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Operators and Safety Manual

1. ii JLG Lift PAGE NO PAGE NO PAGE NO 3120748 SECTION 1 SAFETY PRECAUTIONS SECTION 1 SAFETY PRECAUTIONS 1 1 GENERAL This section prescribes the proper and safe practices for major areas of machine usage In order to promote proper usage of the machine it is mandatory that a daily routine 1 2 DRIVING TOWING Before driving the machine the user must be familiar with the drive steer and stopping characteristics This is espe cially important when driving in close quarters be established based on instructions given in this section A maintenance program must also be established by a qualified person and must be followed to ensure that the machine is safe to operate The user should be familiar with the driving surface before driving The surface should be firm and level and grades should not exceed the allowable grade for the machine NOTE Remember that the key to safe and proper usage is The owner user operator of the machine should not dk common sense and its careful application accept operating responsibility until this manual has been read and understood and operation of the machine under the supervision of an experienced and qualified per son has been completed 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
2. 3 2 Position of Least Backward 3 3 Ground Control Indicator 3 4 Ground Control 3 5 Malfunction Indicator Light and Test 3 6 Platform Station Proportional 5 9 7 Danger and Warning Decal Location 3 8 Control Panel Symbols Sheet 1 2 3 9 Control Panel Symbols Sheet 2 2 4 1 Grade and Sideslope 4 2 Functional Check ii melee a e Enid o e EPA EE 4 3 Machine Tie Down A Models 4 4 Machine Tie Down AJ Models 4 5 Lifting Chart cse p EE ERE ER ESPERE AU 4 6 Drive Disconnect AUD Deere xd e Pe CER LIST OF TABLES TABLE NO TITLE 1 1 Minimum Safe Approach Distances M S A D to energized exposed or insulated power lines and 2 1 Lubrication Chart s Ds huyu ULL pets M be Eu 7 1 Inspection and 00
3. Operators and Safety Model 450A 450AJ 3120748 April 24 2002 IS09001 5 REGISTERED COMPANY JL 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 The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 1702961 JLG Lift FOREWORD FOREWORD The purpose of this manual is to provide users with the operating procedures essential for the promotion of proper machine operation for its intended purpose It is important to over stress proper machine usage All information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the machine YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL Keep it with the machine REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPER ATING PERSONNEL ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER OPERATING CONDITIONS WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN ALTERATION AND OR MODIFICATI
4. GLOW PLUG ENGINE AIR WAIT FILTER BY PASS Figure 3 3 Ground Control Indicator Panel 3120748 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3120748 PLATFORM ROTATE eh UUO PLATFORM LEVELING OVERRIDE ENGINE START AUX POWER POWER EMERGENCY 1 STOP 4 PLATFORM GROUND SELECT SWITCH HOURMETER A Models PLATFORM _ ROTATE PLATFORM LEVELING OVERRIDE ARTICULATING JIB BOOM ENGINESTART AUX POWER POWER EMERGENCY STOP PLATFORM GROUND SELECT SWITCH HOURMETER AJ Models Figure 3 4 Ground Control Station JLG Lift INDICATOR PANEL MAIN TELESCOPE MAIN LIFT INDICATOR PANEL MAIN TELESCOPE MAIN LIFT 3 7 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 17 18 19 Low Fuel Level Indicator When illuminated indicates that the fuel level is 1 8 full or less When the light first turns on there are approximately four usable gallons of fuel remaining Glow Plug Wait Indicator When illuminated indicates the glow plugs are on The glow plugs are automatically turned on with the ignition circuit and remain on for approximately seven seconds Start the engine only after the light goes out Engine Malfunction Indicator Light Ford Engines after S N 46089 When illu
5. Drive Motor Brake and Hub No visible damage no evidence of leakage Wheel Tire Assembly Right Rear Properly secured no loose or missing lug nuts no visible damage Hydraulic Filter Housing secure no visible damage no evidence of leakage Hood Right Side Properly secured no loose or missing parts Control Valve No loose or missing parts evidence of leakage unsupported wires or hoses damaged or broken wires Fuel Supply Filler cap secure no visible damage to the tank or evidence of leaks Ground Controls Switches operable no visible damage decals secure and legible Hydraulic Oil Supply Recommended oil level sight gauge Check level with cold oil systems shut down machine in stowed position Cap in place and secure Wheel Tire Assembly Right Front Properly secured no loose or missing lug nuts no visible damage Oscillating Axle No loose or missing hardware no visible damage Steer Oylinder Properly secured no visible damage or signs of leakage evidence of proper lubrication Tie Rod Ends and Steering Spindles No loose or missing parts no visible damage Wheel Tire Assembly Left Front Properly secured no loose or missing lug nuts no visible damage Battery Proper electrolyte levels cables tight no visible damage or corrosion Engine Air Filter No loose or missing parts no visi ble damage element clean Hood Right Side Properly secured no loose or
6. 3120748 SECTION 4 MACHINE OPERATION gt lt Note When transporting machine over rough terrain or long distance the boom needs to be chocked and strapped whenever the base boom is unable to rest on its pad This prevents the boom from bouncing up and down and preventing possible damage while transporting Figure 4 4 Machine Tie Down AJ Models 3120748 JLG Lift 4 7 SECTION 4 MACHINE OPERATION sS t 2212 591 00Z SL SUIBUISJ os pue 1sn pe sway y u SNOILONULSNI SNIL4I1 5869 541 00t SL 0202 00561 8999 541 00271 oneuinoud pJepuejs 5501 WNUWIUIN 6621 19 NOILVLOH 4 1311 INVHDVIG 3120748 JLG Lift 4 8 SECTION 4 MACHINE OPERATION 4 12 OSCILLATING AXLE LOCKOUT TEST IF EQUIPPED IMPORTANT LOCKOUT SYSTEM TEST MUST BE PERFORMED QUA
7. After towing the machine com plete the following 4 10 JLG Lift 3 Reconnect drive hubs by inverting disconnect cap See Figure 4 6 P J DISCONNECT CAP Drive Hub Engaged Drive Hub Disconnected Figure 4 6 Drive Disconnect Hub 3120748 SECTION 5 OPTIONAL EQUIPMENT SECTION 5 OPTIONAL EQUIPMENT 5 1 DUAL FUEL SYSTEM GAS ENGINE ONLY Description The dual fuel system enables the standard gasoline engine to run on either gasoline or LP gas The system includes pressurized cylinders mounted on the frame and the valves and switches needed to switch the fuel supply from gasoline to LP gas or from LP gas to gasoline A two position FUEL SELECT toggle switch at the plat form control station supplies electrical power to open the gasoline shut off solenoid and close the LP gas shut off solenoid when positioned to the GASOLINE position This switch supplies electrical power to open the LP gas shut off solenoid and close the gasoline shut off solenoid when positioned to the LP position A CAUTION IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOWING THE ENGINE TO STOP EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED Changing From Gasoline to LP Gas 1 Start engine from Ground Control Station 2 Open hand valve on LP gas supply tank by turning counterclockwise 3 While engine is operating on
8. Check Lower Upright for damage wear lubrication and security Check hydraulic lines mounted on upright for dam age leakage and security Check boom pivot bushings for wear Check boom lift cylinder and hydraulic lines for dam age leakage and security Check lift cylinder cross pins for damage wear and security Check all pin and shaft retaining hardware for secu rity and wear Check Upper Upright cross pins and hydraulic lines for damage wear lubrication leakage and security Check Upper Upright for damage wear lubrication and security Check hydraulic lines mounted on upright for dam age leakage and security Check Upper Boom Lift Cylinder and cross pins and hydraulic lines for damage wear lubrication leak age and security 3120748 SECTION 2 PREPARATION AND INSPECTION 3120748 PLATFORM CONSOLE EXTEND A REACH or JIB FLY BOOM BASE BOOM e UPPER CYLINDER ___ MID BOOM MID LIFT CYLINDER Bed na _____ LOWER UPRIGHT TOWER LOWER BOOM TURNTABLE TOWER or LOWER LIFT ____ CYLINDER Figure 2 1 Machine Nomenclature JLG Lift SECTION 2 PREPARATION AND INSPECTION 2 4 15 Check Upper Boom pivot pin for damage wear lubrication and security 16 Check Upper Boom for damage missing parts and security 17 Check Upper Boom wear pads for damage missing parts and security 18 Check Upper Boom tele
9. check to see that it is current and that no entries 5 have been left uncleared leaving machine in an unsafe condition for operation Start each day with a full fuel tank A WARNING AVOID INJURY DO MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED USE OF A MALFUNC TIONING MACHINE IS A SAFETY VIOLATION TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DURING WALK AROUND INSPECTION NOTE NOTE JLG Lift Check 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 Check platform footswitch for proper operation Switch must be released to start engine and depressed to operate machine Check that drive brakes hold when machine is driven up a grade not greater than specified on the serial number placard and stopped 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 Assure that all items requiring lubrication are ser viced Refer to Figure 2 5 Lubrication Diagram for specific requirements 2 5 SECTION 2 PREPARATION AND INSPECTION TT 1 d Figure 2
10. 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
11. ing in 2WD at high engine rpm The center position selects 4WD at mid engine rom The backward posi tion selects 4WD at high engine rpm Drive Speed Switch 2WD Equipped Machines The forward position produces maximum speed by operating at high engine rpm The backward posi tion selects mid engine rpm Creep Speed Indicator Illuminated Green when the Function Speed Con trol is turned to the creep position the indicator acts as a reminder that all functions are set to the slowest speed 14 15 16 17 18 19 JLG Lift Platform Rotate The Platform Rotate control switch allows the opera tor to rotate the basket to the left or right when posi tioned to the desired direction Platform Leveling Override The Platform Level control switch allows the opera tor to adjust the level of the platform by positioning the switch to UP or DOWN Articulating Jib Boom If Equipped Push level toggle switch forward to lift up pull back to lift down Fuel Select Dual Fuel Engine Only If Equipped Gasoline or liquid propane fuel may be selected by moving the switch to the appropriate position It is unnecessary to purge the fuel system before switch ing fuels so there is no waiting period when switch ing fuels while the engine is running Lights If Equipped This switch operates control console panel lights and head lights if the machine is so equipped The ignition switch does not h
12. missing parts Engine Oil Supply Full mark on dipstick filler cap secure Figure 2 3 Daily Walk Around Inspection Sheet 2 of 3 3120748 JLG Lift 2 7 SECTION 2 PREPARATION AND INSPECTION 2 8 Turntable Bearing No loose or missing hardware no visible evidence of proper lubrication no evi dence of loose bolts or looseness between bearing or structure Swing Motor and Worm Gear No loose or missing hardware no visible damage evidence of proper lubrication Muffler and Exhaust System Properly secured no evidence of leakage Auxiliary Power Pump No loose or missing parts no evidence of leakage no damaged wires Hydraulic Pump No loose or missing parts no evi dence of leakage Wheel Tire Assembly Left Rear Properly secured no loose or missing lug nuts no visible damage Rotator Cylinders No visible damage cylinder pins secure hydraulic hoses undamaged and not leak ing Platform Gate Latch stop and hinges in working condition and properly secured no loose or missing parts Figure 2 4 Daily Walk Around Inspection Sheet 3 of 3 JLG Lift 3120748 SECTION 2 PREPARATION AND INSPECTION 2 5 DAILY FUNCTIONAL CHECK A functional check of all systems must 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 gro
13. mum service life and safe operation A IMPORTANT SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON TROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IS THE RESPONSIBILITY OF THE OWNER OPERATOR 2 2 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 telescope works smoothly and brakes operate prop erly coupled with a series of visual inspections The man datory requirements are given in the Daily Walk Around Inspection 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 An annual inspec
