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Operators and Safety Manual

1. 8 AVS S AQVYD AVS poejejd uinipeo Ajdde jou op anbio esau 0165 00085 956 vvec 0992 0998 OOCccvL 0060 HLEL OVOL 0002 00428 0084 00S 1 eL 0706 00407 917 0646 0964 091 OOS9CL 5000 SSZV 09 6 00082 050 L 9 Ov vc OOSLEL 0006 69 6 OOZ 00 76 OOLSLL 0941 904 O9CL 089 00084 OSLEL 0081 eL OZET O0SSLL 40496 2706 0841 08 000701 ccel OOLL 09 00179 054 9 0881 00820 0046 OL9L 004 0002 00996 0051 8 06 0 00966 06 0 00SZ L e 052 00696 0006 571 096 0081 00278 S LL 6001 078 00855 0696 0 Z 0851 00958 9191 SGL 080 00044 96 cog 099 088 005 0968 0 08211 g i L 00 9 0071 0501 096 0851 00 89 078 vil 009 008 00 0 9 0 2 916 00699 00LL 962 072 000 00 64 Gel 59 059 004 00 0990 0001 998 00909 066 289 089 006 00919 9 9 648 087 079 00986 09090 8 S 9 0060S Sel ves 00S 099 00857 044 Scv 09 0 7 00758 06040 05780 147 8 2 998 00c9v 099 598 097 009 0097 SLY 985 056 057 00766 00970 6 00 00515 SOV 955 Oct octy 009 05 896 Occ 006 008 c 0 0 00570 9 596 00758 ocr 105 08 086 0010 6986 Ove 004 092 001 Orte 0 OL Occ 009Sc S9c vO 081 Ove 000 c 06 051 04L 00 9L 09S2 0 05290 81 g s 0 2 00956 Ovc 081 011 Occ 0S 0c SOL Sel OLL OSL 09 0 kW S9L 00
2. s1709 s avs 22205 SM3U9S KINO 1109 31 14 9NIZ 804 SINIYA 2 11 JLG Lift 3120736 SECTION 2 PREPARATION AND INSPECTION This page left blank intentionally 2 12 JLG Lift 3120736 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 RESPONSIBILITY OF THE USER AND HIS OPERATING PERSON NEL This section provides the necessary information needed to understand control functions Included in this section are the operating characteristics and limitations and func tions and purposes of controls and indicators It is impor tant that the user read and understand the proper procedures before operating the machine These proce dures will aid in obtaining optimum service life and safe operation 3 2 PERSONNEL TRAINING The scissor lift is a personnel handling device therefore 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
3. The charger 25 light will come on Solid if in wet mode and flashing if in sealed mode 5 5 seconds later the charger on light will come on the the charger will start recharging the battery a If the battery is depleted the 25 light will stay on until the batteries reach their 80 level where the 80 light come on and the 25 light will go out 3 2 b The following will occur if the batteries being charged are full The charger will read 80 and remain there for approximately 70 minutes during the DV Dt sec tion of the charge after which the charger will go to 100 and shut off as described below If there is a problem wit the battery or if the charge cycle is interrupted the charger could shut down and the abnormal light will come on Ground Control Station A WARNING DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN THE PLATFORM EXCEPT IN AN EMERGENCY A WARNING PERFORM AS MANY PRE OPERATIONAL CHECKS AND INSPEC TIONS FROM THE GROUND CONTROL STATION AS POSSIBLE REFER TO SECTION 2 FOR PRE OPERATIONAL CHECKS AND INSPECTIONS NOTE JLG Lift Power Selector Switch A three position key operated power selector switch supplies operating power to the platform or ground controls as selected When positioned to platform the switch provides power to the emergency stop switch at the platform controls When positioned to ground the switch provides power to the emer gency stop switch a
4. 3252567 2032 2 2 3252568 lt 020063401 1703811 F 170607 71704611 T 7222 1703706 1703812 1704400 2032E2 1704402 1703814 2646E2 1703811 1704403 3246 2 3252699 1703697 Figure 3 11 Decal Installation Chinese 2032E2 2632E2 2646E2 3246E2 Sheet 1 of 2 3 16 JLG Lift 3120736 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 2032E2 2646E2 1704201 3246E2 3252567 2032E2 3252568 n 2646E2 1703694 3252619 1704201 ix Ee 3246E2 1703811 1704609 1703814 1704400 2032E2 NM gt 1704400 2 2032 2 1704402 ZN 1704402 1704614 lt lt 1704403 3246E2 1703814 1703811 1704403 d 1703817 020063401 1703811 1703817 0200063401 gt Figure 3 12 Decal Installation Chinese 2032E2 2632E2 2646E2 3246E2 Sheet 2 of 2 3120736 JLG Lift 3 17 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 18 1703811 1703817 1704277 1704400 2032E2 1704402 2646E2 1704403 3246E2 3252567 1704400 gt 27 2032 2 2032 2 3252568 2646E2 3252619 4 1704402 p 2646E2 v 3246E2 1402403 lt 020063401 1703811 1703814 71701621 71704282 lt 7222 1703706 lt 1703812 1704400 2032 2 1704402 1703814 2646E2 1703811 1704403 3246 2 17038
5. To store the safety prop raise the platform so that the prop can be rotated counterclockwise until it rests on the bracket provided on the scissor arms JLG Lift 4 5 SECTION 4 MACHINE OPERATION 4 11 TIE DOWN AND LIFTING When transporting the machine the platform extension must be fully retracted and the platform fully lowered in the stowed mode with the machine securely tied down to the truck or trailer deck There are tie down eyes located at all four corners of the machine to secure the machine for shipping Refer to Figure 4 2 Lift and Tie Down for specific tie down instructions Figure 4 2 Lift and Tie Down Front and Rear Typical Lifting If it becomes necessary to lift the machine it is possible to lift the machine with a forklift On 2032E2 2632E2 2646E2 and 3246E2 forklift pockets are provided at the front and rear of the machine The 1532E2 and 1932E2 can only be lifted from the rear forklift pockets It is very important that the forklift operator use only the designated lifting areas to lift the machine NOTE Do not lift the machine from the sides Forklifts cranes or other lifting devices must be capable of handling the following weights 1532E2 2 940 Ib 1334 kg 1932E2 2 970 Ib 1 337 kg 2032 2 3 8901 1 764 kg 2632E2 5 325 Ib 2 414 kg 2646E2 4 280 Ib
6. 0c 061 YSL 051 071 04081 SEL 601 06 och OS6ZL 06000 SZ9S 0 8L 9 6 0048 SOL 651 OLL 05 00 9 OcL 86 08 OLL 009 0048 0 eL i 06691 Sel 80 06 OZL oort 00L 08 S9 06 0020L 66610 000 lt 0 oz z OLL 06 02 96 08 OLL 06151 98 89 99 Gl 0506 60 L GL 0 8 06 OL 09 08 00 01 09 05 07 SS 054 48 0 Siero oz 9 2 02 05901 08 9 646 04 0596 SS 94 S 0S 0089 90L0 145 0S 08 8 SS Sv GE 05 006 Ov ce Sc 66 0099 8 800 0S 0 vc 8 5 Sv 0974 0S Or 66 Sv 0004 ge 8c c 06 0767 47 00 9 2 0085 06 Sc 0c Sc 0224 ZL rL 6L 002 08400 SZLE 0 vc Sc OvcS 06 81 9 04 7 6L 9L L ZL 07 lt lt FZS0 0 8L i 14 91 13 81 14781 14 91 14 91 vl 079 021 89 0826 98 och 0656 79 0 0 00520 8c el L 0815 09 801 1443 0982 Gl 96 0404 8100 0 LS 89 0081 95 6v S8cL 000200 0061 0 ce oL Sr 09 08SL ce 0 052100 vc ce 0551 c LE 076 2700 OP9L O 9 9 LE Ly o9z 06 006 007100 ce mE a mE 6L SC 06 L 81 019 9 0100 08170 07 9 Zk EZ 0c8 eL QL 08S 606000 ce 0 L 009 1 6 O0cv 990070 0240 p 6 eL OvS 9 8 08 7090070 07 CAN po 8 Sz po CID NI OS nouos 014 1 35 59 aaoo 8 QVOT amigon 89 ug gig ppm SLNN 8 S1708 8 avs z
7. The drive lift and powered deck extension function Switches have a small green light indicator beside them which is illuminated when that function is active The function switch light indicators will flash once or twice then go out when the platform emer gency stop switch is turned on If the light indicators fail to flash or if they fail to stop flashing re cycle the emergency stop switch To activate the drive lift and powered deck functions press the applicable function switch then activate the joystick within three seconds to operate the function If the joystick is not activated within three seconds power is turned off to the function switch and the switch must be pressed again The posi trac and high drive func tions are used in conjunction with the drive function Do not try to operate the drive lift and powered deck extension functions simultaneously If the drive lift and powered deck extension functions are selected simultaneously no function will operate If this occurs pause then press only one of the func tion switches to activate the function Refer to the fol lowing paragraphs for more information about the function switches Controller Joystick The joystick controls three functions speed direc tion and powered deck extension if equipped The joystick is used in conjunction with the trigger switch and controls the drive high drive lift and powered deck extension switches to control speed and dire
8. 1704277 3252747 1532E2 3252598 1932E2 3252588 ft gt 4 gt Pd P 2 71704282 2 2 1703845 1703811 1703850 N 1703812 1704771 1704399 1703850 1703822 1703840 1704322 Wear Pu 3252747 1532E2 1703819 3252598 1932E2 1703817 1704999 1703811 1703814 Figure 3 6 Decal Installation Japanese 1532E2 amp 1932E2 3120736 JLG Lift 3 11 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 12 3252747 1532E2 3252598 1932E2 1703706 1704399 3252588 3252588 gt A i e gt lt PSS 1703843 1 Dr P 74708841 Ts 1703837 A PN 1703812 1703811 1703842 4 1703895 3252645 1703811 Th og E 3251813 1704771 1704399 1703817 1703842 1703822 1704443 c CS d 1703819 3252598 1932E2 1703811 1703814 Figure 3 7 Decal Installation Latin 1532E2 amp 1932E2 JLG Lift 3120736 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 1704277 3252747 1532E2 3252598 1932E2 3252588 5242 TANS 1703853 SE 7747038 1703811 1703858 ju 4 1703854 3252645 1703811 n Vg gt 5584618 1704771 1704399 1703858 WEZ 1703840 1703822 1704145 U AM p 3252747 1703819 3252598 1932E2 1703817 2 1704399 1703811 1703814 Figure 3 8 Decal
9. 3246E2 3252567 2032E2 3252568 2 2646E2 1203694 3252619 1704201 lt 3246 2 1703811 1703858 1704400 2032bE2 N Ne 2032E2 1704402 gt 1704402 2646E2 2646E2 1704403 3246E2 1703811 1704404 1703817 lt 020063401 1703811 1703817 0200063401 amp gt Figure 3 16 Decal Installation Korean 2032E2 2632E2 2646E2 3246E2 Sheet 2 of 2 3120736 JLG Lift 3 21 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 1703811 1703817 1703815 1704400 2032E2 1704402 2646E2 1704403 3246E2 3252567 Z 2032E2 2 3252568 2 2646 2 YF 2032E2 L 1704402 2646E2 Pd 7 lt EN 2 1702403 2 2020063401 p 1703811 1703814 goo f NS 1702552 m 85 1703841 MONS 71703706 gt lt 71703812 1704400 2032 2 3252645 1704402 1703814 2646E2 1703811 1704403 3246 2 Figure 3 17 Decal Installation Spanish 2032E2 2632E2 2646E2 3246E2 Sheet 1 of 2 3 22 JLG Lift 3120736 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 2032E2 2646E2 1704201 3246 2 3252567 2032E2 3252568 IL 2646 2 1703694 3252619 1704201 JAE 3246E2 1703811 1703842 1703814 1704400 IR s 4704400 2032E2 2 2032E2 1704402 y 7 1704402 2646E2 2646E2 1704403 1704403 3246E2 3246E2 1703817 lt 0200
10. secured no evidence of leakage Motor Pump Unit Properly secured no visible damage no evidence of hydraulic leakage Pothole Protection System Support broilers limit switches and links properly secured no visible damage no loose or missing parts Hourmeter No visible damage Wire Installation No visible damage no loose or broken wires Control Valve Installation No loose or missing parts no evidence of leakage No unsupported wires or hoses no damaged or broken wires Wheel and Tire Assembly Left Rear Properly secured no loose or missing lug nuts no visible damage Drive Motor Left Rear Properly secured no visible damage no evidence of leakage Scissor Arms and Sliding Wear Pads Properly secured no visible damage no loose or missing parts Handle for Manual Descent Pump 2632 2646E2 3246E2 No visible damage Manual Descent Pump 2632 2646E2 3246E2 Properly secured no visible damage no evidence of leakage Manual Descent Cable and Pull Handle 2032 No visible damage Properly secured no loose or miss ing parts Brake Cylinder Properly secured no visible dam age no evidence of leakage Ladder Properly secured no visible damage no loose or missing hardware Scissor Arms and Sliding Wear Pads Properly secured no visible damage no loose or missing parts Drive Motor Right Rear Properly secured no visi ble damage no evidence of leakage Wheel and
