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Operation and Safety Manual

1. Figure 2 4 Daily Walk Around Inspection Sheet 1 of 4 3121217 JLG Lift 2 9 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION GENERAL Begin your Walk Around Inspection at item 1 as noted on the diagram Continue to your right counterclockwise viewed from the top checking each item in sequence for the conditions listed in the following checklist A WARNING TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DUR ING WALK AROUND INSPECTION NOTICE DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE CHECKING THIS AREA MAY RESULT IN DISCOVERY OF CONDITIONS WHICH COULD CAUSE EXTENSIVE MACHINE DAMAGE NOTE each item make sure there no loose or missing parts that they are securely fastened and that no visible damage exists in addition to any other criteria men tioned 1 Platform Assembly Platform mounting pins secure Footswitch in good working order not modified dis abled or blocked Platform amp Ground Control Console Switches and control levers placards secure and legible control lever and switches return to neutral control lever lock functions properly emergency stop switch functions properly control markings legible Rotator See Note All Hydraulic Cylinders No visible damage Pivot pins and hydraulic hoses undamaged not leaking Boom Pivot pins secure Upright in vertical position See Note
2. Figure 4 5 Decal Installation Sheet 1 of 4 JLG Lift 3121217 SECTION 4 MACHINE OPERATION 25 S2 OUTSIDE 24 25 54 INSIDE Figure 4 6 Decal Installation Sheet 2 of 4 3121217 JLG Lift 4 17 SECTION 4 MACHINE OPERATION Figure 4 7 Decal Installation Sheet 3 of 4 3121217 JLG Lift 4 18 SECTION 4 MACHINE OPERATION Figure 4 8 Decal Installation Sheet 4 of 4 3121217 JLG Lift 4 19 SECTION 4 MACHINE OPERATION 4 20 Table 4 1 Decal Legend Prior to S N 0300141450 Item ANSI CE Aus Japan Korean Eng Eng Spanish E
3. Hydraulic Oil Table 6 6 Mobil DTE 11M Specs Table 6 5 Hydraulic Oil ISO Viscosity Grade 15 i Gravity API 31 9 ystem S A E Viscosity x perang Grade Pour Point Max 40 F 40 Temperature Range EISE BNET int Min 40710 1807 TOW L 16622 18 to 83 C Viscosity 0 to 210 F 10W 20 10W30 at40 C 15651 18 to 99 100 4 1cSt 50 to 210 F 20W 20 at 100 F 80SUS 10 to 99 at210 F 43SUS t 30 F 2 NOTE Hydraulic oils must have anti wear qualities at least to API Service Classification GL 3 and sufficient chemical stabil Viscosity Index 140 ity for mobile hydraulic system service Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not con tain the same required additives or be of comparable vis cosities If use of hydraulic oil other than Mobil DTE 11M is desired contact JLG Industries for proper recommen dations 3121217 JLG Lift 6 5 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Major Component Weights Serial Number Location Table 6 7 Component Weights A serial number plate is affixed to the right side of the frame If the serial number plate is damaged or m
4. 3121814 Maximum Work Load Capacity Unrestricted 500 Ib 230 kg Maximum Travel Grade Gradeability 30 with Boom retracted and approximately horizontal Tower Boom fully lowered Maximum Travel Grade Side Slope with Boom retracted and approximately hori zontal Tower Boom fully lowered 5 Tilt Alarm Setting See Section 3 ANSI CSA 5 CE E M600 amp E M600J 4 CEE M600JP 3 Maximum Vertical Platform Height 60ft 18 29 m Maximum Horizontal Platform Reach E600 431 13 11 E600J 42 ft 9in 13 11 m Machine Width 2WD 7 ft 11 7 16 in 2 42 m 4WD 7 ft 11 3 8 in 2 42 m JLG Lift 6 1 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 1 Operating Specifications Prior to S N 0300141450 Table 6 1 Operating Specifications Prior to S N 0300141450 Machine Length E M600 E M600J E M600JP 301 115 16 in 9 43 m 3011 8 15 16 in 9 37 m 331t 33 4 in 10 15 m Turning Radius outside 15ft 3in 4 65 m Gross Machine Weight Platform Empty Priorto S N 0300104944 E600J M600J E600JP M600JP 16 300 Ib 7 393 kg 16 800 Ib 7 620 kg Turning Radius inside Aft 1 23 m Maximum Tire Load 7700 Ibs 3493 kg Maximum Ground Bearing Pressure E600J M600J 52 psi 3 7 kg cm Gross Machine Weight Platform Empty S N 0300104944 to Present E600J M600J
5. 2 5 3121217 SECTION PARAGRAPH SUBJECT PAGE SECTION 3 MACHINE CONTROLS AND INDICATORS 3d GENERAL 2525 lt td a kuda u sha 3 1 3 2 CONTROLS AND INDICATORS 3 1 Ground Control Station 3 1 Platform Control Station 3 6 Platform Control Indicator Panel 3 9 SECTION 4 MACHINE OPERATION 41 DESCRIPTION 4 1 4 2 OPERATING CHARACTERISTICS AND LIMITATIONS 4 1 4 1 Stability 2 RUE 4 1 43 MOTOR OPERATION 4 2 Power Emergency Stop 4 2 Platform Ground Select Switch 4 2 4 4 TRAVELING DRIVING 4 5 Traveling Forward and Reverse 4 5 4 5 STEERING pipe Gang owed 4 7 4 6 4 7 Platform Level Adjustment 4 7 Platform Rotation 4 7 47 BOOM sorore petet iE oe ae ien 4 7 Swinging the 4 8 Raising and Lowering the Upper Boom 4 8 JLG Lift i TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT 48 GENERATOR OPTIONAL Automatic Operating Mode Battery Only Operating Mode Manual Charge Operating Mode 4 9 FUNCTION
6. 6 5 3121217 SECTION PARAGRAPH SUBJECT PAGE 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 6 1 Operating Specifications 6 1 6 2 6 2 6 9 TIS i con ee tig ted eek ERE ey ues 6 3 6 4 Hydraulic 6 3 65 Mobil DTE 11M Specs 6 3 6 6 Component Weights 6 4 6 7 Lubrication Specifications 6 6 6 8 Wheel Torque 6 11 7 1 Inspection and Repair Log 7 1 iii JLG Lift TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE SECTION PARAGRAPH SUBJECT PAGE This page left blank intentionally iv JLG Lift 3121217 SECTION 1 SAFETY PRECAUTIONS 1 1 SECTION 1 SAFETY PRECAUTIONS GENERAL This section outlines the necessary precautions for proper and safe machine operation and maintenance For proper machine use it is mandatory that a daily routine is estab lished based on the content of this manual A maintenance program using the information provided in this manual and the Service and Maintenance Manual must also be estab lished by a qualified person and followed to ensure the machine is safe to operate The owner user operator lessor lessee of the machine sho
7. Drive Axle and Motor See Note Wheel Tire Assembly No loose or missing lug nuts proper inflation pneumatic Inspect for worn tread cuts tears or other discrepancies Inspect wheels for damage and corrosion Frame top and underside See Note Figure 2 5 Daily Walk Around Inspection Sheet 2 of 4 2 10 JLG Lift 3121217 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 9 Boom Limit Switch Switch operable 10 11 BOOM LIMIT 12 SWITCH 13 14 15 16 17 18 19 Cowling and Latches See Note Hydraulic Pump and Reservoir Recommended hydraulic fluid level on dipstick system shut down boom in stowed position Breather cap dipstick secure and working Manual Descent Valve See Note Control Valve No unsupported or damaged wires or hoses Generator Start Battery See Note Engine Oil Supply Full mark on dipstick filler cap and filter secure Battery Compartment Right Side See Note Counterweight See Note Limit Switches Switches operable Tie Rod Ends and Steering Spindles Tie rod end stubs locked Figure 2 6 Daily Walk Around Inspection Sheet 3 of 4 3121217 JLG Lift SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 20 Oscillating Axle and Lockout Valve If Equipped Check the lockout valve plunger in the depre
8. Lube Point s Fill Cap Capacity Refer to engine manual Lube EO Interval Check daily Change in accordance with engine manual 3121217 JLG Lift 6 9 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 3 Hydraulic Tank Lube Point s Fill Cap Capacity Prior to S N 51941 15 gal tank 56 7 L S N 51941 to present 15 9 gal system 56 7L 12 4 gal 46 9 L to Full Mark Lube HO Interval Check Level daily Change every 2 years or 1200 hours of operation 6 10 JLG Lift 4 Hydraulic Filter Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter or as indicated by Condition Indicator Comments Under certain conditions it may be necessary to replace the filter on a more frequent basis 3121217 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 5 Swing Drive Hub S N 58845 to Present 6 Wheel Drive Hub FILL Lube Point s Level Fill Plug Capacity 0 4 gal 1 5 L Lube EPGL Lube Point s Level Fill Plug Interval Check level every 3 months or 150 hrs of Capacity 24 oz 0 7 L operation change every 2 years or 1200 hours of Lube EPGL operation Interval Check level every 3 months or 150 hrs of opera tion change every 2 years or 1200 hours of operation 3121217 JLG Lift 6 11 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 4 OSCILLATING AXLE LOCKOUT TEST IF EQU
9. Operation and Safety Manual ANSI Original Instructions Keep this manual with the machine at all times Boom Lift Models E600 E600J E600JP M600 M600J M600JP 3121217 April 26 2012 FOREWORD 3121217 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 JLG Lift a FOREWORD SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol It is used to alert you to the potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR DEATH THIS DECAL WILL HAVE A RED BACKGROUND A WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY OR DEATH THIS DECAL WILL HAVE AN ORANGE BACKGROUND b JLG Lift A CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO ALERT A
10. u1 01 payepdn HAL 9p AO1d siu esn eseajd 1essooeu 51 UOHEIIJOU 59520 SIY sesn pue 53f uoee 10 s19npoid jo diusisuwo juauno y payepdn ou S 4 sun linq 1 Jo esodand ay 104 no OUM 0 si Aq jonpoud y jo Jeseuound LON 1nq j 1 OL Kueduio uone1od102 usoxuso uy dIHSH3NMO dO H34JSNVHL aIr The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 1702961 PROPOSITION 65 WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Batteries also contain other chemicals known to the State of California to cause cancer Wash hands after handling An Oshkosh Corporation Company Corporate Office JLG Industries Inc 1JLG Drive McConnellsburg PA 17233 9533 USA 717 485 5161 El 717 485 6417 JLG Worldwide Locations 3121217 JLG Indus
