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Operators and Safety Manual

1. 4 4 4 11 RR Rem hte ava RUE EX wei ein aus 4 6 SECTION 5 OPTIONAL EQUIPMENT 5 1 MOTION ALARM oC OE aede o s 5 1 5 2 FOAM EIEEED TIRES metr Ie ine en tie te ARTS 5 1 5 3 NON MARKING TIRES cate o re RODA a 5 1 5 4 ROTATING BEACONS an a o ye et Moe bb nae ted 5 1 5 5 TIETAEARM see en a RR Ro eatis tie ele gas 5 1 5 6 WHEEL COVERS zu LL LEA eM AES 5 1 527 BATTERY PACKS eeu Goodie it edere E AY URS ORE RERUM 5 1 5 8 PLATFORM LIGHTS 5 of suy p bias ayaka d aku Las 5 1 5 9 Control Console Cover ua lE ata pP 5 1 5 10 CYLINDER BELLOWS 2 L zn ee et eee ume edm te d eto ute 5 1 5 11 STEEL HOOD COVERS 30 5 1 5 12 WORK PLATFORM 35 40 n40 45 5 1 5 13 SIMULTANEOUS DRIVE STEER n40 40 45 5 1 3120742 J LG Lift TABLE OF CONTENTS Continued SECTION 6 EMERGENCY PROCEDURES 6 1 GENERAL ccc ace dE RR 6 1 6 2 EMERGENCY TOWING PROCEDURES iced nenn nenn wa ee 6 1 6 3 EMERGENCY CONTROLS AND THEIR 5 6 1 6 4 EMERGENCY OPERATION cee ca est
2. Ud 0 ANOYOL dINV 19 ANOYOL dAV12 331 4715 HOS dV V z ZUR E AV3SU4HL o 8 V Qvo og aves 7 SM3U9S dV KINO SL104 INIZ 803 SINIYA Figure 2 5 Torque Chart 2 17 J LG Lift 3120742 SECTION 2 PREPARATION AND INSPECTION THIS PAGE LEFT BLANK INTENTIONALLY 2 18 J LG Lift 3120742 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS 3 1 GENERAL A IMPORTANT SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION CONFORMANCE WITH GOOD SAFETY PRACTICES IN THESE AREAS IS THE RESPONSI BILITY OF THE USER AND HIS HER OPERATING PERSONNEL This section provides the necessary information needed to understand control functions Included in this section are the operating characteristics and limitations and func tions and purposes of controls and indicators It is impor tant that the user read and understand the proper procedures before operating the machine These proce dures will aid in obtaining optimum lift service and safe operation 3 2 PERSONNEL TRAINING The aerial platform is a personnel handling device there fore it is essential that it be operated and maintained only by authorized and qualified personnel who have demon strated that they understand the proper use and mainte nance of the machine It is importa
3. MANUAL TELESCOPE t SWING 35 n35 40 n40 45 electric MASTER SWITCH MASTER SWITCH OFF TE DONN MAXIMUM UL DOUBLE E WIND SPEED RATED 3120742 J LG Lift 3 15 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS Control Panel Symbols Sheet 3 of 3 FUNCTION UPPER BOOM LIFT 30 electric UPPER BOOM LIFT 35 n35 40 n40 45 electric SYMBOL FUNCTION SYMBOL WARNING J LG Lift 3120742 SECTION 4 MACHINE OPERATION 3120742 SECTION 4 MACHINE OPERATION 4 1 DESCRIPTION This J LG Lift is EE Rated and Certified By Underwriters Laboratories This machine is a self propelled hydraulic lift equipped with a work platform on the end of an elevating articulat ing and rotating boom The J LG Lift s intended purpose is to position personnel with their tools and supplies at posi tions above ground level and can be used to reach work areas located above machinery or equipment The J LG Lift has a primary operator Control Station in the platform From this control station the operator can drive and steer the machine in both forward and reverse direc tions The operator can raise or lower the upper or lower boom or swing the boom to the left or right Standard boom swing is 360 degree non continuous lef
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6. dL Operators and Safety Manual Model 30e 35e n35e 40e n40e 45e 3120742 August 14 2001 ANSI 1509001 IPA REGISTERED COMPANY 015 MG CALIFORNIA PROPOSITION 65 BATTERY 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 WASH HANDS AFTER HANDLING J LG Lift FOREWORD 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 It is important to stress proper machine usage at all times All information in this manual must be read and under stood before any attempt is made to operate the machine Because the manufacturer has no direct control over machine operation and application proper safety prac tices are the responsibility of the owners users operators lessors and lessees All instructions in this manual are based upon the use of the machine under proper operating conditions with no deviations from the original design Any alteration or modification of the machine is strictly forbidden without written approval from J LG Industries Inc Due to continuous product improv
7. NOTE When Lift or Swing is being operated Drive will not function 7 Drive Steer The DRIVE controller provides for driving either for ward or backward when positioned to FORWARD or REVERSE The controller is ramped to allow infinitely variable drive speed between fast and slow Positioning the steer control thumb operated switch RIGHT or LEFT enables steering the machine to the right or left respectively NOTE When lower boom is raised above horizontal or the upper boom is raised approximately 16 inches 40 64 cm above boom rest the high drive function will automatically switch to low drive This also occurs when Function Speed Control is clicked on creep NOTE DRIVE control lever is spring loaded and will auto matically return to neutral OFF position when released NOTE When Drive is being operated Lift and Swing will not function NOTE Lift and Swing will continue to operate when Steer is activated 8 Platform Leveling Override 35 n35 40 n40 45 electric The PLATFORM LEVEL control switch allows the operator to adjust the level orthe platform by position ing the switch to UP or DOWN J LG Lift 3 11 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS 9 10 11 3 12 Platform Rotate 35 n35 40 n40 45 electric The PLATFORM ROTATE control switch allows the operator to rotate the basket to the left or right when positioned to the desired direction Function Speed C
8. Operator Unable to Control Machine IF THE PLATFORM OPERATOR IS PINNED TRAPPED OR UNABLE TO OPERATE OR CONTROL MACHINE 1 Operate the machine from ground controls only with the assistance of other personnel and equipment cranes overhead hoists etc as may be required to safely remove the danger or emergency condi tion 6 2 J LG Lift 2 Other qualified personnel on the platform may use the platform controls DO NOT CONTINUE OPERA TION IF CONTROLS DO NOT FUNCTION PROP ERLY 3 Cranes forklift trucks or other equipment which may be available are to be used to remove platform occupants and stabilize motion of the machine in case machine controls are inadequate or malfunc tion when used Platform or Boom Caught Overhead If the platform or boom becomes jammed or snagged in overhead structures or equipment do not continue opera tion of the machine from either the platform or the ground until the operator and all personnel are safely moved to a secure location Only then should an attempt be made to free the platform using any necessary equipment and per sonnel Do not operate controls to cause one or more wheels to leave the ground 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 cor
9. J LG INDUSTRIES INC MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE J LG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY URY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE J LG PRODUCT FOR Accident Reporting Product Safety Publications Current Owner Updates Questions Regarding Product Safety Standards and Regulations Compliance Information Questions Regarding Special Product Applications Questions Regarding Product Modifications CONTACT Product Safety and Reliability Department JLG Industries Inc 1JLG Drive McConnellsburg PA 17233 Toll Free 877 LG SAFE 877 554 7233 E mail ProductSafety J LG com 3120742 J LG Lift f FOREWORD REVISION LOG September 1997 Original Issue August 14 2001 Revised J LG Lift 3120742 TABLE OF CONTENTS TABLE OF CONTENTS SUBJ ECT SECTION PARAGRAPH PAGE NO SECTION FOREWORD SECTION 1 SAFETY PRECAUTIONS 11 Genetal en apium Ae wer enge 1 1 1 2 a nun e ph Wee dene Dh 1 1 1 3 Operations snes ae Mice inte e REN Ire reel ee t e aw sp tui 1 2 1 4 Towing Lifting And 1 5 1 5 Maintenance r 1 6 SECTION 2 PREPARATION AND INSPECTION 2 1 GENERAL 2 ne ee re Qam KES qas 2 1 2 2 PREPARATION nam t
10. To avoid electrolyte overflow add distilled water to batteries after charging When adding water to the battery fill only to level indicated or 3 8 above separators 2 Remove all vent caps and inspect electrolyte level of each cell Electrolyte level should be to the ring approximately one inch from top of battery Fill bat teries with distilled water only Replace and secure all vent caps 3 Remove battery cables from each battery post one at a time negative first Clean cables with acid neu tralizing solution e g baking soda and water or ammonia and wire brush Replace cables and or cable clamp bolts as required 4 Clean battery post with wire brush then re connect cable to post Coat non contact surfaces with min eral grease or petroleum jelly 5 When all cables and terminal posts have been cleaned ensure all cables are properly positioned and do not get pinched Close battery compartment cover 6 Start hydraulic system and ensure that it functions properly Battery Charging Daily NOTE To avoid excessive battery charging time do not allow batteries to become completely discharged 2 10 J LG Lift To avoid electrolyte overflow add distilled water to batteries after charging When adding water to the battery fill only to level indicated or 3 8 above separators 1 Charge batteries at the end of each work day or when machine performance is significantly reduced due to batteries becoming
11. 3 3 7 3 2 Position of Least Backward Stability 40 n40 45 electric Sheet 3of3 3 8 3 3 Ground Control Station 30 electric Sheet 1 Of 4 3 9 3 4 Platform Conttol Console i eee exu rese be As 3 13 4 1 Grade Side Slopes tizi merde XLI q ARX RS h ca 4 3 4 2 Upright Positioning Models 40 and 45 4 5 4 3 Chassis amp Platform Tie Down All Models 4 7 4 4 Lifting 4 8 LIST OF TABLES LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 Minimum Safe Approach Distances 5 1 4 7 1 Inspection and Repair Log 3 i J LG Lift 3120742 SECTION 1 SAFETY PRECAUTIONS SECTION 1 SAFETY PRECAUTIONS 13 GENERAL This section outlines the necessary precautions for proper and safe machine usage and maintenance In order to promote proper machine usage it is mandatory that a daily routine is established 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 established by a qualified person and must be followed to ensure that machine is safe to operate The owner user operator lessor lessee of the machine should n
12. A CAUTION BEFORE DRIVING MAKE SURE BOOM IS POSITIONED OVER REAR DRIVE AXLE IF BOOM IS OVER STEER WHEELS STEER AND DRIVE CONTROLS WILL MOVE IN OPPOSITE DIRECTIONS TO MACHINE MOTION Traveling Forward and Reverse A IMPORTANT FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNCTION OTHERWISE FUNCTION WILL NOT OPERATE 1 If machine is shut down pull out Emergency Stop at Ground Controls and place Platform Ground Select switch to PLATFORM 2 At Platform Controls pull out Emergency Stop switch and activate footswitch 3 Position Drive controller to FORWARD or REVERSE as desired Angle of controller will determine travel speed 4 5 STEERING Depress footswitch to steer machine position thumb switch on Drive Steer controller to RIGHT for steering right or to LEFT for steering left 3120742 SECTION 4 MACHINE OPERATION SIDESLOPE Figure 4 1 Grade and Side Slopes 4 6 PLATFORM Loading From Ground Level 1 Position chassis on a smooth firm and level surface NOTE Telescope the boom on the MODEL 35 electric approximately 5 ft 1 5 m for platform access 2 If total load personnel tools and supplies is 500 LB 227 kg or less distribute load uniformly on platform floor and proceed to work position Loading From Positions Above Ground Level Before loading weight to platform above ground level l Determine what the total weight will be after addi tional weight
