JLG 15ELI Operator Manual

Operators and Safety Manual

ANSI

MODEL

15ELI

3120778

August 5, 2002

CALIFORNIAN PROPOSITION 65

BATTERY WARNING

Battery posts,

terminals and related

accessories contain

lead and lead compounds,

chemical known to the

State of Califormia

to cause cancer and

reproductive harm.

WASH HANDS

AFTER HANDLING!

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 OPERATING 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 SYMBOL" 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:

DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR DEATH.

CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES.

Also in this Manual "Notes:" are used to provide information of special interest.

JLG INDUSTRIES, INC. 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 COMPLETED ON THE AFFECTED JLG PRODUCT.

WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY OR DEATH.

IMPORTANT OR INSTRUCTIONS PROCEDURES ESSENTIAL FOR SAFE OPERATION AND WHICH, IF NOT FOLLOWED MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE MACHINE.

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

This page left intentionally blank.

INTRODUCTION - OPERATION/SAFETY PRECAUTIONS

All procedures herein are based on the use of the machine under proper operating conditions, with no deviations from original design intent ... as per OSHA regulations.

READ & HEED!

The ownership, use, service, and/or maintenance of this machine is subject to various federal, state and local laws and regulations. It is the responsibility of the owner/user to be knowledgeable of these laws and regulations and to comply with them. The most prevalent regulations of this type 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 determine all applicable laws and regulations and their exact wording and requirements, and to comply with the requirements. Nor shall the listing of these requirements constitute an assumption of responsibility of liability on the part of JLG Industries, Inc.

1. Only trained and authorized operators shall be permitted to operate the aerial lift.

2. A malfunctioning lift shall be shut down until repaired.

3. The controls shall be plainly marked as to their function.

4. The controls shall be tested each day prior to use to determine that they are in safe operating condition.

5. Load limits specified by the manufacturer shall not be exceeded.

6. Instruction and warning placards must be legible.

7. Aerial lifts may be "field modified" for uses other than those intended by the manufacturer only if certified in writing by the manufacturer or an equivalent entity, such as a nationally recognized testing lab, to be in conformity to applicable OSHA safety regulations and to be at least as safe as it was prior to modification.

8. Aerial lifts shall not be used near electric power lines unless the lines have been deenergized or adequate clearance is maintained (see OSHA 29 CFR 1910.67 and 1926.400).

9. Employees using aerial lifts shall be instructed how to recognize and avoid unsafe conditions and hazards.

10. Ground controls shall not be operated unless permission has been obtained from personnel in the platform, except in case of an emergency.

11. Regular inspection of the job site and aerial lift shall be performed by competent persons.

12. Personnel shall always stand on the floor of the platform, not on boxes, planks, railing or other devices for work positioning.

*Applicable Federal OSHA regulations, 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, 29 CFR 1926.400 and 29 CFR 1926.453. Consult the current regulations for the exact wording and full text of the requirements and contact the closest Federal OSHA office for specific interpretations.

3120778 – JLG Lift – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A. GENERAL

This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others or damage to the equipment. A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe to operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLATION.

The specific precautions to be observed during machine maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of component weight and never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER/ OPERATOR.

C. MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.

• REMOVE ALL RINGS, WATCHES, AND JEWELRY WHEN PERFORMING ANY MAINTENANCE.

• DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT.

• OBSERVE AND OBEY ALL DANGER, WARNING, CAUTION AND OTHER INSTRUCTIONS ON MACHINE AND IN SERVICE MANUAL.

• KEEP STANDING SURFACES AND HAND HOLDS FREE OF OIL, GREASE, WATER, ETC.

• NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING.

• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS.

•BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPONENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

B. HYDRAULIC SYSTEM SAFETY

1. It should be particularly noted that the machines hydraulic systems operate at extremely high and potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system.

2. Relieve system pressure by activating the lift DOWN control with the platform completely lowered to direct any line pressure back into the return line to the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss.

b – JLG Lift – 3120778

EFFECTIVITY CHANGES

February 1, 1999 - Original Issue of Manual

April 20, 2000 – Revised – Added Proposition 65 to front of manual.