11. E600JP M600JP 16 7101b 7 580 kg 17 2101b 7 806 kg Table 6 2 Operating Specifications S N 0300141450 to Present Maximum Work Load Capacity ANSI Markets Unrestricted 5001 227 kg E600JP M600JP 51 psi 3 6 kg cm Maximum Drive Speed 3 0 mph 1 3 m s Electrical System Voltage 48 volts Maximum Hydraulic System Pressure 3200 psi 221 Bar Maximum Wind Speed 28 mph 12 5 m s Maximum Manual Force 400N 6 2 Maximum Work Load Capacity CE amp Australia Markets Unrestricted 500 Ib 230 kg Maximum Travel Grade Gradeability 30 with Boom retracted and approximately horizontal Tower Boom fully lowered Maximum Travel Grade Side Slope with Boomretracted and approximately hori zontal Tower Boom fully lowered 5 3121217 JLG Lift SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 2 Operating Specifications S N 0300141450 to Present Table 6 2 Operating Specifications S N 0300141450 to Tilt Alarm Setting See Section 3 ANSI CSA CE E M600 amp E M600J CE E M 600JP Present Electrical System Voltage 48 volts Maximum Hydraulic System Pressure 3200 psi 221 Bar 3 Maximum Wind Speed 28 mph 12 5 m s Maximum Manual Force 400N Maximum Vertical Platform Height 60 ft 18 29 m Maximum Horizontal Platform Reach Gross Machine Weight Platform Empty Prior
12. employer local or governmental regulations are more stringent Maintain distance from electrical lines apparatus or any energized exposed or insulated parts according to the Maintain a clearance of at least 10 ft 3m between any part Minimum Approach Distance MAD as shown in Table 1 of the machine and its occupants their tools and their 1 equipment from any electrical line or apparatus carrying up Allow for machine movement and electrical line swaying to 50 000 volts One foot additional clearance is required for every additional 30 000 volts or less 3121217 JLG Lift 1 5 SECTION 1 SAFETY PRECAUTIONS The minimum approach distance may be reduced if insulat Tipping Hazards ing barriers are installed to prevent contact and the barriers are rated for the voltage of the line being guarded These The user must be familiar with the surface before driving barriers shall not be part of or attached to the machine The Do not exceed the allowable sideslope and grade while minimum approach distance shall be reduced to a distance driving within the designed working dimensions of the insulating e barrier This determination shall be made by a qualified per son in accordance with the employer local or governmental requirements for work practices near energized equipment DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE MAD ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLE
13. trical circuits and if everything is OK the platform alarm will beep once During this time the lights on the indicator panel will also blink once as a bulb check 4 2 JLG Lift 3121217 SECTION 4 MACHINE OPERATION BOOM FULLY EXTENDED 5 ELEVATION P uM c MACHINE WILL OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN QUT OF LEVEL SURFACE LEVELSURFACE Figure 4 1 Position of Least Forward Stability 3121217 JLG Lift 4 3 SECTION 4 MACHINE OPERATION illlqe1S paemyoeg 15297 jo uonisod 2 4 aa3ivA313 NV a3r9vdl3d ATINA INOOS NIYIN 39v4ufis TSAI 130 1010 NV NO 03174340 dO d3QV0 TH3A0 JI NOLLO3IG SIHL NIH3AO diL THM 3NIHOVIA e JOVAYNS 13 41 006 d31VLOW IWd041V 1d 3121217 JLG Lift 4 4 SECTION 4 MACHINE OPERATION 4 4 TRAVELING DRIVING NOTE When the upper boom is raised approximately 11 degrees DRIVE AXLE IF BOOM IS OVER FRONT WHEELS STEER AND DRIVE CONTROLS WILL BE REVERSED above horizontal the high drive function will automatically Traveling Forward and Reverse be in low drive NOTICE IF THE MACHI
14. 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE by JLG Due to size variations between tire brands both tires on the same 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 pres sure and load capacity Size changes such as rim width center piece location larger or smaller diameter etc without written factory recommendations may result in an unsafe condition regarding stability Wheel Installation It is extremely important to apply and maintain proper wheel mounting torque A WARNING WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS BROKEN STUDS AND POSSI BLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL Tighten the lug nuts to the proper torque to prevent wheels from coming loose Use a torque wrench to tighten the fasteners If you do not have a torque wrench tighten the fasteners with a lug wrench then immediately have a service garage or dealer tighten the lug nuts to the proper torque Over tightening will result in breaking the studs or permanently deforming the mounting stud holes in the wheels The proper procedure for attaching wheels is as follows 1 Start all nuts by hand to prevent cross threading DO NOT use a lubricant on threads or nuts 2 Tighten nuts in the following
15. and Safety Manual for more information LIFT HERE CENTER OF GRAVITY TIE DOWN AND LIFT HERE TIE DOWN HERE ROTATION 46 117 pen E 3252673 B Figure 4 4 Lifting and Tie Down Chart 3121217 JLG Lift 4 11 SECTION 4 MACHINE OPERATION 4 13 TOWING INSTRUCTIONS THE MACHINE HAS NO TOWING BRAKES THE TOWING VEHICLE MUST BE ABLE TO CONTROL THE MACHINE AT ALL TIMES TOWING IS NOT PERMITTED ON HIGHWAY A WARNING KEEP ALL BODY PARTS AWAY FROM MOVING COMPONENTS FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH OR SERIOUS INJURY A CAUTION MAXIMUM TOWING SPEED 5 MPH 8 KPH FOR A DISTANCE OF 5 MILES 8K MAXIMUM TOWING GRADE 25 The following instructions are for towing using the optional tow bar 1 Lock the turntable in the travel position with the boom fully lowered and retracted 2 Lower the tow bar to the towing position and connect to the towing vehicle 3 Disengage the drive hubs 4 Position the steer tow selector to the towing out posi tion STEER TOW SELECTOR 5 To return the machine to the self propelled mode follow the above steps in the reverse order 4 12 JLG Lift 3121217 SECTION 4 MACHINE OPERATION 4 14 DRIVE HUB Disengaging for Towing A CAUTION MAKE SURE THE DISCONNECT MEC
16. down under the following conditions Batteries Fully Charged High Oil Temperature Low Oil Pressure Engine Overspeed Overvoltage NOTE The optional generator engine will not start if the batteries are fully charged or if the Generator Enable switch on the platform console is not in the on position 3121217 JLG Lift Ground Control Station See Figure 3 1 Ground Control Station w Function Enable A WARNING DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSON NEL IN THE PLATFORM EXCEPT IN AN EMERGENCY PERFORM AS MANY PRE OPERATIONAL CHECK AND INSPECTIONS FROM GROUND CONTROLS AS POSSIBLE NOTE When machine is shut down the Platform Ground Select switch and Emergency Stop must be positioned to OFF NOTE If equipped the Function Enable switch must be held down in order to operate Telescope Lift Swing Jib Lift Platform Level Override and Platform Rotate functions 1 Power Emergency Stop A two position red mushroom shaped switch furnishes power to Platform Ground Select switch when pulled out on When pushed in off power is shut off to the Plat form Ground Select switch 3 1 SECTION 3 MACHINE CONTROLS AND INDICATORS 13 28 1 2 3 4 5 6 7 8 9 10 11 I 12 i 13 Power Emergency Stop Platform
17. harness with a lanyard attached to an authorized lan yard anchorage point Attach only one 1 lanyard per lan yard anchorage point JLG Lift d1 SECTION 1 SAFETY PRECAUTIONS Before operating the machine make sure all gates are Use extreme caution when entering or leaving platform closed and fastened in their proper position Be sure that the boom is fully lowered It may be neces sary to telescope out to position the platform closer to the ground for entry exit Face the machine maintain three point contact with the machine using two hands and one foot or two feet and one hand during entry and exit Electrocution Hazards This machine is not insulated and does not provide pro tection from contact or proximity to electrical current F Keep both feet firmly positioned on the platform floor at all W times Never use ladders boxes steps planks or similar items on platform to provide additional reach Never use the boom assembly to enter or leave the plat form JLG Lift 3121217 SECTION 1 SAFETY PRECAUTIONS Table 1 1 Minimum Approach Distances M A D Voltage Range MINIMUM APPROACH DISTANCE Phase to Phase in Feet Meters Oto 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
18. in the work area prior to machine operation Do not operate or raise the platform while on trucks trail ers railway cars floating vessels scaffolds or other equip ment unless approved in writing by JLG Do not operate the machine in hazardous environments unless approved for that purpose by JLG Be sure that the ground conditions are able to support the maximum load shown on the decals located on the machine JLG Lift Machine Inspection Before machine operation perform inspections and func tional checks Refer to Section 2 of this manual for detailed instructions Do not operate this machine until it has been serviced and maintained according to requirements specified in the Service and Maintenance Manual Be sure the footswitch and all other safety devices are operating properly Modification of these devices is a safety violation A WARNING MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANU FACTURER Do not operate any machine on which safety or instruction placards or decals are missing or illegible Avoid any buildup of debris on the platform floor Keep mud oil grease and other slippery substances from foot wear and platform floor 3121217 SECTION 1 SAFETY PRECAUTIONS 1 3 OPERATION General 3121217 Do not use the machine for any purpose other than posi tioning personnel their tools and equipment Ne