13. Over500 KV to 750 KV 35 11 Over 750 KV to 1000 KV 45 14 Maintain a clearance of at least 10 ft 3m between any part of the machine and its occupants their tools and their equipment from any electrical line or apparatus carrying up to 50 000 volts One foot additional clear ance is required for every additional 30 000 volts or less A DANGER DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIB ITED ZONE MSAD ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE Tipping Hazards Ensure that the ground conditions are adequate to 1 4 support the maximum tire load indicated on the machine Do not travel on unsupported surfaces J LG Lift The user should be familiar with the driving surface before driving Do not exceed the allowable sideslope and grade while driving Do not elevate platform or drive with platform elevated while on a sloping uneven or soft surface Ensure machine is positioned on a firm level and uniformly supported surface before elevating platform or driving with the platform in the elevated position Before driving on floors bridges trucks and other sur faces check allowable capacity of the surfaces Never exceed the maximum work load as specified on the platform Distribute loads evenly on platform floor Keep all loads within the confines of the platform unless authorized by J LG 3120742 SECTION 1 SAFETY PRE
14. Turn the control CW to increase function speed or CCW to decrease function speed 4 9 SHUT DOWN AND PARK NOTE When parking battery powered units overnight bat teries should be charged in accordance with instruc tions in Section 2 to ensure readiness for following workday 4 4 J LG Lift NOTE 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 Drive machine to a reasonably well protected area 2 Ensure boom is lowered over rear drive axle 3 Shutdown Emergency Stop at Platform Controls 4 Shut down Emergency Stop at Ground Controls Position Platform Ground Select switch to center OFF 5 If necessary cover Platform Controls to protect instruction placards warning decals and operating controls from hostile environment 4 10 MACHINE TIE DOWN Chassis Tie Down All Models See Figure 4 3 When transporting machine by truck or trailer boom must be in stowed position and machine chassis securely tied down to truck or trailer deck Four tie down eyes are pro vided in the frame As shown in figure 4 3 Platform Boom Tie Down Model 30electric See Figure 4 3 Place a 6 x 15cm x 15cm wooden block under plat form support as shown lower boom so the support rests on the wooden block Secure platform by running a suit able tie down strap over the
15. Use the boom functions not the drive function to posi tion 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 operations 1 4 J LG Lift Under all travel conditions the operator must limit travel speed according to conditions of ground sur face congestion visibility slope location of personnel and other factors causing hazards of collision or injury to personnel Be aware of stopping distances in all drive speeds When driving in high speed switch to low speed before stopping Travel grades in low speed only Do not use high speed drive in restricted or close quar ters or when driving in reverse Exercise extreme caution at all times to prevent obsta cles from striking or interfering with operating controls and persons in the platform Ensure that operators of other overhead and floor level machines are aware of the aerial work platform s pres ence Disconnect power to overhead cranes Barri cade floor area if necessary Avoid operating over ground personnel Warn person nel not to work stand or walk under a raised boom or platform Position barricades on floor as necessary 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 powe
16. machine capabilities and operating characteristics of all functions Ref Table 4 1 Machine Operation Never operate a malfunctioning machine If a malfunc tions occurs shut down the machine Remove the unit from service and notify the proper authorities Do not remove modify or disable the footswitch or any other safety devices Never slam a control switch or lever through neutral to an opposite direction Always return switch to neutral and stop before moving the switch to the next function Operate controls with slow and even pressure Hydraulic cylinders should never be left at end of travel fully extended or fully retracted before shutdown or for long periods of time Always bump control in opposite direction slightly when function reaches end of travel This applies both to machines in operation or in the stowed position J LG Lift Do not allow personnel to tamper with or operate the machine from the ground with personnel in the plat form except in an emergency Do not carry materials directly on platform railing unless approved by J LG When two or more persons are in the platform the operator shall be responsible for all machine opera tions Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area When driving always position boom over rear axle in line with the direction of travel Remember if boom is over the front axle the directi
17. parts and security 17 Check Upper Boom telescope cylinder cross pins and hydraulic lines for damage wear lubrication leakage and security 18 Check Platform Leveling Cylinder cross pins and hydraulic lines for damage wear lubrication leak age and security Platform 1 Check platform and control console for damage loose or missing parts and security 3120742 SECTION 2 PREPARATION AND INSPECTION 2 Check control switches and levers for damage loose or missing parts and security Assure that lever and lever lock functions properly 3 Check control switches levers and electrical con nections for tightness and evidence of corrosion and wiring for defects and chafing damage Assure that switches function properly 4 Check footswitch for damage loose or missing parts and security Assure that footswitch functions properly and that wiring has no defects or chafing 5 Check 35 n35 40 n40 45 electric platform rotator mechanism for lubrication Check hydraulic rotator reservoir for leakage damage and security NOTE Check all DANGER WARNING CAUTION and INSTRUCTION placards for legibility and security on the entire machine A WARNING TO AVOID INJ URY DO NOT OPERATE MACHINE IF ALL PLAC ARDS ARE NOT ON THE MACHINE OR ARE DEFACED AND NOT READABLE USE OF MACHINE WITHOUT CORRECT PLAC ARDS IS A SAFETY VIOLATION 2 4 DAILY WALK AROUND INSPECTION It is the operators responsibility to inspe
18. 5 m s This machine can be operated in nominal ambient tem peratures of 0 F to 104 F 20 C to 40 C Consult J LG to optimize operation outside of this temperature range 3120742 J LG Lift 1 1 SECTION 1 SAFETY PRECAUTIONS Machine Inspection Do not operate this machine until the inspections and functional checks have been performed as specified in the Preparation and Inspection section of this manual Do not operate this machine until it has been serviced and maintained according to the maintenance and inspection requirements as specified in the machine s Service and Maintenance Manual Ensure 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 PLAT FORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMIS SION FROM THE MANUFACTURER Do not operate any machine on which the safety or instruction placards or decals are missing or illegible Check the machine for modifications to original com ponents Ensure that any modifications have been approved by J LG Avoid accumulation of debris on platform floor Keep mud oil grease and other slippery substances from footwear and platform deck 13 OPERATION General 1 2 Do not use the machine for any purpose other than positioning personnel their tools and equipment Before operation the user must be familiar with the
19. LOWER qe UPPER BOOM FOOTSWITCH Sem CYLINDER P dd SLAVE CYLINDER TURNTABLE LOWER ND BATTERY CYLINDER FRAME E BOX DRIVE STEER Tm WHEELS WHEELS J 35 135 electric Figure 2 1 Boom Nomenclature 30 35 n35 electric 3120742 J LG Lift 2 3 SECTION 2 PREPARATION AND INSPECTION TELESCOPE CYLINDER UPPER BOOM MASTER CYLINDER 2 4 FOOTSWITCH UPPER SLAVE UPPER LINK CYLINDER UPRIGHT LIFT LOWER CXEINDER UPRIGHT LIFT 0 LOWER CYLINDER LE BOOM LOWER LINK LOWER v LIFT CYLINDER STEER BATTERY WHEELS gt TIE mE 4 DRIVE PLATFORM CONTROL CONSOLE NL PLATFORM p ROTATOR 7 WHEELS Figure 2 2 Boom Nomenclature 40 n45 45electric 9 Check all pin and shaft retaining hardware for secu rity and wear 10 Check Upper Upright cross pins and hydraulic lines for damage wear lubrication leakage and security 11 Check Upper Upright for damage wear lubrication and security 12 Check hydraulic lines mounted on upright for dam age leakage and security 13 Check Upper Boom Lift Cylinder and cross pins and hydraulic lines for damage wear lubrication leak age and security 14 Check Upper Boom pivot pin for damage wear lubrication and security 2 4 J LG Lift 15 Check Upper Boom for damage missing parts and security 16 Check Upper Boom wear pads for damage missing
20. Lifting eyes are provided at the front and rear in the frame slab Each of the four chains or slings used for lifting machine must be adjusted individually so machine remains level when elevated 3120742 SECTION 4 MACHINE OPERATION DO NOT OVERTIGHTEN PLATFORM TIE DOWN MODEL 40 45 electric Figure 4 3 Chassis amp Platform Tie Down All Models 3120742 J LG Lift 4 7 SECTION 4 MACHINE OPERATION 62 9025 91 08521 64 852025 sql 069 11 79 ZS0S SAI 061211 02 9 8 SAI 09201 80 2297 591 00601 By gEELEZ sql OOL S weo4 NOILV LOY 4 1411 06 01 1 seuout 88 18 29 968 e se 211199190ru 511291907 914329120 sulyseyy P epuejs 65016 adAL uonejjelsuj JO 191U92 OL 19915 SIIAON Figure 4 4 Lifting Chart 3120742 J LG Lift 4 8 SECTION 5 OPTIONAL EQUIPMENT SECTION 5 OPTIONAL EQUIPMENT A IMPORTANT WHEN ADDING AN ELECTRICAL OR ELECTRONIC OPTION TO THE MACHINE DO NOT GROUND THE DEVICE TO THE MACHINE CHASSIS AN ELECTRICAL OR ELECTRONIC DEVICE THAT IS GROUNDED TO THE CHASSIS IS SEEN BY THE SEVCON AS A SHORT CIRCUIT AND WILL CAUSE A FAULT CODE TO APPEAR GROUND ALL ELECTRICAL OR EL
21. SUOI IPUOD rer PInIJIIPONN OH pue o pesodxe y ys eqn 1885 einsselg 1943 wom sPumuy ui pesn 104 suonipuoo eseei5 oor DHS eseoJD e1sui Jl uo peseq uoreoriqn OL A35 jo s noy 0021 1olelou Jo s noy 01 llo Y23949 suid jueuie2e dei sBuiusnq Jo 11202 Buiusnq suid 1v 71 Burysng suld suid Bury Bulyeysul 6 d a i 1202 Bulysnqe pulds 1v u usng s lpuias EMITE ee Buueeg rou Figure 2 4 Lubrication C hart 35 n35 electric Sheet 4 of 6 any uo Bnid epis 12 ve aus 1943 ting 2 1 zo 2 qnH eAug 9 9 SINOY 002 pue 5 os 151 Y N 1914 Joye 191 uone1edo Jo sinou 0021 nee ud deo IIO JO sinou 01 llo 32942 51
22. and Specifications section and that any evidence of lack of maintenance malfunction excessive wear damage or modification to the machine be reported immediately to the machine owner or the jobsite supervi sor or Safety manager and that the machine be taken out of service until all discrepancies are corrected The J LG Liftis not intended to be used to lift material other than supplies which personnel in the platform require to do their job Supplies or tools which extend outside the platform are prohibited It must not be used as a forklift crane support for overhead structure or to push or pull another object The J LG Lift is powered using a hydraulic pump and cylin ders for various functions The hydraulic components are controlled by electrically activated hydraulic valves using switches and control levers The speeds of boom func tions are variable from zero to maximum speed depend ing upon the position of the function speed control Functions controlled by toggle switches are either on or off A foot operated switch in the platform must be depressed before any controls will function and provides a means of emergency stop when the operators foot is removed from the footswitch The J LG Lift is a two wheel drive machine with drive power being supplied by an electric motor at each drive wheel Each drive wheel is supplied with an electrically released spring applied brake These brakes are automatically applied any time the Dri