August 5, 2002 – Manual Revised

EFFECTIVITY PAGE

3120778 – JLG Lift – c

EFFECTIVITY PAGE

This page left intentionally blank

d – JLG Lift – 3120778

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

INTRODUCTION -- OPERATION/SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

INTRODUCTION -- MAINTENANCE SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

A GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

B HYDRAULIC SYSTEM SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

C MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

EFFECTIVITY CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D

SECTION 1 - SAFETY PRECAUTIONS

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

1.2 ELECTROCUTION HAZARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 TRANSPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.4 TRANSPORT SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 PRE-OPERATIONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.6 OPERATING SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

SECTION 2 - PREPARATION AND INSPECTION

2.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 PREPARATION FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.3 DELIVERY AND FREQUENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Platform Guard Rail Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Platform Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Mast Chains & Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Control/(Power) Cable(s) for Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Wheels and Casters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Hydraulic Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Machine Controls - (Platform and Ground). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Batteries - (DC Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Power Cord - (AC Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Electric Motor/Hydraulic Pump and Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2.4 DAILY WALK-AROUND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

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

Batteries Charged (DC Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Overall Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Operators & Safety and ANSI Responsibilities Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2.5 DAILY FUNCTIONAL CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.6 TORQUE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.7 BATTERY CHARGING & MAINTENANCE (ELI-DC MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . 2-4

Battery Maintenance and Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Battery Charger Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Abnormal Cycle Indicator LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

3120778 – JLG Lift – i

TABLE OF CONTENTS

SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS

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

3.2 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Operator Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.3 OPERATING CHARACTERISTICS AND LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Placards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.4 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Ground Control Station (See Figure 3-1.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

SECTION 4 - MACHINE OPERATION

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

4.2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3 MACHINE SET-UP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Floor Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Platform Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Platform Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.4 QUICK-CHANGE PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Platform Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Platform Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.5 STOWING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.6 TRANSPORTING, LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Transporting by Pushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

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

Transport Vehicle Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

SECTION 5 - OPTIONAL EQUIPMENT

5.1 OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

22" x 25" Quick-Change Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

26" x 26" Quick-Change Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

28" x 26" Quick-Change Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

25" x 26" Step-in Molded Platform w/Swing-up Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

26" x 50" Quick-Change - ExtendiblePlatform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Tool Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Fluorescent Tube Caddy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Extra Power Pack (DC Battery, Charger & Case) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Lifting Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Platform Auxiliary Power Lowering Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Laser Positioning Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 EXTENDIBLE PLATFORM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Mounting to Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Entering/Exiting Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Extending Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Retracting Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

SECTION 6 - EMERGENCY PROCEDURES

6.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

ii – JLG Lift – 3120778

6.2 EMERGENCY CONTROLS AND THEIR LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Platform Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Ground Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Manual Descent Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Use of Ground Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Operator Unable to Control Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Platform Caught Overhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

Righting of Tipped Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

Post-Incident Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.4 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

SECTION 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

1-1. Electrocution Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-2. Use Handles Provided On Mast Crossbar To Move Machine.. . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-3. Do Not Move Unit on Soft or Uneven Surfaces or Over Obstructions, Bumps, Debris, Etc. . . . . .1-2

1-4. Two People May Be Required on Slopes Up To Five Degrees. Also Always Travel

With Platform End On The Low Side of Slope.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-5. Read Your Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-6. Always Look in the Direction of Movement. Watch for Overhead and Other Obstructions. . . . . .1-4

1-7. Death or Serious Injury Could Occur from a Tip Over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-8. All Personnel Must Stand Clear When Platform Is Being Raised Or Lowered. . . . . . . . . . . . . . . .1-5

1-9. Falling from Platform could cause Death or Serious Injury.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

2-1. Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2-2. Battery Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-3. Battery Box and Charger Assembly. (D.C. Model Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-4. Dual Voltage Battery Charger - Front Panel.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-5. Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-6. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

3-1. Ground Control Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-2. Manual Descent Control Valve Location - Machines Since S/N-0900019526 . . . . . . . . . . . . . . . .3-3

3-3. Platform Control Station.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-4. Decal Locations (Front View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-5. Decal Locations (3124221 decal from Front View). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-6. Decal Locations (Rear View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3-7. Decal Locations (Top View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-8. Decal Locations (Right/Left View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

4-1. Setting & Releasing Floor Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2. Quick Change Platform Mount.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4-3. 15ELI Tie Down Pockets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

5-1. Extendible Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

TABLE OF CONTENTS

LIST OF TABLES

1-1 Minimum Safe Approach Distance (to energized power lines or parts) . . . . . . . . . . . . . . . . . . . .1-1

2-1 Lubrication Intervals for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

4-1 Maximum Platform Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-2 ELI Machine Gross Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

3120778 – JLG Lift – iii

TABLE OF CONTENTS

This page intentionally left blank.

iv – JLG Lift – 3120778

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

This section prescribes the proper and safe practices for major areas of machine usage which have been divided into three basic categories: Transporting, Pre-Operation and Operation. In order to promote proper usage of the machine, it is mandatory that a daily routine be established based on instruction given in this section. A maintenance program must also be established by a qualified person and must be followed to ensure that the machine is safe to operate.