19. instructions and warnings on the machine 3 Rules of the employer and government regulations 4 Use of approved fall protection device 5 Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal function 3121217 JLG Lift 6 The safest means to operate the machine where over head obstructions other moving equipment and obsta cles depressions holes dropoffs 7 Means to avoid the hazards of unprotected electrical conductors 8 Specific job requirements or machine application Training Supervision Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has developed the ability to safely control and operate the machine Operator Responsibility The operator must be instructed that he she has the respon sibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site 2 1 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 2 PREPARATION INSPECTION AND 2 2 MAINTENANCE The following table covers the periodic machine inspections and maintenance recommended by JLG Industries Inc Consult local regulations for further requirements for aerial work platforms The frequency of inspections and mainte nance must be increased as necessary when the machine is used in a harsh or hostile environment if
20. the machine is used with increased frequency or if the machine is used in a severe manner JLG INDUSTRIES INC RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL JLG Lift 3121217 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION Table 2 1 Inspection and Maintenance Table Type Frequenc Primary Service Reference yp q y Responsibility Qualification Pre Start Inspection Before using each day or User or Operator User or Operator Operator and Safety Manual whenever there s an Operator change Pre Delivery Inspection Before each sale lease or rental delivery Owner Dealer orUser Qualified JLG Service and Maintenance See Note Mechanic Manual and applicable JLG inspection form Frequent Inspection In service for 3 months or 150 hours whichever Owner Dealer orUser Qualified JLG Service and Maintenance comes first Mechanic Manual and applicable JLG or inspection form Out of service for a period of more than 3 months or Purchased used Annual Machine Inspection Annually nolaterthan 13 months fromthe date of Owner Dealer orUser Factory Trained Service and Maintenance prior inspection Service Technician Manual and applicable JLG Recommended inspection form Preventative Maintenance Atintervals as specified in the Service and Main Owner D
21. 252739 3252740 3252743 3252741 3252742 53 JLG Lift 3121217 SECTION 4 MACHINE OPERATION 3121217 Table 4 1 Decal Legend Prior to S N 0300141450 Item ANSI CE Aus Japan Korean Eng Eng Spanish Eng French Chinese Eng Port Spa 0270129 14 0275062 5 0270146 12 0270148 13 0270150 13 0270152 14 0270154 13 0270156 13 54 1704254 1704254 1704254 1704254 1704254 1704254 1704254 55 56 57 58 59 60 1703929 1703930 1703931 1703934 61 62 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 63 1702391 1701517 1701517 1701517 1701517 1701517 1701517 1701517 64 1704728 1704728 1704671 1704670 1704732 1704733 1704371 1704618 65 66 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 67 68 69 1705351 1705427 1705910 1705429 70 JLG Lift SECTION 4 MACHINE OPERATION 4 24 Table 4 2 Decal Legend S N 0300141450 to Present Item ANSI CE Aus Japan Korean Eng Eng Spanish Eng French Chinese Eng Port Spa 0270129 15 0275062 5 0270146 13 0270148 14 0270150 14 0270152 15 0270154 14 0270156 14 1 1703797 1705921 1703926 1703927 1703923 1703924 1703925 1703928 2 1704575 1705822 1704667 1704668 3 1703805 1703938 1703939 17039
22. 35 1703936 1703937 1703940 4 1703804 1701518 1703950 1703951 1703947 1703948 1703949 1703952 5 1704661 1704661 1704661 6 1707035 1707035 1707035 7 8 9 10 11 1702868 1704001 1704000 1704002 12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 13 1001121801 1705978 1001121801 1001121918 1001121805 1001121803 1001121810 1001121920 14 1001121814 1705978 1001121814 1001121921 1001121818 1001121816 1001121823 1001121923 15 3251813 1705084 3251813 3251813 3251813 16 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701502 17 1701503 1701503 1701503 1701503 1701503 1701503 1701503 1701503 JLG Lift 3121217 SECTION 4 MACHINE OPERATION 3121217 Table 4 2 Decal Legend S N 0300141450 to Present Item ANSI CE Aus Japan Korean Eng Eng Spanish Eng French Chinese Eng Port Spa 0270129 15 0275062 5 0270146 13 0270148 14 0270150 14 0270152 15 0270154 14 0270156 14 18 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 19 1704007 1704006 1704008 20 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 21 i 22 1706948 3252523 1706948 1706948 1706948 1706948 1706948 1706948 23 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 24 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300 25 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 26 170152
23. 40 420 2661 E mail ProductSafety JLG com Failure to notify the manufacturer of an incident involving a JLG Industries product within 48 hours of such an occur rence may void any warranty consideration on that particular machine 3121217 JLG Lift NOTICE FOLLOWING ANY ACCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS THEN FROM THE PLATFORM CONTROLS DO NOT LIFT ABOVE 10 FT 3 M UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED IF REQUIRED AND THAT ALL CONTROLS ARE OPERATING CORRECTLY 5 3 EMERGENCY OPERATION Operator Unable to Control Machine IF THE PLATFORM OPERATOR IS PINNED TRAPPED OR UNABLE TO OPERATE OR CONTROL MACHINE 1 Other personnel should operate the machine from ground controls only as required 2 Other qualified personnel on the platform may use the platform controls DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY 3 Cranes forklift trucks or other equipment can be used to remove platform occupants and stabilize motion of the machine 5 1 SECTION 5 EMERGENCY PROCEDURES Platform or Boom Caught Overhead TELESCOPING IN AND LOWERING THE BOOM If the platform or boom becomes jammed or snagged in overhead structures or equipment rescue platform occu pants prior to freeing the machine 5 4 EMERGENCY TOWING PROCEDURES Towing this machine is prohibited unless properly equipped However provisions for moving the machin
24. 54 7233 Outside USA Phone 240 420 2661 Fax 301 745 3713 E mail ProductSafety JLG com JLG Lift c FOREWORD REVISION LOG Original Issue June 7 2005 Revised July 21 2006 Revised December 7 2009 Revised March 2 2010 Revised September 1 2010 Revised April 26 2012 JLG Lift 3121217 TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE SECTION 1 SAFETY PRECAUTIONS GENERAL L uu RESI kins aha EOS 1 1 1 2 1 1 Operator Training and Knowledge 1 1 Workplace Inspection 1 2 Machine Inspection 1 2 1 3 OPERATION ul an Rv uqsuy 1 8 General erret er 1 3 Trip FallHazards 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 PREPARATION AND INSPECTION 21 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 4 Function
25. 701509 1701509 1701509 1701509 1701509 1701509 1701509 24 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300 25 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 26 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 27 28 29 30 31 1703953 1701518 1703944 1703945 1703941 1703942 1703943 1703946 32 33 34 3252347 1705828 1703980 1703981 1703983 1703984 1703982 1703985 35 1704708 1704708 1704708 1704708 1704708 1704708 1704708 Lift 4 21 SECTION 4 MACHINE OPERATION 4 22 Table 4 1 Decal Legend Prior to S N 0300141450 Item ANSI CE Aus Japan Korean Eng Eng Spanish Eng French Chinese Eng Port Spa 0270129 14 0275062 5 0270146 12 0270148 13 0270150 13 0270152 14 0270154 13 0270156 13 36 1701644 1701644 1701644 1701644 1701644 1701644 1701644 1701644 37 1704705 1704705 1704705 1704705 1704705 1704705 1704705 1704705 38 1702901 1706392 1704119 1704120 1704117 1704116 1704121 1704118 39 1705514 40 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 41 1704248 1706378 1704381 1704332 1704328 1704329 1704333 1704330 42 1702155 1702155 1702155 1702155 1702155 1702155 1702155 43 1704412 1704412 1704412 1704412 1704412 1704412 1704412 44 45 46 47 48 49 50 51 1703813 1705670 1704342 1704343 1704339 1704340 1704344 1704341 92 3252673 1706377 3252738 3
26. 8 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 degrees F Excellent water resistance and adhesive quali ties and being of extreme pressure type Timken OK 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API Service Clas sification GL 5 or Mil Spec Mil L 2105 HO Hydraulic Oil Mobil DTE 11M OG Open Gear Lube Tribol Molub Alloy 936 Open Gear Com pound JLG Part No 3020027 BG Bearing Grease JLG Part No 3020029 Mobilith SHA 460 LL Synthetic Lithium Lubricant Gredag 741 Grease JLG Part No 3020022 EO Engine crankcase Oil Gas API SF SG class MIL L 2104 Diesel API CC CD class MIL L 2104B MIL L 2104C MPG may be substituted for these lubricants if necessary but service intervals will be reduced 6 8 JLG Lift LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS FOR MACHINES USED IN MULTI SHIFT OPERATIONS AND OR EXPOSED TO HOSTILE ENVIRONMENTS OR CON DITIONS LUBRICATION FREQUENCIES MUST BE INCREASED ACCORD INGLY NOTE It is recommended as a good practice to replace all filters at the same time 1 Swing Bearing Internal Ball Bearing Lube Point s 1 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 3121217 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE
27. 9 1701529 1701529 1701529 1701529 1701529 1701529 1701529 27 28 29 30 31 1703953 1701518 1703944 1703945 1703941 1703942 1703943 1703946 32 33 34 3252347 1705828 1703980 1703981 1703983 1703984 1703982 1703985 35 1704708 1704708 1704708 1704708 1704708 1704708 1704708 Lift 4 25 SECTION 4 MACHINE OPERATION 4 26 Table 4 2 Decal Legend S N 0300141450 to Present Item ANSI CE Aus Japan Korean Eng Eng Spanish Eng French Chinese Eng Port Spa 0270129 15 0275062 5 0270146 13 0270148 14 0270150 14 0270152 15 0270154 14 0270156 14 36 1701644 1701644 1701644 1701644 1701644 1701644 1701644 1701644 37 1704705 1704705 1704705 1704705 1704705 1704705 1704705 1704705 38 1702901 1706392 1704119 1704120 1704117 1704116 1704121 1704118 39 1705514 40 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 41 1704248 1706378 1704331 1704332 1704328 1704329 1704333 1704330 42 1702155 1702155 1702155 1702155 1702155 1702155 1702155 43 1704412 1704412 1704412 1704412 1704412 1704412 1704412 44 45 46 47 48 49 50 51 1703813 1705670 1704342 1704343 1704339 1704340 1704344 1704341 52 3252673 1706377 3252738 3252739 3252740 3252743 3252741 3252742 53 JL G Lift 3121217 SECTION 4 MACHINE OPERATION 3121217 Table 4 2 Decal Legend S N 0300141450 to Pre