14. 3120748 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL UPPER BOOM TELESCOPE HORIZONTAL FULLY EXTENDED eo 94 NTT MID LOWER BOOM STOWED POSITION MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT OF LEVEL SURFACE Figure 3 1 Position of Least Forward Stability 3120748 JLG Lift 3 3 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL ROTATE PLATFORM 90 DEGREES MACHINE WILL TIP OVER IN THIS DIRECTION IF OPERATED OUT OF LEVEL SURFACE UPPER BOOM FULLY ELEVATED MID BOOM FULLY ELEVATED LOWER BOOM FULLY ELEVATED Figure 3 2 Position of Least Backward Stability 3 4 JLG Lift 3120748 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 4 CONTROLS AND INDICATORS NOTE This machines is equipped with control panels that use symbols to indicate control functions Refer to Figure 3 8 and Figure 3 9 for the symbols on the decal located on the control box guard in front of the control box or by the ground controls for these con trol panel symbols and the corresponding functions Ground Controls PERFORM PRE OPERATIONAL CHECKS AND INSPECTIONS FROM THE GROUND CONTROL STA TION WH
15. LATION AND IS A VIOLATION OF OSHA REGULA TIONS AND ANSI STANDARDS DO OPERATE MACHINE WHEN WIND CONDI TIONS EXCEED 30 MPH 48 KMH NEVER OPERATE BOOM FUNCTIONS TELE SWING LIFT WHEN MACHINE IS ON A TRUCK OTHER VEHI CLE OR ABOVE GROUND STRUCTURE THIS MACHINE CAN BE OPERATED IN NOMINAL AMBIENT TEMPERATURES OF 0 F TO 104 F 20 C TO 40 CONSULT FACTORY TO OPTIMIZE OPER ATION OUTSIDE THIS RANGE 1 APPROVED HEAD GEAR MUST BE WORN BY ALL JLG Lift OPERATING AND GROUND PERSONNEL SECTION 1 SAFETY PRECAUTIONS 1 5 READ AND OBEY ALL DANGERS WARNINGS CAU TIONS AND OPERATING INSTRUCTIONS ON MACHINE AND IN THIS MANUAL BE FAMILIAR WITH LOCATION AND OPERATION OF GROUND STATION CONTROLS ALWAYS USE THREE POINT CONTACT WHEN ENTERING OR EXITING THE MACHINE FACE THE MACHINE WHEN YOU ENTER OR LEAVE THREE POINT CONTACT MEANS THAT TWO HANDS AND ONE FOOT OR ONE HAND AND TWO FEET ARE IN CONTACT WITH THE MACHINE AT ALL TIMES DUR ING MOUNT AND DISMOUNT DRIVING t WATCH FOR OBSTRUCTIONS AROUND MACHINE AND OVERHEAD WHEN DRIVING JLG Lift ALWAYS POSITION BOOM OVER REAR DRIVE AXLE IN LINE WITH DIRECTION OF TRAVEL REMEMBER IF BOOM IS OVER FRONT STEER AXLE DIRECTION OF STEER AND DRIVE MOVEMENT WILL BE OPPO SITE FROM NORMAL OPERATION DO NOT USE DRIVE FUNCTION TO POSITION PLAT FORM CLOSE TO OBSTACLES USE BOOM FUNC TION INSTEAD WHEN DRIVING IN HIG
16. OF CONTENTS continued SUBJECT SECTION PARAGRAPH 5 10 Cylinder a Pe eee ere ED erue 5 11 Boom WIpers norem rer unas le KE Q a gua sisa Ea s gee de 5 12 Hostile Environment 5 13 Motion Alarm cett ca o ex RU als asa LE 5 14 Semi Track US e bre UN AP EE SECTION 6 EMERGENCY PROCEDURES 6 1 A Eee s vae vete 6 2 Emergency Towing 6 3 Emergency Controls and Their Locations 6 4 Emergency 6 5 Incident SECTION 7 INSPECTION AND REPAIR LOG LIST OF FIGURES FIGURE NO TITLE 2 1 Machine 2 2 Daily Walk Around Inspection Sheet 1 of 3 2 3 Daily Walk Around Inspection Sheet 2 of 3 2 4 Daily Walk Around Inspection Sheet 3of 3 2 5 Lubrication Diagram is socia E RE unai pa Cu sus ka ue ee aa 2 6 Torque Chart zehn ee a a MMM S 3 1 Position of Least Forward Stability
17. PRODUCT Due to continuous product improvements JLG Industries Inc reserves the right to make specification changes without prior notifica tion Contact JLG Industries Inc for updated information 3120748 JLG Lift a FOREWORD This page left blank intentionally JLG Lift 3120748 FOREWORD 3120748 All procedures herein are based on the use of the machine under proper operating conditions with no deviations from original design intent as per OSHA regulations and applicable ANSI standards READ amp HEED The ownership use service and or maintenance of this machine is subject to various governmental and local laws and regulations It is the responsibility of the owner user to be knowledgeable of these laws and regulations and to comply with them Owner user operator lessor and lessee 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 con cerning safety training inspection maintenance application and operation The most prevalent regu lations of this type in the United States are the Fed eral OSHA Safety Regulations Listed below in abbreviated form are some of the requirements of Federal OSHA regulations in effect as of the date of publication of this handbook The listing of these requirements shall not relieve the owner user of the responsibility and obligation to d
18. UE DP PS bM us hosted e pur d 1 5 1 7 Towing and Hauling mE iE ES PAM CIERRE AE ek a RI ead 1 8 SECTION 2 PREPARATION AND INSPECTION 2 1 General 0 neto tro Seen ed EO eere nasce et 2 1 2 2 Preparation For Use cmi suter Ads Sea raet NERVAE eds 2 1 2 3 Delivery and Frequent 1 2 1 2 4 Daily Walk Around 2 5 2 5 Daily Functional 2 9 2 6 Battery Maintenance Vee 2 10 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 1 Generals irem gle arsen ev gees aia caused F avs Wa 3 1 3 2 Personnel Training wood on k hehe Elle ab ee ge de ae 3 1 3 3 Operating Characteristics and Limitations 3 2 3 4 Gontrols andilndicators 222 Ep ge ete ae eee ind aoe dil ete aed 3 5 3 5 Placards and Decals Luru snus hy are a uma hae ae Par stala 3 11 SECTION 4 MACHINE OPERATION 4 1 x octo ach ma dage MAR Arg Naas eae Dx habe tue ach Husa Fahne 4 1 4 2 General t riq eee ee Sede dy Pese quy ios aov vin grido ce e ees 4 1 4 3 Engine Operations cortes uda Sr est C n 4 2 4 4 Traveling Driving u uten me 4 2 4 5 Steering cs ee sr LER RSEN ae adobe EUR ER RED 4 3 4 6 Parking and
19. line swaying Death or serious injury will occur from contact or being too close to electrical lines 1703805 A 1703805 B 3120748 JLG Lift 3 15 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL FUNCTION SYMBOL FUNCTION SYMBOL DRIVE SELECT PLATFORM LEVEL FUNCTION SPEED CONTROL CHASSIS OUT OF LEVEL PLATFORM ROTATE PLATFORM CAPACITY INDICATOR TOWER TELESCOPE ENGINE DISTRESS ARTICULATING FLY BOOM LOW FUEL LEVEL MAIN TELESCOPE AC GENERATOR ON 3 16 FUEL SELECT Figure 3 8 Control Panel Symbols Sheet 1 of 2 JLG Lift 3120748 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL FUNCTION GLOW PLUG INDICATOR SYMBOL FUNCTION SOFT TOUCH OVERRIDE SYMBOL ENABLE INDICATOR SOFT TOUCH INDICATOR POWER EMERGENCY STOP START AUXILIARY POWER 3120748 Figure 3 9 Control Panel Symbols Sheet 2 of 2 JLG Lift SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL This page left blank intentionally 3 18 JLG Lift 3120748 SECTION 4 MACHINE OPERATION 3120748 SECTION 4 MACHINE OPERATION 4 1 DESCRIPTION This machine is a self propelled aerial work p
20. switch to HIGH For smoother operation when driving with fully extended boom place DRIVE control to SLOW before stopping 4 5 STEERING Depress footswitch to steer machine push on the left side of the switch to steer left on the right side to steer right 3120748 A CAUTION BEFORE OPERATING MACHINE MAKE SURE BOOM IS POSI TIONED OVER REAR AXLE IF BOOM IS OVER FRONT AXLE STEER WHEELS STEER AND DRIVE CONTROLS WILL MOVE IN OPPOSITE DIRECTION THAN INDICATED ON MACHINE PLAC ARDS 4 6 PARKING AND STOWING Park and stow machine as follows 1 Park machine in travel position boom lowered over rear all access panels and doors closed and secured ignition off Check that brakes hold machine in position Chock wheels front and rear Turn off SELECT switch and remove key 4 7 PLATFORM Loading From Ground Level 1 2 JLG Lift Position chassis on a smooth firm and level surface If total load personnel tools and supplies is less then rated capacity distribute load uniformly on plat form floor and proceed to work position 4 3 SECTION 4 MACHINE OPERATION Loading From Positions Above Ground Level Before loading weight to platform above ground level 1 Determine what the total rated capacity weight will be after additional weight is loaded personnel tools and supplies 2 If total weight in platform will be less then rated capacity proceed with adding weight Pl
21. the engine and automati cally come on with the ignition circuit and remain on for a period of seven seconds PLUGS M E TIMER MODULE In addition to the glow plugs the cold weather package also includes an electric immersion heater for the hydrau lic oil tank and an electric blanket type heater for the bat tery These components can be plugged in together or singly to preheat their associated components for easier cold weather starting 3120748 JLG Lift 5 1 SECTION 5 OPTIONAL EQUIPMENT Deutz Engine with Ether Start The ether start system in the diesel engine functions auto matically to provide starting fluid as necessary to the engine A sensor switch mounted on the engine will per mit ether injection when the engine is cold The sensor will not permit ether injection to a warm engine STARTING AID INJECTOR NOZZLE STARTING AID KIT In addition to the ether start system the cold weather package also includes an electric immersion heater for the hydraulic oil tank and an electric blanket type heater for the battery These components can be plugged in together or singly to preheat their associated components for easier cold weather starting Isuzu Engine The cold weather package for the Isuzu engine consists of the engine block heater an electrical heater inst
22. 2 Daily Walk Around Inspection Sheet 1 of 3 2 6 JLG Lift 3120748 SECTION 2 PREPARATION AND INSPECTION GENERAL Begin the Walk Around Inspection at Item 1 as noted on the diagram Continue to the right counterclockwise viewed from top checking each item in sequence for the conditions listed in the Walk Around Inspection Checklist A WARNING TO AVOID INJURY DO NOT OPERATE A MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED USE OF A MALFUNC TIONING MACHINE IS A SAFETY VIOLATION TO AVOID POSSI BLE INJURY BE SURE MACHINE POWER IS OFF DURING WALK AROUND INSPECTION NOTE Do not overlook visual inspection of chassis under side Checking this area often results in discovery of conditions which could cause extensive machine damage Platform Assembly No loose or missing parts no visible damage Lockbolts in place Footswitch in good working order not modified disabled or blocked Platform Control Console Switches and levers return to neutral and are properly secured no loose or missing parts no visible damage decals placards secure and legible control marking legible Slave Cylinder No visible damage pivot pins secure hydraulic hoses undamaged not leaking Boom Sections Uprights Lift Cylinders and Master Cylinder No visible damage pivot pins secure hydraulic hoses undamaged not leaking Uprights in vertical position Horizontal Limit Switches Switches operable no visible damage
23. 3 8am till 4 45pm EST It should be noted that failure to notify the manufacturer of an incident involving a JLG Industries product within 48 hours of such an occurrence may void any warranty con sideration on that particular machine 3120748 SECTION 7 INSPECTION AND REPAIR LOG SECTION 7 INSPECTION AND REPAIR LOG Table 7 1 Inspection and Repair Log Date Comments 3120748 JLG Lift 7 1 SECTION 7 INSPECTION AND REPAIR LOG Table 7 1 Inspection and Repair Log Date Comments 7 2 JLG Lift 3120748 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 current 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 Produ
24. AND ANY ELECTRICAL LINE OR APPARATUS CARRYING UP TO 50 000 VOLTS ONE FOOT ADDI TIONAL CLEARANCE IS REQUIRED FOR EVERY ADDITIONAL 30 000 VOLTS OR LESS 1 4 PRE OPERATIONAL READ YOUR MANUAL UNDERSTAND WHAT YOU VE READ THEN BEGIN OPERATIONS ALLOW ONLY AUTHORIZED AND QUALIFIED PER MAINTAIN SAFE CLEARANCE FROM ELECTRICAL SONNEL TO OPERATE MACHINE WHO HAVE DEM LINES AND APPARATUS ALLOW FOR BOOM SWAY ROCK OR SAG AND ELECTRICAL LINE SWAYING ONSTRATED THAT THEY UNDERSTAND SAFE AND PROPER OPERATION AND MAINTENANCE OF THE THE MACHINE DOES NOT PROVIDE PROTECTION UNIT 1 2 JLG Lift 3120748 SECTION 1 SAFETY PRECAUTIONS 3120748 AN OPERATOR MUST NOT ACCEPT OPERATING RESPONSIBILITIES UNTIL ADEQUATE TRAINING HAS BEEN GIVEN BY COMPETENT AND AUTHORIZED PERSONS BEFORE OPERATION CHECK WORK AREA FOR OVERHEAD ELECTRIC LINES MACHINE TRAFFIC SUCH AS BRIDGE CRANES HIGHWAY RAILWAY AND CONSTRUCTION EQUIPMENT PRECAUTIONS AVOID ALL KNOWN HAZARDS IN THE WORK AREA MUST BE TAKEN BY THE OPERA TOR AND HIS SUPERVISOR BEFORE STARTING THE WORK DO NOT OPERATE THIS MACHINE UNLESS IT HAS BEEN SERVICED AND MAINTAINED ACCORDING TO THE MANUFACTURERS SPECIFICATIONS AND SCHEDULE ENSURE DAILY INSPECTION AND FUNCTION CHECK IS PERFORMED PRIOR TO PLACING MACHINE INTO OPERATION NEVER DISABLE OR MODIFY THE FOOTSWITCH OR ANY OTHER SAFETY DEVICE ANY UNAUTHORIZED MODIFICATION OF THE MACHINE IS A SAFETY VIO