23. er et aaa 6 2 6 5 INCIDENT NOTIFICATION a 6 2 SECTION 7 INSPECTION AND REPAIR LOG LIST OF FIGURES LIST OF FIGURES FIGURE NO TITLE PAGE NO 2 1 Boom Nomenclature 30 35 n35 2 3 2 2 Boom Nomenclature 40 45 45 2 4 2 3 Daily walk around Inspection Sheet 1 073 2 6 2 4 Lubrication Chart 30 electric Sheet 1 076 2 11 2 4 lubrication Chart 30 electric Sheet20f6 2 12 2 4 Lubrication Chart 35 n35 electric Sheet 3016 2 13 2 4 Lubrication Chart 35 n35 electric Sheet40f6 2 14 2 4 Lubrication Chart 40 n40 45 electric Sheet 5016 2 15 2 5 Torque Chart d eh een Uno RR PUN D RE Nd 2 17 3 1 Position of Least Forward Stability 30 electric Sheet10f3 3 3 3 1 Position of Least Forward Stability 35 n35 electric 5 2073 3 4 3 1 Position of Least Forward Stability 40 n40 45 electric Sheet 3of3 3 5 3 2 Position of Least Backward Stability 30 electric Sheet 1073 3 6 3 2 Position of Least Backward Stability 35 n35 electric Sheet2
24. machine using two hands and one foot or two feet and one hand at all times during entry and exit 3120742 Platform to structure transfers at elevated positions are discouraged Where transfer is necessary enter exit through the gate only with the platform within 1 foot 0 3m of a safe and secure structure 100 tie off is also required in this situation utilizing two lanyards One lanyard must be attached to the platform with the second lanyard attached to the structure The lanyard connected to the platform must not be disconnected until such time the transfer to the structure is safe and complete Keep oil mud and slippery substances cleaned from footwear and the platform floor Electrocution Hazards This machine is not insulated and does not provide protection from contact with an electrically charged conductor Maintain safe clearance from electrical lines appara tus or any energized exposed or insulated parts in accordance with the Minimum Safe Approach Distance MSAD as specified in Table 1 1 Allow for machine movement and electrical line swaying J LG Lift 1 3 SECTION 1 SAFETY PRECAUTIONS Table 1 1 Minimum Safe Approach Distances M S A D MINIMUM SAFE APPROACH Voltage Range Phase to Phase DISTANCE in Feet Meters 010 300V AVOID CONTACT Over 300V to 50 KV 10 3 Over 50KV to 200 KV 15 5 Over 200 to 350 20 6 Over 350 to 500 KV 25 8
25. only to the 35 and n35 electric Check Upper Boom wear pads for damage missing parts and security Check Upper Boom telescope cylinder cross pins and hydraulic lines for damage wear lubrication leakage and security Check Platform Leveling Cylinder cross pins and hydraulic lines for damage wear lubrication leak age and security 40 n40 45 electric Boom See Figure 2 2 1 J LG Lift Check Lower Boom and leveling link for damage missing parts and security Check all pin and shaft retaining hardware for secu rity and wear Check hydraulic lines and electrical cable for dam age missing parts and security Check limit switch connections and plunger for cor rosion and security Check Lower Upright cross pins and hydraulic lines for damage wear lubrication leakage and security Check Lower Upright for damage wear lubrication and security Check hydraulic lines mounted on upright for dam age leakage and security Check Mid Boom pivot shaft and lift cylinder for damage missing parts and security 3120742 SECTION 2 PREPARATION AND INSPECTION PLATFORM PLATFORM UPPER CONTROL LIFT CONSOLE CYLINDER LOWER FOOTSWITCH LIFT UPRIGHT CYLINDER TURNTABLE PLATFORM TELESCOPE CONTROL lt CONSOLE CYLINDER lt PLATFORM MASTER BOOM CYLINDER ROTATOR in fio a From Ali as UPRIGHT v dii LOWER
26. time Battery packs are interchangeable and include applicable cables and connectors for plug in use 5 8 PLATFORM LIGHTS Platform lights may be installed on the machine platform rails to provide more lighting for the operator 5 9 CONTROL CONSOLE COVER The control console cover is a one piece clear acrylic cover which attaches to the platform rails over the control console The cover when in position will protect the entire platform control console and the control handle on the right side of the console 5 10 CYLINDER BELLOWS A one piece accordion shaped rubber bellows may be attached to the rod end of the cylinder barrel and the cyl inder rod as close to the rod attach bushing as possible The bellows affords protection to the cylinder rod in either the extended or retracted position The bellows are installed on the lift cylinders slave cylinder master cylin der and steer cylinder 5 11 STEEL HOOD COVERS 30 ELECTRIC The steel covers are positioned over the hood and battery box lids to protect the Fiberglass hood and battery box lids from damage 5 12 WORK PLATFORM 35 40 N40 45 ELECTRIC These machines are available with a 26 in x 60 in 66 x1 52M size platform 5 13 SIMULTANEOUS DRIVE LIFT STEER N40 40 45 ELECTRIC Provides for machines with multifunction performance simultaneously J LG Lift 5 1 SECTION 5 OPTIONAL EQUIPMENT ITHIS PAGE LEFT BLANK INTENTIONALLY 5
27. total power failure to lower the upper and lower booms using gravity To operate the manual descent system proceed as follows 1 Locate manual descent knob on main valve and turn counterclockwise Install handle into manual descent pump and lower the Mid and Lower Booms by pumping the handle until they are completely lowered 2 Turn manual descent knob clockwise and lower the Upper Boom by pumping the handle until it is completely lowered Return manual descent knob to center position and stow handle in bracket provided 3120742 J LG Lift 6 1 SECTION 6 EMERGENCY PROCEDURES Manual Swing Override 30 35 40 n40 45 electric The manual swing override is used to manually swing boom and turntable assembly in the event of a total power failure when the platform is positioned over a structure or obstacle To operate the manual swing override proceed as follows 1 Using a 7 8 inch socket and ratchet wrench locate nut on swing worm gear on left side of machine Install wrench on nut and ratchet in the direction desired 6 4 EMERGENCY OPERATION Use of Ground Controls 1 Know how to use Ground Controls in an emergency situation Ground personnel must be thoroughly familiar with the machine operating characteristics and the ground control functions Training should include operation of the machine review and understanding of this section and hands on operation of the con trols in simulated emergencies
28. visible damage emer gency stop switch functions properly placards secure and legible Manual Descent Valve 40 n40 45 electric No visible damage no evidence of leakage Cowling and Latches 40 n40 45 electric All cowling doors and latches in working condi tion properly secured no loose or missing parts Battery Compartment Batteries have proper electrolyte level cables tight no visible dam age or corrosion Control Valve 40 n40 45 electric No loose or missing parts evidence of leakage unsup ported wires or hoses damaged or broken wires Swing Motor and Worm Gear No loose or missing hardware no visible damage evi dence of proper lubrication Drive Wheel Tire Assembly Left Rear Properly secured no loose or missing wheel bolts no visible damage Drive Motor Brake and Hub Left Rear No visi ble damage no evidence of leakage Frame No visible damage no loose or miss ing hardware top and underside Cowling and Latches All cowling doors and latches in working condition properly secured no loose or missing parts Platform Pivot Pins Properly secured evi dence of proper lubrication Platform Gate Latch and Hinges in working condition properly secured no loose or miss ing parts Figure 2 3 Daily Walk Around Inspection Sheet 3 of 3 J LG Lift 3120742 SECTION 2 PREPARATION AND INSPECTION 2 5 DAILY FUNCTIONAL CHECK A functional check of all syste
29. 2 J LG Lift 3120742 SECTION 6 EMERGENCY PROCEDURES SECTION 6 EMERGENCY PROCEDURES 6 1 GENERAL This section provides information on the procedures to be followed and on the systems and controls to be used in the event an emergency situation is encountered during machine operation Prior to operation of the machine and periodically thereafter the entire operating manual includ ing this section should be reviewed by all personnel whose responsibilities include any work or contact with the machine 6 2 EMERGENCY TOWING PROCEDURES Towing this machine is prohibited However provisions for moving the machine have been incorporated The follow ing procedures are to be used ONLY for emergency movement to a suitable maintenance area 1 Chock wheels securely 2 Engage the mechanical release on both drive brakes by loosening completely reversing and tightening the three nuts on each brake 3 Connect suitable equipment remove chocks and move machine After moving machine complete the following procedure 3 Position machine on a firm level surface 4 Chock wheels securely 5 Disengage the mechanical release on both drive brakes by loosening completely reversing and tightening the three nuts on each brake 6 Remove chocks from wheels as desired 6 3 EMERGENCY CONTROLS AND THEIR LOCATIONS Emergency Stop Switch There is one of these red mushroom shaped switches at either Ground Controls or
30. 2 1 2 3 DELIVERY AND FREQUENT 2 1 2 4 Daily Walk Around 2 5 2 5 dAIEY FUNCTIONAL GHEC Keone ue CR 2 9 2 6 TORQUE REQUIREMENTS Zur oo te eek eee dee DDR E ne 2 9 2 7 BATTERY MAINTENANCE AND 2 10 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS 3 1 GENERAL yuya ia a i uns Be dee Saywa 3 1 3 2 PERSONNEL TRAININGS a alls IB hid Pied ace Bre Dan 3 1 3 3 OPERATING CHARACTERISTICS AND 5 3 2 3 4 CONTROLS AND 5 3 2 SECTION 4 MACHINE OPERATION 4 1 DESCRIPTION tetra e c f m at din Sasa eq 4 1 4 2 GENERAL ss a LR ROS Dee bates MEN eyed RR RETE 4 1 4 3 MOTOR OPERATION z s th t tak tae a wad oC T 4 1 4 4 aan msn Lean 4 2 4 5 STEERING e os uestem nen ee nen 4 2 4 6 PLATEORM z z CUM 4 3 4 7 z Petia bea og SI SS S eee age ae EE 4 3 4 8 BOOM FUNCTION SPEEDS eed ee eee at kad dace desee epa ane 4 4 4 9 SHUT DOWN AND PARK III um Pa Ru ER Ur re ra acia 4 4 4 10 MACHINE TIE
31. 20742 J LG Lift 2 7 SECTION 2 PREPARATION AND INSPECTION 2 8 Ground Controls 35 n35 electric Switches opera ble no visible damage emergency stop switch functions properly placards secure and legible Battery Charger No damage properly secured Valve No loose or missing parts evidence of leakage unsupported wires or hoses dam aged or broken wires Boom Upright No visible damage All pins properly secured Upright in vertical position If Upright does not rest on stop with machine in the stowed position this indicates upright is out of plumb See Section 2 20 in service manual 3120743 for Boom Synchro nizing procedure Steer Wheel Tire Assembly Right Front Prop erly secured no loose or missing wheel bolts no visible damage Counterweight No loose or missing hardware properly secured Steer Cylinder Properly secured no visible damage or signs of leakage evidence of proper lubrication Oscillating axle 35 n35 40 n40 45 electric No loose or missing hardware no visible dam age evidence of proper lubrication Hydraulic Oil Filter Housing 30 electric Secure no visible signs of damage or leakage Tie Rod Ends and Steering Spindles No loose or missing parts no visible damage Tie rod end stubs locked Drive Wheel Tire Assembly Left Rear Properly secured no loose or missing wheel bolts no visible damage Ground Controls 40 n40 45 electric Switches operable no
