JLG 1200SJP Operator Manual

4 (1)

Operation and Safety Manual

Original Instructions - Keep this manual with the machine at all times.

Boom Lift Models 1200SJP 1350SJP

ANSI

 

 

 

 

 

 

 

 

 

 

3121141

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

September 11, 2014

 

 

 

 

 

 

®

 

FOREWORD

FOREWORD

This manual is a very important tool! Keep it with the machine at all times.

The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose.

Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.

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FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A YELLOW BACKGROUND.

INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.

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3121141

FOREWORD

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT.

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.

For:

Accident Reporting

Standards and Regulations

• Product Safety Publica-

 

Compliance Information

 

 

 

tions

Questions Regarding Special

Current Owner Updates

 

Product Applications

 

 

Questions Regarding

• Questions Regarding Prod-

 

uct Modifications

 

Product Safety

 

 

 

 

Contact:

Product Safety and Reliability Department

JLG Industries, Inc.

13224 Fountainhead Plaza

Hagerstown, MD 21742

USA

or Your Local JLG Office

(See addresses on inside of manual cover)

In USA:

Toll Free: 877-JLG-SAFE (877-554-7233)

Outside USA:

Phone: 240-420-2661

Fax: 301-745-3713

E-mail: ProductSafety@JLG.com

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FOREWORD

REVISION LOG

Original Issue

- May 24, 2002

Revised

- June 14, 2002

Revised

- November 1, 2002

Revised

- January 15, 2003

Revised

- May 3, 2005

Revised

- August 30, 2005

Revised

- January 12, 2006

Revised

- June 19, 2006

Revised

- July 17, 2006

Revised

- December 1, 2006

Revised

- April 11, 2007

Revised

- June 19, 2008

Revised

- November 19, 2009

Revised

- August 30, 2010

Revised

- November 3, 2010

Revised

- June 2, 2011

Revised

- September 20, 2012

Revised

- October 7, 2013

Revised

- September 11, 2014

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3121141

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT

PAGE

SECTION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1

Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . . 1-11

1.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Maintenance Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2

Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

SECTION - PARAGRAPH, SUBJECT

PAGE

Boom Control System Check Procedure . . . . . . . . . . . . 2-6

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED). . . . 2-11

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . 3-5

Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-15

SECTION - 4 - MACHINE OPERATION

4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2BOOM OPERATING CHARACTERISTICS AND

 

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

 

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

 

Controlled Arc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2

 

Envelope Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3

 

Controlled Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3

 

Swing Speed Proportioning. . . . . . . . . . . . . . . . . . . . . . . .

4-3

 

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4

4.3

CAPACITY SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4

4.4

ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5

 

Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5

 

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT

PAGE

Fuel Reserve / Shut-Off System. . . . . . . . . . . . . . . . . . . . . 4-6

4.5 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . . 4-9

4.6 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.7 EXTENDING THE AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.8 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-11

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.9 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Raising and Lowering the Boom . . . . . . . . . . . . . . . . . . 4-12

Telescoping the Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Swinging the Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.10 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.11 EMERGENCY TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.12 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4.13 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.14 STOWING THE JIB FOR TRANSPORT . . . . . . . . . . . . . . . . . . 4-15

SECTION - PARAGRAPH, SUBJECT

PAGE

SECTION - 5 - EMERGENCY PROCEDURES

5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.2 INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Operator Unable to Control Machine. . . . . . . . . . . . . . . 5-1 Platform or Boom Caught Overhead . . . . . . . . . . . . . . . 5-2

Boom Movement Prevented By Boom

Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.4 EMERGENCY TOWING PROCEDURES. . . . . . . . . . . . . . . . . . 5-2

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT

PAGE

SECTION - PARAGRAPH, SUBJECT

PAGE

Engine Data - Deutz 2011 Prior to

S/N 0300127698 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Engine Data - Deutz 2011 S/N 0300127698

to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Engine Data - Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . 6-10

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 6.4 TIRES & WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Tire Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

6.5 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 6-30

SECTION - 7 - INSPECTION AND REPAIR LOG

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT

PAGE

SECTION - PARAGRAPH, SUBJECT

PAGE

This Page Left Blank Intentionally.

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3121141

 

 

 

 

LIST OF FIGURES

 

 

 

 

 

 

FIGURE NUMBER - TITLE

PAGE

FIGURE NUMBER - TITLE

PAGE

2-1.

Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 2-7

6-1. Engine Operating Temperature Specifications - Deutz -

2-2.

Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . . .

. . . 2-8

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 6-11

2-3.

Daily Walk-Around Inspection - Sheet 2 of 3 . . . . . . .