25. ATFORM FLOOR NEVER WALK THE BOOM TO GAIN ACCESS TO OR LEAVE PLATFORM NEVER PLACE HANDS OR ARMS IN TOWER BOOM OR UPRIGHT MECHANISM KEEP ALL NON OPERATING PERSONNEL AT LEAST 6 FEET 2 M AWAY FROM THE MACHINE AT ALL TIMES JLG Lift F PLATFORM OR BOOM IS CAUGHT SO THAT ONE OR MORE WHEELS ARE OFF THE FLOOR ALL PER SONNEL MUST BE REMOVED FROM PLATFORM BEFORE ATTEMPTING TO FREE MACHINE USE CRANES FORKLIFT TRUCKS OR OTHER EQUIP MENT TO REMOVE PERSONNEL AND STABILIZE MACHINE MOTION IF NECESSARY THE OPERATOR IS RESPONSIBLE TO AVOID OPER ATING MACHINE OVER GROUND PERSONNEL AND TO WARN THEM NOT TO WORK WALK OR STAND UNDER A RAISED BOOM OR PLATFORM POSITION BARRICADES ON FLOOR IF NECESSARY 3120748 SECTION 1 SAFETY PRECAUTIONS FERING WITH OPERATING CONTROLS AND PER e SONS IN PLATFORM ENSURE THAT OPERATORS OF OTHER OVERHEAD AND FLOOR MACHINES ARE AWARE OF THE AERIAL PLATFORMS PRESENCE DISCONNECT POWER TO OVERHEAD CRANES POSITION BARRICADES ON FLOOR IF NECESSARY NEVER SLAM A CONTROL SWITCH OR LEVER THROUGH NEUTRAL TO THE OPPOSITE DIRECTION ALWAYS RETURN SWITCH TO NEUTRAL AND STOP THEN MOVE SWITCH TO THE DESIRED POSITION OPERATE LEVERS WITH SLOW EVEN PRESSURE DO NOT CARRY MATERIALS ON PLATFORM RAILING UNLESS APPROVED BY JLG INDUSTRIES INC NEVER PUSH OR PULL THE MACHINE OR OTHER OBJECTS BY TELESCOPING THE BOOM NEVER USE BOOM FOR ANY PURPOSE OTHER THAN POSITIONING PERSONN
26. CHINERY IF ANY CONTROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE OFF POSI TION WHEN RELEASED TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP SWITCH TO STOP MACHINE Swinging the Boom Depress footswitch to swing boom with footswitch acti vated position SWING control switch to RIGHT or LEFT for direction desired IMPORTANT WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TO CLEAR SURROUNDING WALLS PAR TITIONS AND EQUIPMENT Raising and Lowering the Lower and Mid Boom To raise or lower the Lower and Mid Boom with footswitch activated position Lower Boom Lift switch to UP or DOWN as desired 3120748 SECTION 4 MACHINE OPERATION Raising and Lowering the Main Upper Boom NOTE Lift up will not function when the boom is near full elevation and the platform is out of level To raise or lower the Main Upper Boom with footswitch activated position Upper Boom Lift switch to UP or DOWN until desired height is reached Telescoping the Main Boom To extend or retract the main boom with the footswitch activated position the Main Telescope Control Switch to the in or out position and hold until the platform reaches the desired position 4 9 LIFT UP AND PLATFORM LEVEL DOWN DISABLE SWITCH FUNCTIONAL CHECK The purpose of the disable switch
27. Chart Interval Hours Number Type i Components Capacity Lube e Comments Lube Points 1 Year 2 Years Months Months gophrs 1200hrs 150 hrs 300 hrs Lubrication 1 Swing Bearing Internal 2 Grease Fitting AR MPG X Ball Bearing 2 Swing Bearing Teeth Spray On A R OGL X Morefrequent lubrication intervals may be required 2b EndBearings Worm 2 AR MPG X Remove grease fittings and install plugs after Gear greasing 3 Wheel Bearings 2WD Repack AR MPG X Only 4 Wheel Drive Hub Level Fill Plug 1702 1 2 full EPGL M Change after first 150 hours then every 1200 hours of operation 5 Hydraulic Return Filter N A N A N A X Change after first 50 hours and every 300 hours thereafter or as indicated by condition indicator 6 Hydraulic Charge Filter N A N A N A X Change after first 50 hours and every 300 hours thereafter or as indicated by condition indicator 7 Hydraulic Oil Fill Cap 30 6 Gal Tank HO X Checklevel daily 32 7 Gal System Change every 1200 hours 8 Suction Strainers In Tank 2 N A N A X Removeand cleanattime of hydraulic oil change 9 Steer Cylinder 4 AR MPG X 10 Oscillation Cylinders 2 AR MPG X Engines 11 Oil Change w Filter Ford Fill Cap Spin on 5 Quarts 4 7 L EO X Check level daily change every 150 hours Element Adjust final oil level by mark on dipstic
28. EET 2 M OF AN OBSTRUC TION DO NOT USE DRIVE TO MANEUVER PLATFORM CLOSE TO AN OBSTRUCTION USE ONE OF THE BOOM FUNCTIONS A CAUTION BEFORE DRIVING MAKE SURE BOOM IS POSITIONED OVER REAR AXLE IF BOOM IS OVER FRONT AXLE STEER WHEELS STEER AND DRIVE CONTROLS WILL MOVE IN OPPOSITE DIREC TIONS TO MACHINE CONTROLS Traveling Forward or Reverse 1 With engine running depress footswitch and posi tion DRIVE control to FORWARD and hold for the duration of forward travel desired NOTE When DRIVE or STEER functions are being oper ated there is an interlock which prevents operation of boom functions 2 Depress footswitch and position DRIVE control to REVERSE and hold for duration of reverse travel desired 3 Depress footswitch and position STEER control to RIGHT for traveling right and LEFT for traveling left 3120748 SECTION 4 MACHINE OPERATION DO NOT DRIVE MACHINE ON GRADES AND SIDESLOPES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLACARD 4 NOTE Figure 4 1 Grade and Sideslope To obtain maximum travel speed position the DRIVE controller to FAST and activate the following switches Position DRIVE SPEED TORQUE SELECT switch to FAST Forward Position Prior to stopping the machine position switches as follows Position DRIVE SPEED TORQUE SELECT switch to LOW Backward Position For traveling up grades position switches as fol lows Position DRIVE SPEED TORQUE SELECT
29. EL THEIR TOOLS AND EQUIPMENT NEVER EXCEED MANUFACTURERS RATED PLAT FORM CAPACITY REFER TO CAPACITY DECAL ON MACHINE DISTRIBUTE LOADS EVENLY ON PLAT FORM FLOOR NEVER OPERATE A MALFUNCTIONING MACHINE IF A MALFUNCTION OCCURS SHUT DOWN THE MACHINE RED TAG IT AND NOTIFY PROPER AUTHORITIES DO NOT REMOVE MODIFY OR DISABLE FOOT SWITCH BY BLOCKING OR ANY OTHER MEANS DO NOT ASSIST A STUCK OR DISABLED MACHINE 1 BY PUSHING OR PULLING EXCEPT BY PULLING AT ENSURE MACHINE IS POSITIONED ON FIRM LEVEL AND UNIFORM SUPPORTING SURFACE BEFORE RAISING OR EXTENDING BOOM CHASSIS TIE DOWN LUGS NEVER ATTEMPT USING BOOM AS A CRANE STRUCTURAL DAMAGE OR TIPPING MAY OCCUR STOW BOOM AND SHUT OFF ALL POWER BEFORE LEAVING MACHINE NO STUNT DRIVING OR HORSEPLAY IS PERMITTED CHECK CLEARANCES ABOVE ON SIDES AND BOT TOM OF PLATFORM WHEN RAISING LOWERING SWINGING AND TELESCOPING BOOM EXERCISE EXTREME CAUTION ALL TIMES TO PREVENT OBSTACLES FROM STRIKING OR INTER 3120748 JLG Lift 1 7 SECTION 1 SAFETY PRECAUTIONS NEVER ATTEMPT TO FREE A MACHINE STUCK IN SOFT GROUND OR ASSIST A MACHINE UP A STEEP HILL OR RAMP BY USING BOOM LIFT TELE SCOPE OR SWING FUNCTIONS NEVER ATTACH WIRE CABLE OR ANY SIMILAR ITEMS TO PLATFORM DO NOT PLACE BOOM OR PLATFORM AGAINST ANY STRUCTURE TO STEADY PLATFORM OR SUPPORT STRUCTURES DO NOT USE THE LIFT SWING OR TELESCOPE FUNCTIONS FOR THE BOOM TO M
30. EN PERSONNEL ARE IN THE PLATFORM OPERATION OF THE BOOM WILL ONLY BE PER FORMED WITH THE PERMISSION OF THE PLATFORM OCCUPANT S NOTE When Power Emergency Stop switch is in the on position and engine is not running an alarm will sound indicating Ignition is on A CAUTION WHEN THE MACHINE IS SHUT DOWN THE MASTER EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERY 1 Power Emergency Stop Switch Pull out on off Power Emergency Stop Switch to turn on engine ignition and power to the electrical sys tem Push in to shut off engine and remove power from the controls The Ground Control Emergency Stop Switch must be pulled out to operate the machine from either Ground Control or Platform Control This allows the machine to be shut down in emergency situations by those untrained in the operation of the lift but who recognize the Emer gency Stop Switch The keyed Master Switch can also be used for the same purpose 2 Engine Start Auxiliary Power Switch A toggle type Engine Start Auxiliary Power control switch on the ground control panel energizes the engine starter or the electrically operated auxiliary hydraulic pump when actuated To start the engine the switch must be held up until the engine starts To use auxiliary power the switch must be held down for duration of auxiliary pump use NOTE Auxiliary power only works if there is no oil pressure and is disabled if engine is
31. GASOLINE under a no load condition place FUEL SELECT switch at Plat form Control to LP position Changing From LP Gas to Gasoline 1 With engine operating on LP under a no load condi tion position FUEL SELECT switch at Platform Con trol Station to GASOLINE position 2 Close hand valve on LP gas supply tank by turning clockwise 5 2 OSCILLATING AXLE The oscillating front axle is attached to the frame by a pivot pin which allows all four wheels to remain on the ground when traveling on rough terrain The oscillating axle also incorporates two lockout cylinders connected between the frame and each wheel end The lockout cylin ders permit axle oscillation when the boom is centered over the rear and lock and hold the axle when the boom is moved off center 5 3 PLATFORM W SOFT TOUCH PROXIMITY SYSTEM BUMPER This optional system incorporates a lower padded rail slightly larger than the platform Four Proximity switches are attached to each corner of the lower rail The proximity switches are set so that when the antenna comes into contact with an object electrical power is cut off from the platform controls shutting down all functions 5 4 FOUR WHEEL DRIVE Provides drive motors brakes rear only and torque hubs at each wheel to give extra traction The system is avail able with either a fixed or oscillating front axle 5 5 COLD WEATHER PACKAGE Deutz Engine with Glow Plugs The glow plugs are installed in
32. H SPEED SWITCH TO LOW SPEED BEFORE STOPPING TRAVEL GRADES IN LOW DRIVE HIGH ENGINE ONLY DO NOT USE HIGH SPEED DRIVE WHEN IN RESTRICTED OR CLOSE QUARTERS OR WHEN DRIVING IN REVERSE BE AWARE OF STOPPING DISTANCES WHEN TRAV ELING IN HIGH AND LOW SPEEDS ALWAYS POST A LOOKOUT AND SOUND HORN WHEN DRIVING IN AREAS WHERE VISION IS OBSTRUCTED KEEP NON OPERATING PERSONNEL AT LEAST 6 FEET 2 M AWAY FROM MACHINE DURING DRIVING OPERATIONS 3120748 SECTION 1 SAFETY PRECAUTIONS 3120748 CHECK TRAVEL PATH FOR PERSONS DEPRES SIONS HOLES BUMPS DROP OFFS OBSTRUC TIONS DEBRIS AND COVERINGS WHICH MAY HOLES AND OTHER HAZARDS TRAVEL IS PERMITTED ON GRADES NO GREATER THAN THOSE INDICATED ON THE SERIAL NUMBER PLATE DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 OPERATION WITH BOOM RAISED IS RESTRICTED TO FIRM LEVEL AND UNIFORM SURFACE DO NOT TRAVEL ON SOFT OR SURFACES AS TIPPING WILL OCCUR ENSURE THAT GROUND CONDITIONS ARE ADE QUATE TO SUPPORT THE MAXIMUM TIRE LOAD DO NOT DRIVE MACHINE NEAR PITS LOADING DOCKS OR OTHER DROP OFFS 1 6 JLG Lift OPERATION READ YOUR MANUAL UNDERSTAND WHAT YOU VE READ THEN BEGIN OPERATIONS PRIOR TO ENTERING AND EXITING PLATFORM AT GROUND LEVEL FULLY LOWER THE BOOM EXTEND BOOM UNTIL END OF FLY BOOM CON TACTS GROUND WITH BOOM LIFT IN THIS CONFIG URATION ENTER AND OR EXIT PLATFORM THROUGH GATE OPENING OSHA RE
33. OG LHL 0481 00 0 0690 0546 08 8 0062 05 000 0089 0228 14 81 0227 1441 79500 8600 000400 05 00 7 71 00 00700 SLOLO O 60600 0 L9900 0 1 NI 81 NI 81 NI 81 127 uo 272 3111901 zac 3111901 592201 Cam yo aya HOLVd 13 201 HLM M383S 4 2 131205 531935 0961 SM34JIS dvd qaividNn anouuo NI 871 NI 81 NI 81 2 zvz 3111901 9 augon M anouo avol dINV 15 SLNN 8 JAVYD 61108 8 IVS SLNN 9 51108 s IAVYD IVS KINO S1108 G31vTd INIZ 804 SANTWA 7090070 NI OS 59318 Qv3sHL 3120748 JLG Lift 2 14 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 1 GENERAL 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 and or ope
34. ON OF THE MACHINE IS STRICTLY FORBIDDEN WITHOUT WRITTEN APPROVAL FROM JLG INDUSTRIES PER OSHA REGULATIONS AND APPLICABLE ANSI STANDARDS Safety of personnel and proper use of the machine are of primary concern DANGER WARNING CAU TION IMPORTANT INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these areas They are defined as follows THIS SAFETY ALERT SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED A DANGER DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR DEATH A CAUTION CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES A WARNING WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY OR DEATH A IMPORTANT IMPORTANT OR INSTRUCTIONS INDICATES A PROCEDURES ESSENTIAL FOR SAFE OPERATION AND WHICH IF NOT FOL LOWED MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE MACHINE A IMPORTANT JLG INDUSTRIES MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT CONTACT JLG INDUSTRIES INC OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR YOUR JLG PRODUCT ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COM PLETED ON THE AFFECTED JLG