28. ES 5 2 4 8 5 5 MANUAL DESCENT SYSTEM 5 2 4 8 4 8 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR 3121217 TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE LIST OF FIGURES 2 1 Basic Nomenclature Sheet 1 of 3 2 6 2 2 Basic Nomenclature Sheet 2 of 3 2 7 2 3 Basic Nomenclature Sheet 3 of 3 2 8 2 4 Daily Walk Around Inspection Sheet 1 of 4 2 9 2 5 Daily Walk Around Inspection Sheet 2 of 4 2 10 2 6 Daily Walk Around Inspection Sheet 3 of 4 2 11 2 7 Daily Walk Around Inspection Sheet 4 of 4 2 12 3 1 Ground Control Station 3 2 3 1 Ground Control Station w Function Enable 3 3 3 1 Platform Control Station 3 8 3 2 Platform Control Indicator Panel 3 10 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 6 4 4 Lifting and Tie Down Chart 4 11 4 5 Decal Installation Sheet 1 of 4 4 16 4 6 Decal Installation Sheet 2 0f 4 4 17 4 7 Decal Installation Sheet 3 of 4 4 18 4 8 Decal Installation Sheet 4 4 4 19 5 1 Manual Descent Decal 5 5 6 1 Serial Number Location 6 4 6 2 Operator Maintenance and Lubrication Diagram
29. G ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM INCORRECT USE COULD CAUSE THE LOAD OCCUPANT TO SHIFT OR FALL FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY 4 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 situations such as ascending descending a grade 5 Boom Lift Provides for raising and lowering of the Boom 6 Telescope Provides for extension and retraction of the Boom 7 Swing This switch provides 400 degrees non continuous turn table rotation To activate SWING position switch to LEFT or RIGHT JLG Lift 3121217 SECTION 3 MACHINE CONTROLS AND INDICATORS 8 Battery Indicator and Hourmeter 11 Articulating Jib Boom If Equipped An hourmeter is installed in the upper portion of the This switch provides raising and lowering of the jib Ground Control Box The hourmeter registers up to 5 3 9 999 9 hours and cannot be reset 12 Rotate IF Equipped 9 Generator Enabled Indicator A three position switch permits rotation of the jib and platform The generator enabled indicator lights to signify the gen erator is enabled and may start at any time as the batter ies require If the indicator flashes it signifies an abnormal condition for the generator engine high oil temperature or low oil pressure or on all electric 14 Functio
30. GAINST UNSAFE PRACTICES THIS DECAL WILL HAVE A YELLOW BACKGROUND NOTICE INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO TECTION OF PROPERTY 3121217 FOREWORD A WARNING 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 NOTICE 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 NOTICE 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 3121217 For Accident Reporting Standards and Regulations Product Safety Compliance Information Publications Questions Regarding Current Owner Updates e Product Applica Questions Regarding Product Safety Questions Regarding Product Modifications 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 5
31. Ground Select Platform Rotate Platform Leveling Override Main Lift Telescope Swing Battery Indicator and Hourmeter Generator Enabled Indicator Generator Engine Start JibBoom Jib Rotate Platform Overload 3 2 Figure 3 1 Ground Control Station JLG Lift 3121217 SECTION 3 MACHINE CONTROLS AND INDICATORS Power Emergency Stop Platform Ground Select Platform Rotate Platform Leveling Override Main Lift Telescope Swing Battery Indicator and Hourmeter Generator Enabled Indicator 10 Generator Engine Start 11 Jib Boom 12 Jib Rotate 7 13 Platform Overload 14 Function Enable Figure 3 1 Ground Control Station w Function Enable 3121217 JLG Lift 3 3 SECTION 3 MACHINE CONTROLS AND INDICATORS 2 Platform Ground Select A three position key operated switch supplies power to the platform control console when positioned to PLAT FORM With the switch key held in the GROUND posi tion power is shut off to platform and only ground controls are operable NOTE With PLATFORM GROUND SELECT switch in the center 3 4 position power is shut off to controls at both operating stations 3 Rotate A three position switch permits rotation of the platform A WARNIN
32. HANISM IS ONLY OPERATED WITH THE MACHINE AT A STANDSTILL BOLT 1 Remove the two hex head bolts from the cover 2 Remove the cover 3121217 JLG Lift 4 13 SECTION 4 MACHINE OPERATION COVER Rotate the cover to show the inside diameter COVER ROTATED 4 Install the bolts and torque 6 3 ft Ibs 8 8 Nm until they are flush with the cover 5 The machine is ready to be towed A WARNING BEFORE THE MACHINE IS SEPARATED FROM THE TOWING VEHICLE EITHER THE DRIVE HUB HAS TO BE REENGAGED OR PROPER STEPS MUST BE TAKEN TO PREVENT THE MACHINE FROM MOVING JLG Lift 3121217 SECTION 4 MACHINE OPERATION Engaging after Towing is Complete A WARNING THE COVER IS UNDER SPRING FORCE 1 Remove the 2 hex head bolts securing the cover evenly and remove the cover 2 Rotate the cover 180 degrees and secure with the two hex head bolts Torque the hex head bolts 6 3 ft lbs 8 8 Nm 4 The gear drive should now be reengaged and the machine can be disconnected from the towing vehicle 3121217 JLG Lift 4 15 SECTION 4 MACHINE OPERATION T 7 INSIDE ___ m a zc 22 33 20 40 64 SHOWN OPENED 4 16
33. IONS amp OPERATOR MAINTENANCE NOTES 6 16 JLG Lift 3121217 SECTION 7 INSPECTION AND REPAIR LOG Machine Serial Number SECTION 7 INSPECTION AND REPAIR LOG Table 7 1 Inspection and Repair Log Date Comments 3121217 JLG Lift 7 1 SECTION 7 INSPECTION AND REPAIR LOG Table 7 1 Inspection and Repair Log Date Comments 7 2 JLG Lift 3121217 amp Aou pinoys noA u ouM 55 UNI Jo ojeg 2 SseJppy SnolA8Jd ees J9poi Siu1 uo pepnjour eg JOU pinous p lu 1 posee 310N L2 Gv4 LO L XeJ 1699 981 21 1 uoud l 1 vsn 29712 aW eze d peeuurejunoJ 2261 saeujsnpuJ jueunjedeg 1 ueu L MOJ q peyroeds se oj 1ueunjedoeg 9 1onpoud 991 01 pejejduioo 5 s19npoid Jo diusieuwo 1u uino
34. IPPED NOTICE LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY ANY TIME A SYSTEM COMPONENT IS REPLACED OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED NOTE Ensure boom is fully retracted lowered and centered 6 12 between drive wheels prior to beginning lockout cylinder test Place a 6 inches 15 2 cm high block with ascension ramp in front of left front wheel From platform control station start engine Place the Drive control lever to the forward position and carefully drive machine up ascension ramp until left front wheel is on top of block Carefully activate Swing control lever and position boom over right side of machine With boom over right side of machine place Drive con trol lever to Reverse and drive machine off of block and ramp Have an assistant check to see that left front or right rear wheel remains elevated in position off of ground 7 10 11 12 13 JLG Lift Carefully activate Swing control lever and return boom to stowed position centered between drive wheels When boom reaches center stowed position lockout cylinders should release and allow wheel to rest on ground it may be necessary to activate Drive to release cylinders Place the 6 inches 15 2 cm high block with ascension ramp in front of right front wheel Place Drive control lever to Forward and carefully drive machine up ascension ramp until right front wheel is on top of block With boom over left
35. NE CONTROLS AND INDICATORS 3 14 8 Drive Orientation Indicator 9 Soft Touch Indicator If Equipped When the boom is swung beyond the rear drive tires or further in either direction the Drive Orientation indicator will illuminate when the drive function is selected This is a signal for the operator to activate the Drive Orientation Override Switch and verify the drive control direction is correct JLG Lift When illuminated Yellow the Soft Touch bumper is against an object All controls are disabled until the override button is pushed at which time controls are active in the Creep mode 3121217 SECTION 4 MACHINE OPERATION SECTION 4 MACHINE OPERATION 4 1 DESCRIPTION 4 2 OPERATING CHARACTERISTICS AND This machine is a self propelled hydraulic lift equipped with a LIMITATIONS work platform on the end of an elevating articulating and d rotating boom Capacities The primary operator control station is in the platform From this control station the operator can drive and steer the machine in both forward and reverse directions The opera tor can raise or lower the upper or lower boom or swing the 1 Machine is positioned on a smooth firm and level sur boom to the left or right Standard boom swing is 400 degree face non continuous left and right of the stowed position The The boom can be raised above horizontal with or without any load in platform if machine has a Ground Control Station which will over
36. NE IS OPERATED AT A VERY SLOW SPEED OR STALLED WHEN CLIMBING A GRADE OF 20 OR GREATER DRIVE FUNCTION WILL STOP REMOVE YOUR FOOT FROM FOOT SWITCH AND PUSH THE FOOTSWITCH DOWN AGAIN TO RESET IT A WARNING DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH FIRM AND LEVEL SURFACE TO AVOID LOSS OF TRAVEL CONTROL OR TIP OVER DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THE PLATFORM IS ELEVATED BEFORE DRIVING MAKE SURE BOOM IS POSITIONED OVER REAR 3121217 JLG Lift 1 At Platform Controls pull out Emergency Stop switch and activate footswitch 2 Position Drive controller to FORWARD or REVERSE as desired This machine is equipped with a Drive Orientation Indicator The yellow light on the platform control console indicates that the boom is swung beyond the rear drive tires and the machine may Drive Steer 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 plat form control panel and the chassis to determine the direction the machine will travel 2 Push and release the Drive Orientation Override switch Within 3 seconds slowly move the Drive control toward the arrow matching the intended direction