11. ACID DOES NOT COME INTO CONTACT WITH SKIN OR CLOTHING NOTE Be sure to disconnect and store any extension cords after charging batteries and before putting machine into service To avoid electrolyte overflow add distilled water to batteries after charging JLG Lift 2 3 SECTION 2 PREPARATION AND INSPECTION 2 4 NOTE Item 37 not shown on illustration 4 Item 37 applies to items throughout the machine Figure 2 1 Daily Walk Around Inspection 2032E2 2632E2 2646E2 3246E2 Sheet 1 of 3 JLG Lift 3120736 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 Check list A WARNING TO AVOID INJURY DO NOT OPERATE MACHINE UNTIL ALL MAL FUNCTIONS HAVE BEEN CORRECTED USE OF A MALFUNC TIONING MACHINE IS A SAFETY VIOLATION A WARNING TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DURING WALK AROUND INSPECTION NOTE Do not overlook visual inspecti
12. Installation Korean 1532E2 amp 1932E2 3120736 JLG Lift 3 13 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 14 1703811 1703817 1703815 1704400 2032E2 1704402 2646E2 1704403 3246E2 3252567 lt 2032E2 4 1705013 2632E2 2 3252568 2646E2 704400 7 2032E2 l 1704402 221702153 71703818 1 2 ta 71703706 lt 4703812 1704400 2032E2 1704402 1703814 2646E2 1703811 1704403 3246E2 3252645 Figure 3 9 Decal Installation English 2032E2 2632E2 2646E2 3246E2 Sheet 1 of 2 JLG Lift 3120736 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 1703821 3246E2 74 703694 2032E2 2646E2 Cw 1704201 2646E2 3252619 1704201 lt 3246 2 1703811 1703823 1703814 1704400 2032 2 MIN 1704400 2032 2 1704402 IE MAU 2646E2 1704402 1704403 i 1703814 3246E2 1703811 1704 403 1703817 lt 020063401 1703811 1703817 0200063401 amp gt Figure 3 10 Decal Installation English 2032E2 2632E2 2646E2 3246E2 Sheet 2 of 2 3120736 JLG Lift 3 15 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 1703811 1703817 1703815 1704400 2032E2 1704402 2646E2 1704403 3246E2 Kx A 1704400 2 7 2032 2 gt 1704402 lt 2646E2 2 1704403 gt
13. MADE ONLY WITH PRIOR WRITTEN PERMIS SION FROM THE MANUFACTURER Do not operate any machine on which the safety or instruction placards or decals are missing or illegible Check the machine for modifications to original compo nents Ensure that any modifications have been approved by JLG Avoid accumulation of debris on platform deck Keep mud oil grease and other slippery substances from foot wear and platform deck 1 3 OPERATION General Do not use the machine for any purpose other than posi tioning personnel their tools and equipment Before operation the user must be familiar with the machine capabilities and operating characteristics of all functions Never operate a malfunctioning machine If a malfunctions occurs shut down the machine Remove the unit from service and notify the proper authorities Do not remove modify or disable any safety devices Never slam a control switch or lever through neutral to an opposite direction Always return switch to neutral and stop before moving the switch to the next function Oper ate controls with slow and even pressure Hydraulic cylinders should never be left at end of travel fully extended or fully retracted before shutdown or for long periods of time Always bump control in opposite direction slightly when function reaches end of travel This applies both to machines in operation or in the stowed position Do not allow personnel to tamper with or operate
14. Power is removed from the platform controls when the footswitch is released Motor Activation With the power selector switch in the appropriate position platform or ground and the applicable emergency stop switch in the on position and a function switch or control ler is operated and held the motor becomes activated and operates the desired function When operating from the ground controls the power selector switch must be held in the ground position while the function is being operated When operating the platform controls the lift switch must be used in conjunction with the enable 4 2 JLG Lift Switch to drive the lever must be depressed in conjunc tion with the joystick travel IMPORTANT IF A MOTOR MALFUNCTION NECESSITATES UNSCHEDULED SHUTDOWN DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANY OPERATION IMPORTANT ALWAYS POSITION POWER SELECTOR AND EMERGENCY STOP SWITCHES TO THE OFF POSITION WHEN MACHINE IS NOT IN USE 4 4 RAISING AND LOWERING LIFTING A WARNING DO NOT RAISE PLATFORM EXCEPT ON A HARD LEVEL SUR FACE FREE OF OBSTRUCTIONS AND HOLES NOTE The lift switch will not operate if the red trigger switch on the joystick is depressed Raising 1 If the machine is shut down place the power selec tor switch to the desired position platform or ground 2 Position the applicable emergency stop switch to the on position 3120736 SECTION 4 MACHINE OPERATION NOTE
15. RR PRAE 2 10 2 8 Torque Chart a adatto Tcv 2 11 3 1 Ground Control Station oem ette rape nt e Rn De RU CRUS Eod GER e E die 3 3 3 2 Platform Control Station 2 2 2222222222 2 3 4 3 3 Platform Control Station Proportional 3 6 3 4 Decal Installation English 1532 2 amp 1932 2 3 9 3 5 Decal Installation Chinese 1532 2 amp 1932 2 3 10 3 6 Decal Installation Japanese 1532 2 amp 1932 2 3 11 3 7 Decal Installation Latin 1532 2 amp 1932 2 3 12 3 8 Decal Installation Korean 1532 2 amp 1932 2 3 13 3 9 Decal Installation English 2032E2 2632E2 2646E2 3246E2 Sheet 1 2 3 14 3 10 Decal Installation English 2032E2 2632E2 2646E2 3246E2 Sheet 2 2 3 15 3 11 Decal Installation Chinese 2032E2 2632E2 2646E2 3246E2 Sheet 1 2 3 16 3 12 Decal Installation Chinese 2032E2 2632E2 2646E2 3246E2 Sheet 2 2 3 17 3 13 Decal Installation Japanese 2032E2 2632E2 2646E2 3246E2 Sheet 1of 2 3 18 3 14 Decal Installation Japanese 2032E2 2632E2 2646E2 3246E2 Sheet 2 2 3 19 3 15 Decal Install
16. Walk around Inspection 40 2 2 2 5 Functional Che6ck ee eatin 2 3 2 6 Torque 1 2 3 2 7 sn a puyum re ree kr dec etn poe hon dp ERU Rer d bera 2 3 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 1 General iicet tat a eir er Scc M ep e eat a efe I egi 3 1 3 2 Personnel Training om Oi 3 1 3 3 Operating Characteristics and Limitations 3 1 3 4 Controls and Indicators for Non Proportional 3 2 3 5 Controls and Indicators for Proportional 3 6 SECTION 4 MACHINE OPERATION 4 1 Descriptioni xr Re EIUS eerie UA eb ae 4 1 4 2 General REC 4 2 4 3 Motor Opet alion 2 22 2 4 2 4 4 Raising and Lowering Lifting 1 0 4 2 4 5 Pl tformiExtension uy Reed osa m ERE CURA Es 4 3 4 6 Steering at te Lx e RA UR Pr i vert o sae EON Ce 4 3 4 7 Traveling DIVING o aa eet ede eee akapa UR OG ea EN e QE 4 3 4 8 Parking and StoWIRg uu l supa p user RR SEIEN Pp EM eor etin 4 5 4 9 Platform
17. Where transfer is necessary enter exit through the gate only with the platform within 1 foot 0 3m of a safe and secure structure 100 tie off is also required in this situation utilizing two lanyards One lan yard must be attached to the platform with the second lan yard attached to the structure The lanyard connected to the platform must not be disconnected until such time the transfer to the structure is safe and complete Keep oil mud and slippery substances cleaned from footwear and the platform floor Electrocution Hazards This machine is not insulated and does not provide pro tection from contact with an electrically charged conduc tor ZN Maintain safe clearance from electrical lines apparatus or any energized exposed or insulated parts in accordance with the Minimum Safe Approach Distance MSAD as specified in Table 1 1 Allow for machine movement and electrical line swaying Table 1 1 Minimum Safe Approach Distances M S A D MINIMUM SAFE APPROACH Voltage Range Phase to Phase DISTANCE in Feet Meters 010 300V AVOID CONTACT Over 300V to 50 KV 10 3 Over 50KV to 200 KV 15 5 Over 200 KV to 350 KV 20 6 Over 350 KV to 500 KV 25 8 Over 500 KV to 750 KV 35 11 Over 750 KV to 1000 KV 45 14 DANGER DONOT maneuver machine or personnel inside PROHIBITED ZONE ASSUME all electrical parts and wiring are ENERGIZED unless known otherwise Th
18. indicate the number of hours the machine has been operated The hourmeter operates when a machine function is operating or when key switch and emer gency stop switch are on Platform Control Station 1 3120736 Emergency Stop Switch A two position red mushroom shaped emergency stop switch functions to provide power to the plat form control station and also to turn off power to the platform function controls in the event of an emer gency With the power selector switch positioned to platform power is turned on by pulling the switch out on and is turned off by pushing the switch in off Enable Switch The enable switch is located on the left side of the platform control box This switch must be depressed and held before and during actuation of the lift function and for the duration of lift The enable Switch works in conjunction with the lift switch 3 NOTE Drive The joystick is used to drive the machine forward and reverse To drive the red trigger on the front of the joystick must be depressed and held Then the joystick must be pushed forward for forward travel or pulled backward for reverse travel The adjustment between low and high speed is determined by the joystick travel When motor is first activated you are in low speed high speed is achieved by moving the joystick approx 1 4 of the way in either direction from the off position When the machine is raised and a door is opened the machine
19. shop practices This chart is provided as an aid to the operator in the event he she notices a condition that requires prompt attention during the walk around inspection or during operation until the proper ser vice personnel can be notified The Service and Mainte nance Manual provides specific torque values and periodic maintenance procedures with a listing of individ ual components Utilizing this Torque Chart in conjunction with the preventive maintenance procedures in the Ser vice and Maintenance Manual will enhance safety reliabil ity and performance of the machine 2 7 BATTERY CHARGING At the end of the work day the batteries should be charged for the next day s work Position the Emergency Stop switch to OFF Prior to charging be sure electrolyte level is above battery plates Connect the battery charger to a properly grounded 110 Volt receptacle using a suit able extension cord After charging check the electrolyte level of the batteries and adjust accordingly Add distilled water only to batteries A fully charged battery will have a specific gravity above 1 260 on a hydrometer A CAUTION WHEN ADDING DISTILLED WATER TO THE BATTERIES A NON METALLIC CONTAINER AND OR FUNNEL MUST BE USED ADD WATER ONLY TO LEVEL INDICATOR OR 3 8 INCH 0 95 CM ABOVE SEPARATORS CAUTION NO OPEN FLAMES OR SMOKING WHEN CHARGING BATTERIES CAUTION CHARGE BATTERIES ONLY IN A WELL VENTILATED AREA A CAUTION ENSURE THAT BATTERY