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33. 85 uey Kun eseei5 L 44291 Aeids 1885 usdO 90 uey jeAJojul Pete En hum WR ND L NOILVOItign1 SUH 0021 SHH 00 SHH 051 HV3A Z SHLNOW 9 SHLNOW SLNIOd B Ez SLNAWWOS SunoH BENT SIN3NOdINOD 3120742 J LG Lift 2 14 SECTION 2 PREPARATION AND INSPECTION 3120742 CAUTION DO NOT OVER GREASE BEARINGS OVER GREASING WILL RESULT IN BLOWING OUTER SEAL IN HOUSING Figure 2 4 Lubrication Chart 40 n40 45 electric Sheet 5 of 6 J LG Lift 2 15 SECTION 2 PREPARATION AND INSPECTION eids INSZE SellIqoN eqn uedo 90 se 1o esoding niniw esee15 Depe15 JuesugnT 3 1 ulu S 11 ver PInIJIIPON onneip H OH San 189 55 19d3 esea1t 9 SHS 58 SLNVOIYENT OL A35 jo s noy 0021 Aano JO s noy 0 i n yoouD suid Buyyeysul q i 1202 suid Bury jueuieoe dei q i 1202 any uo 1943 fing 2 1 zozr nareH 6nia 1 Sinou 00 pue sinou 05 151 V
34. ACHINE UNTIL ALL MAL FUNCTIONS HAVE BEEN CORRECTED USE OF A MALFUNC TIONING MACHINE IS A SAFETY VIOLATION TO AVOID POSSIBLE INJ URY BE SURE MACHINE POWER IS OFF DURING WALK AROUND INSPECTION NOTE Do not overlook visual inspection of chassis under side Checking this area may result in discovery of conditions which could cause extensive machine damage The following inspection steps are for all 30 35 n35 40 n40 45 electric models except where noted Platform Assembly No loose or missing parts no visible damage Platform mounting pins secure Footswitch in good working order not modified disabled or blocked Platform Control Console Switches and con trol lever properly secured no loose or missing parts no visible damage placards secure and legible control lever and switches return to neutral control lever lock functions properly emergency stop switch functions properly control markings legible Fly Boom Nose and Platform Support Ensure fly boom nose and platform support are free of debris obstructions etc Rotator Motor and Rotator Cylinder 35 n35 40 n40 45 electric No visible damage motor and cylinder pins secure hydraulic hoses undamaged not leaking Slave Cylinder 35 n35 40 n40 45 electric No visible damage pivot pins secure hydraulic hoses undamaged not leaking Boom Sections Lift Cylinders and Master Cylin der No visible damage pivot pins secure hydraulic hoses undamaged not l
35. CAUTIONS Keep the chassis of the machine a minimum distance of 2 ft 0 6m from holes bumps drop offs obstruc tions debris concealed holes and other potential hazards at the ground level Never push or pull the machine or other objects by telescoping or retracting the boom Never attempt to use the machine as a crane Do not tie off machine to any adjacent structure Never attach wire cable or any similar items to platform Do not operate the machine when wind conditions exceed 30 mph 12 5 m s Do not cover the platform sides or carry large surface area items in the platform when operating outdoors The addition of such items increases the exposed wind area of the machine Do not increase the platform size with unauthorized deck extensions or attachments Ifboom assembly or platform is caught so that one or more wheels are off the ground all persons must be removed before attempting to free the machine Use cranes forklift trucks or other appropriate equipment to stabilize machine and remove personnel Crushing and Collision Hazards 3120742 Approved head gear must be worn by all operating and ground personnel Keep hands and limbs away from boom assembly dur ing operation Watch for obstructions around machine and overhead when driving Check clearances above on sides and bottom of platform when lifting or lowering platform t During operation keep all body parts inside platform railing
36. E FIELD INSPECTION AND MAINTENANCE SAFETY IS THE RESPONSIBILITY OF THE OWNER OPERATOR 2 22 PREPARATION FOR USE Before a new machine is put into operation it must be carefully inspected for any evidence of damage resulting from shipment and inspected periodically thereafter as outlined in Delivery and Frequent Inspection see section 2 3 During initial start up and run the unit should be thoroughly checked for hydraulic leaks A check of all components should be made to assure their security All preparation necessary to place the machine in opera tion readiness status is the responsibility of management personnel Preparation requires good common sense i e lift works smoothly and brakes operate properly cou pled with a series of visual inspections The mandatory requirements are given in the Daily Walk Around Inspec tion see section 2 4 It should be assured that the items appearing in the Deliv ery and Frequent Inspection and Functional Check are complied with prior to putting the machine into service 2 33 DELIVERY AND FREQUENT INSPECTION NOTE This machine requires periodic safety and mainte nance inspections by an authorized JLG Dealer A decal located on the frame provides a place to record stamp inspection dates Check decal and notify dealer if inspection is overdue NOTE ANSI SIA 92 5 1992 also requires an annual inspec tion to be performed See annual machine inspection report CGF330 The follow
37. E FUNCTION WILL NOT OPERATE The motor becomes activated and operates the desired function when the Emergency Stop switch is pulled out on the Platform Ground select switch is in the appropriate position and the Footswitch is depressed A CAUTION IF A MOTOR MALFUNCTION NECESSITATES UNSCHEDULED SHUTDOWN DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANY OPERATION A IMPORTANT ALWAYS POSITION EMERGENCY STOP SWITCH TO THE OFF POSITION PUSHED IN WHEN MACHINE IS NOT IN USE 44 TRAVELING DRIVING NOTE When lower boom is raised above horizontal or the upper boom is raised approximately 16 inches 40 64 cm above boom rest the high drive function will automatically be in low drive A IMPORTANT IF THE MACHINE IS OPERATED AT A VERY SLOW SPEED OR STALLED WHEN CLIMBING A GRADE OF 20 OR GREATER DRIVE FUNCTION WILL STOP REMOVE FOOT FROM FOOT SWITCH AND DEPRESS FOOTSWITCH TO RESET 4 2 J LG Lift A WARNING DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ONA SMOOTH FIRM AND LEVEL SURFACE TO AVOID LOSS OF TRAVEL CONTROL OR TIP OVER ON GRADES AND SIDE SLOPES DO NOT DRIVE MACHINE ON GRADES OR SIDE SLOPES EXCEEDING THOSE SPECIFIED ON WARNING PLACARD AT PLATFORM AVOID ANY TERRAIN FEATURES WHICH COULD CAUSE THE MACHINE TO TIPOVER USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN DRIVING WITH PLATFORM ELEVATED AND WHEN DRIVING WITH ANY PART OF MACHINE WITHIN 6 FEET OF ANY OBSTRUCTION
38. ECTRONIC DEVICES TO THE APPROPRIATE TERMINAL OF THE SEVCON CONTROLLER 5 1 MOTION ALARM A motion alarm horn provides an audible warning when the platform controls are selected at the PLATFORM GROUND SELECT switch the EMERGENCY STOP switch is ON and the footswitch is depressed The alarm warns personnel in the jobsite area to avoid the operating machine 5 2 FOAM FILLED TIRES Eliminates flats by filling tires with polyurethane foam For use where sharp objects are frequently encountered on operating surface of jobsite 5 3 NON MARKING TIRES For indoor use these tires are made from a special com pound that unlike regular tires will not leave black skid marks on floors and other surfaces 5 4 ROTATING BEACON An amber rotating beacon may be installed on the machine hood and is activated whenever platform con trols are selected at the PLATFORM GROUND SELECT switch When activated the light provides a visual warning of the machine s operation 5 5 TILT ALARM An audible warning horn that will sound when the machine is out of level five degrees in any direction with the boom raised above horizontal 5 6 WHEEL COVERS Provide protection for wheels and wheel bearings from dirt grease mud rocks etc 3120742 5 7 BATTERY PACKS Spare battery packs are available to enable the operator to remove battery packs for charging and replace them with fresh battery packs to keep machine operating with minimal down
39. H EMERGENCY STOP SWITCH SWING CONTROL SWITCH 35 n35 40 n40 45 electric Figure 3 4 3120742 ROTATOR CONTROL SWITCH CIRCUIT BREAKERS JLG Lift DRIVE STEER CONTROLLER FUNCTION SPEED CONTROL SWITCH LOWER BOOM LIFT CONTROL SWITCH PLATFORM LEVELING CONTROL SWITCH DRIVE STEER CONTROLLER LOWER BOOM LIFT CONTROL SWITCH Platform Control Console SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS Table 3 1 Control Panel Symbols Sheet 1 of 3 BATTERY EXPLOSION CHARGING HAZARD DADA XUL FACTORY CAUTION 2 772 722222225222222222222 2222222222 MUTU AL ALERT CHASSIS OUT OF LEVEL CIRCUIT FUNCTION BREAKER CONTROL GROUND CONTROL HAND CRUSHING HYDRAULIC OIL HYDRAULIC ELECTRICAL OIL LEVEL HAZARD HYDRAULIC OIL LEVEL 3 14 J LG Lift 3120742 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS Control Panel Symbols Sheet 2 of 3 N N ON MBO POWER NO LIFT EMERGENCY STOP PLATFORM CONTROL x IMPORTANT LOWER BOOM PLATFORM LIFT LEVEL Fi 30 electric 35 n35 40 n40 45 electric LOWER BOOM PLATFORM LIFT ROTATOR 35 n35 40 n40 45 electric 35 n35 40 n40 45 electric MANUAL SLOW A MANUAL DESCENT STEER MANUAL DESCENT PUMP SWING W os HANDLE
40. IN V N V N Jojje 1u ui uonejedo s noy 0021 Jo s noy 01 429u5 52916 910jeq uo pue Buisnou wom shu eseoJD J 5 Buiusnq lpuids gar E se 0 Puneo iu utels s 8 SIED 0 peseo4oul serouenboej suonipuoo sjueuluoJiAue e I1sou pesodxe 1o pue 4 Y ys ninw ui pesn 104 suonipuoo jeuuou uo s BAJejul uomeoriqn Bulysng suld Buiusng se puids 14911 o1nespAH des pinid Figure 2 4 Lubrication Chart 40 n40 45 electric Sheet 6 of 6 ue u SUH 0051 SHH 009 SHH 008 SHH 051 HYJAL SHLNOW 9 SHLNOW SunoH ALIOVdV o SLNIOd 3801 UM3SW DN 3120742 J LG Lift 2 16 SECTION 2 PREPARATION AND INSPECTION
41. OUTER SEAL IN HOUSING Figure 2 4 Lubrication Chart 30 electric Sheet 1 of 6 J LG Lift 2 11 SECTION 2 PREPARATION AND INSPECTION Ae ds ONSZE SeHIGOW eqn1 1809 uedo 90 esodinq niniw ese 1S Lpz jue uqn 7 uniulr1 11 ber PINIHIPON 189 einsseJd 1943 esea15 Buueeg oor DHS ulll qolN suid Bullle su old sBuiusnq q l 1205 suid Bury shulysng qr 1202 5 OL A33 1 Buiusnq suid Jueujeo2e de4 Buiusnq ejpuids yy Bulseaib 910Jeq uo s e 16 pue Buisnou wom shui eseelb jeysul JI 15 5915 5 10 li sou p sodx ninw ui p sn 104 suonipuoo Japun uo p seq w w ae emm Se qnu uo Bnid epis 191Je 1 u1 sinou 002 pue sinou 05 15 1ueuieje uonejedo sinou 0021
42. Platform Controls When depressed it will immediately stop all functions at that sta tion and shut down the machine A WARNING CHECK DAILY TO MAKE SURE EMERGENCY STOP SWITCH IS FUNCTIONING AND THAT CONTROL INSTRUCTIONS ARE IN PLACE AND LEGIBLE Ground Control Station The Ground Control Station is located on the Right 30 35 n35 electric Left 40 n40 45 electric side of the turntable The controls on this panel provide the means for overriding the platform controls and for controlling boom swing and lift from the ground The PLATFORM GROUND SELECT SWITCH is a self centering switch Hold SELECT SWITCH in GROUND position and operate the desired function switch Manual Descent System 30 35 n35 electric The manual descent system is used in the event of total power failure to lower the upper and lower booms using gravity To operate the manual descent system proceed as follows 1 Open needle valve on lower boom lift cylinder counterclockwise and allow boom to lower until it stops Control boom speed by opening and closing valve 2 Close needle valve clockwise to resume normal operation 3 Open needle valve on upper boom lift cylinder counterclockwise and allow boom to lower until it stops Control boom speed by opening and closing valve 4 Close needle valve clockwise to resume normal operation Manual Descent System 40 n40 45 electric The manual descent system is used in the event of