37. ONSIBILITIES MACHINE PREPARATION AND INSPECTION Battery Pack Fuel Tank Hydraulic Tank Main Terminal Box Swing Drive Turntable Lock Frame Turntable Battery Charger 0 Generator Control Module M Models Figure 2 1 Basic Nomenclature Sheet 1 of 3 2 6 JLG Lift 3121217 S LL 2 Main Valve 3 Generator Start Battery M Models 4 Generator M Models 5 Battery Pack 6 Ground Control 7 Turntable aa 2 7 JLG Lift SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION ANS TSS ss YI A NAM Figure 2 2 Basic Nomenclature Sheet 2 of 3 3121217 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION JO 1 us ounjej ouauioN oiseg 2 2 oJnBi4 041007 721 qi LL lepuiA 5 0 J pul 9 19 SPIN yur woog 149 0 woog iu6udn YN woog 101008 4 CN CO ON co 3121217 JLG Lift 2 8 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION
38. REMOVE ALL SPOOL PLUGS BEFORE RETURNING UNIT TO SERVICE 5 4 JLG Lift 3121217 SECTION 5 EMERGENCY PROCEDURES 2 69 9 2 Ly 9 j M 1 G Y NO Lr n E FEN Va i 1704705 C Figure 5 1 Manual Descent Decal 5 5 JLG Lift 3121217 SECTION 5 EMERGENCY PROCEDURES ex NOTES 5 6 JLG Lift 3121217 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 1 INTRODUCTION 6 2 OPERATING SPECIFICATIONS This section of the manual provides additional necessary 6 1 Operating Specifications Prior to S N 0300141450 information to the operator for proper operation and mainte nance of this machine The maintenance portion of this section is intended as infor mation to assist the machine operator to perform daily main tenance tasks only and does not replace the more thorough Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual Other Publications Available 3121217 Service and Maintenance Manual ANSI 5 3121117 Service and Maintenance Manual CE 3121813 Illustrated Parts Manual ANSI CSA 3121118 Illustrated Parts Manual CE
39. RN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED IF THE PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP SWITCH TO STOP THE MACHINE 4 7 SECTION 4 MACHINE OPERATION Swinging the Boom To swing boom use SWING control switch to select RIGHT or LEFT direction NOTICE WHEN SWINGING THE B00M MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TO CLEAR SURROUNDING WALLS PARTITIONS AND EQUIP MENT Raising and Lowering the Upper Boom To raise or lower the Upper Boom use Upper Boom Lift switch to select UP or DOWN movement 4 8 GENERATOR OPTIONAL Automatic Operating Mode The generator will operate in automatic mode when 1 Ground Control EMS is pulled out on and 2 The Generator Enable switch on the platform control console is in the On or Enable position When the above conditions apply the generator s controller will monitor status of the batteries will turn on automatically when the battery voltage drops as a result of discharge and will turn off when batteries are fully charged Battery Only Operating Mode The machine will operate in the battery only mode when 1 Ground Control EMS is pulled out and 2 The switch on the platform control console is in the Off or Disable position The batteries can be used until they are fully discharged Manual Charge Operating Mode The generator will operate in manual mode when 1 Grou
40. ROLS AND INDICATORS 11 Posi Track Control Activating the Posi Track switch distributes available power evenly between the two drive wheels for improved traction The control system may also engage the posi track function automatically when more traction is required NOTE The optional 4 Wheel Assist will also engage with the Posi Track Control A WARNING ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM INCORRECT USE COULD CAUSE THE LOAD OCCUPANT TO SHIFT OR FALL FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY 12 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 situations such as ascending descending a grade 13 Horn If pressed this switch supplies power to the horn 14 15 3 10 JLG Lift Drive Orientation Override When the boom is swung over the rear tires or further in either direction the Drive Orientation indicator will illumi nate when the drive function is selected Push and release the switch and within 3 seconds move the Drive Steer control to activate drive or steer Before driv ing locate the black white orientation arrows on both the chassis and the platform controls and match the control direction arrow to the intended chassis direction Soft Touch Override Switch If equipped This switch enables the functions that were c
41. SE 176 27 Jarfalla Sweden 46 0 850 659 500 El 446 0 850 659 534 www jlg com
42. SPEED CONTROL 4 10 OSCILLATING AXLE LOCKOUT TEST IF EQUIPPED 4 11 SHUT DOWN AND PARK 4 12 LIFTING AND TIE DOWN Lifting nionem mnis GE Sei Re ale eA Tie DOWhIz ase eie me teer Ya 4 13 TOWING 4 14 DRIVE 2225205 eR Res Disengaging for Towing Engaging after Towing is Complete SECTION 5 EMERGENCY PROCEDURES 5 1 GENERAL ley ED 5 2 INCIDENT 5 3 EMERGENCY Operator Unable to Control Machine Platform or Boom Caught Overhead 4 9 MAINTENANCE 6 1 INTRODUCTION 4 9 6 2 OPERATING SPECIFICATIONS 4 9 Capacities 4 10 WIGS erdt EE eg eR 4 10 Hydraulic 4 10 Major Component Weights 4 12 Serial Number Location 4 13 6 3 OPERATOR MAINTENANCE 4 18 6 4 OSCILLATING AXLE LOCKOUT TEST 4 15 IFEQUIPPED 65 TIRES amp WHEELS Tire Inflation 5 1 TireDamage 5 1 Tire Replacement 5 1 Wheel Replacement 5 1 Wheel Installation 5 2 6 6 SUPPLEMENTAL INFORMATION SECTION 7 INSPECTION AND REPAIR LOG JLG Lift PAGE SECTION PARAGRAPH SUBJECT PAGE 4 8 5 4 EMERGENCY TOWING PROCEDUR
43. SS KNOWN OTHERWISE 1 6 JLG Lift 3121217 SECTION 1 SAFETY PRECAUTIONS Do not elevate platform or drive with platform elevated f boom assembly or platform is in a position that one or while on a sloping uneven or soft surface more wheels are off the ground all persons must be removed before attempting to stabilize the machine Use cranes forklift trucks or other appropriate equipment to stabilize machine Before driving on floors bridges trucks and other sur faces check allowable capacity of the surfaces Never exceed the maximum platform capacity Distribute loads evenly on platform floor Crushing and Collision Hazards Do not raise the platform or drive from an elevated posi Approved head gear must be worn by all operating and tion unless the machine is on firm level and smooth sur ground personnel faces Check work area for clearances overhead on sides and Keep the chassis of the machine at least 2 ft 0 6m from bottom of platform when lifting or lowering platform and holes bumps drop offs obstructions debris concealed driving holes and other potential hazards on the floor surface Do not push or pull any object with the boom Never attempt to use the machine as a crane Do not tie off machine to any adjacent structure Do not operate the machine when wind conditions exceed 28 mph 12 5 m s Refer to Table 1 2 Beaufort Scale For Reference Only Do not inc
44. e have been incorporated For specific procedures refer to Section 4 5 5 MANUAL DESCENT SYSTEM The manual descent system is used in the event of total power failure to lower the boom using gravity To operate the manual descent system proceed as follows 1 Install the spool plug in the location shown and push the control lever on the valve up 2 Install the handle into the hand pump and pump the handle until the desired platform position is reached 3 Push the control lever down when complete Remove the handle from the hand pump and the spool plug from the valve 5 2 JLG Lift 3121217 SECTION 5 EMERGENCY PROCEDURES LOWERING THE BOOM SWING RIGHT 1 Push the control lever on the valve up 1 Install the spool plug in the location shown 2 Install the handle into the hand pump and pump the 2 Install the handle into the hand pump and pump the handle until the desired platform position is reached handle until the desired platform position is reached 3 Push the control lever down when complete Remove 3 Remove the handle from the hand pump the handle from the hand pump 3121217 JLG Lift 5 3 SECTION 5 EMERGENCY PROCEDURES SWING LEFT 1 Install the spool plug in the location shown 2 Install the handle into the hand pump and pump the handle until the desired platform position reached 3 Remove the handle from the hand pump A CAUTION
45. ealer orUser Qualified JLG Service and Maintenance tenance Manual Mechanic Manual NOTE Inspection forms are available from JLG Use the Service and Maintenance Manual to perform inspections 3121217 JLG Lift 2 3 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION Pre Start Inspection The Pre Start Inspection should include each of the follow 2 4 ing 1 Cleanliness Check all surfaces for leakage oil fuel or battery fluid or foreign objects Report any leakage to the proper maintenance personnel Decals and Placards Check all for cleanliness and legibility Make sure none of the decals and placards are missing Make sure all illegible decals and placards are cleaned or replaced Operators and Safety Manuals Make sure a copy of the Operator and Safety Manual EMI Safety Manual Domestic only and ANSI Manual of Responsibilities Domestic only is enclosed in the weather resistant storage container Walk Around Inspection Refer to Figure 2 4 Fig ure 2 5 and Figure 2 7 5 Battery Charge as required 6 Fuel Combustion Engine Powered Machines Add the proper fuel as necessary 7 Hydraulic Oil Check the hydraulic oil level Ensure hydraulic oil is added as required 8 Function Check Once the Walk Around Inspection is complete perform a functional check of all systems in an area free of overhead and ground level obstructio