The user/operator of the machine should not accept operating responsibility until this manual has been READ and UNDERSTOOD, and operating instructions of the machine under the supervision of an experienced and qualified operator, has been completed. If there is a question on application and/or operation, JLG Industries Product Safety and Reliability Department should be consulted.

MODIFICATION OF THE MACHINE WITHOUT APPROVAL OF JLG INDUSTRIES INC., OR CERTIFICATION BY A NATIONALLY RECOGNIZED TESTING LAB TO BE IN CONFORMITY WITH APPLICABLE OSHA REGULATIONS, AND TO BE AT LEAST AS SAFE AS BEFORE MODIFICATION, IS PROHIBITED AND IS A VIOLATION OF OSHA RULES.

Table 1-1. Minimum Safe Approach Distance

(to energized power lines or parts)

VOLTAGE RANGE

(PHASE TO PHASE)

0-300V – Avoid Contact

Over 300V to 50KV – 10 f t. [3 m]

Over 50KV to 200KV – 15 f t. [4.6 m]

Over 200KV to 350KV – 20 f t. [6 m]

Over 350KV to 500KV – 25 f t. [7.6 m]

Over 500KV to 750KV – 35 ft. [10.6 m]

Over 750KV to 1000KV – 45 ft. [13.7 m]

MINIMUM SAFE DISTANCE -

Feet [m]

1.2 ELECTROCUTION HAZARD

Minimum safe approach distances (M.S.A.D.) to energized (exposed or insulated) power lines and parts.

DO NOT MANEUVER MACHINE OR PERSONNEL TO DISTANCE LESS THAN M.S.A.D (SEE TABLE 1-1.). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE.

THIS MACHINE DOES NOT PROVIDE PROTECTION FROM CONTACT WITH OR PROXIMITY TO AN ELECTRICALLY CHARGED CONDUCTOR. MAINTAIN A CLEARANCE OF AT LEAST 10 FT. (3M) BETWEEN ANY PART OF THE MACHINE AND ANY ELECTRICAL LINE OR APPARATUS CARRYING UP TO 50,000 VOLTS. 1 FT. (0.3M) ADDITIONAL CLEARANCE IS REQUIRED FOR EVERY ADDITIONAL 30,000 VOLTS OR LESS. ALLOW FOR PLATFORM SWAY, ROCK OR SAG AND ELECTRICAL LINE SWAYING, (SEE

FOLLOWING TABLE).

Figure 1-1. Electrocution Hazard.

1.3 TRANSPORTING

Before transporting the machine the user/operator must be familiar with the proper procedures for transporting the machine, as well as the weight and size of the machine.

The user/operator should be familiar with the surrounding work area and surface before transporting the machine. The work area must be a smooth, firm surface on which machine is capable of being leveled.

NOTE: Remember that the key to safe and proper usage is

common sense and its careful application.

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION AND ON MACHINE MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.

3120778 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

1.4 TRANSPORT SAFETY

• FULLY LOWER AND COMPLETELY EMPTY PLATFORM OF TOOLS AND DEBRIS BEFORE MOVING MACHINE.

• NEVER ALLOW PERSONNEL IN PLATFORM WHILE MOVING MACHINE.

FAILURE TO OBSERVE THE FOLLOWING TIPPING HAZARD INSTRUCTIONS COULD CAUSE THE UNIT TO TIP OVER OR BE HARD TO CONTROL WHEN BEING MOVED, WHICH COULD RESULT IN SERIOUS INJURY OR DEATH DUE TO BEING PINNED OR CRUSHED BY THE UNIT.

• ON A LEVEL SURFACE, ALWAYS TRAVEL WITH THE PLATFORM END LEADING THE WAY.

• WATCH FOR OBSTRUCTIONS AROUND MACHINE AND OVERHEAD WHEN MOVING.

• CHECK TRAVEL PATH FOR PERSONS, HOLES, BUMPS, DROP-OFFS, OBSTRUCTIONS, DEBRIS, AND COVERINGS WHICH MAY CONCEAL HOLES AND OTHER HAZARDS, AS TIPPING COULD OCCUR.