43. Platform Ground controls should not operate 2 6 TORQUE REQUIREMENTS The Torque Chart Figure 2 5 consists of standard torque values based on bolt diameter and grade also specifying dry wet and loctite torque values in accordance with rec ommended shop practices This chart is provided as an aid to the operator in the event he she notices a condition that requires prompt attention during the walk around inspection or during operation until the proper service personnel can be notified The Service and Maintenance section provides specific torque values and periodic main tenance procedures with a listing of individual compo nents Utilizing this torque chart in conjunction with preventive maintenance section will enhance safety reli ability and performance of the machine J LG Lift 2 9 SECTION 2 PREPARATION AND INSPECTION 2 7 BATTERY MAINTENANCE AND CHARGING A WARNING TO AVOID URY FROM AN EXPLOSION DO NOT SMOKE OR ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVIC ING ALWAYS WEAR EYE AND HAND PROTECTION WHEN SER VICING BATTERIES Battery Maintenance Quarterly 1 Open battery compartment cover to allow access to battery terminals and vent caps CAUTION WHEN ADDING WATER TO BATTERIES ADD WATER UNTIL ELECTROLYTE COVERS PLATES DO NOT CHARGE BATTERIES UNLESS ELEC TROLYTE COVERS THE PLATES NOTE When adding distilled water to batteries non metallic containers and or funnels must be used
44. SING BOOM TRAVELING WITH BOOM BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE SLOPES SPECIFIED ON WARNING PLAC ARD AT PLATFORM TO AVOID SERIOUS INJ URY DO NOT OPERATE MACHINERY IF ANY CONTROL LEVER OR TOGGLE SWITCH CONTROLLING J LG Lift 4 3 SECTION 4 MACHINE OPERATION PLATFORM MOVEMENT DOES NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED TO AVOID A COLLISION AND INJ URY IF 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 Swinging the Boom Depress footswitch to swing boom with footswitch acti vated position SWING control switch to RIGHT or LEFT for direction desired A IMPORTANT WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TO CLEAR SURROUNDING WALLS PAR TITIONS AND EQUIPMENT NOTE Models 30 35 n35 electric do not have a Mid Boom Raising and Lowering the Lower and Mid Boom Depress footswitch to raise or lower the Lower and Mid Boom with footswitch activated position Lower Boom Lift switch to UP or DOWN as desired Raising and Lowering the Upper Boom Depress footswitch to raise or lower the Upper Boom with footswitch activated position Upper Boom Lift switch to UP or DOWN until desired height is reached 4 8 BOOM FUNCTION SPEEDS The Function Speed Control affects the speed of boom functions LIFT TELESCOPE 35 n35 40 n40 45 electric and SWING
45. ached to a designated attach point on the plat form at all times 5 Sufficient knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunction 6 The safest means to operate the machine where overhead obstructions other moving equipment and obstacles depressions holes dropoffs etc on the supporting surface exist 7 Meansto avoid the hazards of unprotected electrical conductors 8 Any other requirements of a specific job 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 a machine in congested work locations Operator Responsibility The operator must be instructed that he she has the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site and to request further informa tion from his her supervisor or an authorized J LG Distribu tor before proceeding NOTE Manufacturer or Distributor will provide qualified per sons for training assistance with first unit s delivered and thereafter as requested by the user or his her personnel 3120742 J LG Lift 3 1 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS 3 3 OPERATING CHARACTERISTICS AND LIMITATIONS General A thorough knowledge of the operating cha
46. all the way toward the boom and tele scope fly boom section out until rotator support rests on a 6 x 6 15cm x 15cm wooden block Secure platform support to truck or trailer using a suitable tie down strap as shown in figure 4 3 DO NOT OVERTIGHTEN OR DAMAGE WILL OCCUR TO BOOM OR PLATFORM Platform Boom Tie Down Model 40electric 45electric See Figure 4 3 Tilt platform forward all the way toward the boom and tele scope fly boom section out until rotator support rests on truck deck Secure platform support to truck or trailer using a suitable tie down strap as shown in figure 4 3 DO NOT OVERTIGHTEN OR DAMAGE WILL OCCUR TO BOOM OR PLATFORM A CAUTION FAILURE TO TIE DOWN PLATFORM AND BOOM AS SHOWN IN FIGURE 4 3 MAY ALLOW PLATFORM TO ELEVATE DURING TRANSPORTING 4 6 J LG Lift 4 11 MACHINE LIFTING The four lugs on the machine frame are intended for lifting the machine When lifting the machine attach a lifting chain to each of the four lugs ensuring that the chains are adjusted to keep the machine level NOTE Crane and lifting devices chains slings etc must be capable of handling at least 30 ELECTRIC 5 325 LB 2415 KG 35 ELECTRIC 10 000 LBS 4536 KG N35 ELECTRIC 11 270 LB 5112 KG 40 ELECTRIC 11 350 LB 5148 KG N40 ELECTRIC 12 250 LB 5556 KG 45 ELECTRIC 12 320 LBS 5588 KG A IMPORTANT THE ABOVE IS A MINIMUM WEIGHT CHECK WEIGHT OF UNIT PRIOR TO LIFTING NOTE
47. as they pertain to your utilization and application of the machine Workplace Inspection Precautions to avoid all hazards in the work area must be taken by the user before operation of the machine Do notoperate or raise the platform from a position on trucks trailers railway cars floating vessels scaffolds or other equipment unless the application is approved in writing by J LG FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE PROP ERTY DAMAGE PERSONAL INJ URY OR DEATH Before operation check work area for overhead haz ards such as electric lines bridge cranes and other potential overhead obstructions 1 2 PRE OPERATION Check floor surfaces for holes bumps drop offs obstructions debris concealed holes and other Operator Training and Knowledge sns nas The Operators and Safety Manual must be read and understood entirety before operating the machine For clarification questions or additional information regarding any portions of this manual contact J LG Industries Inc 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 Check the work area for hazardous locations Do not operate the machine in hazardous environments unless approved for that purpose by J LG Do not operate the machine when wind conditions exceed 30 mph 12
48. ce Tannochside Park Uddingston G71 5PH Scotland Phone 44 1 698 811005 Fax 44 1 698 811055 JLG Industries UK Unit 12 Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industries Pty Ltd Unit 1 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone 27 11 453 1334 Fax 27 11 453 1342 JLG Deutschland GmbH Max Planck Strasse 21 D 27721 Ritterhude Ihlpohl Bei Bremen Germany Phone 49 421 693 500 Fax 49 421 693 5035 JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47 6682 2001 Plataformas Elevadoras JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755Castellbisbal Spain Phone 34 93 77 24700 Fax 34 93 77 11762 JLG Industries Italia Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 02 9359 5210 Fax 39 02 9359 5845 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 200 JLG Industries Sweden Enkopingsvagen 150 Box 704 SE 175 27 Jarfalla Sweden Phone 46 8 506 59500 Fax 46 8 506 59534
49. ct the machine before the start of each workday It is recommended that each operator inspect the machine before operation even if the machine has already been put into service under another operator This Daily Walk Around Inspection is the preferred method of inspection These checks are also to be performed after maintenance has been performed on the machine In addition to the Daily Walk Around Inspection be sure to include the following as part of the daily inspection 1 Overall cleanliness Check all standing surfaces for oil fuel and hydrau lic oil spillage and foreign objects Ensure overall cleanliness 2 Placards Keep all information and operating placards clean and unobstructed Cover when spray painting or shot blasting to protect legibility 3 Operator s and Safety Manual Ensure a copy of this manual and the ANSI A92 5 1992 Responsibilities are enclosed in the manual storage box 3120742 J LG Lift 4 Machine Log Ensure a machine operating record or log is kept check to see that it is current and that no entries have been left uncleared leaving machine in an unsafe condition for operation 5 Start each day with a full fuel tank A WARNING TO AVOID IN URY DO NOT OPERATE A MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED USE OF A MALFUNC TIONING MACHINE IS A SAFETY VIOLATION TO AVOID POSSIBLE URY BE SURE MACHINE POWER IS OFF DURING WALK AROUND INSPECTION NOTE Ch
50. discharged 2 Charge batteries in accordance with the following procedure a Open battery compartment and battery charger compartment covers A WARNING WHEN BATTERY CHARGER IS TO BE USED CHARGING HAR NESS MUST BE PLUGGED INTO A GROUNDED 110 VOLT RECEP TACLE IF RECEPTACLE IS NOT GROUNDED AND A MALFUNCTION SHOULD OCCUR THE MACHINE COULD CAUSE SERIOUS ELECTRICAL SHOCK b Remove charging harness cable and connect to a 110 volt receptacle c Allow batteries to charge until ammeter on charger if equipped is reading zero 0 Normal charging time is 8 10 hours NOTE When batteries are completely charged disconnect charging harness cable from receptacle Store charging harness cable d Ensure battery cables are positioned and are not pinched Close and secure all compartment doors 3 The battery packs on each side of the frame are designed to be easily removed so that a machine can have two sets of them in order to keep the machine functioning longer Disconnect the cable quick connects and remove the two clevis pins on top of the frame Now using the forklift pockets under the packs have a forklift move them to a place where they can be recharged The new battery packs can be installed by reversing the above pro cedure NOTE Battery packs are interchangeable 3120742 SECTION 2 PREPARATION AND INSPECTION 3120742 CAUTION DO NOT OVER GREASE BEARINGS OVER GREASING WILL RESULT iN BLOWING
51. eaking Telescope Cylinder and Power Track 35 n35 40 n40 45 electric No visible damage no loose or missing hardware Limit Switches Switches operable no visible damage Drive Motor Brake and Hub Right Rear No visible damage no evidence of leakage Drive Wheel Tire Assembly Right Rear Prop erly secured no loose or missing wheel bolts no visible damage Hydraulic Oil Filter Housing 40 n40 45 electric Secure no visible signs of damage or leak age Hydraulic Pump and Reservoir Properly secured no visible damage or hydraulic leaks Recommended hydraulic fluid level on dipstick system shut down boom in stowed position Breather cap dipstick secure and working Turntable Bearing No loose or missing hard ware no visible damage evidence of proper lubrication No loose bolts or looseness between bearing and structure Battery Compartment Right Side Batteries have proper electrolyte level cables tight no visible damage or corrosion Cowling and Latches All cowling doors and latches in working condition properly secured no loose or missing parts Ground Controls 30 electric Switches opera ble no visible damage emergency stop switch functions properly placards secure and legi ble Control Valve 30 35 n35 electric No loose or missing parts evidence of leakage unsup ported wires or hoses damaged or broken wires Figure 2 3 Daily walk Around Inspection Sheet 2 of 3 31
