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