. . . 2-9

6-2. Engine Operating Temperature Specifications - Deutz -

2-4.

Daily Walk-Around Inspection - Sheet 3 of 3 . . . . . . .

. . 2-10

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 6-12

3-1.

Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 3-2

6-3. Engine Operating Temperature Specifications - Caterpillar

3-2.

Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . .

. . . 3-5

- Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 6-13

3-3.

Platform Control Console - Prior to S/N 79596. . . . . .

. . . 3-8

6-4. Engine Operating Temperature Specifications - Caterpillar

3-4.

Platform Control Console - S/N 79596 to 93078 . . . .

. . . 3-9

- Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 6-14

3-5.

Platform Control Console - w/Boom Control Select.

. . 3-10

6-5. Lubrication and Maintenance Point Location . . . . . . .

. 6-15

3-6.

Platform Control Indicator Panel - Prior

 

6-6. Deutz 2011 Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . .

. 6-22

 

 

to S/N 79596 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 3-16

 

 

 

3-7.

Platform Control Indicator Panel - S/N 79596

 

 

 

 

 

 

to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 3-17

 

 

 

3-8.

Fuel Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 3-19

 

 

 

4-1.

Position of Least Forward Stability . . . . . . . . . . . . . . . . .

. . . 4-7

 

 

 

4-2.

Position of Least Backward Stability . . . . . . . . . . . . . . .

. . . 4-8

 

 

 

4-3.

Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 4-10

 

 

 

4-4.

Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 4-13

 

 

 

4-5.

Lifting and Tie Down Chart - Sheet 1 of 2 . . . . . . . . . .

. . 4-16

 

 

 

4-6.

Lifting and Tie Down Chart - Sheet 2 of 2 . . . . . . . . . .

. . 4-17

 

 

 

4-7.

Decal Location Sheet 1 of 5. . . . . . . . . . . . . . . . . . . . . . . .

. . 4-18

 

 

 

4-8.

Decal Location Sheet 2 of 5. . . . . . . . . . . . . . . . . . . . . . . .

. . 4-19

 

 

 

4-9.

Decal Location Sheet 3 of 5. . . . . . . . . . . . . . . . . . . . . . . .

. . 4-20

 

 

 

4-10.

Decal Location Sheet 4 of 5. . . . . . . . . . . . . . . . . . . . . . . .

. . 4-21

 

 

 

4-11.

Decal Location Sheet 5 of 5. . . . . . . . . . . . . . . . . . . . . . . .

. . 4-22

 

 

 

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LIST OF FIGURES

FIGURE NUMBER - TITLE

PAGE FIGURE NUMBER - TITLE

PAGE

This Page Left Blank Intentionally.

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3121141

LIST OF TABLES

TABLE NUMBER - TITLE

PAGE TABLE NUMBER - TITLE

PAGE

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6 1-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-9 2-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3 4-1 Decal Legend - Prior to S/N 0300141473 . . . . . . . . . . . . .4-23 4-2 Decal Legend - S/N 0300141473 to Present . . . . . . . . . .4-27 6-1 Operating Specifications - Prior to S/N 0300141473 . . . 6-1 6-2 Operating Specifications - S/N 0300141473

to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6-3 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6-4 Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6-5 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6-6 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6-7 Deutz BF4M2011 Specifications . . . . . . . . . . . . . . . . . . . . . . 6-4 6-8 Deutz TD2011L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-5 6-9 Deutz TCD2.9L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-5 6-10 Caterpillar 3.4T Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6-11 Hydraulic Oil Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6-12 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6-13 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6-14 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 6-15 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 6-16 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 6-17 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 6-18 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16 6-19 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30 7-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

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LIST OF TABLES

TABLE NUMBER - TITLE

PAGE TABLE NUMBER - TITLE

PAGE

This Page Left Blank Intentionally.

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SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1GENERAL

This section outlines the necessary precautions for proper and safe machine usage and maintenance. It is mandatory that a daily routine is established based on the content of this manual to promote proper machine usage. A maintenance program, using the information provided in this manual and the Service and Maintenance Manual, must also be established by a qualified person and must be followed to ensure that the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine must not accept operating responsibility until this manual has been read, training is accomplished, and operation of the machine has been completed under the supervision of an experienced and qualified operator.

This section contains the responsibilities of the owner, user, operator, lessor, and lessee concerning safety, training, inspection, maintenance, application, and operation. If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“JLG”).

FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

1.2PRE-OPERATION

Operator Training and Knowledge

The Operation and Safety Manual must be read and understood in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc.

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SECTION 1 - SAFETY PRECAUTIONS

An operator must not accept operating responsibilities until adequate training has been given by competent and authorized persons.

Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and maintenance 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 determined by JLG.

All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specified in this manual.

Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to 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 and during operation of the machine.

Do not operate or raise the platform from a position on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless the application is approved in writing by JLG.

Before operation, check work area for overhead hazards such as electric lines, bridge cranes, and other potential overhead obstructions.

Check operating surfaces for holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards.

Check the work area for hazardous locations. Do not operate the machine in hazardous environments unless approved for that purpose by JLG.

Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel. Do not travel on unsupported surfaces.

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SECTION 1 - SAFETY PRECAUTIONS

Machine Inspection

Do not operate this machine until the inspections and functional checks as specified in Section 2 of this manual have been performed.

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. Modification of these devices is a safety violation.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION 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 components. Ensure that any modifications have been approved by JLG.

Avoid accumulation of debris on platform floor. Keep mud, oil, grease, and other slippery substances from footwear and platform floor.

1.3OPERATION

General

Machine operation requires your full attention. Bring the machine to a full stop before using any device, i.e. cell phones, two-way radios, etc. that will distract your attention from safely operating the machine.

Do not use the machine for any purpose other than positioning 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 malfunction 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. Operate controls with slow and even pressure.

Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency.

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Do not carry materials directly on platform railing unless approved by JLG.

When two or more persons are in the platform, the operator 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.

When driving, always position boom over rear axle in line with the direction of travel. Remember, if boom is over the front axle, steer and drive functions will be reversed.

Do not assist a stuck or disabled machine by pushing or pulling except by pulling at the chassis tie-down lugs.

Fully lower platform and shut off all power before leaving machine.

Remove all rings, watches, and jewelry when operating machine. Do not wear loose fitting clothing or long hair unrestrained which may become caught or entangled in equipment.

Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical control must not operate this machine.

Trip and Fall Hazards

During operation, occupants in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point. Attach only one (1) lanyard per lanyard anchorage point..

Enter and exit only through gate area. Use extreme caution when entering or leaving platform. Ensure that the platform 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.

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• Before operating the machine, make sure all gates are closed Electrocution Hazards and fastened in their proper position.

• This machine is not insulated and does not provide protection from contact or proximity to electrical current.

Keep both feet firmly positioned on the platform floor at all times. Never position ladders, boxes, steps, planks, or similar items on unit to provide additional reach for any purpose.

Keep oil, mud, and slippery substances cleaned from footwear and the platform floor.

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SECTION 1 - SAFETY PRECAUTIONS

Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum Approach Distance (MAD) as shown in Table 1-1.

Allow for machine movement and electrical line swaying.

Table 1-1. Minimum Approach Distances (M.A.D.)

Voltage Range

 

MINIMUM APPROACH DISTANCE

(Phase to Phase)

 

in Feet (Meters)

 

 

 

0to50KV

 

10(3)

 

 

 

Over50KVto200KV

 

15(5)

 

 

 

Over200KVto350KV

 

20(6)

 

 

 

Over350KVto500KV

 

25(8)

 

 

 

Over500KVto750KV

 

35(11)

 

 

 

Over750KVto1000KV

 

45(14)

 

 

 

NOTE: This 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 carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.

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SECTION 1 - SAFETY PRECAUTIONS

The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier. This determination shall be made by a qualified person in accordance with the employer, local, or governmental requirements for work practices near energized equipment

DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE.

Tipping Hazards

The user must be familiar with the surface before driving. Do not exceed the allowable sideslope and grade while driving.

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 smooth surface before elevating platform or driving with the platform in the elevated position.

Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.

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SECTION 1 - SAFETY PRECAUTIONS

Never exceed the maximum work load as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG.

Keep the chassis of the machine a minimum of 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards at the ground level.

Do not push or pull any object with the boom.

Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure. Never attach wire, cable, or any similar items to platform.

Do not operate the machine when wind conditions exceed 28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Reference Only).

Do not increase the surface area of the platform or the load. Increase of the area exposed to the wind will decrease stability.

Do not increase the platform size with unauthorized deck extensions or attachments.

If boom assembly or platform is in a position that one or more wheels are off the ground, all persons must be removed before attempting to stabilize the machine. Use cranes, forklift trucks, or other appropriate equipment to stabilize machine.

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SECTION 1 - SAFETY PRECAUTIONS

DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/

S).