35. OVE EITHER THE MACHINE OR OTHER OBJECTS HYDRAULIC CYLINDERS SHOULD NEVER BE LEFT FULLY EXTENDED OR RETRACTED FOR ANY LENGTH OF TIME ALWAYS BUMP CONTROL IN OPPOSITE DIRECTION SLIGHTLY WHEN FUNCTION BEING USED REACHES END OF TRAVEL THIS APPLIES TO MACHINES IN OPERATION OR IN STOWED MODE DO NOT OPERATE ANY MACHINE ON WHICH DAN GER WARNING CAUTION OR INSTRUCTION PLAC ARDS OR DECALS ARE MISSING OR ILLEGIBLE JLG Lift MACHINE MUST ALWAYS BE SHUT DOWN WHEN REFUELING NO SMOKING IS MANDATORY NEVER REFUEL DURING AN ELECTRICAL STORM ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES 1 7 TOWING AND HAULING DO NOT TOW A MACHINE EXCEPT IN AN EMER GENCY SEE SECTION 6 FOR EMERGENCY TOWING PROCEDURES LOCK TURNTABLE BEFORE TRAVELING LONG DIS TANCES OR BEFORE HAULING MACHINE ON A TRUCK OR TRAILER 3120748 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
36. QUIRES ALL PERSONS IN THE PLATFORM TO WEAR LANYARDS WITH AN APPROVED FALL PROTECTION DEVICE SECURE LANYARD TO DES IGNATED LANYARD ATTACH POINT ON PLATFORM KEEP GATE CLOSED AT ALL TIMES TO AVOID FALLING USE EXTREME CAUTION WHEN ENTERING OR LEAVING PLATFORM ABOVE GROUND ENTER OR EXIT THRU GATE ONLY PLAT FORM FLOOR MUST BE WITHIN 1 FOOT 30 CM OF ADJACENT SAFE AND SECURE STRUCTURE ALLOW FOR PLATFORM VERTICAL MOVEMENT AS WEIGHT IS TRANSFERRED TO OR FROM PLAT FORM SECTION 1 SAFETY PRECAUTIONS 1 6 TRANSFERS BETWEEN A STRUCTURE AND THE AERIAL PLATFORM EXPOSE OPERATORS TO FALL HAZARDS THIS PRACTICE SHOULD BE DISCOUR AGED WHEREVER POSSIBLE WHERE TRANSFER MUST BE ACCOMPLISHED TO PERFORM THE JOB TWO LANYARDS WITH AN APPROVED FALL PRO TECTION DEVICE WILL BE USED ONE LANYARD SHOULD BE ATTACHED TO THE AERIAL PLATFORM THE OTHER TO THE STRUCTURE THE LANYARD THAT IS ATTACHED TO THE AERIAL PLATFORM SHOULD NOT BE DISCONNECTED UNTIL SUCH TIME AS THE TRANSFER TO THE STRUCTURE IS COMPLETE OTHERWISE DO NOT STEP OUTSIDE OF PLATFORM DO NOT ADD NOTICE BOARDS OR SIMILAR ITEMS TO THE PLATFORM ADDITION OF SUCH ITEMS INCREASES THE EXPOSED WIND AREA OF THE MACHINE NEVER POSITION LADDERS STEPS OR SIMILAR ITEMS ON UNIT TO PROVIDE ADDITIONAL REACH FOR ANY PURPOSE WHEN RIDING IN OR WORKING FROM PLATFORM BOTH FEET MUST BE FIRMLY POSITIONED ON THE FLOOR KEEP OIL MUD AND SLIPPERY SUBSTANCES CLEANED FROM FOOTWEAR AND PL
37. RTERLY ANY TIME A SYSTEM CONPONENT IS REPLACED OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED NOTE Ensure boom is fully retracted lowered and cen tered between drive wheels prior to beginning lock out cylinder test 1 Place a 6 inches 15 2 cm high block with ascen sion ramp in front of left front wheel 2 From platform control station start engine3 Place HIGH ENGINE DRIVE SPEED and WHEEL MOTOR SPEED if equipped control switches to their respective LOW positions 3 Place DRIVE control lever to FORWARD position and carefully drive machine up ascension ramp until left front wheel is on top of block 4 Carefully activate SWING control lever and position boom over right side of machine 5 With boom over right side of machine place DRIVE control lever to REVERSE and drive machine off of block and ramp 6 Have an assistant check to see that left front wheel remains locked in position off of ground 10 11 12 13 14 3120748 JLG Lift Carefully activate SWING control lever and return boom to stowed position centered between drive wheels When boom reaches center stowed posi tion lockout cylinders should release and allow wheel to rest on ground it may be necessary acti vate DRIVE to release cylinders Place the 6 inches 15 2 cm high block with ascen sion ramp in front of right front wheel Place DRIVE control lever to FORWARD and care fully drive machine up ascension ramp unt
38. Stowing iv ede BAe pene eee SEG 4 3 4 7 e cai Ib rcd ER REA CURAE ELA REG MERGER C RU NE shan 4 3 4 8 lE 4 4 4 9 Lift Up and Platform Level Down Disable Switch Functional Check 4 5 4 10 Shut Down and Parku wed ees asa Sus ek hed bt EL Ee ease 4 5 4 11 Tie Dowrrand Lifting 4 5 4 12 Oscillating Axle Lockout Test If Equipped 4 9 4 13 TOWING ele Ga ae EEUU ET uere oT TES 4 10 SECTION 5 OPTIONAL EQUIPMENT 5 1 Dual Fuel System Gas Engine 5 1 5 2 Oscillating Axle 3 3 L k r S Reip teu 5 1 5 3 Platform W soft Touch Proximity System 5 1 5 4 Four Wheel Drive ai u ulasan Deine Uv ee da a duel DE ee aa E ODE 5 1 5 5 Cold Weather 5 1 5 6 Travel Alarm 5 4 uei ged REI Noch Gee odd paq i sq 5 2 5 7 Electric Generato u ose Les Ren ER is ke forenet bad Gace dag Ba 5 2 5 8 Foam Filled hah relser dage 5 2 5 9 Rotating Beacon ber Ee rud end pec cte CA S C ERR e e kiste 5 2 3120748 JLG Lift TABLE OF CONTENTS Continued TABLE
39. Y POWER switch to ON and hold 5 Release AUXILIARY POWER switch and appropriate control switch or controller 6 Position POWER EMERGENCY STOP switch to OFF 3120748 JLG Lift 6 1 SECTION 6 EMERGENCY PROCEDURES 6 4 EMERGENCY OPERATION Use of Ground Controls KNOW HOW TO USE THE GROUND CONTROLS IN AN 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 controls in simulated emergen cies Operator Unable to Control Machine IF THE PLATFORM OPERATOR IS PINNED TRAPPED OR UNABLE TO OPERATE OR CONTROL THE MACHINE A WARNING 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 Post Incident Inspection and Repair Following any incident thoroughly inspect the machine and test all functions first from the ground controls then from the platform controls Do not lift above 10 feet 3 m
40. alled in the left front core plug hole an electric immersion heater for the hydraulic oil tank and an electric blanket type heater for the battery These components can be plugged in together or singly to preheat their associated compo nents for easier cold weather starting Ford Engine Two different options are available for cold weather with the Ford engine an engine block heater and a cold weather package which also includes the engine block heater The engine block heater is an electrical heater installed in the left intake side core plug hole When plugged in it heats the engine coolant to warm the engine prior to start ing The cold weather package consists of the engine block heater mentioned above an immersion heater for the hydraulic oil tank and an electric blanket type heater for the battery These components can be plugged in together or singly to preheat their associated components for easier cold weather starting 5 2 JLG Lift 5 6 TRAVEL ALARM A 12 volt alarm horn mounted on the turntable provides an audible warning when the machine is in the travel DRIVE mode It will function in FORWARD or REVERSE to warn jobsite personnel the machine is traveling 5 7 ELECTRIC GENERATOR An electric generator mounted on the machine functions to supply electrical power to the platform This device will provide enough power to run assorted power tools 5 8 FOAM FILLED TIRES Eliminates flats by
41. an be controlled from either the Platform Control Station or the Ground Control Station Follow the instructions placed at the control stations The JLG Lift is hydraulically powered using hydraulic motors and cylinders for various machine motions The hydraulic components are controlled by electrically acti vated hydraulic valves using switches and control levers The speeds of functions controlled by control levers are variable from zero to maximum speed depending upon the position of the control lever Functions controlled by toggle switches are either on or off and higher or lower speed is possible when the Function Speed control switch is used in conjunction with the function toggle switch A foot operated switch in the platform must be depressed before any controls will function and provides a means of emergency stop when the operator s foot is removed from the footswitch The JLG Lift is a two wheel drive four wheel drive avail able machine with drive power being supplied by a hydraulic motor for each drive wheel Each drive wheel is supplied with a hydraulically released spring applied brake AWD machines only have brakes on the rear These brakes are automatically applied any time the Drive Control lever is returned to the neutral position The unrestricted capacity of the JLG Lift is 500 Ibs 230 kg This means that with a platform load of 500 Ibs 230 kg or less the platform may be positioned anywhere the boom will reac
42. atform Level Adjustment 1 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 Platform Rotation 1 Depress footswitch to rotate platform to the left PLATFORM ROTATE control is positioned to the LEFT and held until desired position is reached 2 Depress footswitch to rotate platform to the right PLATFORM ROTATE control is positioned to the RIGHT and held until desired position is reached 4 4 JLG Lift 4 8 BOOM A WARNING AN ORANGE TILT WARNING LIGHT IS LOCATED ON THE CON TROL 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 THE TILT ALARM INDICATES THE CHASSIS IS ON A SEVERE SLOPE 5 DEGREE OR GREATER CHASSIS MUST BE LEVEL BEFORE SWINGING OR RAISING BOOM ABOVE HORI ZONTAL TO AVOID MACHINE UPSET IF THE ORANGE TILT WARNING LIGHT ILLUMINATED WHEN THE BOOM IS RAISED ABOVE HORI ZONTAL LOWER THE PLATFORM TO GROUND LEVEL THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVEL BEFORE RAISING BOOM TRAVELING WITH BOOM BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE SLOPES SPECIFIED ON SERIAL NUMBER PLACARD TO AVOID SERIOUS INJURY DO NOT OPERATE MA
43. ave to be on to operate the lights so care must be taken to avoid draining the battery if left unattended The master switch and or the ignition switch at the ground control will turn off power to all lights Engine Distress Indicator Light Yellow The light turns on and an alarm sounds when machine s power system requires immediate ser vice Any of the following conditions will turn on light and alarm low engine oil pressure high engine coolant temperature clogged engine air filter low alternator output clogged hydraulic oil return filter or clogged charge pump filter 3 11 Updated 4 24 02 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 20 21 22 23 Soft Touch Indicator If Equipped When illuminated Yellow the Soft Touch bumper is against an object All controls are cut out until the override button is pushed at which time controls are active in the Creep mode AC Generator Green When illuminated Green the light indicates the generator is in operation Low Fuel Indicator Yellow When illuminated Yellow the fuel tank is 1 8 full or less When the light first turns on there are approxi mately four usable gallons of fuel remaining Auxiliary Power A toggle type Auxiliary Power control switch ener gizes the electrically operated hydraulic pump when actuated Switch must be held ON for dura tion of auxiliary pump use The auxiliary pump functions to provide suffi
44. battery Check engine tray pivot assembly for damage loose or missing parts and security Check engine and accessories for damage loose or missing parts leakage and security Check throttle solenoid and linkage for damage electrical connec tions for tightness and evidence of corrosion and wiring for insulation damage Check fuel lines for damage leakage and security Check all access doors for damage proper opera tion of latches props and security Check fuel tank for damage leakage and filler cap for security Check hydraulic reservoir and hydraulic lines for damage leakage and security JLG recommends replacing the hydraulic filter ele ment after the first 50 hours of operation and then every 300 hours thereafter unless system indicator require earlier replacement 12 13 Check all pin and shaft retaining hardware rity and wear Check all electrical cables for defects damage loose or corroded connections Boom 1 10 11 12 13 14 JLG 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
45. be reset Platform Rotate A three position Rotate control switch permits rota tion of the platform when positioned to the left or right Platform Leveling Override A three position Platform Leveling Override control switch allows the operator to compensate for any difference in the automatic self leveling system by positioning the control switch up or down Articulating Jib Boom If Equipped The Articulating Jib Boom control switch provides raising and lowering of the jib when positioned up or down Updated 9 19 00 3 6 JLG Lift 12 Battery Charging Indicator When illuminated indicates a problem in the battery or charging circuit and service is required 13 Engine Air Filter Indicator When illuminated indicates that the air filter is too restrictive and needs to be replaced 14 Engine Oil Pressure Indicator When illuminated indicates that engine oil pressure is below normal and service is required 15 Engine Coolant Temperature Ford and Isuzu Indicator When illuminated indicates that engine coolant tem perature is abnormally high and service is required 16 Engine Oil Temperature Indicator Deutz When illuminated indicates that the temperature of the engine oil which also serves as engine coolant is abnormally high and service is required ENGINE MALFUNCTION INDICATOR LOWENGINE PENGINE OIL INDICATOR FUEL HIGH ENGINE WATER TEMP BATTERY CHARGING 2
