JLG 1930ES, 2030ES, 2630ES, 3246ES, 2646ES Operation And Safety Manual

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Page 1

Operation and Safety Manual

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

ANSI

Models

1930ES/2030ES/ 2630ES/ 2646ES/3246ES

P/N - 3121165

May 1, 2013

Page 2

FOREWORD

3121165 – JLG Lift – a

FOREWORD

IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTA NC E O F 1 2 IN CH E S ( 3 0. 5 C M ) A WAY F R OM TH E SE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.

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

b – JLG Lift – 3121165

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

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

INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD

RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL

WILL HAVE AN ORANGE BACKGROUND.

INDICATES A POTENTIALITY 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.

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

Page 4

FOREWORD

3121165 – JLG Lift – c

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETYRELATED 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.

Contact:

Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742

or Your Local JLG Office (See addresses on manual rear cover)

In USA:

Toll F re e: 87 7-JL G- SA FE ( 87 7-554 -7 23 3)

Outside USA:

Phone: 240-420-2661 E-mail: ProductSafety@JLG.com

For:

•Accident Reporting

•Product Safety Publications

• Current Owner Updates

•Questions Regarding Product Safety

•Standards and Regulations Compliance Information

•Questions Regarding Special Product Applications

•Questions Regarding Product Modifications

Page 5

FOREWORD

d – JLG Lift – 3121165

REVISION LOG

Original Issue. . . . . . . . . . . . . . . . . . .March 31, 2003

Revised . . . . . . . . . . . . . . . . . . . . . . . .April 30, 2003

Revised . . . . . . . . . . . . . . . . . . . . . . . .May 21, 2003

Revised . . . . . . . . . . . . . . . . . . . . . . . .June 13, 2003

Revised . . . . . . . . . . . . . . . . . . . . . . . .June 25, 2003

Revised . . . . . . . . . . . . . . . . . . . . . . . .August 26, 2003

Revised . . . . . . . . . . . . . . . . . . . . . . . .December 3, 2003

Revised . . . . . . . . . . . . . . . . . . . . . . . .March 3, 2004

Revised . . . . . . . . . . . . . . . . . . . . . . . .September 17, 2004

Revised . . . . . . . . . . . . . . . . . . . . . . . .June 15, 2005

Revised . . . . . . . . . . . . . . . . . . . . . . . .September 12, 2005

Revised . . . . . . . . . . . . . . . . . . . . . . . .October 21, 2005

Revised . . . . . . . . . . . . . . . . . . . . . . . .February 16, 2006

Revised . . . . . . . . . . . . . . . . . . . . . . . .April 11, 2007

Revised . . . . . . . . . . . . . . . . . . . . . . . .February 19, 2010

Revised . . . . . . . . . . . . . . . . . . . . . . . .January 18, 2011

Revised . . . . . . . . . . . . . . . . . . . . . . . .July 13, 2011

Revised . . . . . . . . . . . . . . . . . . . . . . . .September 28, 2012

Revised . . . . . . . . . . . . . . . . . . . . . . . .May 1, 2013

Page 6

TABLE OF CONTENTS

3121165 – JLG Lift – i

SECTION - PARAGRAPH, SUBJECT PAGE 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 . . . . . . . . . . . . . . 1-8

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . 1-9

1.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . 1-10

Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION & 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

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

SECTION - 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

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

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

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

Training Supervision. . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . 3-2

3.3 OPERATING CHARACTERISTICS AND

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

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

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

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

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

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

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

3.5 PLATFORM CONTROL STATION . . . . . . . . . . . . . . . . .3-5

3.6 MDI (MULTIFUNCTION DIGITAL INDICATOR) . . . . .3-9

MDI Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

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TABLE OF CONTENTS

ii – JLG Lift – 3121165

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

SECTION - 4 - MACHINE OPERATION

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

4.2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Platform/Ground Select Switch . . . . . . . . . . . . . . 4-1

Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . 4-1

4.3 RAISING AND LOWERING. . . . . . . . . . . . . . . . . . . . . . . .4-2

Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Arm Guards (If equipped) . . . . . . . . . . . . . . . . . . . . 4-3

Platform Extension . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Fold-Down Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.4 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.5 DRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Driving Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Driving in Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.6 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . . . . .4-7

4.7 BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Battery Charger Fault Codes . . . . . . . . . . . . . . . . . 4-9

4.8 PLATFORM LOADING . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.9 SAFETY PROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.10 TIE DOWN/LIFT LUGS . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.11 LIFTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.12 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Remote Electric Brake Release. . . . . . . . . . . . . . . 4-13