46. em fault are trols and applies the drive brakes a The seven second enable time has been allowed to lapse or a function was selected before pushing WARNING down the footswitch TO AVOID SERIOUS INJURY DO NOT REMOVE MODIFY OR DISABLE b The maximum power limit has been reached and THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS the machine is not moving This condition is the same as stalling the engine by asking it to provide A WARNING more power than it was designed to do WARNING FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY OPERATES WITHIN LAST 1 4 OF TRAVEL TOP OR BOT TOM 6 Low Battery Light c There is some other fault in one of the circuits Refer to the service manual 4 Posi Track Indicator This indicator lights when posi traction is operating This light indicates when battery voltage is below 45 5 Footswitch Enable Indicator volts and flashes below 40 volts The machine will shut down below 33 volts To operate any function the footswitch must be depressed and the function selected within seven sec onds The enable indicator shows that the controls are enabled If a function is not selected within seven sec onds or if a seven second lapse between ending one 7 Creep Speed Indicator When the Function Speed Control is turned to the creep position the indicator acts as a reminder that all func tions are set to the slowest speed 3121217 JLG Lift 3 13 SECTION 3 MACHI
47. escription Land Conditions 0 0 0 0 2 Calm Calm Smoke rises vertically 1 1 3 0 3 1 5 Lightair Wind motion visible in smoke 2 4 7 1 6 3 3 Light breeze Wind felt on exposed skin Leaves rustle 3 8 12 3 4 5 4 Gentle breeze Leaves and smaller twigs in constant motion 4 13 18 5 5 7 9 Moderate breeze Dust and loose paper raised Small branches begin to move 5 19 24 8 0 10 7 Fresh breeze Smaller trees sway 6 25 31 10 8 13 8 Strong breeze Large branches in motion Whistling heard overhead wires Umbrella use becomes difficult 7 32 38 13 9 17 1 NearGale Moderate Gale Whole trees in motion Effort needed to walk againstthe wind 8 39 46 17 2 20 7 Fresh Gale Twigs broken from trees Cars veer on road 9 47 54 20 8 24 4 Strong Gale Light structure damage 1 10 JL G Lift 3121217 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 1 PERSONNEL TRAINING The aerial platform is a personnel handling device so it is necessary that it be operated and maintained only by trained personnel 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 Operator Training Operator training must cover 1 Use and limitations of the controls in the platform and at the ground emergency controls and safety systems 2 Control labels
48. f the basket left or right 3121217 JLG Lift 3 7 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 8 6 6 h Bom Pijn R 9 uL 2 zo amp 1 Power EmergencyStop 5 Telescope 8 Platform Rotate 11 Posi Track Generator Enable 6 Articulating Jib Boom 9 FunctionSpeed 12 Platform Leveling Override Lights 7 Jib Rotate 10 MainLift Swing 13 Horn Drive Steer Figure 3 1 Platform Control Station JLG Lift 3121217 SECTION 3 MACHINE CONTROLS AND INDICATORS 3121217 Lights Drive Steer Set Power EmergencyStop 5 Telescope Generator Enable x NE x be cj e 5 7 9 Function Speed 13 Horn 14 Drive Orientation Override 6 ArticulatingJibBoom 10 Main Lift Swing 15 Soft Touch Override 7 Jib Rotate 11 Posi Track 8 Platform Rotate 12 Platform Leveling Override Figure 3 2 Platform Control Station w Drive Orientation JLG Lift 3 9 SECTION 3 MACHINE CONT
49. his switch allows the operator to prevent the generator engine from starting to charge the batteries when using the machine indoors Lights If Equipped This switch operates accessory light packages if the machine is so equipped Drive Steer The DRIVE joystick provides for driving either forward or backward The controller is ramped to allow variable drive speed Steering is controlled by a thumb operated switch on top of the joystick 3121217 SECTION 3 MACHINE CONTROLS AND INDICATORS 5 Telescope Control 9 Function Speed Control This switch allows extension and retraction of the main Controls the speed of Boom and Swing Functions boom Rotate CCW for slower speed and CW for faster speed To adjust to creep turn knob fully CCW until it clicks 10 Main Lift Swing 6 Articulating Jib If Equipped This switch controls the raising and lowering of the jib up or down The dual axis joystick is provided for main lift and swing Push forward to lift up pull backward to lower Move fr T Equipped right to swing right move left to swing left Proportional control of these functions can be attained by using the A three position switch permits rotation of the jib and Function Speed control platform left or right NOTE Main lift and swing functions may be selected at the same time Maximum speed is reduced when both functions are selected 8 Platform Rotate This switch controls the rotation o
50. if neces sary 1 4 JLG Lift TOWING LIFTING AND HAULING Never allow personnel in platform while towing lifting or hauling This machine should not be towed except in the event of emergency malfunction power failure or loading unload ing Refer to the Emergency Procedures section of this manual for emergency towing procedures Ensure boom is in the stowed position and the turntable locked prior to towing lifting or hauling The platform must be completely empty of tools When lifting machine lift only at designated areas of the machine Lift the unit with equipment of adequate capac ity Refer to the Machine Operation section of this manual for lifting information 3121217 SECTION 1 SAFETY PRECAUTIONS 1 5 ADDITIONAL HAZARDS SAFETY Do not refuel the machine with the engine running Battery fluid is highly corrosive Avoid contact with skin Do not use machine as a ground for welding and clothing at all times When performing welding or metal cutting operations precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter Charge batteries only in a well ventilated area 3121217 JLG Lift 1 9 SECTION 1 SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH 12 5 M S Table 1 2 Beaufort Scale For Reference Only D
51. issing the machine Component Pounds Kilograms serial number is stamped on the left side of the frame at the top Frame bare 1381 626 T T bare 2093 950 Boom Assembly E M 600 4464 2025 Boom Assembly E M 600J 4464 2025 Tire amp Wheel 226 102 5 Swing Drive 70 32 Swing Bearing 100 454 Platform Console 25 11 Side Entry Platform 30x72 175 80 bare Side Entry Platform 30x48 144 66 bare Counterweight 2560 1161 SERIAL NUMBER STAMPED ON FRAME Figure 6 1 Serial Number Location 6 6 JLG Lift 3121217 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 3121217 ZZ WILLD BC LL WAU Ub ESSA UI Figure 6 2 Operator Maintenance and Lubrication Diagram JLG Lift 6 7 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 3 OPERATOR MAINTENANCE NOTE The following numbers correspond to those in Figure 6 2 Operator Maintenance and Lubrication Diagram Table 6
52. m Ground Select switch to center OFF If necessary cover Platform Controls to protect instruc tion placards warning decals and operating controls from hostile environment 4 9 SECTION 4 MACHINE OPERATION 4 12 LIFTING AND TIE DOWN Tie Down peng 1 Refer to the Machine Serial Number Plate call JLG WHEN TRANSPORTING THE MACHINE THE BOOM MUST BE FULLY LOWERED INTO THE BOOM REST Industries or weigh the individual unit to find out the Gross Vehicle Weight 1 Place the boom in the stowed position 2 Place the boom in the stowed position 2 Remove all loose items from the machine 3 Remove all loose items from the machine Secure the chassis and the platform using straps or 4 Properly adjust the rigging to prevent damage to the chains of adequate strength machine and so the machine remains level 4 10 JLG Lift 3121217 SECTION 4 MACHINE OPERATION IMPORTANT LIFTING INSTRUCTIONS TIE DOWN INSTRUCTIONS 1 See the Operators and Safety Manual for approximate 1 Place boom in the stowed position with turntable locked gross weight of machine as originally manufactured 2 Remove all loose items from machine 2 Place boom in the stowed position with turntable locked 3 Secure the chassis and the platform using straps or 3 Remove all loose items from machine chains of adequate strength 4 Properly adjust rigging to prevent damage to machine and so machine remains level Refer to the Operators
53. n Enable If Equipped machines an electrical system fault 13 Platform Overload If Equipped Indicates the platform has been overloaded If equipped the enable switch must be held DOWN to NOTE Refer to the Service Manual for the generator fault codes enable all boom controls when the engine is running 10 Generator Engine Start Button if equipped The generator engine start push button switch allows the generator to be started manually to top off the bat tery charge The generator will start automatically when the batteries reach a low charge level 3121217 JLG Lift 3 5 SECTION 3 MACHINE CONTROLS AND INDICATORS Platform Control Station See Figure 3 1 Platform Control Station 1 Power Emergency Stop A two position red mushroom shaped switch furnishes power to PLATFORM Controls when pulled out on When pushed in off power is shut off to the platform functions Within about 2 seconds of pulling the switch out the machine will perform a diagnostic check of the various electrical circuits and if everything is OK the platform alarm will beep once During this time the lights on the indicator panel will also blink once as a bulb check A WARNING TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CON TROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED 3 6 JLG Lift Generator Enable Control if equipped T