20. the machine from the ground with personnel in the platform except in an emergency Do not carry materials directly on platform railing unless approved by JLG 1 2 Trip and Fall Hazards JLG Lift JLG Industries Inc recommends that all persons in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point while operating this machine For further information regarding fall protec tion requirements on JLG products contact JLG Indus tries Inc Prior to operation ensure all gates are fastened and secured in their proper position Identify the designated lanyard anchorage point s at the platform and securely attach the lanyard Attach only one 1 lanyard per lanyard anchorage point Keep both feet firmly positioned on the platform floor at all times Never position ladders boxes steps planks or similar items on unit to provide additional reach for any purpose Never use the scissor arm assembly to gain access to or leave the platform Use extreme caution when entering or leaving platform Ensure that the scissor arm assembly is fully lowered Face the machine when entering or leaving the platform Always maintain three point contact with the machine using two hands and one foot or two feet and one hand at all times during entry and exit 3120736 SECTION 1 SAFETY PRECAUTIONS Platform to structure transfers at elevated positions are discouraged
21. the operator better access to worksites To extend the deck pull the plunger pin attached to lanyards located at the right side of the platform extension extend platform extension and release the pin so that it locks in the front hole in the rail Do not drive machine unless plat form extension is properly pinned To retract the deck remove pin pull platform extension back in and install pin back into rear hole Do not drive machine unless platform extension is properly pinned Maximum capacity of the deck extension is 250 Ib 120 kg 1 person 3120736 4 6 STEERING To steer the machine the thumb operated steer control Switch on the joystick is positioned to the right for traveling right or to the left for traveling left When released the Switch will return to the center off position and the wheels will remain in the previously selected position To return the wheels to the straightened position the switch must be activated in the opposite direction until the wheels are centered 4 7 TRAVELING DRIVING NOTE High drive is cut out when the platform is raised above the following preset heights Table 4 2 High Drive Cutout Model In m 1532E2 46 55 12 14 1932 2 48 60 1 2 1 5 2032E2 84 2 1 2646E2 102 2 6 2632E2 114 2 9 3246E2 60 65 1 5 1 7 A WARNING DO NOT DRIVE WITH PLATFORM RAISED EXCEPT ON A SMOOTH FIRM AND LEVEL SURFACE FREE OF OBSTRUCTIONS AND HOLES TO AVOID LOSS OF TRA
22. 1 941 kg 3246E2 6180lb 2 803 kg TOWING JLG Lift It is not recommended that this machine be towed except in the event of an emergency such as a machine malfunc tion or a total machine power failure Refer to Section 6 for emergency towing procedures 3120736 SECTION 4 MACHINE OPERATION Bnrm B dg I Figure 4 3 Lifting Chart 3120736 JLG Lift 4 7 SECTION 4 MACHINE OPERATION This page left blank intentionally 4 8 JLG Lift 3120736 SECTION 5 EMERGENCY PROCEDURES SECTION 5 EMERGENCY PROCEDURES 5 1 GENERAL This section provides information on the procedures to be followed and on the systems and controls to be used in 5 3 EMERGENCY CONTROLS AND THEIR LOCATIONS the event an emergency situation is encountered during machine operation Prior to operation of the machine and periodically thereafter the entire operating manual including this section should be reviewed by all person nel whose responsibilities include any work or contact with the machine Emergency Stop Switch These large red buttons one located at the Ground Co
23. 246E2 Maximum Occupants 2 2 2 2 2 2 Maximum Workload Capacity 600 Ib 500 Ib 750 Ib 50016 75010 70010 Extension Only 25010 25010 25010 25016 25016 25010 Maximum Travel Grade Gradeability 2096 20 25 25 25 25 Maximum Platform Height 15ft 19ft 20ft 26ft 26ft 32ft Maximum Tire Load Reference Decal on Machine Maximum Drive Speed 2 5 mph 2 5 mph 2 5 mph 2 0 mph 2 0 mph 2 0 mph Gross Machine Weight 2925 Ib 3000 Ib 391016 532510 432516 61006 4 3 MOTOR OPERATION Power Selector Switch The power selector switch functions to direct battery power to the desired control station With the switch in the ground position battery power is supplied to the emer gency stop switch at the ground control station When the switch is in the platform position battery power is sup plied to the emergency stop switch at the platform control station The power selector switch should be in the off position when recharging the batteries and or parking the machine overnight Emergency Stop Switch This switch when in the on out position provides battery power to the ground controls or platform controls as applicable In addition the switch can be used to turn off power push the switch in to the function controls in the event of an emergency NOTE If the machine is equipped with a footswitch Japa nese Specification Only the footswitch must be depressed in conjunction with the red trigger switch located on the joystick
24. 50 3252749 1703697 Figure 3 13 Decal Installation Japanese 2032E2 2632E2 2646E2 3246E2 Sheet 10f 2 JLG Lift 3120736 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 2032E2 2646E2 1704201 3246E2 1703850 ZZ 1704400 2032bE2 1704402 2646E2 1704403 3246E2 22 1703811 1703817 0200063401 gt 3252567 2032 2 3252568 2646 2 3246 2 1703788 TS 1704201 3252619 1703845 2032E2 2646E2 3246E2 1703811 1703814 1703811 1703817 020063401 2032E2 1704402 2646E2 1704403 3246E2 Figure 3 14 Decal Installation Japanese 2032E2 2632E2 2646E2 3246E2 Sheet 2 of 2 3120736 JLG Lift 3 19 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 1703811 1703817 1703815 1704400 2032E2 1704402 2646E2 1704403 3246E2 3252567 2032E2 7 3252568 2646E2 1 3252619 1704402 2646E2 3246E2 lt 1704403 5 020063401 1703811 1703814 1704400 2 7 2032E2 71703857 Le e i 1703706 1703812 1704400 2032 2 1704402 1703814 2646E2 1703811 1704403 3246E2 3252645 Figure 3 15 Decal Installation Korean 2032E2 2632E2 2646E2 3246E2 Sheet 1 of 2 3 20 JLG Lift 3120736 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 2032E2 2646E2 1704201
25. 63401 1703811 1703817 0200063401 amp gt Figure 3 18 Decal Installation Spanish 2032E2 2632E2 2646E2 3246E2 Sheet 2 of 2 3120736 JLG Lift 3 23 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL This page let blank intentionally 3 24 JLG Lift 3120736 SECTION 4 MACHINE OPERATION 3120736 SECTION 4 MACHINE OPERATION 4 1 DESCRIPTION This machine is a self propelled aerial work platform on top of an elevating scissor mechanism The Scissor Lift s 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 machinery or equipment positioned at ground level The JLG Scissor Lift has a primary operator Control Sta tion in the platform From this Control Station the operator can drive and steer the machine in both forward and reverse directions and raise and lower the platform The machine has a Ground Control Station which will override the Platform Control Station Ground Controls operate lift up and down Ground Controls are to be used only for pre operational check and in an emergency to lower the plat form to the ground or retract the platform extension should the operator in the platform be unable to do so Instructions 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 wha
26. 9 Compartment Cover and Latches Cover and properly latches in working condition properly secured no 34 Scissor Arms and Sliding Wear Pads Properly visible damage no loose or missing parts secured no visible damage no loose or missing 30 Wheel and Tire Assembly Right Front Properly parts secured no loose or missing lug nuts no visible 35 Not Shown on Illustration Valves Valve Fittings damage Hosing and Tubing Properly secured no loose or 31 Drive Motor Right Front Properly secured no visi missing parts rio visible damage no evidence ot leakage ble damage no evidence of leakage 32 Handrail Installation All railings securely attached no visible damage no missing parts chain in proper working order Figure 2 2 Daily Walk Around Inspection 1532E2 1932E2 Sheet 3 of 3 3120736 JLG Lift 2 9 SECTION 2 PREPARATION AND INSPECTION Note 100 Hrs 3 months 200 Hrs 6 months 400 Hrs 1 Year 800 Hrs 2 Years 3 H 3 2032E2 2646E2 3246E2 3 1532E2 1932E2 Figure 2 3 Lubrication Diagram Table 2 2 Lubrication Chart Key To Lubricants MPG Multi Purpose Grease HO Hydraulic Oil Mobilfluid 424 A WARNING TO AVOID PERSONAL INJURY USE SAFETY PROP FOR ALL MAINTENANCE R
27. EQUIRING PLATFORM TO BE ELEVATED 2 10 NOTE JLG Lift INDEX NO TYPE LUBE INTERVAL NUMBER COMPONENT TYPE LUBE METHOD HOURS COMMENTS 1 Hydraulic Oil Fill Cap Drain Plug Check HO Level 8 800 Check oil level every 8 hours HO Change HO Change oil every 800 hours 2 Hydraulic Filter Ele N A N A 50 400 Change filter after first 50 hours of operation ment then every 400 hours thereafter 1 year 3 Wheel Bearings Frontor Rear Wheels MPG Repack 800 2 years 4 Kingpin Housing Grease Fittings MPG Pressure Gun 100 3 months NOTE Be sure to lubricate like items on each side of the machine Recommended lubricating intervals are based on machine operations under normal condi tions For machines used in multi shift opera tions and or exposed to hostile environments or conditions lubricating frequencies must be increased accordingly On all machines built before serial number 0200082630 operate lift function through one complete cycle before checking oil level Oil level should be at the full mark or within 1 2 below the full mark On machines built after and including serial number 0200082630 check oil level to insure proper level 3120736 SECTION 2 PREPARATION AND INSPECTION yeys nbiol e z
28. If the machine is equipped with a footswitch Japa nese Specification Only the footswitch must be depressed in conjunction with the red trigger switch located on the joystick Power is removed from the platform controls when the footswitch is released 3 If operating from the ground controls position the lift switch to up and hold until desired elevation is achieved If operating from the platform controls press and hold the enable switch move the lift switch forward up and hold until desired elevation is reached The lift switch works in conjunction with the enable switch Lowering A WARNING ENSURE SCISSOR ARM AREA IS FREE OF PERSONNEL PRIOR TO LOWERING PLATFORM NOTE The machine i s equipped with a decent alarm which will sound as the machine is being lowered If operating from the ground controls position the lift switch to down and hold until desired elevation is achieved or until platform is fully lowered If operating from the platform controls press the enable switch and push the lift switch backward down and hold until desired elevation is reached or until platform is fully low ered The lift switch works in conjunction with the enable Switch A WARNING DO NOT LIFT DOWN WITHOUT COMPLETELY RETRACTING THE PLATFORM EXTENSION 4 5 PLATFORM EXTENSION Manual Platform Extension The machine is equipped with a mechanically extendible deck which adds 3 ft 0 9 m to the front of the platform giving