Push Button Electric Brake Release. . . . . . . . . . 4-13

Mechanical Brake Release . . . . . . . . . . . . . . . . . . 4-14

Mechanical Brake Release . . . . . . . . . . . . . . . . . . 4-15

Mechanical Brake Release . . . . . . . . . . . . . . . . . . 4-16

4.13 DIAGNOSTIC TROUBLE CODES (DTC). . . . . . . . . . . 4-18

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4.14 DTC CHECK TABLES - CONTROL MODULE . . . . . . 4-19

0-0 Help Comments. . . . . . . . . . . . . . . . . . . . . . . . 4-19

2-1 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

2-2 Platform Controls . . . . . . . . . . . . . . . . . . . . . . 4-21

2-3 Ground Controls . . . . . . . . . . . . . . . . . . . . . . . 4-23

2-5 Function Prevented . . . . . . . . . . . . . . . . . . . . 4-23

3-1 Line Contactor Open Circuit . . . . . . . . . . . . 4-25

3-2 Line Contactor Short Circuit . . . . . . . . . . . . 4-26

3-3 Ground Output Driver . . . . . . . . . . . . . . . . . . 4-26

4-2 Thermal Limit (SOA) . . . . . . . . . . . . . . . . . . . . 4-29

4-4 Battery Supply . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

6-6 Communication. . . . . . . . . . . . . . . . . . . . . . . . 4-30

6-7 Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

7-7 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

8-1 Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

8-2 Platform Load Sense . . . . . . . . . . . . . . . . . . . 4-33

9-9 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

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TABLE OF CONTENTS

3121165 – JLG Lift – iii

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

SECTION - 5 - EMERGENCY PROCEDURES

5.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . 5-1

Manual Descent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . 5-2

Operator Unable to Control Machine. . . . . . . . . 5-2

Platform Caught Overhead . . . . . . . . . . . . . . . . . . 5-3

Righting of Tipped Machine . . . . . . . . . . . . . . . . . 5-3

Post-Incident Inspection. . . . . . . . . . . . . . . . . . . . . 5-3

5.3 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . 5-3

SECTION - 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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

6.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 6-2

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

Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.3 CRITICAL STABILITY WEIGHTS . . . . . . . . . . . . . . . . . . .6-9

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6.4 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . .6-11

Oil Check Procedure (1) . . . . . . . . . . . . . . . . . . . . 6-12

Lower (2) & Upper Slide Pads (3) . . . . . . . . . . . . 6-13

6.5 TIRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Tire Wear and Damage. . . . . . . . . . . . . . . . . . . . . . 6-15

Wheel and Tire Replacement . . . . . . . . . . . . . . . . 6-15

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6.6 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . 6-16

SECTION - 7 - INSPECTION AND REPAIR LOG

Page 9

TABLE OF CONTENTS

iv – JLG Lift – 3121165

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

LIST OF FIGURES

2-1. Daily Walk-Around Inspection - Sht. 1 of 3 . . . . . . .2-7

2-2. Daily Walk-Around Inspection - Sht. 2 of 3 . . . . . . .2-8

2-3. Daily Walk-Around Inspection - Sht. 3 of 3 . . . . . . .2-9

2-4. Switch Location - 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-5. Switch Location - 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . 2-11

3-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-2. Battery Charger Status . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-3. Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-4. MDI Indicator - Location and Description . . . . . . . .3-9

3-4. Decal Location - 1930ES- Sht. 1 of 2 . . . . . . . . . . . 3-11

3-5. Decal Location - 1930ES - Sht. 2 of 2 . . . . . . . . . . . 3-12

3-6. Decal Location - 2030ES & 2630ES - Sht. 1 of 2 . 3-13 3-7. Decal Location - 2030ES & 2630ES - Sht. 2 of 2 . 3-14 3-8. Decal Location - 2646ES & 3246ES - Sht. 1 of 2 . 3-15 3-9. Decal Location - 2646ES & 3246ES - Sht. 2 of 2 . 3-16

4-1. Grade and Sideslope. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-2. Securing Control Station to Platform . . . . . . . . . . . .4-7

4-3. Lifting and Tie Down Diagram . . . . . . . . . . . . . . . . 4-12

4-4. Manual Disengage. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-5. Manual Disengage. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4-6. Manual Disengage. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-7. Lifting and Tie Down Chart. . . . . . . . . . . . . . . . . . . . 4-17

6-1. Lubrication Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-2. Lower Slide Pad Channel. . . . . . . . . . . . . . . . . . . . . . 6-13