54. nd Alarm This orange illuminator indicates that the chassis is on a slope An alarm will also sound when the chassis is on a slope and the boom is above horizontal If lit when boom is raised or extended retract and lower to below hori zontal then reposition machine so that it is level before continuing operation If the boom is above horizontal and the machine is on a slope the tilt alarm warning light will illuminate and an alarm will sound and CREEP is automatically activated A WARNING IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR 1 Tilt 6 Low Battery EXTENDED RETRACT AND LOWER TO BELOW HORIZONTAL THEN 2 PlatformOverload 7 Creep REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING 3 System Distress 8 Drive Orientation Override BOOM OR RAISING BOOM ABOVE HORIZONTAL 4 Posi Track 9 Soft Touch Indicator 5 Enable 2 Platform Overload If Equipped Figure 3 4 Platform Control Indicator Panel w h Indicates the platform has been overloaded Drive Orientation 3 12 JLG Lift 3121217 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 System Distress Light function and beginning the next function the enable light will go out and the footswitch must be released and The system distress light indicates an abnormal condi depressed again to enable the controls tion for machine control system Releasing the footswitch removes power from all con The three likely causes of a syst
55. nd Control EMS is pulled out and 2 The switch on the platform control console is in the On or Enable position and 3 The Manual Charge push button is activated Activation of the Manual Charge button will start the engine and begin the charging cycle even if the batteries are charged above the level of automatic start 4 8 JLG Lift 3121217 SECTION 4 MACHINE OPERATION 4 9 FUNCTION SPEED CONTROL 4 11 SHUT DOWN AND PARK This control affects the speed of all boom functions and Plat NOTE form Rotate When in the CCW maximum position Drive is placed in creep speed NOTE 4 10 OSCILLATING AXLE LOCKOUT TEST IF EQUIPPED NOTICE LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY ANY TIME A SYSTEM COMPONENT IS REPLACED OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED Refer to Section 6 4 Oscillating Axle Lockout Test If Equipped for procedure 3121217 JLG Lift When parking overnight batteries should be charged properly to ensure readiness for following workday Electric machines are equipped with a static strap due to static electricity build ups Strap is located under rear of machine chassis To shut down and park the machine the procedures are as follows 1 gt Drive machine to a reasonably well protected area Ensure boom is lowered over rear drive axle Push in the Emergency Stop at Platform Controls Push in the Emergency Stop at Ground Controls Posi tion Platfor
56. ng French Chinese Eng Port Spa 0270129 14 0275062 5 0270146 12 0270148 13 0270150 13 0270152 14 0270154 13 0270156 13 1 1703797 1705921 1703926 1703927 1703923 1703924 1703925 1703928 2 1704575 1705822 1704667 1704668 3 1703805 1703938 1703939 1703935 1703936 1703937 1703940 4 1703804 1701518 1703950 1703951 1703947 1703948 1703949 1703952 5 1704661 1704661 1704661 6 1707035 1707035 1707035 7 8 9 10 11 1702868 1704001 1704000 1704002 12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 13 1701645 1705978 1701645 1707058 1707056 1707055 1707060 1707134 14 1707013 1705978 1707013 1707042 1707049 1707047 1707044 1707133 15 3251813 1705084 3251813 3251813 3251813 16 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701502 17 1701503 1701503 1701503 1701503 1701503 1701503 1701503 1701503 JL G Lift 3121217 SECTION 4 MACHINE OPERATION 3121217 Table 4 1 Decal Legend Prior to S N 0300141450 Item ANSI CE Aus Japan Korean Eng Eng Spanish Eng French Chinese Eng Port Spa 0270129 14 0275062 5 0270146 12 0270148 13 0270150 13 0270152 14 0270154 13 0270156 13 18 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 19 1704007 1704006 1704008 20 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 21 i 22 1706948 3252523 1706948 1706948 1706948 1706948 1706948 1706948 23 1701509 1
57. ns Refer to Section 4 for more specific instructions A WARNING IF THE MACHINE DOES NOT OPERATE PROPERLY TURN OFF THE MACHINE IMMEDIATELY REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION JLG Lift 3121217 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION Function Check Perform the Function Check as follows 1 From the ground control panel with no load in the plat form a b 3121217 Check that all guards protecting the switches or locks are in place Operate all functions and check all limiting and cut out switches Check auxiliary power or manual descent Ensure that all machine functions are disabled when the Emergency Stop Button is activated JLG Lift 2 From the platform control console a b Ensure that the control console is firmly secured in the proper location Check that all guards protecting the switches or locks are in place Operate all functions and check all limiting and cut out switches Ensure that all machine functions are disabled when the Emergency Stop Button is pushed in With machine in the transport stowed position drive on a grade not to exceed the rated gradeabil ity and stop to ensure the brakes hold With machine in the transport stowed position check the tilt sensor indicator light to ensure proper operation 2 5 SECTION 2 USER RESP
58. of machine travel The indicator light will flash during the 3 second interval until the drive function is selected 4 5 SECTION 4 MACHINE OPERATION LEVEL DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON MANUFACTURER S NAMEPLATE Figure 4 3 Grade and Side Slopes 4 6 JLG Lift 3121217 SECTION 4 MACHINE OPERATION 4 5 STEERING Position thumb switch on Drive Steer controller to RIGHT for steering right or to LEFT for steering left 4 6 PLATFORM Platform Level Adjustment To Level Up or Down Position the Platform Level control switch Up or Down and hold until the platform is level A WARNING ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM INCORRECT USE COULD CAUSE THE LOAD OCCUPANT TO SHIFT OR FALL FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY Platform Rotation To rotate the platform to the left or right use the Platform Rotate control switch to select the direction and hold until desired position is reached 3121217 JLG Lift 4 7 BOOM DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN MACHINE IS OUT OF LEVEL DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS TO AVOID TIP OVER LOWER PLATFORM TO GROUND LEVEL THEN DRIVE MACHINE TO A LEVEL SURFACE BEFORE RAISING BOOM TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CON TROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVE MENT DOES NOT RETU
59. placement of the tire or tire assembly 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 3121217 JLG Lift any damage to the bead area cords of the tire If a tire is damaged but is within the above noted criteria the tire must be inspected on a daily basis to insure the damage has not propagated beyond the allowable criteria Tire Replacement JLG recommends a replacement tire be the same size ply and brand as originally installed on the machine Please refer to the JLG Parts Manual for the part number of the approved tires for a particular machine model If not using a JLG approved replace ment tire we recommend that replacement tires have the follow ing characteristics Equal or greater ply load rating and size of original Tire tread contact width equal or greater than original Wheel diameter width and offset dimensions equal to the original Approved for the application by the tire manufacturer including inflation pressure and maximum tire load Unless specifically approved by JLG Industries Inc do not replace a foam filled or ballast filled tire assembly with a pneu matic tire When selecting and installing a replacement tire ensure that all tires are inflated to the pressure recommended 6 13 SECTION
60. rease the surface area of the platform or the load Increase of the area exposed to the wind will decrease stability Do not increase the platform size with unauthorized deck or attachments During operation keep all body parts inside platform rail ing 3121217 JLG Lift 1 7 SECTION 1 SAFETY PRECAUTIONS Use the boom functions not the drive function to position the platform close to obstacles Always post a lookout when driving in areas where vision is obstructed Keep non operating personnel at least 6 ft 1 8m away from machine during all driving and swing operations Limit travel speed according to conditions of ground sur face congestion visibility slope location of personnel and other factors which may cause collision or injury to personnel Be aware of stopping distances in all drive speeds When driving in high speed switch to low speed before stop ping 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 to prevent obstacles from striking or interfering with operating controls and per sons in the platform Be sure that operators of other overhead and floor level machines are aware of the aerial work platform s pres ence Disconnect power to overhead cranes Warn personnel not to work stand or walk under a raised boom or platform Position barricades on floor
61. ride 2 Loadis within manufacturer s rated capacity the Platform Control Station Ground Controls operate Boom 3 All machine systems are functioning properly Lift and Swing and are to be used in an emergency to lower the platform to the ground should the operator in the plat 4 Proper tire pressure form be unable to do so The Ground Control is also to be 5 Machine is as originally equipped from JLG used in Pre Start Inspection 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 See Figure 4 1 and its position of least BACKWARD stability is shown in See Figure 4 2 3121217 JLG Lift 4 1 SECTION 4 MACHINE OPERATION WARNING Platform Ground Select Switch TO AVOID FORWARD OR BACKWARD TIPPING D0 NOT OVERLOAD 3 The Platform Ground Select switch directs power to the MACHINE OR OPERATE THE MACHINE ON AN OUT OF LEVEL SURFACE Ground or Platform controls as selected For power the POWER EMERGENCY STOP switch must also be pulled out 4 8 MOTOR OPERATION on Power Emergency Stop This red mushroom shaped switch provides battery power when pulled out on for all machine functions The switch should be pushed in off when recharging the batteries or parking the machine overnight Within about 2 seconds of pulling the switch out the machine will perform a diagnostic check of the various elec