29. L IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED Safety of personnel and proper use of the machine are of primary concern DANGER WARNING CAUTION IMPORTANT INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these areas They are defined as follows 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 MODER ATE 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 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 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 PRODUCT CALL 1 877 JLG SAFE Due to continuous product improvements JLG Industries Inc reserves the right to make specification changes without prior notifica
30. Loading s ERR RERO IM RE kus RO RES MERE 4 5 4 10 Safety Prop i ep obe gerat Quse deor odii te D 4 5 4 11 Tie Down and Lifting ir exer Fane eek e Re E RR De Rc RR d 4 6 SECTION 5 EMERGENCY PROCEDURES 5 1 General os init edna po ROS ue aw exe 5 1 5 2 Emergency Towing 5 1 5 3 Emergency Controls and Their Locations 5 1 5 4 Emergency 1 7 5 2 5 5 Incident Notification rie u qua e eec Rd 5 2 SECTION 6 INSPECTION AND REPAIR LOG 3120736 JLG Lift TABLE OF CONTENTS Continued FIGURE NO TITLE PAGE NO 2 1 Daily Walk Around Inspection 2032E2 2632E2 2646E2 3246E2 Sheet 1 3 2 4 2 1 Daily Walk Around Inspection 2032E2 2632E2 2646E2 3246E2 Sheet 2 2 5 2 1 Daily Walk Around Inspection 2032E2 2632E2 2646E2 3246E2 Sheet 3 of 3 2 6 2 2 Daily Walk Around Inspection 1532E2 1932E2 Sheet 1 3 2 7 2 2 Daily Walk Around Inspection 1532E2 1932E2 Sheet 2 3 2 8 2 2 Daily Walk Around Inspection 1532E2 1932E2 Sheet 3 3 2 9 2 3 Lubrication Diagram s v e REG ee gu e mac ERE REGIE
31. SE COMPONENTS IF ELECTRICAL ELECTRONIC COMPO NENTS ARE SPRAYED SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION Ground Control Station NOTE Refer to the Ground Control Station for Non Propor tional Control machines Platform Control Station 1 Emergency Stop Switch A two position red mushroom shaped emergency stop switch functions to provide power to the plat form control station and also to turn off power to the platform function controls in the event of an emer gency With the power selector switch positioned to platform power is turned on by pulling the switch out on and is turned off by pushing the switch in off Turning the emergency stop switch off and then on again will reset the smart system if a system fault has occurred and the machine has shut down 3120736 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3120736 2 Footswitch Japanese Specification Only For machines built to Japanese specifications a footswitch is provided as part of the operating sys tem The footswitch must be depressed in conjunc tion with the red trigger switch on the joystick to operate any function Membrane Switch Panel The function switches at the platform control station are an integral part of a membrane switch panel which contains switches for drive high drive lift powered deck extension if equipped and posi trac plus a red tilt indicator light if equipped
32. SE HIGH DRIVE SPEED WHEN DRIVING IN CLOSE QUARTERS OR WHEN DRIVING IN REVERSE A CAUTION IF HIGH DRIVE IS SELEC TED WHEN OIL TEMPERATURE IS VERY COLD BELOW 40 F 4 C HIGH DRIVE WILL NOT ENGAGE IMMEDIATELY AS OIL WARMS ABOVE 40 F 4 C IF HIGH DRIVE IS SELECTED IT WILL ENGAGE AUTOMATICALLY WHILE DRIVING JLG Lift 3120736 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 1704277 3252747 1532E2 3252598 1932E2 lt 1703816 3252588 w 1703821 1703811 1703823 N 71703812 A 1 2 Ca 1703695 3252645 7 1703819 1703811 1704771 1704399 1703823 1703822 1703813 1532 2 1703819 3252598 1932 2 1704017 x 22 3252747 1703817 1704399 1703811 1703814 Figure 3 4 Decal Installation English 1532E2 amp 1932 2 3120736 JLG Lift SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 10 1704277 3252747 1532E2 3252598 1932E2 3252588 7 x T 22 Wp 1704611 1704610 4 1703811 1704609 IN 71703812 3252699 1703811 Vg asiga 1704771 1704399 1703817 1704609 NEZ 1703813 1703822 3252747 1532E2 1703819 3252598 1932E2 1703817 1704399 1703811 1703814 Figure 3 5 Decal Installation Chinese 1532E2 amp 1932E2 JLG Lift 3120736 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL
33. Tire Assembly Right Rear Properly secured no loose or missing lug nuts no visible damage Lift Cylinder Properly secured no visible damage no loose or missing parts no evidence of leakage Tilt Switch Properly secured no loose or missing parts no visible damage no loose or broken wiring Figure 2 1 Daily Walk Around Inspection 2032E2 2632E2 2646E2 3246E2 Sheet 2 of 3 3120736 JLG Lift 2 5 SECTION 2 PREPARATION AND INSPECTION 29 30 31 32 33 Battery Installation Proper electrolyte cables secure no damage or corrosion level Pothole Protection System Support bar rollers limit switches and links properly secured no visi ble damage no loose or missing parts Battery Charger No visible damage properly secured Compartment Cover and Latches Cover and latches in working condition properly secured no visible damage no loose or missing parts Wheel and Tire Assembly Right Front Properly Secured no loose or missing lug nuts no visible damage 34 35 36 37 Handrail Installation All railings securely attached no visible damage no missing parts chain in proper working order Platform Assembly No loose or missing parts no visible damage platform deck extension operates properly Scissor Arms and Sliding Wear Pads Properly secured no visible damage no loose or missing parts Not Shown on Illustration Valves Val
34. VEL CONTROL OR UPSET ON GRADES AND SIDESLOPES ON 1532E2 AND 1932E2 DO NOT DRIVE MACHINE ON GRADES EXCEEDING 20 ON 2032E2 2632E2 2646E2 3246E2 DO NOT DRIVE MACHINE ON GRADES EXCEED ING 25 A WARNING TRAVEL GRADES IN LOW DRIVE SPEED ONLY 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 FEET 1 8 METERS OF AN OBSTRUCTION TO GO BACK DOWN THE GRADE IF TRAVELING FORWARD UP THE GRADE BUMP THE CONTROL HANDLE FORWARD SLIGHTLY TO ENSURE THE BRAKES ARE RELEASED BEFORE DESCENDING THE GRADE JLG Lift 4 3 SECTION 4 MACHINE OPERATION HORIZONTAL Figure 4 1 Grade and Sideslope A WARNING MAKE SURE DECK EXTENSION IS LOCKED IN PLACE BEFORE DRIVING MACHINE NOTE The machine is equipped with a Pothole Protection System which lowers automatically when the plat form is raised or a door is opened If the pothole pro tection does not fully lower the drive function is cut out until the platform is completely lowered NOTE When the machine is raised and a door is opened the machine will not drive Traveling Forward 1 Place power selector switch at ground control sta tion to platform 2 Position emergency stop switch at platform control station to on position 3 Using the speed select switch select low or high speed 4 Squeeze controller joystick depressing red trigger on front of joys
35. achine as specified in this manual Read understand and obey all applicable employer local and governmental regulations as they pertain to your utilization and application of the machine Workplace Inspection Precautions to avoid all hazards in the work area must be taken by the user before operation of the machine Do not operate or raise the platform from a position on trucks trailers railway cars floating vessels scaffolds or other equipment unless the application is approved in writing by JLG FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE PROP ERTY DAMAGE PERSONAL INJURY OR DEATH SUB SECTION Before operation check work area for overhead hazards such as electric lines bridge cranes and other potential overhead obstructions Check floor surfaces for holes bumps drop offs obstruc tions debris concealed holes and other potential haz ards 1 2 PRE OPERATION Check the work area for hazardous locations Do not operate the machine in hazardous environments unless approved for that purpose by JLG Operator Training and Knowledge The Operators and Safety Manual must be read in its entirety before operating the machine For clarification questions or additional information regarding any por tions of this manual contact JLG Industries Inc Ensure that the ground conditions are adequate to sup port the maximum tire load indicated on the tire loa
36. ards caution and warning decals so that they will be protected from hostile environment Chock at least two wheels when parking machine for an extended period of time Turn switch to off and remove key to disable machine from unauthorized use 4 9 PLATFORM LOADING The platform maximum rated load capacity is shown on a placard located on the platform and the manufactures nameplate located at the front of the machine and is based upon the following criteria 1 NOTE Machine is positioned on a smooth firm and level surface All braking devices are engaged Maximum platform capacity for each model in its standard configuration is as follows 1532E2 600 Ib 270 kg 1932E2 500 Ib 230 kg 2032E2 750 Ib 340 kg 2632E2 500 Ib 230 kg 2646E2 750 Ib 340 kg 3246E2 700 Ib 320 kg Maximum capacity of the manual platform extension is 250 Ib 120 kg 1 person The weight in the platform should be uniformly dis tributed in the platform The total combined weight of personal tools and supplies must not exceed the above figures 4 10 SAFETY PROP A WARNING THE SAFETY PROP MUST BE USED WHENEVER MAINTENANCE PERFORMED ON THE MACHINE REQUIRES THE SCISSOR ARMS TO BE RAISED To engage the safety prop raise the platform then remove the prop from the prop bracket until it hangs verti cally Lower the platform until the safety prop rests on the point provided on the arm Maintenance can now begin
37. ation Korean 2032E2 2632E2 2646E2 3246E2 Sheet 1 2 3 20 3 16 Decal Installation Korean 2032E2 2632E2 2646E2 3246E2 Sheet 2 2 3 21 3 17 Decal Installation Spanish 2032E2 2632E2 2646E2 3246E2 Sheet 1 of 2 3 22 3 18 Decal Installation Spanish 2032E2 2632E2 2646E2 3246E2 Sheet 2 2 3 23 4 1 Grade and Sidesl obe u uu u n DE Kd e top AUR at e hae ened 4 4 4 2 Liftiand Tie DOWD sete reete cie VETE ERO DV gore 4 6 4 3 Lifting Charte pc RUEDA cuya qa m C sa ususi ANE 4 7 LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 Minimum Safe Approach Distances 5 1 3 2 1 High Drive Cut Out i eorr eae aw ae PAS E Shea PRAE RU 2 3 2 2 Lubrication Chart uo 2 10 4 1 Operating 4 2 6 1 Inspection 00 4 6 1 LIST FIGURES JLG Lift 3120736 SECTION 1 SAFETY PRECAUTIONS SECTION 1 SAFETY PRECAUTIONS 1 1 GENERAL This section outlines the necessary precautions for proper and safe machine usage and maintenance In order to promote proper machine usage it is mandatory that a daily routine is established based on the content of this manual A maintenance prog
38. c tion for the selected function The drive high drive and posi trac functions may be operated simulta neously but the drive lift and powered deck exten sion functions must be operated independently of each other If the drive lift and powered deck exten sion functions are selected simultaneously no func tion will operate If this occurs pause then press only one of the function switches to activate the function To operate the joystick squeeze the red trigger switch then position the joystick to forward or reverse as desired 5 NOTE JLG Lift Steer Switch The thumb operated steer switch located on top of the joystick works in conjunction with the trigger Switch and activates the steer wheels in the direction the switch is moved left or right Drive Switch The drive switch when used in conjunction with the joystick provides for driving the machine in forward or reverse Drive is activated by pressing the drive Switch in conjunction with the trigger switch and moving the joystick forward forward or backward reverse Drive speed is determined by the distance the joystick is moved forward or backward Increased drive speed is possible when the high drive speed switch is pressed either simultaneously with the drive switch or while operating the drive function The drive switch is part of the enable cir cuit which provides power to the joystick and the drive function for 3 seconds when the drive swit