52. eck boom limit switches on upright for proper operation and security both visually and manually The lower switch cuts out drive speed when the lower boom is above horizontal The upper switch cuts out drive speed when the upper boom is above horizontal Only creep drive speed will continue to function 6 Check platform footswitch for proper operation Switch must be released to start engine and depressed to operate machine 7 Check that drive brakes hold when machine is driven up a grade not greater than specified on the serial number placard and stopped NOTE 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 8 Assure that all items requiring lubrication are ser viced Refer to Lubrication Chart Figure 2 3 for spe cific requirements 2 5 SECTION 2 PREPARATION AND INSPECTION Figure 2 3 Daily walk around Inspection Sheet 1 of 3 2 6 J LG Lift 3120742 SECTION 2 PREPARATION AND INSPECTION GENERAL BEGIN YOUR WALK AROUND INSPECTION AT ITEM 1 AS NOTED ON THE DIAGRAM CONTINUE TO YOUR RIGHT COUNTER CLOCKWISE VIEWED FROM THE TOP CHECKING EACH ITEM IN SEQUENCE FOR THE CONDITIONS LISTED IN THE FOLLOWING CHECKLIST A WARNING TO AVOID IN URY DO NOT OPERATE M
53. ees Check for smooth motion 6 With the aid of an assistant to monitor the CHASSIS OUT OF LEVEL indicator light on the platform con sole manually activate the indicator light by com pressing one of the three tilt indicator mounting springs If the light does not illuminate shut down machine and contact a qualified service technician before continuing operation 7 Check that platform self leveling system functions properly during raising and lowering of boom 3120742 8 On models 35 n35 40 n40 45 electric check rota tor for smooth operation and assure platform will rotate 75 degrees in both directions from centerline of boom 9 Drive forward and reverse check for proper opera tion 10 Steer left and right check for proper operation 11 Footswitch A WARNING FOOTSWITCH MUST BE ADJ USTED SO THAT FUNCTIONS WILL OPERATE WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF TRAVEL IF SWITCH OPERATES WITHIN LAST 1 4 6 MM OF TRAVEL TOP OR BOTTOM IT SHOULD BE ADJ USTED A IMPORTANT FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNCTION CONTROL OTHERWISE THE FUNCTION WILL NOT WORK With footswitch depressed operate LIFT and hold control Remove foot from footswitch motion should stop If it does not shut down machine and contact a qualified service technician 12 Holding the GROUND PLATFORM SELECT switch to GROUND Platform controls should not operate 13 Place GROUND PLATFORM SELECT switch to OFF
54. ent with appropriate safety props blocking or overhead supports Always relieve hydraulic pressure from all hydraulic cir cuits before loosening or removing hydraulic compo nents Always disconnect batteries when servicing electrical components or when performing welding on the machine Shut down the engine if equipped while fuel tanks are being filled Ensure replacement parts or components are identical or equivalent to original parts or components e Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position Ensure adequate support is provided when raising components of the machine 1 6 Remove all rings watches and jewelry when perform ing any maintenance Do not wear loose fitting cloth ing or long hair unrestrained which may become caught or entangled in equipment Use only clean approved non flammable cleaning sol vents Never alter remove or substitute any items such as counterweights tires batteries platforms or other items that may reduce or affect the overall weight or stability of the machine Reference the Service and Maintenance Manual for the weights of critical stability items A WARNING MODIFICATION OR ALTERATION OF AN AERIAL WORK PLAT FORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMIS SION FROM THE MANUFACTURER Battery Hazards Always disconnect batteries when servicing electrical components o
55. for damage leak age and security 8 Check pump motor and accessories for damage loose or missing parts leakage and security Check electrical connections for corrosion and tightness and wiring for insulation damage Check hydraulic filter for condition of element Replace as required 9 Check hydraulic reservoir and hydraulic lines for damage leakage and security 3120742 J LG Lift 2 1 SECTION 2 PREPARATION AND INSPECTION 10 Check batteries for damage loose or missing vent caps electrical connections for tightness and evi dence of corrosion and electrolyte level Add only clean distilled water to battery after it has been charged Turntable 11 12 13 14 NOTE Check turntable for damage loose or missing parts and security Check lift cylinders and hydraulic lines for damage leakage and security Check swing drive motor for damage loose or missing parts hydraulic lines and component housings for evi dence of leakage worm gear for proper mesh with swing gear Check swing bearing for damage wear lubrication and loose or missing bearing bolts Check valves and hydraulic lines for damage leak age security and electrical connections for tightness and evidence of corrosion Check ground controls for damage loose or miss ing parts security electrical connections for tight ness and evidence of corrosion and wiring for insulation damage Assure that all switches function p
56. ift 3120742 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS Platform Control Station See Figure 3 4 1 Footswitch A safety feature the footswitch must be depressed before boom drive or steer functions will operate WARNING TO AVOID SERIOUS INJ URY DO NOT REMOVE MODIFY OR DIS ABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS A IMPORTANT FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNCTION CONTROL OTHERWISE THE FUNCTION WILL NOT OPERATE A WARNING FOOTSWITCH MUST BE ADJ USTED SO THAT FUNCTIONS WILL OPERATE WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF TRAVEL IF SWITCH OPERATES WITHIN LAST 1 4 OF TRAVEL TOP OR BOTTOM IT SHOULD BE ADJ USTED 2 Power Emergency Stop A two position red mushroom shaped switch fur nishes power to PLATFORM Controls when pulled out on When pushed in off power is shut off to the platform functions 3 Lower Boom Lift Provides for raising and lowering of Lower and Mid Boom 40 n40 45 electric when positioned to UP or DOWN 4 Upper Boom Lift Provides for raising and lowering of Upper Boom when positioned to UP or DOWN 5 Telescope Control 35 n35 40 n40 45 electric The TELESCOPE control switch affords extension and retraction ofthe main boom when positioned to IN or OUT 3120742 6 Swing The SWING control switch provides 360 degrees non continuous turntable rotation To activate SWING position switch to LEFT or RIGHT
57. ing checklist provides a systematic inspection to assist in detecting defective damaged or improperly installed parts The checklist denotes the items to be inspected and conditions to examine Frequent inspection shall be performed every 3 months or 150 hours whichever come first or more often when required by environment severity and frequency of usage This inspection checklist is also applicable and must be followed for all machines that have been in storage or for all machines that have been exposed to harsh or chang ing climates These checks are also to be performed after maintenance has been performed on the machine Chassis 1 Check front tires and wheel assemblies for loose or worn spindles components and hardware for secu rity tires for wear damage and proper inflation 2 Check front axle for loose missing and worn parts pivot pin for security 3 Check steering assembly for loose or bent steer cyl inder rods steer cylinder and hydraulic lines for leaks and security and hardware for proper installa tion 4 Check rear tires and wheel assemblies for security tires for wear damage and proper inflation 5 Check drive hubs for damage and leaks and motors and brakes for damage 6 Check oil level in drive hubs by removing fill plug on top and check plug on side Fill from top with EPGL SAE90 until oil flows from check plug Replace both plugs 7 Check valves and hydraulic lines
58. is loaded personnel tools and sup plies 2 Iftotal weight in platform will be 500 LBS 227 kg or less proceed with adding weight Platform Level Adjustment 35 n35 40 n40 45 electric l Leveling UP Depress footswitch to raise platform position PLATFORM LEVEL control switch UP and hold until platform is level 2 Leveling DOWN Depress footswitch to lower plat form position PLATFORM LEVEL control switch to DOWN and hold until platform is level 3120742 Platform Rotation 35 n35 40 n40 45 electric 1 Depress footswitch to rotate platform to the left PLATFORM ROTATE control switch is positioned to the LEFT and held until desired position is reached 2 Depress footswitch to rotate platform to the right PLATFORM ROTATE control switch is positioned to the RIGHT and held until desired position is reached 4 7 BOOM A WARNING A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE WHICH LIGHTS WHEN THE CHASSIS IS ON A 5 DEGREE OR GREATER SLOPE DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN LIGHT IS LIT DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS TILT ALARM INDICATES CHASSIS IS ON A SEVERE SLOPE 5 DEGREE OR GREATER CHASSIS MUST BE LEVEL BEFORE SWINGING OR RAISING BOOM ABOVE HORI ZONTAL TO AVOID UPSET IF RED TILT WARNING LIGHT LIGHTS WHEN BOOM IS RAISED ABOVE HORIZONTAL LOWER PLATFORM TO GROUND LEVEL THEN REPOSITION MACHINE SO THAT CHAS SIS IS LEVEL BEFORE RAI
59. lity hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices When installed on the machine this Signal Word will have a Yellow background as part of a decal The IMPORTANT Safety Signal Word may also appear in this manual or on the machine This Safety Signal Word typically will not appear with the Safety Alert Symbol but contains important information that must be followed for safe and proper operation The IMPORTANT Safety Signal Word definition and associated color is as follows IMPORTANT Indicates procedures essential for safe operation and which if not followed may result in a machine malfunctioned dam age When installed in a machine this Signal Word will have a Green background as part of a decal J LG Lift 3120742 FOREWORD A WARNING ALL SAFETY RELATED BULLETINS MUST BE ACCOMPLISHED ON THIS PRODUCT J LG INDUSTRIES INC MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR THIS JLG PRODUCT CONTACT J LG INDUSTRIES INC OR THE LOCAL AUTHORIZED J LG DEALER FOR INFORMATION REGARDING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT IMPORTANT FOR THE PURPOSE OF RECEIVING SAFETY RELATED BULLETINS IT IS IMPORTANT THAT THE CURRENT OWNER OF THIS UNIT ENSURES J LG INDUSTRIES INC HAS UPDATED OWNERSHIP INFORMATION CONTACT J LG INDUSTRIES INC TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE IMPORTANT
60. ments J LG Industries Inc reserves the right to make specification changes without prior notification Contact LG Industries Inc for updated information 3120742 J LG Lift d FOREWORD SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS potential personal injury hazards Obey all safety messages This is the Safety Alert Symbol It is used to alert you to the that follow this symbol to avoid possible injury or death The Safety Alert Symbol will be used with the appropriate Safety Signal Word of DANGER WARNING or CAUTION to a potential hazard and designate a level of seriousness The Safety Signal Words are inserted throughout this manual in Black White On the machine the Safety Signal Words will have either a Red Orange or Yellow background as part of a safety sign or decal The DANGER WARNING and CAUTION Safety Signal Words definitions and associated colors are as follows A DANGER Indicates an imminently hazardous situation which if not avoided will result in serious injury or death This signal word is used in the most extreme cases When installed on the machine this Signal Word will have a Red background as part of a decal A WARNING Indicates a potentiality hazardous situation which if not avoided could result in serious injury or death When installed on the machine this Signal Word will have an Orange background as part of a decal A CAUTION Indicates a potentia