• BEFORE MOVING MACHINE ON FLOORS, TRUCKS AND OTHER SURFACES, CHECK ALLOWABLE CAPACITY OF SURFACES.

• TWO PEOPLE ARE REQUIRED ON SLOPES UP TO 5 DEGREES. A FORKLIFT MUST BE USED WHEN MOVING UNITS ON SLOPES GREATER THAN 5 DEGREES.

Figure 1-3. Do Not Move Unit on Soft or Uneven Sur-

faces or Over Obstructions, Bumps, Debris, Etc.

• ALWAYS TRAVEL UP OR DOWN A SLOPE WITH THE PLATFORM END OF THE MACHINE POSITIONED TOWARDS THE LOW SIDE OF THE SLOPE. THE OPERATOR AND ASSISTANT MUST WALK BESIDE AND GUIDE THE MACHINE WITH THE HANDLES ON THE MAST CROSSBAR.

• NEVER POSITION THE UNIT SIDEWAYS ON A SLOPE.

• USE CAUTION AND CHECK CLEARANCES WHEN

MOVING MACHINE IN RESTRICTED OR CLOSE QUARTERS.

• ALWAYS USE AN ASSISTANT WHEN MOVING MACHINE IN AREAS WHERE VISION IS OBSTRUCTED.

• KEEP NON-OPERATING PERSONNEL AT LEAST 6 FEET (1.8 M) AWAY FROM MACHINE DURING TRANSPORTING OPERATIONS.

Figure 1-2. Use Handles Provided On Mast Crossbar

To Move Machine.

•

1-2 – JLG Lift – 3120778

SECTION 1 - SAFETY PRECAUTIONS

Figure 1-4. Two People May Be Required on Slopes Up To Five Degrees.

Also Always Travel With Platform End On The Low Side of Slope.

1.5 PRE-OPERATIONAL SAFETY

Figure 1-5. Read Your Manual.

• READ YOUR MANUAL. UNDERSTAND WHAT YOU’VE READ - THEN BEGIN OPERATIONS.

• ALLOW ONLY THOSE AUTHORIZED AND QUALIFIED PERSONNEL TO OPERATE MACHINE WHO HAVE DEMONSTRATED THAT THEY UNDERSTAND SAFE AND PROPER OPERATION AND MAINTENANCE OF THE UNIT.

• AN OPERATOR MUST NOT ACCEPT OPERATING RESPONSIBILITIES UNTIL ADEQUATE TRAINING HAS BEEN GIVEN BY COMPETENT AND AUTHORIZED PERSONS.

• BEFORE OPERATION CHECK WORK AREA FOR OVERHEAD ELECTRIC LINES. (SEE ELECTROCUTION

HAZARD, SECTION 1-2.)

• BEFORE OPERATION CHECK WORK AREA FOR MACHINE TRAFFIC SUCH AS FORKLIFTS, CRANES, AND OTHER CONSTRUCTION EQUIPMENT.

• SET-UP MACHINE FOR OPERATION ONLY ON A SMOOTH, FIRM LEVEL SURFACE.

• ENSURE THAT OPERATORS OF OTHER OVERHEAD AND FLOOR LEVEL MACHINES ARE AWARE OF THE AERIAL PLATFORMS PRESENCE. DISCONNECT POWER TO OVERHEAD CRANES. BARRICADE FLOOR AREA IF NECESSARY.

• PRECAUTIONS TO AVOID ALL KNOWN HAZARDS IN THE WORK AREA MUST BE TAKEN BY THE OPERATOR AND HIS SUPERVISOR BEFORE STARTING THE WORK.

• DO NOT OPERATE THIS MACHINE UNLESS IT HAS BEEN SERVICED AND MAINTAINED ACCORDING TO THE MANUFACTURERS SPECIFICATIONS AND SCHEDULE.

• ENSURE DAILY INSPECTION AND FUNCTION CHECK IS PERFORMED PRIOR TO PLACING MACHINE INTO OPERATION. HAVE AUTHORIZED PERSONNEL TAKE ANY NECESSARY CORRECTIVE ACTION BEFORE PLACING MACHINE INTO OPERATION.

• NEVER DISABLE OR MODIFY ANY SAFETY DEVICE. ANY MODIFICATION OF THE MACHINE IS A SAFETY VIOLATION AND IS A VIOLATION OF OSHA AND ANSI RULES.

• DO NOT OPERATE MACHINE WHEN EXPOSED TO HIGH WIND, RAIN OR SNOW.

3120778 – JLG Lift – 1-3

+ 35 hidden pages