39. c motors and cylinders for the various machine motions The hydraulic components are controlled by electrically acti vated hydraulic valves using switches and control levers The drive speeds are controlled by a toggle switch from low to high speed Functions controlled by toggle or push button switches are either on or off The JLG Scissor Lift is a two wheel drive machine with drive power being supplied by a hydraulic motor for each drive wheel The rear wheels are supplied with spring applied hydraulically released brakes These brakes are automatically applied any time the Drive controller joy stick is returned to the neutral position The weight in the platform should be uniformly distributed in the platform The total combined weight of personnel tools and supplies must not exceed the figures in Figure 4 1 Operating Specificatoins NOTE The platform may be raised only when positioned on firm level and uniform surfaces JLG Lift 4 1 SECTION 4 MACHINE OPERATION 4 2 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 the machine It is important that the user read and understand the proper procedures before operating the machine Table 4 1 Operating Specificatoins Model 1532E2 1932E2 2032E2 2632E2 2646E2 3
40. ca 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 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
41. ch is pressed If the joystick is not activated within 3 sec onds the drive switch must be pressed again before activating the joystick When the joystick is returned to the center off position the operator has 3 sec onds to re activate the joystick or select another function before power is removed by the enable cir cuit In addition the posi trac switch can be engaged while operating the drive function to give a more evenly distributed oil flow to each drive motor Do not try to operate the drive lift and powered deck extension functions simultaneously If the drive lift and powered deck extension functions are selected simultaneously no function will operate If this occurs pause then press only one of the func tion switches to activate the function The machine is equipped with a Pothole Protection System which lowers automatically when the plat form is raised If the Pothole Protection System does not fully lower the DRIVE function is cut out until the platform is completely lowered 3 7 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 7 High Drive Speed Switch The high drive speed switch when used in conjunc tion with the joystick being operated in the drive mode provides additional oil flow to the drive circuit for increased travel speed To operate high drive depress the high drive speed switch either simulta neously with the drive switch or while operating the drive function A CAUTION DO NOT U
42. checks in accordance with paragraph 2 5 Functional Check before attempting to operate the machine 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 2 4 WALK AROUND INSPECTION It is the user s responsibility to inspect the machine before the start of each workday It is recommended that each user inspect the machine before operation even if the machine has already been put into service under another user This Walk Around Inspections Figures 2 1 and 2 2 are the preferred method of inspection In addition to the Walk Around Inspection be sure to include the following as part of the daily inspection Overall Cleanliness Check all standing surfaces for oil fuel and hydraulic oil spillage and foreign objects Ensure overall cleanliness 2 2 JLG Lift 3120736 SECTION 2 PREPARATION AND INSPECTION 2 5 FUNCTIONAL CHECK 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 A functional check of all systems should be performed under no load once the walk around inspection is com plete in an area free of overhead and ground level obstructions Perform pre load functional check in accor dance with the following procedure 1 Ensure batteries are fully charged 2 From ground control raise and lower platf
43. d decals located on the chassis adjacent to each wheel Do not operate the machine when wind conditions exceed 28 mph 12 5 m s This machine can be operated in nominal ambient tem peratures of 0 F to 104 F 20 C to 40 C Consult to optimize operation outside of this temperature range Machine Inspection Do not operate this machine until the inspections and functional checks have been performed as specified in Section 2 of this manual An operator must not accept operating responsibilities until adequate training has been given by competent and authorized persons 3120736 JLG Lift 1 1 SECTION 1 SAFETY PRECAUTIONS Do not operate this machine until it has been serviced and maintained according to the maintenance and inspection requirements as specified in the machine s Service and Maintenance Manual Ensure all safety devices are operating properly Modifica tion of these devices is a safety violation A WARNING When two or more persons are in the platform the opera tor shall be responsible for all machine operations Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area Do not assist a stuck or disabled machine by pushing or pulling except by pulling at the chassis tie down lugs Stow scissor arm assembly and shut off all power before MODIFICATION OR ALTERATION OF AN AERIAL WORK PLAT leaving machine FORM SHALL BE
44. dL Operators and Safety Manual ANSI 1509001 IPA REGISTERED COMPANY 015 Model 1532E2 1932E2 2032E2 2632E2 2646E2 3246E2 3120736 November 21 2003 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 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 MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN WITHOUT WRITTEN APPROVAL FROM JLG INDUSTRIES PER OSHA REGULATIONS THIS SAFETY ALERT SYMBO
45. dam age 22 Scissor Arms and Sliding Wear Pads Properly secured no visible damage no loose or missing Drive Motor Left Front Properly secured no visi parts ble damage no evidence of leakage 23 Wheel and Tire Assembly Right Rear Properly Wheel and Tire Assembly Left Front Properly secured no loose or missing lug nuts no visible secured no loose or missing lug nuts no visible damage damage T 24 Lift Cylinder Properly secured no visible damage Drive Cutout Switch Properly secured no visible no loose or missing parts no evidence of leakage damage no loose or missing parts m 25 Tilt Switch Properly secured no loose or missing Compartment Cover and Latches Cover and parts no visible damage no loose or broken wir latches in working condition properly secured no ing loose or missing parts 26 Battery Installation Proper electrolyte level cables Ground Controls No visible damage switches secure no damage Or corrosion operable placards secure and legible 27 Pothole Protection System Support bar rollers limit switches and links properly secured no visible 2 8 Figure 2 2 Daily Walk Around Inspection 1532E2 1932E2 Sheet 2 of 3 JLG Lift 3120736 SECTION 2 PREPARATION AND INSPECTION 28 Battery Charger No visible damage properly 33 Platform Assembly No loose or missing parts no secured visible damage platform deck extension operates 2
46. ed to low until the platform is lowered completely CAUTION DO NOT OPERATE MACHINE IF HIGH DRIVE SPEED OPERATES WHEN PLATFORM IS RAISED ABOVE THE STOWED POSITION 3 4 JLG Lift NOTE The machine is equipped with a Pothole Protection System which lowers automatically when the plat form is raised The Pothole Protection System will also lower when either of the doors are opened but only on the side of the opened door and this will not provide tip over protection If the Pothole Protection System does not fully lower the DRIVE function is cut out until the platform is completely lowered 1 Tilt Alarm Warning Horn The Tilt Alarm Warning is activated by the Tilt Alarm Switch when the chassis is on a severe slope and lifted above stowed position 1532 2 1932 2 2032 2 1 5 2632E2 2646E2 3246E2 2 All Japanese Models 5 A WARNING IF TILT ALARM I ON WHEN PLATFORM IS RAISED LOWER PLATFORM COMPLETELY THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE RAISING PLATFORM 3120736 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 8 Tilt Alarm Warning Light A red warning light on the control box panel will illu minate when the chassis is on a severe slope 3120736 1532E2 1932E2 2032E2 1 5 2632E2 2646E2 3246E2 2 All Japanese Models 5 10 JLG Lift Horn If Equipped This push button switch when activated permits the operator to warn jobsite personnel when the machine is ope
47. erhead structures or equipment do not continue operation 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 personnel Do not operate controls to cause one or more wheels to leave the ground Righting of Tipped Machine A forktruck of suitable capacity or equivalent equipment should be placed under the elevated side of the chassis with a crane or other suitable lifting equipment used to lift the platform while the chassis is lowered by the forklift or other equipment Post Incident Inspection JLG Lift Following any accident thoroughly inspect the machine and test all functions first from the ground controls then from the platform controls Do not lift above 3 meters until you are certain that all damage has been repaired if required and that all controls are operating correctly 5 5 INCIDENT NOTIFICATION 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 Product Safety and Reliability Department at the factory should be con tacted by telephone and provided with all necessary details It should be noted that failure to notify the Manufacturer of an incident involving a JLG Industries product within 48 hours of such an occurrence may v
48. eries when servicing electrical components or when performing welding on the machine Shut down the engine if equipped while fuel tanks are being filled Ensure replacement parts or components are identical or equivalent to original parts or components Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position Ensure adequate support is pro vided when raising components of the machine Remove all rings watches and jewelry when performing any maintenance Do not wear loose fitting clothing or long hair unrestrained which may become caught or entangled in equipment Use only clean approved non flammable cleaning sol vents Never alter remove or substitute any items such as coun terweights tires batteries platforms or other items that may reduce or affect the overall weight or stability of the 3120736 machine Reference the Service and Maintenance Manual for the weights of critical stability items A WARNING MODIFICATION OR ALTERATION OF AN AERIAL WORK PLAT FORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMIS SION FROM THE MANUFACTURER Battery Hazards Always disconnect batteries when servicing electrical components or when performing welding on the machine Do not allow smoking open flame or sparks near battery during charging or servicing Do not contact tools or other metal objects across the bat tery terminals Always wear