61. ms should be performed once the walk around inspection is complete in an area free of overhead and ground level obstructions First using the ground controls check all functions controlled by the ground controls Next using the platform controls check all functions controlled by the platform controls A WARNING TO AVOID SERIOUS INJ URY DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENTS DO NOT RETURN TO THE OFF POSI TION WHEN RELEASED A WARNING TO AVOID A COLLISION AND INJ URY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP MACHINE 1 Check boom limit switches Raise and lower the Lower Boom Check for smooth operation Check Boom Upright tilting See Figure 4 2 Upright posi tioning Models 40e and 45e NOTE Perform checks from ground controls first then from platform controls 2 Raise extend retract and lower the Upper Boom Check for smooth operation 3 On models 40 n40 45 electric if tower boom does not rest on stop with machine in the stowed position this indicates upright is out of plumb Ref 2 20 of service manual 3120743 for Boom Synchronizing procedure 4 On models 35 n35 40 n40 45 electric telescope boom IN and OUT several cycles at various degrees of elevation lengths Check for smooth telescope operation 5 Swing turntable to LEFT and RIGHT a minimum of 45 degr
62. nt that all personnel who are assigned to and are responsible for the operation and maintenance of the machine undergo a thorough training program and check out period in order to become familiar with the characteristics prior to operating the machine In addition personnel operating the machine should be familiar with ANSI standard A92 5 1992 Responsibilities Section This outlines the responsibilities of the owners users operators lessors and lessees concerning safety training inspection maintenance application and opera tion Persons under the influence of drugs or alcohol or who are subject to seizures dizziness or loss of physical con trol must not be permitted to operate the machine Operator Training Operator training must include instruction in the following areas 1 Use and limitations of the platform controls ground controls emergency controls and safety systems 2 Knowledge and understanding ofthis manual and of the control markings instructions and warnings on the machine itself 3 Knowledge and understanding of all safety work rules ofthe employer and of Federal State and local statutes including training in the recognition and avoidance of potential hazards in the work place with particular attention to the work to be performed 4 Proper use of all required personnel safety equip ment in particular the wearing of a safety harness or other approved fall protection devices with a lanyard att
63. om when positioned to UP or DOWN 7 Telescope 35 n35 40 n40 45 electric Provides for extension and retraction of Upper Boom when positioned to IN or OUT 8 Swing The SWING control switch provides 360 degrees non con tinuous turntable rotation To activate SWING position switch to LEFT or RIGHT 9 Circuit Breakers March 1995 to Present The circuit breakers open pop out to indicate a short or overload somewhere on the machine 10 Battery Indicator and Hourmeter An hourmeter installed in the upper portion of the Ground Control Box registers the amount of machine operating time The hourmeter registers up to 9 999 9 hours and cannot be reset SWING LOWER BOOM UPPER BOOM CONTROL LIFT LIFT SWITCH CONTROL SWITCH CONTROL SWITCH BATTERY EMERGENCY CONDITION STOP INDICATOR SWITCH PLATFORM GROUND SELECT SWITCH Figure 3 3 Ground Control Station 30 electric Sheet 1 Of 4 3 9 J LG Lift 3120742 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS ROTATOR CONTROL SWITCH PLATFORM LEVELING BATTERY CONDITION CONTROL INDICATOR SWITCH amp z HOUR METER UPPER BOOM LIFT CONTROL TELESCOPE CONTROL SWITCH SWING LOWER MID LIFT CONTROL CONTROL SWITCH SWITCH CIRCUIT BREAKER 17 Q PLATFORM GROUND SELECT SWITCH EMERGENCY STOP SWITCH Figure 3 3 Ground Control Station 35 n35 40 n40 45 electric Sheet 2 of 2 3 10 J LG L
64. on of steer and drive will be opposite from normal operation Do not assist a stuck or disabled machine by pushing pulling or by using boom functions Assist only by pulling at the chassis tie down lugs 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 3120742 SECTION 1 SAFETY PRECAUTIONS Trip and Fall Hazards J LG Industries Inc requires that all persons in the plat form wear a full body harness with a lanyard attached to an authorized lanyard anchorage point while operating this machine For further information regarding fall protec tion requirements on J LG products contact J LG Indus tries Inc Io Prior to operation ensure all gates are fastened and secured in their proper position Identify the desig nated lanyard anchorage point s atthe platform and securely attach the lanyard Attach only one 1 lan yard per lanyard anchorage point Keep both feet firmly positioned on the platform floor at alltimes Never position ladders boxes steps planks or similar items on unit to provide additional reach for any purpose Never use the boom assembly to gain access to or leave the platform Use extreme caution when entering or leaving plat form Ensure that the boom is fully lowered Face the machine when entering or leaving the platform Always maintain three point contact with the
65. ontrol Adjusts speed of Boom and Swing Functions Rotate CCW for slower speed and CW for faster speed Adjust Drive Function to creep Rotate CCW until the Function Control knob clicks Machine Out Of Level This red illuminator indicates that the chassis is on a slope over 5 degrees Ifthe boom is above horizon tal and the machine is on a 5 degree slope an alarm will sound and CREEP is automatically activated 12 Horn A push type HORN switch supplies electrical power to an audible warning device when pressed 13 Circuit Breakers The circuit breakers open pop out to indicate a short or overload somewhere on the machine 14 110 Volt AC Outlet This feature allows electrical powerto be supplied to the platform Plug an extension cord into a grounded 110 VAC outlet and then into the plug on the right side ofthe hood Power will now be sup plied to the outlet in the basket to run portable elec tric tools lights etc A WARNING TO AVOID SERIOUS INJ URY DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED J LG Lift 3120742 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS EMERGENCY STOP SWITCH UPPER BOOM LIFT CONTROL OUT OF LEVEL SWIER 30 electric SWING CONTROL SWITCH CIRCUIT BREAKERS UPPER BOOM LIFT CONTROL SWITCH OUT OF LEVEL TILT TELESCOPE CONTROL SWITC
66. ot accept operating responsibility until this man ual has been read training is accomplished and opera tion of the machine has been completed under the supervision of an experienced and qualified operator The owner user operator lessor lessee must be familiar with Sections 6 7 8 9 10 of ANSI A92 5 1992 These sections contain the responsibilities of the owner user operator lessor and lessee concerning safety training inspection maintenance application and operation If there are any questions with regard to safety training inspection maintenance application and operation please contact LG Industries Inc J LG A WARNING An operator must not accept operating responsibilities until adequate training has been given by competent and authorized persons Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and mainte nance ofthe unit Read understand and obey all DANGERS WARN INGS CAUTIONS and operating instructions on the machine and in this manual Ensure that the machine is to be used in a manner which is within the scope of its intended application as determined by J LG 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
67. r failure or loading unloading Refer to the Emergency Procedures sec tion of this manual for emergency towing procedures Ensure boom is in the stowed position and the turnta ble locked prior to towing lifting or hauling The plat form must be completely empty of tools When lifting machine lift only at designated areas of the machine Lift with lifting equipment of adequate capacity Refer to the Machine Operation section of this manual for lifting information 1 5 SECTION 1 SAFETY PRECAUTIONS 15 MAINTENANCE General This section contains general safety precautions which must be observed during maintenance of this machine Additional precautions to be observed during machine maintenance are inserted at the appropriate points in this manual and in the Service 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 quali fied person and must be followed to ensure that the machine is safe Maintenance Hazards Shut off power to all controls and ensure that all oper ating systems are secured from inadvertent motion prior to performing any adjustments or repairs Never work under an elevated platform until it has been fully lowered to the full down position if possible or otherwise supported and restrained from movem
68. r when performing welding on the machine Do notallow smoking open flame or sparks near bat tery during charging or servicing Do not contact tools or other metal objects across the battery terminals Always wear hand eye and face protection when ser vicing batteries Ensure that battery acid does not come in contact with skin or clothing A WARNING BATTERY FLUID IS HIGHLY CORROSIVE AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION Charge batteries only in a well ventilated area Avoid overfilling the battery fluid level Add distilled water to batteries only after the batteries are fully charged J LG Lift 3120742 SECTION 2 PREPARATION AND INSPECTION SECTION 2 PREPARATION AND INSPECTION 2 1 GENERAL This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and lists checks that are performed prior to use of the machine It is important that the information contained in this section be read and understood before any attempt is made to operate the machine Ensure that all the necessary inspections have been completed successfully before placing the machine into service These procedures will aid in obtaining maxi mum service life and safe operation A IMPORTANT SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON TROL OVER TH
69. rac teristics and limitations of the machine is always the first requirement for any user regardless of the users experience with similar types of equipment Placards Important points to remember during operation are provided at the control stations by DAN GER WARNING CAUTION IMPORTANT and INSTRUCTION placards This information is placed at various locations for the express pur pose of alerting personnel of potential hazards constituted by the operating characteristics and load limitations of the machine See FORE WORD for definitions of the above placards Capacities Raising boom above horizontal with or without any load in platform is based on the following criteria 1 Machine is positioned on a smooth firm and level surface Load is within manufacturers rated design capacity All machine systems are functioning properly Pus Proper tire pressure 5 Machine is as originally equipped from J LG Stability This machine as originally manufactured by JLG Indus tries Inc when operated within its rated capacity on a smooth firm and level supporting surface and in accor dance with the instructions provided on the machine and in this manual provides a stable machine for all positions Machine stability is based on two 2 conditions which are called FORWARD stability and BACKWARD stability The machine s position of least FORWARD stability is shown in Figure 3 1 and its position of lea