46. c lines for damage and leaks 6 Check oil level in drive hub by removing pipe plug on side and feeling for oil level Contact Service Personnel for assistance if needed NOTE Torque hubs should be one half full of lubricant 7 Check oscillating axle if equipped for loose miss ing and worn parts pivot pin and lockout cylinder pins for security lockout cylinders and hydraulic hoses for damage and leaks 3120748 JLG Lift 2 1 SECTION 2 PREPARATION AND INSPECTION Turntable 10 11 NOTE 2 2 1 Check turntable for damage loose or missing parts and security Check swing drive and brake for dam age loose or missing parts hydraulic lines and component housings for evidence of leakage worm gear for proper mesh with swing gear Check swing bearing for damage wear lubrication and loose or missing bearing bolts Check solenoid valves and hydraulic lines for dam age leakage security and electrical connections for tightness and evidence of corrosion Check ground controls for damage loose or miss ing parts security electrical connections for evi dence of corrosion and tightness and wiring for insulation damage Assure that all switches function properly Check battery for damage loose or missing vent caps electrical connections for tightness and evi dence of corrosion hold down brackets for tight ness and electrolyte for proper water level Add only clean distilled water to
47. ce and Maintenance manual provides specific torque values and periodic maintenance procedures with a listing of individual components Utiliz ing this Torque Chart in conjunction with the preventive maintenance section in the Service and Maintenance manual will enhance safety reliability and performance of the machine 3120748 SECTION 2 PREPARATION AND INSPECTION 2 4 DAILY WALK AROUND INSPECTION It is the operators responsibility to inspect 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 3120748 Overall cleanliness Check all standing surfaces for oil fuel and hydrau lic oil spillage and foreign objects Ensure overall cleanliness Placards Keep all information and operating placards clean and unobstructed Cover when spray painting or shot blasting to protect legibility 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 Machine Log Ensure a machine operating record or log is kept
48. cient oil flow to operate the basic machine functions should the main pump or engine fail The auxiliary pump will operate tower boom lift tower telescope main boom lift main telescope and swing It should be noted that the functions will operate at a slower than normal rate because of the lower gpm delivered IMPORTANT WHEN OPERATING ON AUXILIARY POWER DO NOT OPERATE MORE THAN ONE FUNCTION AT THE SAME TIME SIMULTA NEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP MOTOR 3 12 NOTE The main function of auxiliary power is to lower the platform in the event of primary power failure Deter mine the reason for primary power failure and have the problem corrected by a certified JLG service technician Operate as follows a Position Platform Ground switch to Platform b Position Power Emergency Stop switch to the on position c Depress and hold footswitch d Operate appropriate control switch or lever for desired function and hold e Position Auxiliary Power switch to the on posi tion and hold f Release Auxiliary Power switch selected control Switch or lever and footswitch g Position Power Emergency Stop switch to the off position 3 5 PLACARDS AND DECALS Read and understand all placards and decals Do not operate any machine on which DANGER WARNING CAUTION OR INSTRUCTION PLACARDS OR DECALS ARE MISSING OR ILLEGIBLE Replace placards and decals if damaged missing or illegible Decals are mad
49. ct 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 Industrles 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 Date Of Transfer Current Owner Address State 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 P O 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 Place 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
50. ctuated NOTE Engine Start Auxiliary Power Main Lift Swing Plat form Level Main Telescope Tower Lift and Platform Rotator control switches are spring loaded and will automatically return to neutral off when released A CAUTION WHEN OPERATING THE BOOM ENSURE THERE ARE NO PER SONNEL AROUND OR UNDER PLATFORM A CAUTION TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED JLG Lift 3 5 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 10 11 Tower Lift The Tower Lift control switch provides raising and lowering of the lower and mid booms when posi tioned up or down Main Lift Control The Main Lift control switch provides raising and lowering of the main boom when positioned up or down Main Telescope Control The Main Telescope control switch provides exten sion and retraction of the main boom when posi tioned to in or out Swing Control The Swing control switch provides 360 degrees non continuous turntable rotation when positioned to the right or left Hourmeter An hourmeter installed in the bottom left of the Ground Control box registers the amount of time the machine has been in use with engine running By connecting into the oil pressure circuit of the engine only engine run hours are recorded The hourmeter registers up to 9 999 9 hours and cannot
51. e of Lexan Pressure Sensitive Adhesive with a protective film on the front Remove the damaged decal and thoroughly clean surface before installing a new decal Simply peel off the back and press new decal onto surface NOTE Placards and Decals can be ordered by using part numbers located by each placard or decal See Fig ure 3 7 Danger and Warning Decal Location JLG Lift 3120748 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL CRUSHING HAZARD 1703804 A 1703798 CRUSHING HAZARD ADANGER 1703797 CRUSHING HAZARD 1703804 A Figure 3 7 Danger and Warning Decal Location 3120748 JLG Lift 3 13 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 14 A DANGER ELECTROCUTION HAZARD This machine is not insulated Maintain a clearance of at least 10 ft between any part of machine or load and any electrical line or apparatus charged up to 50 000 volts One foot additional clearance is required for each additional 30 000 volts or less Allowances must be made for operator error machine deflection and electrical line swaying Death or serious injury will occur from contact or being too close to electrical lines TIP OVER HAZARD Machine must be on a smooth firm and level surface before swinging elevating and or extending boom DO NOT e
52. ed from personnel in the platform except in case of an emer gency 12 Regular inspection of the job site and aerial lift shall be performed by competent persons 13 Personnel shall always stand on the floor of the platform not on boxes planks railing or other devices for a work position Applicable Federal OSHA regulations for the United States as of the date of publication of this manual include but are not limited to 29 CFR 1910 67 29 CFR 1926 20 29 CFR 1926 21 29 CFR 1926 28 and 29 CFR 1926 453 JLG Lift FOREWORD REVISON LOG Original Issue May 1998 Revised June 1 1999 3 6 Updated 9 21 99 3 8 Updated 9 21 99 3 6 Updated 10 14 99 2 12 and 2 13 Updated 11 8 99 5 3 Updated 2 2 00 Prop 65 page added Updated 4 20 00 4 1 Updated 4 20 00 3 6 Updated 9 19 00 3 11 Updated 4 24 02 d JLG Lift 3120748 TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO SECTION FOREWORD SECTION 1 SAFETY PRECAUTIONS 1 1 General IEEE RUM REEF RAE 1 1 1 2 eras ees Soe rever VP per EIS Sen Ron de JG DEO va eR Inr petas 1 1 1 3 Electrocution 2222 2 a Eee ka 1 2 1 4 ur u e pep endow det Rp ex wa PUn ose d delig aldre 1 2 1 5 Driving i s shan eee ea eed uc me n P 1 4 1 6 Operation iere
53. ee Figure 4 3 and Figure 4 4 If it becomes necessary to lift the machine using an over head or mobile crane it is very important that the lifting devices are attached only to the designated lifting eyes See Figure 4 5 Lifting Chart NOTE Crane and lifting devices chains slings etc must be capable of handling at least 450A 2WD pneumatic tires 14 700 155 6668 kg 450AJ 2WD pneumatic tires 15 500 Ibs 7030 kg 450A 2WD foam filled tires 15 400 Ibs 6985 kg 450AJ 2WD foam filled tires 15 700 Ibs 7122 kg A IMPORTANT ABOVE ARE MINIMUM WEIGHTS CHECK WEIGHT OF UNIT PRIOR TO LIFTING NOTE 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 3120748 JLG Lift 4 5 SECTION 4 MACHINE OPERATION Note When transporting machine over rough terrain or long distance the boom needs to be chocked and strapped whenever the base boom is unable to rest on its pad This prevents the boom from bouncing up and down and preventing possible damage while transporting 4 6 Figure 4 3 Machine Tie Down A Models JLG Lift
54. epressing the footswitch recycle footswitch 1 Footswitch This feature makes it necessary to depress the foot switch to allow operation of the platform controls A WARNING TO AVOID SERIOUS INJURY DO NOT REMOVE MODIFY OR DIS ABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS FOOTSWITCH MUST BE ADJUSTED 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 ADJUSTED 2 Power Emergency Stop An on off Power Emergency Stop switch and a sep arate Engine Start Auxiliary Power toggle switch on the platform console supply electrical power to the starter solenoid when the ignition switch is placed in the ON position and the ENGINE START switch is push forward 3 Enable Indicator Green This green illuminator indicates that the footswitch is depressed and the platform controls are ready for use To enable the controls depress the footswitch and select any function within seven seconds The controls will then remain active as long as there is not a delay of seven seconds between stopping one function and starting the next one If the seven sec ond interval is exceeded the enable light will go out and the controls will not operate To enable the con trols again remove your foot from the footswitch and depress the footswitch 4 Travel Warning Horn 3120748 A push type horn switch supplie
55. etermine all applicable laws and regulations and their exact wording and requirements and to com ply with the requirements Nor shall the listing of these requirements constitute an assumption of responsibility of liability on the part of JLG Indus tries Inc 1 Only trained and authorized operators shall be permitted to operate the aerial lift 2 A malfunctioning lift shall be shut down until repaired 3 The controls shall be plainly marked as to their function 4 The controls shall be tested each day prior to use to determine that they are in safe operating condition 5 All personnel in the platform shall at all times wear approved fall protection devices and other safety gear as required 6 Load limits specified by the manufacturer shall not be exceeded 7 nstruction and warning placards must be legi ble 8 Aerial lifts may be field modified for uses other than those intended by the manufacturer only if certified in writing by the manufacturer to be in conformity to JLG requirements and to be at least as safe as it was prior to modification 9 Aerial lifts shall not be used near electric power lines unless the lines have been de energized or adequate clearance is maintained See OSHA 29 CFR 1910 67 and 1926 453 10 Employees using aerial lifts shall be instructed on how to recognize and avoid unsafe condi tions and hazards 11 Ground controls shall not be operated unless permission has been obtain
56. eviewed by all personnel whose responsibilities include any work or contact with the machine 6 2 EMERGENCY TOWING PROCEDURES Towing this machine is prohibited unless properly equipped However provisions for moving the machine in case of a malfunction or power failure have been incorpo rated The following procedures are to be used ONLY for emergency movement to a suitable maintenance area 1 Chock wheels securely 2 Disengage drive hubs by reversing disconnect caps 3 Connect suitable equipment remove chocks and move machine After moving machine complete the following proce dures 1 Position machine on a firm and level surface 2 Chock wheels securely 3 Engage drive hubs by reversing disconnect caps on hubs 4 Remove chocks from wheels as needed 6 3 EMERGENCY CONTROLS AND THEIR LOCATIONS Power Emergency Stop Switches 1 There is one of these red mushroom shaped Switches at both the Ground Controls and Platform Controls When depressed it will immediately stop the machine A WARNING CHECK MACHINE DAILY TO MAKE SURE EMERGENCY STOP SWITCH GUARD IS IN PLACE AND THAT GROUND CONTROL INSTRUCTIONS ARE IN PLACE AND LEGIBLE 2 Installed on the Platform Console this round red Switch is pulled up for normal machine functions In an emergency push the button to the down position with your palm and machine will immediately stop Ground Control Station The Ground Control Station is located on t