49. f these requirements constitute an assumption of responsibility of liability on the part of JLG Industries Inc 1 Only trained and authorized operators shall be per mitted 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 Allpersonnel 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 Instruction and warning placards must be legible 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 ade quate 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 conditions and hazards 11 Ground controls shall not be operated unless permis sion has been obtained from personnel in the plat form except in case of an emergency 12 Regular inspection of the job site and aerial lift shall be performed by co
50. fully retracted and completely empty of tools prior to towing lifting or hauling 3120736 SECTION 1 SAFETY PRECAUTIONS When lifting machine with a forklift position forks only at designated areas of the machine Lift with a forklift of ade quate capacity Refer to Section 4 for lifting information 1 5 MAINTENANCE General This section contains general safety precautions which must be observed during maintenance of this machine Additional precautions to be observed during machine maintenance are inserted at the appropriate points in this manual and in the Service and Maintenance Manual It is of utmost importance that maintenance personnel pay strict attention to these precautions to avoid possible injury to personnel or damage to the machine or property A maintenance program must be established by a quali fied person and must be followed to ensure that the machine is safe Maintenance Hazards Shut off power to all controls and ensure that all operating systems are secured from inadvertent motion prior to per forming any adjustments or repairs Never work under an elevated platform until it has been fully lowered to the full down position if possible or other wise supported and restrained from movement with appropriate safety props blocking or overhead supports Always relieve hydraulic pressure from all hydraulic cir cuits before loosening or removing hydraulic compo nents Always disconnect batt
51. hand eye and face protection when servic ing batteries Ensure that battery acid does not come in contact with skin or clothing A WARNING BATTERY FLUID IS HIGHLY CORROSIVE AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION Charge batteries only in a well ventilated area Avoid overfilling the battery fluid level Add distilled water to batteries only after the batteries are fully charged JLG Lift 1 5 SECTION 1 SAFETY PRECAUTIONS This page intentionally left blank 1 6 JLG Lift 3120736 SECTION 2 PREPARATION AND INSPECTION SECTION 2 PREPARATION AND INSPECTION 2 1 GENERAL This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and lists checks that are performed prior to use of the machine It is important that the information contained in this section be read and understood before any attempt is made to operate the machine Ensure that all the necessary inspections have been completed successfully before placing the machine into service These procedures will aid in obtaining maxi mum service life and safe operation 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 mach
52. he chocks from the wheels Power Selector Switch The key operated POWER SELECT switch located at the Ground Control Station can also be used to shut down the machine in an emergency situation To shut off machine power turn the POWER SELECT switch to the center OFF O position Ground Control Station The Ground Control Station is located on the left side of the machine frame The controls on this panel provide the means for overriding the platform controls and for control ling the platform lift up and down functions from the ground Place the power select switch in the ground posi tion and operate the lift switch to lift up or down Manual Descent The manual descent valve is used in the event of total power failure to lower the platform using gravity The manual descent handle is located at the rear of the machine behind the ladder on the 1932E2 and 2032E2 Pulling the manual descent handle opens the valve spool lowering the platform The 2646E2 3246E2 may be equipped with either a man ual descent lever or a manual decent pump both located at the rear of the machine behind the ladder If your 2646E2 or 3246E2 is equipped with a manual descent lever Pushing the manual descent lever opens the valve spool lowering the platform If your 2646E2 or 3246E2 is equipped with a manual pump operate as follows 1 Turn knob clockwise on lowering valve untill fully closed 2 Install handle and pump until holding val
53. ine is put into operation it must be carefully inspected for any evidence of damage resulting from shipment and inspected periodically thereafter as outlined in paragraph 2 3 Delivery and Periodic Inspec tion The unit should be thoroughly checked for hydraulic leaks during initial start up and run A check of all compo nents should be made to assure their security All preparations necessary to place the machine in opera tion readiness status are the responsibility of manage ment personnel Preparation requires good common sense i e lift works smoothly and brakes operate prop erly coupled with a series of visual inspections The man datory requirements are given in paragraph 2 4 Walk Around Inspection It should be assured that the items appearing in the Deliv ery and Periodic Inspection and Functional Check are complied with prior to putting the machine into service 2 3 DELIVERY AND PERIODIC INSPECTION NOTE This machine requires periodic safety and mainte nance inspections by a JLG distributor or certified JLG mechanic A decal located on the frame pro vides a place to record stamp inspection dates Check decal and notify dealer if inspection is over due An annual inspection shall be performed on the aerial plat form no later than thirteen 18 months from the date of the prior annual inspection The inspection shall be per formed by person s qualified as a mechanic on the spe cific make and model of the ae
54. is requirement shall apply except where employer local or governmental regulations are more stringent Maintain a clearance of at least 10 ft 3m between any part of the machine and its occupants their tools and their equipment from any electrical line or apparatus car rying up to 50 000 volts One foot additional clearance is required for every additional 30 000 volts or less A DANGER DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIB ITED ZONE MSAD ASSUME ALL ELECTRICAL PARTS AND WIR ING ARE ENERGIZED UNLESS KNOWN OTHERWISE Tipping Hazards Ensure that the ground conditions are adequate to sup port the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel Do not travel on unsupported surfaces The user should be familiar with the driving surface before driving Do not exceed the allowable sideslope and grade while driving 3120736 JLG Lift 1 3 SECTION 1 SAFETY PRECAUTIONS Do not elevate platform or drive with platform elevated while on or near a sloping uneven or soft surface Ensure machine is positioned on a firm level and uniformly sup ported surface before elevating platform or driving with the platform in the elevated position Before driving on floors bridges trucks and other sur faces check allowable capacity of the surfaces Never exceed the maximum work load as specified on the platform Distribute loads evenly on platform floor Kee
55. ition no visi ble oil leakage on the ground 3120736 JLG Lift 2 1 SECTION 2 PREPARATION AND INSPECTION Steer Cylinder Placards No rust nicks scratches or foreign material on piston rod no leakage Steer Linkage No loose or missing parts no visible damage Front Spindle Assemblies No excessive wear no damage Control Boxes Platform and Ground Switches operable no visible damage placards secure and legible controller operable no visible damage Batteries Proper electrolyte level cable connections tight no visible damage no corrosion at battery cable connections Ensure batteries are fully charged Motor Pump Unit and Valves No leakage units secure Platform Placards No visible damage placards secure and legible Keep all information and operating placards clean and unobstructed Cover when spray painting or shot blasting to protect legibility Operators and Safety Manual Ensure a copy of this manual is enclosed in the manual storage box Machine Log Ensure a machine operating record or log is kept Check to see that it is current and that no entries have been left uncleared leaving machine in an unsafe condition for operation Lubrication For those items pointed out in the Walk Around Inspection requiring daily lubrication refer to Table 2 2 Lubrication Chart for specific requirements Functional Check Perform functional
56. ment JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 Telephone 717 485 5161 Fax 717 485 6573 NOTE Leased or rented units should not be included on this form Mfg Model Serial Number Previous Owner Address City 9 Zip Telephone Date Of Transfer Current Owner Address City Telephone Who in your organization should we notify Name Title e Corporate Office JLG Industries Inc 1 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 25 England Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industries Pty Ltd Unit 1 24 Industrial Complex Herman Street Meadowdale Germiston South Afri
57. mpetent persons 13 Personnel shall always stand on the floor of the plat form 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 April 1998 Original Issue February 1999 Revised November 17 1999 Revised July 31 2000 Revised August 27 2001 Revised June 20 2002 Revised October 10 2002 Revised June 16 2003 Revised November 21 2003 Revised d JLG Lift 3120736 TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO SECTION FOREWORD SECTION 1 SAFETY PRECAUTIONS 1 1 General m 1 1 1 2 Pre Operati n c aep UR e e ER me Leg 1 1 1 3 Operation uu pU E werte 1 2 1 4 Towing Lifting and 0 71 III 1 4 1 5 Maintenance beu bed eee qeu dece pepe per ps 1 5 SECTION 2 PREPARATION AND INSPECTION 2 1 y puqu Re ERE DU D A EM ror ER ES 2 1 2 2 Preparation aw ek kuna e aepo e rere 2 1 2 3 Delivery and Periodic Inspection 2 1 2 4
58. n trol Station and one at the Platform Control Station will immediately stop the machine when depressed A WARNING CHECK MACHINE DAILY TO MAKE SURE EMERGENCY STOP BUTTON IS IN PLACE AND THAT GROUND CONTROL INSTRUC TIONS ARE IN PLACE AND LEGIBLE 5 2 EMERGENCY TOWING PROCEDURES 3120736 Although towing the machine is prohibited provisions for moving the machine in case of a malfunction power fail ure or for loading on a truck have been incorporated The following procedures are to be used ONLY for emer gency movement to a suitable maintenance area or to load the machine on a truck These procedures are also found on a decal affixed to the frame at the rear of the machine 1 Chockthe wheels securely 2 Turn the black knob on the main control valve coun terclockwise all the way out to disengage the drive motors 3 Using a 3 4 in wrench release the parking brake by moving the brake cams to the horizontal position 4 Using suitable equipment for assistance remove the chocks and move the machine to an appropriate maintenance area or onto the truck After moving the machine complete the following pro cedures 1 Position the machine on a firm level surface 2 Chockthe wheels securely 3 Using a 3 4 in wrench engage the parking brake by moving the brake cams to the vertical position 4 Turn the black knob on the main control valve clock wise all the way in to engage the drive motors 5 Remove t