6-3. Upper Slide Pad Channel . . . . . . . . . . . . . . . . . . . . . . 6-14

LIST OF TABLES

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-6

2-1 Inspection and Maintenance Table . . . . . . . . . . . . . 2-3

2-2 Tilt vs. Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 High Drive Speed Cutout Height. . . . . . . . . . . . . . . . 2-6

3-1 Decal Location Legend . . . . . . . . . . . . . . . . . . . . . . . .3-17

4-1 Battery Charger Flash Codes. . . . . . . . . . . . . . . . . . . . 4-9

6-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-4 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-5 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-6 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-7 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-8 Hydraulic Oil Specifications. . . . . . . . . . . . . . . . . . . .6-10

6-9 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

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

Page 10

SECTION 1 - SAFETY PRECAUTIONS

3121165 – JLG Lift – 1-1

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 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 should 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.

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

FAILURE TO COMPLY WIT H T HE SAFE TY PRE CAUTION S LIS TED IN THI S M ANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

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SECTION 1 - SAFETY PRECAUTIONS

1-2 – JLG Lift – 3121165

1.2 PRE-OPERATION

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 portions of this manual, contact JLG Industries, Inc.

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

Page 12

SECTION 1 - SAFETY PRECAUTIONS

3121165 – JLG Lift – 1-3

• Check the work area for hazardous locations. Do not oper-

ate 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 operate the machine when wind conditions exceed 28 mph (12.5 m/s).

• This machine can be operated in nominal ambient temperatures of 0

F to 104oF (-20oC to 40oC). Consult JLG to opti-

mize 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.

• 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 deck. Keep mud, oil, grease, and other slippery substances from footwear and platform deck.

1.3 OPERATION

General

• 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.

Page 13

SECTION 1 - SAFETY PRECAUTIONS

1-4 – JLG Lift – 3121165

• 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.

• 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.

• 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 leaving machine.

Electrocution Hazards

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

• Maintain safe clearance from electrical lines, apparatus, or any energized (exposed or insulated) parts in accordance with the Minimum Approach Distance (M.A.D.) as specified in Table 1-1 on page 1-5

• Allow for machine movement and electrical line swaying.

• Maintain a clearance of at least 10 ft (3 m) 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.

Page 14

SECTION 1 - SAFETY PRECAUTIONS

3121165 – JLG Lift – 1-5

• The minimum approach distance may be reduced if insulat-

ing 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 (M.A.D.). ASSUME ALL ELECTRICAL PA RTS AND WI RIN G A RE EN ERG IZE D UNLESS KNOWN OTHERWISE.

Tab le 1 -1.M in im um A pp roac h Di sta nc es ( M. A.D. )

Volt age R ange

(Phase to Phase)

MINIMUM APPROACH DISTANCE

in Feet (Meters)

0 to 50KV 10 (3)

Over 50 KV 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)

NOTE: This requirement shall apply except where

employer, local or governmental regulations are more stringent.

Page 15

SECTION 1 - SAFETY PRECAUTIONS

1-6 – JLG Lift – 3121165

Trip and Fall Hazards

• 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 protection requirements on JLG products, contact JLG Industries, Inc.

• Prior to operation, ensure all gates and rails 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.

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

Page 16

SECTION 1 - SAFETY PRECAUTIONS

3121165 – JLG Lift – 1-7

Tipping Hazards

• 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.

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

• Do not elevate platform or drive with platform elevated while on 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.

• 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 0.6 m (2 ft) from holes, bumps, drop-offs, obstructions, debris, concealed 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 cover the platform sides or carry large surface-area items in the platform when operating outdoors. The addition of such items increases the exposed wind area of the machine.

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

Page 17

SECTION 1 - SAFETY PRECAUTIONS

1-8 – JLG Lift – 3121165

• 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.

• Watch for obstructions around machine and overhead when driving. Check clearances above, on sides, and bottom of platform when lifting or lowering platform.

• During operation, keep all body parts inside platform railing.

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

• Keep non-operating personnel at least 1.8 m (6 ft) away from machine during all driving 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 causing hazards of collision or injury to personnel.

• Be aware of stopping distances in all drive speeds. When driving in high speed, switch to low speed before stopping. Travel grad es in low spee d 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.

• Ensure that operators of other overhead and floor level machines are aware of the aerial work platform’s presence. 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. Position barricades on floor as necessary.

Page 18

SECTION 1 - SAFETY PRECAUTIONS

3121165 – JLG Lift – 1-9

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/unloading. Refer to emergency towing procedures.

• Ensure platform is fully retracted and completely empty of tools prior to towing, lifting or hauling.