Table 1-2. Beaufort Scale (For Reference Only)

Beaufort

Wind Speed

Description

Land Conditions

Number

mph

m/s

 

 

 

 

 

 

 

0

0

0-0.2

Calm

Calm.Smokerisesvertically

 

 

 

 

 

1

1-3

0.3-1.5

Lightair

Windmotionvisibleinsmoke

 

 

 

 

 

2

4-7

1.6-3.3

Lightbreeze

Windfeltonexposedskin.Leavesrustle

 

 

 

 

 

3

8-12

3.4-5.4

Gentlebreeze

Leavesandsmallertwigsinconstantmotion

 

 

 

 

 

4

13-18

5.5-7.9

Moderatebreeze

Dust andloosepaperraised.Smallbranchesbegintomove.

 

 

 

 

 

5

19-24

8.0-10.7

Freshbreeze

Smallertreessway.

 

 

 

 

 

6

25-31

10.8-13.8

Strongbreeze

Largebranchesinmotion.Flagswavingnearhorizontal.Umbrellause

 

 

 

 

becomesdifficult.

 

 

 

 

 

7

32-38

13.9-17.1

NearGale/ModerateGale

Wholetreesin motion.Effortneededtowalkagainstthewind.

 

 

 

 

 

8

39-46

17.2-20.7

FreshGale

Twigsbrokenfromtrees.Carsveeronroad.

 

 

 

 

 

9

47-54

20.8-24.4

StrongGale

Lightstructuredamage.

 

 

 

 

 

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SECTION 1 - SAFETY PRECAUTIONS

Crushing and Collision Hazards

Approved head gear must be worn by all operating and ground personnel.

Check work area for clearances overhead, on sides, and bottom of platform when lifting or lowering platform, and driving.

During operation, keep all body parts inside platform railing.

Use the boom functions, not the drive function, to position the platform close to obstacles.

Always post a lookout when driving in areas where vision is obstructed.

Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving and swing operations.

Under all travel conditions, the operator must limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors which may cause collision or injury to personnel.

Be aware of stopping distances in all drive speeds. When driving in high speed, switch to low speed before stopping. Travel grades in low speed only.

Do not use high speed drive in restricted or close quarters or when driving in reverse.

Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and persons in the platform.

Be sure that operators of other overhead and floor level machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes.

Warn personnel not to work, stand, or walk under a raised boom or platform. Position barricades on floor if necessary.

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SECTION 1 - SAFETY PRECAUTIONS

1.4 TOWING, LIFTING, AND HAULING

1.5 MAINTENANCE

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/unloading. Refer to the Emergency Procedures section of this manual for emergency towing procedures.

Ensure boom is in the stowed position and the turntable locked prior to towing, lifting or hauling. The platform must be completely empty of tools.

When lifting machine, lift only at designated areas of the machine. Lift the unit with equipment of adequate capacity.

Refer to the Machine Operation section of this manual for lifting information.

This sub-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 qualified person and must be followed to ensure that the machine is safe.

Maintenance Hazards

Shut off power to all controls and ensure that all moving parts are secured from inadvertent motion prior to performing any adjustments or repairs.

Never work under an elevated platform until it has been fully lowered to the full down position, if possible, or otherwise supported and restrained from movement with appropriate safety props, blocking, or overhead supports.

DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the machine is powered on or when the hydraulic system is under pressure.

Always relieve hydraulic pressure from all hydraulic circuits before loosening or removing hydraulic components.

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SECTION 1 - SAFETY PRECAUTIONS

DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help protect hands from spraying fluid.

Do not use machine as a ground for welding.

When performing welding or metal cutting operations, precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter.

Do not refuel the machine with the engine running.

Use only approved non-flammable cleaning solvents.

Do not replace items critical to stability, such as batteries or solid tires, with items of different weight or specification. Do not modify unit in any way to affect stability.

Refer to the Service and Maintenance Manual for the weights of critical stability items.

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 provided when raising components of the machine.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.

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SECTION 1 - SAFETY PRECAUTIONS

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 battery terminals.

Always wear hand, eye, and face protection when servicing batteries. Ensure that battery acid does not come in contact with skin or clothing.

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.

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JLG 1200SJP Operator Manual

SECTION 1 - SAFETY PRECAUTIONS

NOTES:

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.

Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical control must not operate this machine.

Operator Training

Operator training must cover:

1.Use and limitations of the controls in the platform and at the ground, emergency controls and safety systems.

2.Control labels, instructions, and warnings on the machine.

3.Rules of the employer and government regulations.

4.Use of approved fall protection device.

5.Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunction.

6.The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes, drop-offs.

7.Means to avoid the hazards of unprotected electrical conductors.

8.Specific job requirements or machine application.

Training Supervision

Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has developed the ability to safely control and operate the machine.

Operator Responsibility

The operator must be instructed that he/she has the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site.

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

The following table covers the periodic machine inspections and maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.

JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-QUALIFIED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.

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