59. oid any warranty con sideration on that particular machine 3120736 SECTION 6 INSPECTION AND REPAIR LOG SECTION 6 INSPECTION AND REPAIR LOG Table 6 1 Inspection and Repair Log Date Comments 3120736 JLG Lift 6 1 SECTION 6 INSPECTION AND REPAIR LOG Table 6 1 Inspection and Repair Log Date Comments 6 2 JLG Lift 3120736 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 Product Safety amp Reliability Department via facsimile 717 485 6573 or mail to address as specified on the back of this form Thank you Product Safety amp Reliability Depart
60. on of chassis under side Checking this area often results in discovery of conditions which could cause extensive machine damage 1 Platform Controls Properly secured no loose or missing parts no visible damage to control box or controller joystick Placards secure and legible control markings legible operators and safety man ual in manual storage box 2 Steer Cylinder and Linkage Properly secured no loose or missing parts no visible damage no evi dence of steer cylinder leakage 3 Safety Prop Properly secured no visible damage no loose or missing parts 4 Scissor Arms and Sliding Wear Pads Properly secured no loose or missing parts no visible dam age 5 Wheel and Tire Assembly Left Front Properly secured no loose or missing lug nuts no visible damage 6 Drive Cutout Switch Properly secured no visible damage no loose or missing parts 7 Compartment Cover and Latches Cover and latches in working condition properly secured no loose or missing parts 8 Ground Controls No visible damage switches operable placards secure and legible 9 Hydraulic Reservoir No visible damage no loose or missing parts no evidence of leakage Recom mended hydraulic fluid level on side of tank Breather cap secure and working 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Hydraulic Filter No visible damage properly
61. ons until the trainee has developed the ability to safely control a scissor lift in congested work locations Operator Responsibility The operator must be instructed that he has the responsi bility 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 information from his supervisor or JLG Distributor before proceeding NOTE Manufacturer or Distributor will provide qualified per sons for training assistance with first unit s deliv ered and thereafter as requested by user or his personnel 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 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 3120736 JLG Lift 3 1 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL Capacities Raising platform with or without any load in platform is based on the foll
62. order to become familiar with the characteristics prior to operating the machine 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 fol lowing 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 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 per formed 4 Proper use of all required personnel safety equip ment 5 Sufficient knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunction 6 The safest means to operate near overhead obstruc tions other moving equipment obstacles depres sions holes dropoffs etc on the supporting surface 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 operator or supervisor in an open area free of obstructi
63. orm rail ing Always post a lookout when driving in areas where vision is obstructed Keep non operating personnel at least 6 ft 1 8m away from machine during all driving operations Under all travel conditions the operator must limit travel speed according to conditions of ground surface conges tion visibility slope location of personnel and other fac tors causing hazards of collision or injury to personnel Be aware of stopping distances in all drive speeds When driving in high speed switch to low speed before stop ping Travel grades in low speed only Do not use high speed drive in restricted or close quarters or when driving in reverse Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and per sons in the platform Ensure that operators of other overhead and floor level machines are aware of the aerial work platform s pres ence Disconnect power to overhead cranes Barricade floor area if necessary Avoid operating over ground personnel Warn personnel not to work stand or walk under a raised platform Posi tion barricades on floor as necessary 1 4 TOWING LIFTING AND HAULING Never allow personnel in platform while towing lifting or hauling This machine should not be towed except in the event of emergency malfunction power failure or loading unload ing Refer to Section 6 for emergency towing procedures Ensure platform is
64. orm sev eral times Check for smooth elevation and lowering From the platform control station check for High Drive cut out as platform begins to raise Check that pothole protection system is lowered when platform is raised Attempt to drive machine with platform raised to the heights listed per model in Table 2 1 High Drive Cut Out and pothole protection system blocked from lowering on one side then repeat for the other side Machine should not drive with plat form elevated unless pothole protection system is fully lowered and locked When pothole protection system is fully lowered there should be approxi mately 3 4 in of ground clearance Table 2 1 High Drive Cut Out Model Cut Out Height in Cut Out Height m 1532E2 84 2 1 1932E2 104 2 6 2032E2 84 2 1 2632E2 2646E2 102 2 6 3246E2 63 1 6 3 Drive forward and reverse check for proper opera tion 4 Check that drive brake holds when machine is driven up a hill not to exceed 25 grade and stopped 5 Steer left and right Check for proper operation 6 Check fluid level on hydraulic oil reservoir Refer to Figure 2 3 Lubrication Diagram 7 Check to be sure that drive cannot be activated while lifting 3120736 2 6 TORQUE REQUIREMENTS The Torque Chart Figure 2 3 Torque Chart consists of standard torque values based on bolt diameter and grade also specifying dry and wet torque values in accordance with recommended
65. owing criteria 1 Machine is positioned on a smooth firm and level surface 2 Loadis within manufacturer s rated capacity 3 All machine systems are functioning properly Stability This machine as originally manufactured by JLG and operated within its rated capacity on a smooth firm and level supporting surface provides a stable aerial platform for all platform positions 3 4 CONTROLS AND INDICATORS FOR NON PROPORTIONAL CONTROL The machine is equipped with control panels that use symbols instead of words to indicate control functions Battery Charger NOTE If batteries are run down to under 6 volts the sup plied battery charger will not pick up the charge The battery charger is located in the right side battery door The charger is a 20 Amp SCR style charger equipped with a manual switch that allows the operator to select 110 125 Volt input or 220 250 Volt input A rocker Switch circuit breaker is included to reset the charger in the event of a loss of power LED s on the front panel of the charger indicate the status of charger operation Charge Complete 8096 Charge Incomplete Charge Charger On Abnormal Cycle Under normal operation the battery charger should work as follows NOTE Make sure the DC is connected and then plug the charger into the AC outlet All 5 lights will flash times Each light will flash once from top to bottom All 5 lights will flash more times
66. p all loads within the confines of the platform unless autho rized by JLG Keep the chassis of the machine a minimum of 2 ft 0 6m from holes bumps drop offs obstructions debris con cealed holes and other potential hazards at the ground level Never attempt to use the machine as a crane Do not tie off machine to any adjacent structure Never attach wire cable or any similar items to platform Do not operate the machine when wind conditions exceed 30 mph 12 5 m s Do not cover the platform sides or carry large surface area items in the platform when operating outdoors The addi tion of such items increases the exposed wind area of the machine Do not increase the platform size with unauthorized deck extensions or attachments If scissor arm assembly or platform is caught so that one or more wheels are off the ground all persons must be removed before attempting to free the machine Use cranes forklift trucks or other appropriate equipment to stabilize machine and remove personnel Crushing and Collision Hazards Approved head gear must be worn by all operating and ground personnel Keep hands and limbs out of the scissor arm assembly during operation 1 4 JLG Lift Watch for obstructions around machine and overhead when driving Check clearances above on sides and bot tom of platform when lifting or lowering platform t During operation keep all body parts inside platf
67. ram using the information provided in this manual and the Service and Maintenance Manual must also be established by a qualified person and must be followed to ensure that the machine is safe to operate The owner user operator lessor lessee of the machine should not accept operating responsibility until this man ual has been read training is accomplished and opera tion of the machine has been completed under the supervision of an experienced and qualified operator The owner user operator lessor lessee must be familiar with Sections 6 7 8 9 10 of ANSI A92 6 1999 These sec tions contain the responsibilities of the owner user oper ator lessor and lessee concerning safety training inspection maintenance application and operation If there are any questions with regard to safety training inspection maintenance application and operation please contact JLG Industries Inc LG A WARNING Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and mainte nance of the unit Read understand and obey all DANGERS WARNINGS CAUTIONS and operating instructions on the machine and in this manual Ensure that the machine is to be used in a manner which is within the scope of its intended application as deter mined by JLG All operating personnel must be familiar with the emer gency controls and emergency operation of the m
68. rating in the area Battery Discharge Indicator The battery discharge indicator is a gauge that pro vides a visual indication of the condition of the bat teries SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL Emergency Stop Switch Posi Trac Switch Battery Discharge Indicator Drive Switch High Drive Speed Switch Lift Switch Figure 3 3 Platform Control Station Proportional Control 3 5 CONTROLS AND INDICATORS FOR PROPORTIONAL CONTROL The machine is equipped with control panels that use symbols instead of words to indicate control functions Refer to Symbols figure for these symbols and their corre sponding functions JLG SMART System The machine is controlled by the JLG SMART System a 24 volt multiplex motor controller which works in conjunc tion with a joystick and several switches to operate all machine functions Special operating characteristics of the JLG SMART System are noted where applicable Special attention should be paid to these operating characteristics as they may be somewhat different from those on previous JLG machines IMPORTANT IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI CAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC REC OMMENDS A MAXIMUM PRESSURE OF 750 PSI 52 BAR AT A 3 6 JLG Lift MINIMUM DISTANCE OF 12 INCHES 30 5 CM AWAY FROM THE