62. sent Item ANSI CE Aus Japan Korean Eng Eng Spanish Eng French Chinese Eng Port Spa 0270129 15 0275062 5 0270146 13 0270148 14 0270150 14 0270152 15 0270154 14 0270156 14 54 1704254 1704254 1704254 1704254 1704254 1704254 1704254 55 56 57 58 59 E 60 1703929 1703930 1703931 1703934 61 62 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 63 1702391 1701517 1701517 1701517 1701517 1701517 1701517 1701517 64 1704728 1704728 1704671 1704670 1704732 1704733 1704371 1704618 65 E 66 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 67 68 is 69 1705351 1705427 1705910 1705429 70 JLG Lift SECTION 4 MACHINE OPERATION NOTES 4 28 JLG Lift 3121217 SECTION 5 EMERGENCY PROCEDURES SECTION 5 EMERGENCY PROCEDURES 5 1 GENERAL This section explains the steps to be taken in case of an emergency situation while operating INCIDENT NOTIFICATION JLG Industries Inc must be notified immediately of any inci dent involving a JLG product Even if no injury or property damage is evident the factory should be contacted by tele phone and provided with all necessary details In USA JLG Phone 877 JLG SAFE 554 7233 8am till 4 45pm EST 9 2 Outside USA 2
63. sequence 6 14 JLG Lift 3121217 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 3 The tightening of the nuts should be done in stages Fol lowing the recommended sequence tighten nuts per wheel torque chart Table 6 9 Wheel Torque Chart TORQUE SEQUENCE 1stStage 2nd Stage 3rd Stage 40 ft Ibs 100 ft Ibs 170 ft Ibs 55 Nm 130 Nm 255 Nm 4 Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal Check torque every 3 months or 150 hours of operation 3121217 Lift 6 6 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 Weighted sound pressure level at the work platform is less than 70dB A For combustion engine powered machines guaranteed Sound Power Level LWA per European Directive 2000 14 EC Noise Emission in the Environment by Equipment for Use Outdoors based on test methods in accordance with Annex III Part B Method 1 and 0 of the directive is 104 dB The vibration total value to which the hand arm system is subjected does not exceed 2 5 m s The highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0 5 m s 6 15 SECTION 6 GENERAL SPECIFICAT
64. side of machine place Drive control lever to Reverse and drive machine off of block and ramp Have an assistant check to see that right front or left rear wheel remains elevated in position off of ground Carefully activate Swing control lever and return boom to stowed position centered between drive wheels When boom reaches center stowed position lockout cylinders should release and allow wheel to rest on ground it may be necessary activate Drive to release cylinders If lockout cylinders do not function properly have quali fied personnel correct the malfunction prior to any fur ther operation 3121217 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 5 TIRES amp WHEELS Tire Inflation The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics Tire Damage For pneumatic tires JLG Industries Inc recommends that when any cut rip or tear is discovered that exposes sidewall or tread area cords in the tire measures must be taken to remove the JLG product from service immediately Arrangements must be made for replacement of the tire or tire assembly For polyurethane foam filled tires JLG Industries Inc recom mends that when any of the following are discovered measures must be taken to remove the JLG product from service immedi ately and arrangements must be made for re
65. ssed position Swing the turntable until the axle lockout bracket passes the plunger and make sure the plunger is fully extended as shown below 1 75 4 45 cm fully extended n AXLE LOCKOUT VALVE LOCKOUT BRACKET OSCILLATION CYLINDER A CAUTION X IF PLUNGER IS NOT FULLY EXTENDED AS SHOWN CONTACT A QUALIFIED SERVICE TECHNICIAN BEFORE 7 OPERATING THE MACHINE Oo YY fN CAL 2 12 21 22 23 24 25 26 27 28 JLG Lift Battery Compartment See Note Fuel Supply Fuel filler cap secure Tank Decals secure and legible Hydraulic Oil Filter Housing See Note Battery Charger See Note Turntable Bearing Evidence of proper lubrication No loose bolts or looseness between bearing and struc ture Swing Motor Evidence of proper lubrication Platform Pivot Pins See Note Platform Gate Latch and Hinges in working condi tion Figure 2 7 Daily Walk Around Inspection Sheet 4 of 4 3121217 SECTION 3 MACHINE CONTROLS AND INDICATORS SECTION 3 MACHINE CONTROLS AND INDICATORS 3 1 GENERAL NOTICE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES This section provides the necessary information needed to understand control functions 3 2 CONTROLS AND INDICATORS NOTE The optional generator engine will automatically shut
66. to S N 0300104944 E600J M600J E600JP M600JP 16 300 Ib 7 393 kg 16 800 Ib 7 620 kg E600 43 ft 13 11 m E600J 42 ft 9 in 13 11 m Machine Width 2WD Tft 11 7 16in 2 42 m 4WD 7 ft 11 3 8 in 2 42 m Machine Length E M600 30 ft 115 16 in 9 43 E M600J 30 ft 8 15 16 in 9 37 m E M600JP 33 ft 3 3 4 in 10 15 m Gross Machine Weight Platform Empty S N 0300104944 to Present E600J M600J E600JP M600JP 16 7101b 7 580 kg 17 2101b 7 806 kg Turning Radius outside 15ft 3in 4 65 m Turning Radius inside Aft 1 23 m Maximum Tire Load 7700 Ibs 3493 kg Maximum Ground Bearing Pressure E600J M600J 52 psi 3 7 kg cm E600JP M600JP 51 psi 3 6 kg cm Maximum Drive Speed 3 0 mph 1 3 m s 3121217 JLG Lift 6 3 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Capacities Tires Table 6 3 Capacities Generator Fuel Tank M Models Only 13gallons 49 2 liters Hydraulic Tank Priorto S N 51941 15 gallons 57 liters S N 51941 to Present 15 9 gal 60 2 L 12 4 gal 46 9 L to full mark Drive Hub 0 4 gal 1 5 liters JLG Lift 6 4 Table 6 4 Tires Size Type Pressure 36 14LL 22 5 pneumatic 55 psi 4 0 Bar 36 14 LL 22 5 foam filled N A 3121217 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE
67. tries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 461265811111 61 2 65813058 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil f 55 19 3295 0407 55 19 3295 1025 pia JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 44 0 161 654 1000 125 44 0 161 654 1001 JLG France SAS 241 de Baulieu 47400 Fauillet France 33 0 5 53 88 31 70 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany 40 49 0 421 69 350 20 EL 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 amp 852 2639 5797 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy 39 029 359 5210 El 39 029 359 5845 Oshkosh JLG Singapore Technology Equipment Pte Ltd 29 Tuas Ave 4 Jurong Industrial Estate Singapore 639379 65 6591 9030 d 65 6591 9031 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755 Castellbisbal Barcelona Spain 34 93 772 4700 34 93 771 1762 JLG Sverige AB Enkopingsvagen 150 Box 704
68. uld not operate the machine until this manual has been read training is accomplished and operation of the machine has been completed under the supervision of an experi enced and qualified operator If there are any questions with regard to safety training inspection maintenance application and operation please contact JLG Industries Inc JLG A WARNING FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE PROPERTY DAM AGE PERSONAL INJURY OR DEATH 3121217 JLG Lift 1 2 PRE OPERATION Operator Training and Knowledge Read and understand this manual before operating the machine Do not operate this machine until complete training is per formed by authorized persons Only authorized and qualified personnel can operate the machine 1 1 SECTION 1 SAFETY PRECAUTIONS Read understand and obey all DANGERS WARNINGS CAUTIONS and operating instructions on the machine and in this manual Use the machine in a manner which is within the scope of its intended application set by JLG All operating personnel must be familiar with the emer gency controls and emergency operation of the machine as specified in this manual Read understand and obey all applicable employer local and governmental regulations as they pertain to operation of the machine Workplace Inspection The operator is to take safety measures to avoid all haz ards
69. ut out by the Soft Touch system to operate again at creep speed allowing the operator to move the platform away from the obstacle that caused the shutdown situation 3121217 SECTION 3 MACHINE CONTROLS AND INDICATORS Platform Control Indicator Panel See Figure 3 3 Platform Control Indicator Panel NOTE The platform control indicator panel uses different shaped symbols to alert the operator to different types of opera tional 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 yel low Indicates taam intormatonrtsoardiia the 1 TiltAlarm Warning 5 Footswitch Enable Indicator p g g 2 Overloadindicator 6 Low Battery Indicator operating condition i e procedures essential for 3 System Dist 7 C Indicat safe operation This indicator will be green with ys em 1517685 reep indicator the exception of the capacity indicator which will 4 Posi Track 8 11 NotUsed be green or yellow depending upon platform Figure 3 3 Platform Control Indicator Panel position 3121217 JLG Lift 3 11 SECTION 3 MACHINE CONTROLS AND INDICATORS 1 Tilt Alarm Warning Light a
70. ver operate a machine that is not working properly If a malfunctions occurs shut down the machine 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 Oper ate controls 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 Do not carry materials directly on platform railing Contact JLG for approved material handling accessories When two or more persons are in the platform the opera tor 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 Supplies or tools which extend outside the platform are prohibited unless approved by JLG 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 pulling or by using boom functions Only pull the unit from the tie down lugs on the chassis Do not place boom or platform against any structure to steady the platform or to support the structure Stow boom and shut off all power before leaving machine Trip and Fall Hazards During operation occupants in the platform must wear a full body

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