57. filling tires with polyurethane foam For use where sharp objects are frequently encountered on operating surface of jobsite 5 9 ROTATING BEACON An amber or red rotating beacon may be installed on the hood or platform and can be controlled by a two position toggle switch mounted on the platform control console When the switch is placed in the ON position the light is activated and provides a visual warning to the machine s operation 5 10 CYLINDER BELLOWS A one piece accordion shaped rubber bellows may be attached to the rod end of the cylinder barrel and to the cylinder rod as close to the rod attach bushing as possi ble The bellows affords protection to the cylinder rod in either the extended or retracted position The bellows are installed on the lift cylinder slave cylinder master cylinder and steer cylinder 5 11 BOOM WIPERS A one piece U shaped neoprene strip be attached to the front of the base boom section wipes the top and both sides of the fly section The bottom side of the fly section is protected by a straight neoprene strip which also attaches to the base section 3120748 SECTION 5 OPTIONAL EQUIPMENT 3120748 5 12 HOSTILE ENVIRONMENT PACKAGE The hostile environment package provides additional pro tection against the entry of dust dirt sand and other abra sive materials into the hydraulic system control handles and switches cylinders boom wire ropes and wear pads and the air inle
58. h 42 GENERAL This section provides the necessary information needed to operate the machine Included in this section are the procedures for starting stopping traveling steering park ing platform loading and transporting It is important that the user read and understand the proper procedures before operating the machine Updated 4 20 00 JLG Lift 4 1 SECTION 4 MACHINE OPERATION 4 33 ENGINE OPERATION NOTE Initial starting should always be performed from the Ground Control station Starting Procedure 1 Check engine oil If necessary add oil in accor dance with the Engine Manufacturer s manual 2 Check fuel level Add fuel if necessary 3 Check that air cleaner components are in place and securely fastened CAUTION IF ENGINE FAILS TO START PROMPTLY DO NOT CRANK FOR AN EXTENDED PERIOD SHOULD ENGINE FAIL TO START ONCE AGAIN ALLOW STARTER TO COOL OFF FOR 2 3 MINUTES IF ENGINE FAILS AFTER SEVERAL ATTEMPTS REFER TO ENGINE MAINTENANCE MANUAL NOTE Machines with diesel engines After turning on igni tion operator must wait until glow plug indicator light goes out before cranking engine 4 Turn key of SELECT switch to GROUND Position POWER EMERGENCY STOP switch to ON then push the ENGINE START switch to the upward posi tion until engine starts A CAUTION ALLOW ENGINE TO WARM UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD 5 After engine has had sufficient ti
59. he right front side of the turntable The controls on this panel provide the means for overriding the platform controls and for controlling the platform level boom and swing functions from the ground Place the KEY SELECT switch to GROUND position and operate the proper switch to lift swing or telescope the boom or level the platform Auxiliary Power A toggle type auxiliary power control switch is located on the platform control station and another is located on the ground control station Operation of either switch turns on the electrically driven auxiliary hydraulic pump This should be used in case of failure of the main power plant The auxiliary pump will operate boom lift telescope and swing To activate auxiliary power 1 Position PLATFORM GROUND SELECT KEY SWITCH to PLATFORM 2 Position POWER EMERGENCY STOP switch to ON 3 Depress and hold footswitch 4 Operate appropriate control switch lever or control ler for desired function and hold 5 Position AUXILIARY POWER switch to ON and hold 6 Release AUXILIARY POWER switch selected control Switch lever or controller and footswitch 7 Position POWER EMERGENCY STOP switch to OFF To activate auxiliary power from the ground control sta tion 1 Position PLATFORM GROUND SELECT KEY SWITCH to GROUND 2 Position POWER EMERGENCY STOP switch to ON 3 Operate appropriate control switch or controller for desired function and hold 4 Position AUXILIAR
60. il right front wheel is on top of block Carefully activate SWING control lever and position boom over left side of machine With boom over left side of machine place DRIVE control lever to REVERSE and drive machine off of block and ramp Have an assistant check to see that right front wheel remains locked in position off of ground Carefully activate SWING control lever and return boom to stowed position centered between drive wheels When boom reaches center stowed posi tion lockout cylinders should release and allow wheel to rest on ground it may be necessary acti vate DRIVE to release cylinders If lockout cylinders do not function properly have qualified personnel correct the malfunction prior to any further operation 4 9 SECTION 4 MACHINE OPERATION 4 13 TOWING A WARNING RUNAWAY VEHICLE MACHINE HAZARD MACHINE HAS NO ING BRAKES TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES ON HIGHWAY TOWING NOT PERMIT TED FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERI OUS INJURY OR DEATH MAXIMUM TOWING SPEED 5 M P H 8 K M H FOR NO LONGER THAN 30 45 MINUTES MAXIMUM TOWING GRADE 25 Prior to towing the machine complete the following A CAUTION DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED 1 Retract lower and position boom over rear drive wheels in line with direction of travel 2 Disconnect drive hubs by inverting disconnect cap See Figure 4 6
61. is to prevent lift up when the boom is near full elevation and the platform is out of level PROXIMITY SWITCH CONTACT PLATE COIN Figure 4 2 Functional Check IMPORTANT DISABLE SWITCH FUNCTIONAL CHECK MUST BE PERFORMED QUARTERLY ANY TIME A SYSTEM COMPONENT IS REPLACED OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED 1 Tape a small piece of metal to the end of the limit switch e g a coin 2 Using the controls in the platform basket test the lift up and platform level down functions Both opera tions should be locked out and not function 3 Remove metal coin and return machine to service 4 10 SHUT DOWN AND PARK 4 Drive machine to a protected area 5 Assure main boom is fully retracted and lowered over rear Drive axle all access panels and doors closed and secured 6 Remove all load and allow engine to operate 3 5 minutes at LOW setting to permit reduction of engine internal temperatures 7 At Ground Controls turn KEY SELECT switch to center OFF Position POWER EMERGENCY STOP switch down to OFF Remove key 8 Cover Platform Control console to protect instruction placards warning decals and operating controls from hostile environment 4 11 TIE DOWN AND LIFTING When transporting machine boom must be in the stowed mode and machine securely tied down to truck or trailer deck Four tie down eyes are provided in the frame slab one at each corner of the machine S
62. k 12 Oil Change w Filter Deutz Fill Cap Spin on 6 3 qts 6L crankcase EO X Checklevel daily change every 600 hours Element 5qts 4 5L cooler Adjust final oil level by mark on dipstick 13 Oil Change w Filter Isuzu Fill Cap Spin on 5 6L crankcase EO X Checklevel daily change every 150 hours Element 6 5qts 6 1 L wicooler Adjust final oil level by mark on dipstick 14 Fuel Filter Ford Replaceable N A N A X Element 15 FuelFilter Deutz Replaceable N A N A X Element 16 Fuel Filter Isuzu Replaceable N A N A X Element 17 AirFilter Ford Replaceable N A N A X Orasindicated by condition indicator Element Updated 11 8 99 2 12 JLG Lift 3120748 SECTION 2 PREPARATION AND INSPECTION Table 2 1 Lubrication Chart Interval Hours Number Type Components Capacity Lube Comments Lube Points 1 Year 2 Years Months Months 600 hr 1200 hrs 150hrs 300hrs y 18 AirFilter Deutz Replaceable N A N A X Orasindicated by condition indicator Element 19 AirFilter Isuzu Replaceable N A N A X Orasindicated by condition indicator Element NOTES KEY TOLUBRICANTS Lubrication intervals are based on machine operation under normal conditions For machines used in multi shift operations and or exposed to hostile envi EO Engine Oil ronments or conditions lubrication frequencies must be increased accordingly EPGL Extreme Pressure Gear Lube HO Hydraulic Fluid M
63. latform on the end of an elevating telescoping and rotating boom The JLG Lift is intended purpose is to position personnel with their tools and supplies at positions above ground level The machine can be used to reach work areas located above and over machinery or equipment The JLG 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 lower extend or retract the boom swing the boom to the left or right and when equipped with a platform rotator can rotate the platform around the boom end Standard boom swing is 357 non continuous left and right of the stowed position The machine has a Ground Control Station which will override the Platform Control Station Ground Controls operate Tower Lift Main Boom Lift Main Boom Telescope and Swing and are to be used only in an emergency to lower the platform to the ground should the operator in the plat form be unable to do so Instruction and hazard warnings are posted adjacent to both operator control stations and at other places on the machine It is extremely important that operators know what instructions and warnings 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 JLG Lift is designed to provide efficien
64. lessees concerning safety training inspection maintenance application and operation If there is a question on application and or operation JLG Industries Inc should be consulted The machine is not equipped with provisions for towing Refer to Section 6 for emergency towing procedures SPECIAL NOTE A WARNING FAILURE CONPLY WITH PRECAUTIONS LISTED IN THIS SECTION AND ON THE MACHINE COULD RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND IS A A WARNING SAFETY VIOLATION MODIFICATION OR ALTERATION OF AN AERIAL PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION OF THE MANUFACTURER 3120748 JLG Lift 1 1 SECTION 1 SAFETY PRECAUTIONS Table 1 1 Minimum Safe Approach Distances M S A D to energized exposed or insulated power lines and parts Voltage Range MINIMUM SAFE APPROACH DISTANCE Phase to Phase in Feet Meters Oto 300V AVOID CONTACT Over 300V to 50 KV 10 3 Over 50KV to 200 KV 15 5 Over 200 KV to 350 KV 20 6 Over 350 KV to 500 KV 25 8 Over 500 KV to 750 KV 35 11 Over 750 KVto 1000 KV 45 14 DANGER DO NOT maneuver machine or personnel inside PROHIBITED ZONE ASSUME all electrical parts and wiring are ENERGIZED unless known otherwise FROM CONTACT WITH OR PROXIMITY TO AN ELEC 1 3 ELECTROCUTION HAZARD TRICALLY CHARGED CONDUCTOR MAINTAIN A CLEARANCE OF AT LEAST 10 FEET 3 M BETWEEN ANY PART OF THE MACHINE OR ITS LOAD
65. machine itself 3 Knowledge and understanding of all safety work rules of the 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 attached to the platform 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 drop offs etc on the supporting surface exist 7 Means to 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 JLG Di
66. 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 this manual provides a stable machine for all platform positions 3 2 Machine stability is based on two positions which are called FORWARD STABILITY and BACKWARD STABILITY The machines position of least forward stability is shown in Figure 3 1 and its position of least backward stability is shown in Figure 3 2 A WARNING TO AVOID FORWARD OR BACKWARD UPSET DO NOT OVER LOAD MACHINE OR OPERATE ON AN OUT OF LEVEL SURFACE Boom Synchronizing Procedure JLG Lift If the lower boom does not fully lower use the following procedure 1 Remove all personnel from the platform 2 Pull out the red EMS emergency stop knob located on the ground control station 3 Turn the platform ground select switch to the ground control position 4 Ifapplicable start the engine 5 Pull and hold out the red re level knob on the syn chronizing valve located beside the main control valve 6 From the ground controls activate the lift control Switch and raise the lower boom approximately 6 feet 2 m 7 After raising the lower boom release the red knob 8 Activate the lift control switch and fully lower the boom and continue to hold down the switch for an additional 5 seconds 9 Repeat steps 5 thru 8 if necessary