69. rial 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 Periodic inspection shall be performed monthly or more often when required by environment severity and frequency of usage Handrail Assemblies Properly installed no loose or missing parts no visible damage Platform Assembly No visible damage free of dirt and debris Sizzor Arms No visible damage abrasions and or distortions Electrical Cable No visible damage properly secured Pivot Pins No loose or missing retaining hardware no visible dam age no evidence of pin or bushing wear Lift Cylinders No rust nicks scratches or foreign material on piston rod no leakage Frame No visible damage loose or missing hardware top and underside Tire and Wheel Assemblies No loose or missing lug nuts no visible damage Pothole Protection System No loose or missing parts no visible damage no debris Sliding Wear Pad Blocks No excessive wear no visible damage Hydraulic Oil Supply On all machines built before serial number 0200082630 operate lift function through one complete cycle before checking oil level Oil level should read at full mark or within 1 2 below full mark on side of hydraulic tank all systems shut down machine in stowed pos
70. sible ee TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS 15 Wire Installation No visible damage noloose or OFF DURING WALK AROUND INSPECTION broken wires 16 Wheel and Tire Assembly Left Rear Properly NOTE Do not overlook visual inspection of chassis under secured no loose or missing lug nuts no visible side Checking this area often results in discovery damage rO OKIENNA Machine 17 Scissor Arms and Sliding Wear Pads Properly secured no visible damage no loose or missing Platform Controls Properly secured no loose or parts missing parts no visible damage to control box or 18 Manual Descent Cable and Pull Handle No visible controller joystick Placards secure and legible damage Properly secured no loose or missing control markings legible operators and safety parts manual in manual storage box 19 Brake Cylinder Properly secured no visible dam Steer Cylinder and Linkage Properly secured no age no evidence of leakage loose or missing parts no visible damage no evi T dence of steer cylinder leakage 20 Ladder Properly secured no visible damage no loose or missing hardware Safety Prop Properly secured no visible damage 1 no loose or missing parts 21 Control Valve Installation No loose or missing parts no evidence of leakage No unsupported Scissor Arms and Sliding Wear Pads Properly wires or hose no damaged or broken wires secured no loose or missing parts no visible
71. t 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 Scissor Lift is designed to provide efficient and safe operation when maintained and operated in accor dance with warnings on the machine the Operating and Safety Manual the Service and Maintenance Manual and all jobsite and government rules and regulations As with any type of machinery the operator is very important to efficient and safe operation Owner User Operator must be familiar with section 6 7 8 of ANSI A92 6 1999 It is absolutely necessary that the JLG Lift be regularly main tained in accordance with this manual and the machine Service and Maintenance Manual and that any evidence of lack of maintenance malfunction excessive wear dam age or modification to the machine be reported immedi ately to the machine owner or the jobsite supervisor or safety manager and that the machine be taken out of ser vice until all discrepancies are corrected The JLG Scissor Lift is not intended to be used to lift mate rial other than supplies which personnel in the platform require to do their job Supplies or tools which extend out side the platform are prohibited It must not be used as a forklift crane support for overhead structure or to push or pull another object The JLG Scissor Lift is powered using hydrauli
72. t the ground controls With the power selector switch in the center off position power is shut off to both platform and ground con trols With the power selector switch in the off position the key can be removed in order to avoid unauthorized use of the machine Low speed is the default speed for all functions when the platform is fully lowered When the platform is elevated all functions operate in creep speed only Emergency Stop Switch A two position red mushroom shaped emergency stop switch when positioned to on pulled out with the power selector switch positioned to ground fur nishes operating power to the ground control sta tion In addition the switch can be used to turn off power to the function controls in the event of an emergency Power is turned on by pulling the switch out on and is turned off by pushing the switch in off 3120736 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL PLATFORM GROUND SELECT SWITCH EMERGENCY STOP SWITCH LIFT SWITCH Figure 3 1 Ground Control Station 3 Lift Switch A three position momentary contact switch pro vides raising and lowering of the platform when positioned to up or down Circuit Breaker A push button reset 15 Amp circuit breaker located behind the pump motor in the left side door returns interrupted power to the machine functions when depressed Hourmeter The machine may be equipped with an hourmeter to
73. tick and move joystick forward for duration of travel For additional drive speed push the joystick completely forward this will run the machine in high drive IMPORTANT WHEN TRAVELING A GRADE MAXIMUM TRACTION IS OBTAINED BY TRAVELING IN REVERSE ON 1532E2 AND 1932E2 REVERSE TRAVEL SHOULD BE USED WHEN LOADING ON A TRUCK OR WHEN ADEQUATE TRACTION IS NOT ACHIEVED BY TRAVELING FORWARD Traveling in Reverse 1 Position power selector switch at ground control sta tion to platform 2 Position emergency stop switch at platform control station to on position 3 Squeeze joystick depressing red trigger on front of joystick and move joystick backward reverse for duration of travel For additional drive speed pull joy stick completely back this will run the machine in high drive When driving in reverse only use low speed 4 4 JLG Lift 3120736 SECTION 4 MACHINE OPERATION A WARNING MAKE SURE DECK EXTENSION IS PINNED IN PLACE BEFORE DRIVING MACHINE 4 8 PARKING AND STOWING NOTE When parking battery powered units overnight bat teries should be charged in accordance with instruc tions in Section 2 to ensure readiness for the following workday Park and stow machine as follows 1 3120736 Drive machine to reasonably well protected and well ventilated area Ensure platform is fully lowered Position emergency stop switch to off position If necessary cover the instruction plac
74. tion Contact JLG Industries Inc for updated information 3120736 JLG Lift a FOREWORD This page intentionally left blank JLG Lift 3120736 FOREWORD 3120736 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 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 operator lessor lessee to be knowledgeable of these laws and regulations and to comply with them operator lessor lessee must also be familiar with Sections 6 7 8 9 and 10 of ANSI A92 6 1999 These sections con tain the responsibilities of the owner users operators les sors and lessees concerning safety training inspection maintenance application and operation The most preva lent regulations of this type in the United States are the Federal 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 deter mine all applicable laws and regulations and their exact wording and requirements and to comply with the requirements Nor shall the listing o
75. ve Fittings Hosing and Tubing Properly secured no loose or missing parts no visible damage no evidence of leakage 2 6 Figure 2 1 Daily Walk Around Inspection 2032E2 2632E2 2646E2 3246E2 Sheet 3 of 3 JLG Lift 3120736 SECTION 2 PREPARATION AND INSPECTION NOTE Item 35 not shown on illustration Item 35 applies to items throughout the machine Figure 2 2 Daily Walk Around Inspection 1532E2 1932E2 Sheet 1 of 3 3120736 JLG Lift 2 7 SECTION 2 PREPARATION AND INSPECTION GENERAL 10 Hydraulic Reservoir No visible damage no loose Begin Wak vound Inspecion at fom 1 as noted Ped Pano ul leakage Hore on the diagram Continue to the right counterclockwise Breather cap secure and working viewed from top checking each item in sequence for the conditions listed in the Walk Around Inspection Check 11 Hydraulic Filter No visible damage properly list secured no evidence of leakage 12 Motor Pump Unit Properly secured no visible WARNING damage no evidence of hydraulic leakage TO AVOID INJURY DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED USE OF A MAL FUNCTIONING MACHINE IS A SAFETY VIOLATION ers limit switches and links properiy Secured no visible damage no loose or missing parts A WARNING 14 MR i vi
76. ve opens and desired descent speed is attained 3 When platform is fully lowered turn knob on lower ing valve counterclockwise to reopen valve and return handle to stowed position JLG Lift 5 1 SECTION 5 EMERGENCY PROCEDURES 5 4 EMERGENCY OPERATION Use of Ground Controls A WARNING KNOW HOW TO USE THE GROUND CONTROLS IN AN EMER GENCY 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 A WARNING IF THE PLATFORM OPERATOR IS PINNED TRAPPED OR UNABLE TO OPERATE OR CONTROL THE MACHINE 1 Operate the machine from ground controls ONLY with the assistance of other personnel and equip ment cranes overhead hoists etc as may be required to safely remove the danger or emergency condition 2 Other qualified personnel on the platform may use the platform controls DO NOT CONTINUE OPERA TION IF CONTROLS DO NOT FUNCTION NOR MALLY 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 5 2 Platform Caught Overhead If the platform becomes jammed or snagged in ov
77. will not drive The drive system may make an occasional cavitating noise when driving with steer wheels turned all the way in one direction or while going down hill This noise is a byproduct of the drive system Lift The lift switch when used in conjunction with the enable switch will raise or lower the machine Lift is activated by pressing and holding the enable and moving the lift switch forward lift up or backward lift down A CAUTION DO NOT LIFT DOWN WITHOUT COMPLETELY RETRACTING THE PLATFORM EXTENSION JLG Lift 3 3 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL TILT LIGHT HORN OPTIONAL EMERGENCY STOP SWITCH ENABLE SWITCH LIFT SWITCH BATTERY DIS O CHARGE INDICATOR OPTIONAL TRIGGER STEER SWITCH JOYSTICK SPEED SWITCH Figure 3 2 Platform Control Station 5 Steer Switch The thumb operated steer switch located on top of the joystick controller activates the steer wheels in the direction the switch is moved left or right A CAUTION DO NOT USE HIGH DRIVE SPEED WHEN DRIVING IN CLOSE QUARTERS OR WHEN DRIVING IN REVERSE 6 Drive Speed Select Switch The speed select switch is a toggle switch which allows you to select high or low speed NOTE The High Drive Speed switch will cut out when the platform is raised above the stowed position return ing drive spe

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