• When lifting machine with a forklift, position forks only at designated areas of the machine. Lift with a forklift of adequate 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 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 operating systems are secured from inadvertent motion prior to performing any adjustments or repairs.

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

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

• Always disconnect batteries when servicing electrical components or when performing welding on the machine.

Page 19

SECTION 1 - SAFETY PRECAUTIONS

1-10 – JLG Lift – 3121165

• 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 provided 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 solvents.

• 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 machine.

• Reference the Service and Maintenance Manual for the weights of critical stability items.

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

Page 20

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION & INSPECTION

3121165 – JLG Lift – 2-1

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION & 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

Train ing mu st be done und er 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.

Page 21

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION & INSPECTION

2-2 – JLG Lift – 3121165

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

The table below covers the periodic machine inspections and maintenance recommended 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.

Tabl e 2- 1. In sp ec ti on a nd M ai nt en an ce Ta bl e

Type Frequency

Primary

Responsibility

Service

Qualification

Reference

Pre-Start Inspection Before using each day; or

whenever there’s an Operator change.

User or Operator User or Operator Operation and Safety Manual

Pre-Delivery Inspection

(see note below)

Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG

Mechanic

Service and Maintenance Manual and applicable JLG inspection form

Frequent Inspection In service for 3 months or 150 hours, whichever comes

first; or Out of service for a period of more than 3 months; or Purchased used.

Owner, Dealer, or User Qualified JLG

Mechanic

Service and Maintenance Manual and applicable JLG inspection form

Annual Machine Inspection

(see note below)

Annually, no later than 13 months from the date of prior inspection.

Owner, Dealer, or User Factory Trained

Service Technician (Recommended)

Service and Maintenance Manual and applicable JLG inspection form

Preventative Maintenance At intervals as specified in the Service and Mainte-

nance Manual.

Owner, Dealer, or User Qualified JLG

Mechanic

Service and Maintenance Manual

NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.

JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAI NING SCH OOL FOR THE S PECIFIC JLG PRODU CT MO DEL.

NOTICE

Page 22

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION & INSPECTION

3121165 – JLG Lift – 2-3

Pre-Start Inspection

The Pre-Start Inspection should include each of the following:

1. Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.

2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies.

3. Decals and Placards – Check all for cleanliness and legibility. Make sure none of the decals and placards are missing. Make sure all illegible decals and placards are cleaned or replaced.

4. Operation and Safety Manuals – Make sure a copy of the Operator and Safety Manual, AEM Safety Manual (ANSI markets only), and ANSI Manual of Responsibili-

ties (ANSI markets only) is enclosed in the weather resistant storage container.

5. “Walk-Around” Inspection – Refer to Figure 2-1

6. Battery – Charge as required.

7. Fuel (Combustion Engine Powered Machines) – Add

the proper fuel as necessary.

8. Engine Oil Supply (If equipped) - Ensure the engine oil level is at the full mark on the dipstick and the filler cap is secure.

9. Fluid Levels – Check the hydraulic oil level. Ensure hydraulic oil is added as required.

10. Accessories/Attachments - Reference the Operator and Safety Manual of each attachment or accessory installed upon the machine for specific inspection, operation, and maintenance instructions.

11. Function Check – Once the “Walk-Around” Inspection is complete, perform a functional check of all systems in an area free of overhead and ground level obstructions. Refer to Section 4 for more specific operating instructions.

Parent Metal Crack

Wel d Crac k

Page 23

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION & INSPECTION

2-4 – JLG Lift – 3121165

Function Check

Perform the Function Check as follows:

1. From the ground control console with no load in the platform:

a. Check that all guards protecting the function con-

trol switches and controllers are in place.

b. Operate all functions and check all limiting and

cutout switches.

c. Check manual descent. d. Ensure that all machine functions are disabled

when the Emergency Stop Button is depressed.

2. From the platform control console: a. Ensure that the control console is firmly secured

in the proper location.

b. Check that all guards protecting the function con-

trol switches and controllers are in place.

c. Operate all functions and check all limiting and

cutout switches.

d. Ensure that all machine functions are disabled

when the Emergency Stop Button is depressed.

3. With the platform in the transport (stowed) position: a. Drive the machine on a grade, not to exceed the

rated gradeability, and stop to ensure the brakes hold.

b. Check the tilt indicator light to ensure proper

operation. The light should be illuminated when tilted.