67. me to warm up shut engine off 6 Turn key of SELECT switch to PLATFORM 7 From Platform position POWER EMERGENCY STOP switch to ON then push the ENGINE START switch to the forward position until engine starts NOTE Footswitch must be in released up position before starter will operate If starter operates with footswitch in the depressed position DO NOT OPERATE MACHINE Shutdown Procedure CAUTION IF AN ENGINE MALFUNCTION NECESSITATES UNSCHEDULED SHUTDOWN DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANY OPERATION 4 2 JLG Lift 1 Remove all load and allow engine to operate at low speed setting for 3 5 minutes this allows for further reduction of internal engine temperature 2 Position POWER EMERGENCY STOP switch to OFF 3 Turn key of MASTER switch to OFF position NOTE Refer to Engine Manufacturers manual for detailed information 4 4 TRAVELING DRIVING A WARNING DO NOT DRIVE WITH BOOM EXTENDED OR ABOVE HORIZONTAL EXCEPT ON A SMOOTH FIRM AND LEVEL SURFACE TO AVOID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES AND SIDESLOPES DO NOT DRIVE MACHINE ON GRADES OR SIDESLOPES EXCEEDING THOSE SPECIFIED ON MACHINE INFORMATION PLACARD ON THE LEFT SIDE OF THE FRAME TRAVEL GRADES WITH DRIVE SPEED TORQUE SELECT SWITCH IN THE FORWARD POSITION USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN DRIVING WITH PLATFORM ELEVATED AND ESPECIALLY WHEN DRIVING WITH ANY PART OF MACHINE WITHIN 6 F
68. minated indicates that the Engine Control Module has detected a malfunction in the Electronic Fuel Injection System and a Diagnostic Trouble Code has been set in the ECM Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval Updated 9 21 99 3 8 JLG Lift The malfunction indicator light will illuminate for 2 3 seconds when the key is positioned to the on posi tion to act as a self test ENGINE MALFUNCTION INDICATOR LIGHT TT NN TEST BUTTON c ro BEH e Figure 3 5 Malfunction Indicator Light and Test Button 20 System Test Button Ford Engines after S N 46089 By pushing and holding the system test button on the side of the ground control box the Diagnostic Trouble Codes will be displayed on the Malfunction Indicator Light Refer to the Service Manual for instructions concerning the trouble codes and trou ble code retrieval 3120748 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL Platform Station NOTE For engine starting the footswitch must be in the released up position Footswitch must be actuated in order for the platform controls to function NOTE These machines have a 7 second delay timer If function has not been activated within 7 seconds after d
69. nting 3120748 springs If the light does not illuminate shut down machine and contact a qualified service technician before continuing operation 6 Check that platform self leveling system functions properly during raising and lowering of boom 7 Check rotator for smooth operation and assure plat form will rotate 75 degrees in both directions from centerline of boom 8 Drive forward and reverse check for proper opera tion 9 Steer left and right check for proper operation 10 Footswitch IMPORTANT FOOTSWITCH MUST BE ADJUSTED 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 ADJUSTED a Activate hydraulic system by depressing foot switch Operate Telescope and hold control Remove foot from footswitch motion should stop If it does not shut down machine and con tact a certified JLG service technician b 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 certified JLG service technician c With engine power shut down depress the foot Switch Attempt to start engine Engine should not attempt to start when footswitch is depressed If starter engages or engine turns over shut down machine and contact a certified JLG service technician 11 Auxiliary Power Operate each function control s
70. obil DTE 11M MPG Multi Purpose Grease necessary install grease fittings into worm gear housing and grease bearings OGL Open Gear Lubricant Mobiltac 375 or equivalent A CAUTION DO NOT OVERGREASE BEARINGS OVERGREASING BEARINGS WILL RESULT IN BLOWING OUTER SEAL IN HOUSING GREASE FITTINGS When changing oil in the Deutz oil cooled engine drain both the crankcase and the cooler When refilling itis acceptable to overfill crankcase 11 3 qts 10 5L capacity of both crankcase and cooler combined Start engine allow the engine to run until the thermostat opens approximately 221 degrees F cooler will fill up within minutes shut down and wait for approximately two minutes Check oil level fill oil to max marking on dipstick 3120748 JLG Lift Updated 11 8 99 2 13 SECTION 2 PREPARATION AND INSPECTION 8 IVS 69 9 00089 79 2 S IAVYD IVS si u sej oj Ajdde jou op nbio s u L SJON 00S0bL 00592 00S L 008 OOGG LL 00000 00520 00996 00696 00278 00998 00077 00292 00289 00599 00269 00909 00919 0060S 00897 9 00917 00 7 00922 00vEE 00 06 00954 00022 009cc 0S 0c 00202 0928 0028 0079 06691 442
71. oper use of this machine could cause death or serious injury DOM 1703797 CRUSHING HAZARD Do not stand under a raised platform or boom or between a rotating platform and the boom Keep all body parts away from any moving components Failure to follow these instructions could result in death or serious injury 1703804 A JLG Lift 1703804 3120748 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL A DANGER ELECTROCUTION HAZARD This machine is not insulated Maintain a clearance of at least 10 ft between any part of machine or load and any electrical line or apparatus charged up to 50 000 volts e One foot additional clearance is required for each additional 30 000 volts or less Allowances must be made for operator error machine deflection and electrical line swaying Death or serious injury will occur from contact or being too close to electrical lines CRUSHING HAZARD Personnel shall not position themselves or other objects UNDER boom and platform or BETWEEN boom and turntable or chassis When operating from ground control station avoid being BETWEEN rotating superstructure and chassis or other immovable objects Failure to follow these instructions could result in death or serious injury THIS MACHINE MUST NOT BE USED UNTIL IT IS INSPECTED AND OPERATING PROPERLY DO NOT operate this machine unless you have been properly trained as described in the JLG Operation and Safe
72. platform is positioned over the front axle end Always look at the decals on the chassis and drive steer control for proper direction Keep all body parts inside of platform during operation Failure to follow instructions could result in death or serious injury 1703797 HIS MACHINE MUST NOT BE USED UNTIL IT IS INSPECTED AND OPERATING PROPERLY DO NOT operate this machine unless you have been properly trained as described in the JLG Operation and Safety Manual by a qualified person and authorized to operate this machine Your training includes reading and understanding the safety operating and maintenance instructions in manufacturer s manuals knowing your employers work rules and applicable governmental regulations Follow the instructions in the Operating Manual and sections 6 7 and 8 of ANSI A92 5 1992 for daily frequent and annual inspections These may be obtained from your authorized JLG Industries Inc equipment dealer or JLG Industries Inc DO NOT replace items i e batteries tires counterweight etc with items of different weight or specification because this will affect the stability of the machine DO NOT modify or change this machine without written approval from the manufacturer Operate this machine with extreme caution STOP all operation if a malfunction occurs Test foot switch for proper operation Test high engine and high drive cut out switches for proper operation Impr
73. rator read and understand the proper procedures before operating the machine These procedures 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 important that all personnel who are assigned to and 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 of this manual and of the control markings instructions and warnings on the
74. rizontal and any of the following switches Drive Speed torque Select or Function Speed are positioned to High high func lion speeds are automatically cut out and the machine continues to operate at a lower speed 3120748 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL A CAUTION DO NOT OPERATE MACHINE IF DRIVE SPEED TORQUE SELECT OR FUNCTION SPEED SWITCHES OPERATE WHEN BOOM IS ABOVE HORIZONTAL 10 11 12 13 3120748 Function Speed The knob provides variable speed control of all boom functions grouped to the right of the knob For smoothest operation of these functions use two hands rotate the knob counterclockwise to the slowest position select the function switch and while holding the switch on rotate the knob to the desired speed To achieve a smooth stop rotate the knob ccw to a slow speed prior to letting go of the function switch Rotating the knob fully counterclockwise until a click is heard puts all controls including drive main lift and swing into creep speed This slow speed is used for fine positioning of the platform when close to obstacles A snail symbol is used to indicate creep speed and is shown at the Function Speed knob as well as near the proportional controllers to act as a reminder Drive Speed Switch 4WD Equipped Machines On machines equipped with 4WD the drive speed switch also selects 2WD or 4WD modes The for ward position produces maximum speed by operat
75. running a The auxiliary pump functions to provide suffi cient oil flow to operate the basic machine func tions should the main pump or engine fail The 3120748 auxiliary pump enables the tower boom lift and telescope and swing to be operated b It should be noted that the functions will operate at a slower than normal rate because of the lower flow of hydraulic fluid delivered NOTE When operating on auxiliary power do not operate more than one function at a time Simultaneous operation can overload the 12 volt auxiliary pump motor c Position PLATFORM GROUND switch to GROUND d Position POWER EMERGENCY STOP switch to ON e Operate appropriate control switch or lever for desired function and hold f Position ENGINE START AUXILIARY POWER switch to DOWN and hold g Release AUXILIARY POWER switch followed by the selected control switch or lever h Position the POWER EMERGENCY STOP SWITCH to off 3 Control Station Selector A three position center off key activated PLAT FORM GROUND SELECT switch supplies power to the platform control console when positioned to PLATFORM With the switch in GROUND position power is shut off to the platform control console and only the controls on the ground control panel are operable NOTE With the Platform Ground Select Switch in the center position power is shut off to controls at both operat ing stations Remove the key to prevent the controls from being a
76. s electrical power to an audible warning device when pressed 5 Tilt Alarm Warning Light Orange This orange illuminator indicates that the chassis is on a slope over 5 degrees If illuminated when boom is raised or extended retract and lower to below horizontal then reposition machine so that it is level before extending boom or raising boom above horizontal If the boom is above horizontal and the machine is on a 5 degree slope an alarm will sound and Creep is automatically activated A WARNING IF ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSI TION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL 6 Tower or Lower Boom Lift The three position center off toggle switch provides for raising and lowering of the lower and mid booms when positioned up or down NOTE Main Lift Swing and Drive control levers are spring loaded and will automatically return to neutral off position when released A WARNING TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEU TRAL POSITION WHEN RELEASED 7 Main Lift Swing Controller The dual axis joystick is provided for main lift and swing Push forward to lift up pull backward to lift down Move right to swing right move left to swing left Moving the joystick activates switches to pro vide the func