70. rd Stability 30 electric Sheet 1 of 3 3 6 J LG Lift 3120742 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS 3120742 PLATFORM ROTATED 90 DEGREES MACHINE WILL TIP OVER IN THIS DIRECTION IF OPERATED ON AN OUT OF LEVEL SURFACE UPPER BOOM FULLY ELEVATED LOWER BOOM HORIZONTAL Figure 3 2 Position of Least Backward Stability 35 n35 electric Sheet 2 of 3 J LG Lift 3 7 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS PLATFORM ROTATED 90 DEGREES MACHINE WILL TIP OVER IN THIS DIRECTION IF OPERATED ON AN OUT OF LEVEL SURFACE UPPER BOOM FULLY ELEVATED MID BOOM FULLY ELEVATED LOWER BOOM FULLY ELEVATED Figure 3 2 Position of Least Backward Stability 40 n40 45 electric Sheet 3 of 3 3 8 JLG Lift 3120742 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS 3 Rotate 35 n35 40 n40 45 electric A three position ROTATE control switch permits rotation of the platform when positioned to left or right 4 Platform Leveling Override 35 n35 40 n40 45 electric A three position LEVEL control switch allows the operator to compensate for any difference in the automatic self lev eling system by positioning the control switch to UP or DOWN 5 Lower Boom Lift Provides for raising and lowering of Lower Boom and Mid Boom on 40 n40 45 electric when positioned to UP or DOWN 6 Upper Boom Lift Provides for raising and lowering of Upper Bo
71. rectly 6 5 INCIDENT NOTIFICATION It is imperative that J LG Industries Inc be notified imme diately of any incident involving a J LG product Even if no injury or property damage is evident the Product Safety and Reliability Department at the factory should be con tacted by telephone and provided with all necessary details It should be noted that failure to notify the Manufacturer of an incident involving a J LG Industries product within 48 hours of such an occurrence may void any warranty con sideration on that particular machine 3120742 SECTION 7 INSPECTION AND REPAIR LOG SECTION 7 INSPECTION AND REPAIR LOG Table 7 1 Inspection and Repair Log Date Comments 3120742 J LG Lift 7 1 SECTION 7 INSPECTION AND REPAIR LOG Table 7 1 Inspection and Repair Log Date Comments 7 2 J LG Lift 3120742 Please cut on the dotted line and fax to 717 485 6573 Q e JLG Industries Inc TRANSFER OF OWNERSHIP To JLG Gradall Lull and Sky Trak product owner If you now own but ARE NOT the original purchaser of the product covered by this manual we would like to know who you are For the purpose of receiving safety related bulletins it is very important to keep JLG Industries Inc updated with the curren
72. roperly JLG recommends replacing the hydraulic filter ele ment after the first 50 hours of operation and then every 300 hours thereafter unless operating condi tions require earlier replacement Check all cowl and access doors for damage proper operation and security Check Lower Boom pivot bushings for lubrication and wear Check Lower Boom Lift Cylinder and hydraulic lines for damage leakage and security Check all pin and shaft retaining hardware for secu rity and wear Check all electrical cables for damage loose and corroded connections 30 35 n35 electric Boom See Figure 2 1 2 2 1 Check Lower Boom and leveling link for damage missing parts and security Check all pin and shaft retaining hardware for secu rity and wear Check hydraulic lines and electrical cable for dam age missing parts and security Check limit switch connections and plunger for cor rosion and security 10 NOTE Check limit switch connections and plunger for cor rosion and security Check Upright for damage wear lubrication and security Check Upper Boom lift cylinder and cross pins and hydraulic lines for damage wear lubrication leak age and security Check Upper Boom pivot pin for damage wear lubrication and security Check Upper Boom for damage missing parts and security Check hydraulic lines mounted on upright for dam age leakage and security The following 10 thru 12 apply
73. st BACKWARD stability is shown in Figure 3 2 32 J LG Lift A WARNING TO AVOID FORWARD OR BACKWARD UPSET DO NOT OVER LOAD MACHINE OPERATE ON OUT OF LEVEL SURFACE OR OPERATE WITH THE BOOM UPRIGHT TILTING SEE FIGURE 4 2 UPRIGHT POSITIONING 3 4 CONTROLS AND INDICATORS These machines are equipped with control panels that use symbols and words to indicate control functions On some machines the control panels may use symbols only Refer to Table 3 1 for these symbols and their corre sponding functions Ground Control Station Figure 3 3 A WARNING DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL 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 posi tioned to OFF 1 Power Emergency Stop Switch 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 PLATFORM GROUND SELECT switch 2 Platform Ground Select Switch 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 position power is shut off to platform and only ground controls are operable When released from GROUND position the switch spring returns to the off posi
74. supports under platform floor and secure to truck or trailer as shown in figure 4 3 DO NOT OVERTIGHTEN OR DAMAGE WILL OCCUR TO BOOM OR PLATFORM Secure lower boom by running a suitable tie down strap over the lower boom and underthe lift cylinder as shown and secure to truck or trailer DO NOT OVERTIGHTEN OR DAMAGE WILL OCCUR TO BOOM OR PLATFORM 3120742 SECTION 4 MACHINE OPERATION SNIZINOHHONAS WOO JHL 1980216 TWANVIN 39IAH3S NI 02 2 NOILO3S 335 STOHLNOI WHOSLV Td JHL SNIVHd3dO 3HO4J38 LHDIddN 3Hl LSNfrav NOILO3HIO NI 33853G 51 NVHL 3HON SI 1 Al 0 dO SNOIY3S NI LINS3Y A1NOI H3AO dll V HO3 LHDIddN IHL 19345 ATIVNSIA STOHLNOD 3H1 009 H3M01 3Hl SNIVA3T3 803 WOO WOOd 3NIHOVIN 3498340 LON OQ s31dWVX3 338 unoSo q1noo dl SI LHSI4AN WOOd AHL H3AO dlL SNINSVM V 1 1 1 erri t NOILO3UIG YAHLIA NI S334930 S L NVHL SHOW Ad LON 15 LH9IHd AHL V Figure 4 2 Upright Positioning Models 40 45 4 5 J LG Lift 3120742 SECTION 4 MACHINE OPERATION Platform Boom Tie Down Model 35electric See Figure 4 3 Tilt platform forward
75. t and right of the stowed position The machine has a Ground Control Station which will override the Platform Control Station Ground Controls operate Upper and Lower Boom Lift and Swing and are to be used in an emergency to lower the platform to the ground should the operator in the platform be unable to do so Ground Control also to be used in Pre Operation check Instructions and hazard alerts are posted on the operator control stations and at other places on the machine It is extremely important that operators know what instructions and hazard alerts are placed on the machine and review these periodically so that they are fresh in their minds Vibrations emitted by these machines are not hazardous to an operator in the work platform The J LG Lift is designed to provide efficient and safe oper ation when maintained and operated in accordance with warnings on the machine in the Operators amp Safety Man ual and all jobsite and government rules and regulations As with any type of machinery the operator is very impor tant to efficient and safe operation Owner user operator must be familiar with Sections 6 7 8 9 and 10 of ANSI A92 5 1992 These sections contain the responsibilities of the owner users operators lessors and lessees concern ing safety training inspection maintenance application and operation It is absolutely necessary that the J LG Lift be regularly maintained in accordance with this section and the Service
76. t ownership of all JLG products JLG maintains owner information for each JLG product and uses this information in cases where owner notification is necessary Please use this form to provide JLG with updated information with regard to the current ownership of JLG Products Please return completed form to the JLG Product Safety amp Reliability Department via facsimile 717 485 6573 or mail to address as specified on the back of this form Thank you Product Safety amp Reliability Department JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 Telephone 717 485 5161 Fax 717 485 6573 NOTE Leased or rented units should not be included on this form Mfg Model Serial Number Previous Owner Address City State Zip Telephone 1 1 Date Of Transfer Current Owner Address City _ Zip Telephone Who in your organization should we notify Name Title Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Phone 717 485 5161 Fax 717 485 6417 JLG Worldwide Locations JLG Industries Australia Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 2 65 811111 Fax 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Industries Europe Kilmartin Pla
77. tion NOTE With PLATFORM GROUND SELECT switch in the center position power is shut off to controls at both operating stations 3120742 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS 3120742 UPPER BOOM HORIZONTAL LOWER BOOM FULLY ELEVATED MACHINE WILL THIS DIRECTION IF LOADED OR OPERATED ON AN OUT OF LEVEL SURFACE Figure 3 1 Position of Least Forward Stability 30 electric Sheet 1 of 3 J LG Lift 3 3 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS UPPER BOOM TELESCOPE HORIZONTAL FULLY EXTENDED MACHINE WILL TIP OVER IN THIS DIRECTION IF OVER LOADED OR OPERATED ON AN OUT OF LEVEL SURFACE LOWER BOOM FULLY ELEVATED Figure 3 1 Position of Least Forward Stability 35 n35 electric Sheet 2 of 3 3 4 J LG Lift 3120742 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS 3120742 UPPER BOOM TELESCOPE HORIZONTAL FULLY EXTENDED MACHINE WILL TIP OVER IN THIS DIRECTION IF OVER LOADED OR OPERATED ON AN OUT OF LEVEL SURFACE MID LOWER BOOM STOWED POSITION Figure 3 1 Position of Least Forward Stability 40 n40 45 electric Sheet 3 of 3 J LG Lift 3 5 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROLS MACHINE WILL TIP OVER IN THIS DIRECTION IF OPERATED ON AN OUT OF LEVEL SURFACE UPPER BOOM FULLY ELEVATED LOWER BOOM HORIZONTAL Figure 3 2 Position of Least Backwa
78. ve switch is returned to neutral position The unrestricted capacity of the J LG Lift is 500 LBS 227 kg This means that with a platform load of 500 LB 227 kg or less the platform may be positioned anywhere the boom will reach with the machine on a smooth firm and level surface 4 2 GENERAL This section provides the necessary information needed to operate the machine Included in this section are proce dures for traveling steering parking platform loading and transporting It is important that the user read and under stand the proper procedures before operating the machine 4 3 MOTOR OPERATION Power Emergency Stop This red mushroom shaped switch provides battery power to the Platform Ground Select switch when pulled out on for all machine functions The switch should be pushed in off when recharging the batteries or parking the machine overnight JLG Lift 4 1 SECTION 4 MACHINE OPERATION Platform Ground Select Switch The Platform Ground Select switch functions to direct bat tery power to the desired control station when the POWER EMERGENCY STOP switch is pulled out on With the switch held in the GROUND position battery power is supplied to the ground control station When the switch is in the PLATFORM position battery power is sup plied to the platform control station Motor Activation A IMPORTANT FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNCTION OTHERWIS

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