77. scope cylinder cross pins and hydraulic lines for damage wear lubrication leakage and security 19 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 2 Check control switches and levers for damage loose or missing parts and security Assure that levers function 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 access gate hinges stop and latch for proper operation damage and security 5 Check platform rotator mechanism for proper opera tion damage security Check hydraulic lines for leakage damage and security NOTE Check all DANGER WARNING CAUTION and INSTRUCTION placards for legibility and security on the entire machine Torque Requirements JLG Lift The Torque Chart Figure 2 6 consists of standard torque values based on bolt diameter and grade also specifying dry and wet torque values in accordance with recom mended 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 inspec tion or during operation until the proper service personnel can be notified The Servi
78. stribu 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 3120748 JLG Lift 3 1 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 3 OPERATING CHARACTERISTICS AND LIMITATIONS General A thorough knowledge of the operating characteristics and limitations of the machine is always the first require ment for any user regardless of the user s experience with similar types of equipment Placards Important points to remember during operation are pro vided at the control stations by DANGER WARNING CAUTION IMPORTANT and INSTRUCTION placards This information is placed at various locations for the express purpose of alerting personnel of potential hazards consti tuted by the operating characteristics and load limitations of the machine See FOREWORD for definitions of the above placards Capacities Raising boom above horizontal and or extension of boom beyond retracted position with or without any load in plat form is based on the following criteria 1 Machine is positioned on a smooth firm and level surface 2 Load is within manufacturer s rated design capacity 3 Allmachine systems are functioning properly 4 Proper tire pressure exists in the tires 5 Machine is as originally equipped from JLG Stability This machine as originally
79. t and safe oper ation when maintained and operated in accordance with warnings on the machine in the Operators and Safety Manual and all jobsite and government rules and regula tions As with any type of machinery the operator is very important 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 responsi bilities of the owner users operators lessors and lessees concerning safety training inspection maintenance application and operation It is absolutely necessary that the JLG Lift be regularly maintained in accordance with this manual and the machine Service and Maintenance manual 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 supervisor or safety manager and that the machine be taken out of service until all discrepancies are corrected The JLG Lift is 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 be used as a forklift crane support for overhead structure or to push or pull another object The machine is equipped with an auxiliary battery oper ated power unit which will provide hydraulic power in the event of a primary engine power loss Auxiliary power c
80. t of the engine The package is intended for machines that will be exposed to painting sandblasting or other similar hostile conditions The hostile environment package includes boom wipers cylinder bellows heavy duty reservoir breather an engine air cleaner and control console cover as required 5 13 MOTION ALARM A motion alarm horn provides an audible warning when the platform controls are selected at the PLATFORM GROUND SELECT switch the POWER EMERGENCY STOP switch is ON and the footswitch is depressed The alarm warns personnel in the jobsite area to avoid the operating machine 5 14 SEMI TRACK The semi track option consists of steel tracks and idler wheels The idler wheels are mounted to the chassis just forward of the drive wheels The steel tracks are installed around the drive wheels and idler wheels This option pro vides increased traction for operation in rough terrain Updated 2 2 2000 JLG Lift 5 3 SECTION 5 OPTIONAL EQUIPMENT This page left blank intentionally 5 4 JLG Lift 3120748 SECTION 6 EMERGENCY PROCEDURES SECTION 6 EMERGENCY PROCEDURES 61 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 r
81. tion shall be performed on the aerial platform no later than thirteen 13 months from the date of the prior annual inspection The inspection shall be performed by person s qualified as a mechanic on the specific make and model of the aerial platform The following 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 comes 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 will be exposed to harsh or changing cli mates 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 and damage 2 Check steering assembly for loose or bent tie rod cylinder and hydraulic lines for leaks and security and hardware for proper installation 3 If equipped with 4WD check drive hubs hydraulic motors brakes and hydraulic lines for damage and leaks 4 Check rear tires and wheel assemblies for security tires for wear and damage 5 Check drive hubs hydraulic motors brakes and hydrauli
82. tions selected Proportional control of these functions can be attained by using the Func tion Speed knob NOTE Main lift and swing functions may be selected in combination The handle features a round gate so that maximum speed is reduced when multiple func lions are selected JLG Lift 3 9 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL TILT INDICATOR ENABLE INDICATOR INDICATOR PLATFORM LEVELING OVERRIDE ENGINE DISTRESS INDICATOR POWER EMERGENCY FUEL STOP SELECT LIGHTS FD B TAN SBC 7 MAIN LIFT SWING FUNCTION SPEED PLATFORM ROTATE TELESCOPE TOWER or LOWER ARTICULATING JIB BOOM Figure 3 6 Platform Station Proportional Controls 8 Main Telescope Control The Main Telescope control switch allows extension and retraction of the main boom when positioned to in or out 9 Drive Steer Proportional single axis joystick is provided to con trol drive Push forward to drive forward pull back to drive in reverse Steering is accomplished via a thumb activated rocker switch on the end of the 3 10 JLG Lift handle Push on the left side of the switch to steer left on right side to steer right NOTE Both drive and steer functions work in the opposite direction when the boom is positioned over front of the chassis NOTE When boom is positioned above ho
83. ty Manual by a qualified person and authorized to operate this machine Your training includes reading and understanding the safety operating and maintenance instructions in manufacturer s manuals knowing your employers work rules and applicable governmental regulations DO NOT replace items i e Batteries tires counterweight etc with items of different weight or specification because this will affect the stability of the machine DO NOT modify or change this machine without written approval from the manufacturer Make sure all tires are in good condition and air filled tires are properly inflated Operate this machine with extreme caution STOP all operation if a malfunction occurs Check all functions at ground control and platform control stations Select an area free of obstructions Refer to the JLG Operation and Safety Manual for further daily frequent annual checks and the walk around inspection Read and understand decals and placards If this machine is not properly maintained death or serious injury could occur DOM 1703798 1703798 B A DANGER ELECTROCUTION HAZARD This machine is not insulated e Maintain a clearance of at least 10 ft between any part of machine or load and any electrical line or apparatus charged up to 50 000 volts e One foot additional clearance is required for each additional 30 000 volts or less Allowances must be made for operator error machine deflection and electrical
84. und controls Next using the platform controls check all functions controlled by the platform controls A WARNING TO AVOID SERIOUS INJURY DO OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENTS DO NOT RETURN TO THE OFF OR NEU TRAL POSITION WHEN RELEASED WARNING TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP THE MACHINE NOTE When the boom is raised above horizontal high drive speed is cut out 1 Check boom horizontal limit switches to see that they are operable and not damaged Raise and lower Lower Boom Check for smooth operation Check Boom Upright tilting for proper synchroniza tion If the upright is tilted or the boom will not fully lower refer to the Boom Synchronizing Procedure in Section 3 NOTE Perform checks from ground controls first then from platform controls 2 Raise extend retract and lower Upper Boom Check for smooth operation 3 Telescope boom IN and OUT several cycles at vari ous degrees of elevation lengths Check for smooth telescope operation 4 Swing turntable to LEFT and RIGHT a minimum of 45 degrees Check for smooth motion 5 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 mou
85. until you are sure that all damage has been repaired if required and that all controls are operating correctly A cold weather start system in the diesel engine functions automatically to provide starting fluid as necessary to the engine A sensor switch mounted on the engine will per DO NOT OPERATE WITH PRIMARY POWER SOURCE ENGINE OR ELECTRIC MOTOR IF PERSONS ARE PINNED OR TRAPPED USE AUXILIARY POWER INSTEAD mit ether injection when the engine is cold The sensor will not permit ether injection to a warm engine 1 Operate the machine from ground controls ONLY 6 5 INCIDENT NOTIFICATION with the assistance of other personnel and equip ment cranes overhead hoists etc as may be be required to safely remove the danger or emergency condition 2 Other qualified personnel on the platform may use the platform controls with regular or auxiliary power DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION NORMALLY 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 6 2 JLG Lift It is imperative that JLG Industries Inc be notified imme diately of any incident involving a JLG product Even if no injury or property damage is evident the factory should be contacted by telephone and provided with all neces sary details JLG Phone 877 JLG SAFE 554 723
86. witch e g Tele Lift and Swing to assure that they function in both directions using auxiliary power instead of engine power 12 Ground Controls Place Ground Platform Select switch to Ground Start engine Platform controls should not operate JLG Lift 2 9 SECTION 2 PREPARATION AND INSPECTION 2 6 BATTERY MAINTENANCE A WARNING AVOID INJURY FROM EXPLOSION DO ALLOW SPARKS OR FLAME NEAR BATTERY DURING SERVIC ING A WARNING ALWAYS WEAR EYE PROTECTION WHEN SERVICING BATTER IES 1 The battery is maintenance free except for occa sional battery terminal cleaning as noted in the fol lowing 2 10 JLG Lift 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 Clean battery post with wire brush then re connect cable to post Coat non contact surfaces with min eral grease or petroleum jelly Vaseline When all cables and terminal posts have been cleaned ensure all cables are properly positioned and are not pinched Close battery compartment cover 3120748 SECTION 2 PREPARATION AND INSPECTION Figure 2 5 Lubrication Diagram 3120748 JLG Lift 2 11 SECTION 2 PREPARATION AND INSPECTION Table 2 1 Lubrication
87. xceed platform rated capacity Make sure the operating surface will support the machine DO NOT drive with platform raised or raise platform when on uneven sloping or soft surfaces including trucks trailers railway cars floating vessels scaffolds or similar areas DO NOT raise platform during high winds DO NOT drive near drop offs holes or other hazards Make sure all tires are in good condition and air filled tires are properly inflated To drive on a slope boom must be retracted lowered below horizontal and centered between the rear wheels When Chassis out of level indicator light is on retract and lower boom and move machine to a level surface Driving with boom above horizontal or extended is restricted to smooth firm and level surfaces free of obstructions Death or serious injury could result from a tip over FALLING HAZARD Check the condition of the approved fall protection device lanyard and the designated attachment point to the platform Wear approved fall protection items and attach to marked locations Keep both feet on platform floor Ensure entrance area is properly closed DO use planks ladders similar items in platform to added reach Falling from platform could cause death or serious injury CRUSHING HAZARD Always look in the direction of movement Keep clear of obstructions Direction of drive and steer functions are opposite to the motion of the controls when the

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