Page 24

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION & INSPECTION

3121165 – JLG Lift – 2-5

Tabl e 2- 2. Ti lt A ct iv at io n vs. H ei gh t

Model

Tilt Setting

(front to back)

Tilt Setting

(side to side)

Maximum Deck

Elevation

Degrees Feet Meters

1930ES

1.5 18.75 (Full) 5.7

2144.3

2.5 11 3.4 3 9 2.7

2030ES

1.5 20 (Full) 6

2154.5

2.5 12 3.7 3103

2630ES

1.5 25.4 (Full) 7.7 2206

2.5 16 4.9 3134

2646ES

226 (Full)7.9

2.5 22 6.7 3206

3246ES

231.75 (Full)9.7

2.5 22 6.7 3206

Tabl e 2- 3. Hi gh D ri ve S pe ed C ut ou t He ig ht

Model High Drive Speed Cutout Height

1930ES 54 in. 1.4 m

2030ES 66 in. 1.7 m

2630ES 76 in. 1.9 m

2646ES 76 in. 1.9 m

3246ES 76 in. 1.9 m

Page 25

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION & INSPECTION

2-6 – JLG Lift – 3121165

Figure 2-1. Daily Walk-Around Inspection - Sheet 1 of 2

Page 26

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION & INSPECTION

3121165 – JLG Lift – 2-7

General

Begin the “Walk-Around Inspection” at Item 1, as noted on the diagram. Continue Left (counterclockwise viewed from top) checking each item in sequence for the conditions listed in the following checklist.

TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS “OFF” DURING “WALK-AROUND INSPECTION”.

NOTICE

DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE. CHECKING THIS AREA OFTEN RESULTS IN DISCOVERY OF CONDITIONS WHICH COULD CAUSE EXTENSIVE MACHINE DAMAGE.

NOTE: On each item, make sure there are no loose or missing

parts, that they are securely fastened, and that no visible damage exists in addition to any other criteria mentioned.

1. Platform Control Console - Placard secure and legible, control lever and switches return to neutral, control lever lock and emergency stop switch function properly, manual in storage box.

2. Steer Cylinder - See Note

3. Spindle, Tie Rod, Drive Motor and Steer Linkage (left

front) - See Note

4. Wheels and Tires - Properly secured, no missing lug nuts. Refer to Section 6, Tires and Wheels. Inspect wheels for damage and corrosion.

5. Pothole Protection System - See Note

6. Battery Compartment - Proper electrolyte level.

7. Proximity Switch - See Note

8. Manual Descent - See Note

9. Beacon - See Note

10. Ground Controls - Placard secure and legible, control

switches return to neutral position, emergency stop switch functions properly. Control markings legible.

11. Rotary Angle Switch - See Note

12. Hydraulic Pump/Motor, Control Valve Installation - No

unsupported wires or hoses; no damaged or broken wires - See Note

13. Lift Cylinder - See Note

14. Spindle, Tie Rod, Drive Motor and Steer Linkage (left

front) - See Note

15. Sizzor Arms, Pivot Pins and Sliding Wear Pads (Not Shown) - See Note

16. Platform/Handrail Installation (Not Shown) - See Note

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

Page 27

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION & INSPECTION

2-8 – JLG Lift – 3121165

SWITCHES THROUGHOUT

MACHINE

NOTE: Item 2 - location for machines prior to S/N’s:

1930ES - USA built - S/N 0200150266

- Belgium built - S/N 1200007882

2030ES/2630ES - USA built - S/N 0200152825

- Belgium built - S/N 1200008481

2646ES/3246ES - USA built - S/N 0200151606

- Belgium built - S/N 1200008265

NOTE: Item 1 - location for machines prior to S/N’s:

1930ES - USA built - S/N 0200150266

- Belgium built - S/N 1200007882 2030ES/2630ES - USA built - S/N 0200152825

- Belgium built - S/N 1200008481 2630ES/3246ES - USA built - S/N 0200151610

- Belgium built - S/N 1200008265

1. Pothole Switch - (Typical on opposite side of machine)

2. Proximity Switch 3. Rotary Angle Switch

Figure 2-3. Switch Location - 1 of 2

Page 28

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION & INSPECTION

3121165 – JLG Lift – 2-9

SWITCHES THROUGHOUT

MACHINE

NOTE: Item 1 - location for machines from S/N’s to present:

1930ES - USA built - S/N 0200151266

- Belgium built - S/N 1200007882 2030ES/2630ES - USA built - S/N 0200152825

- Belgium built - S/N 1200008481 2630ES/3246ES - USA built - S/N 0200151610

- Belgium built - S/N 1200008265

Figure 2-5. Switch Location - 2 of 2

1. Pothole Switch (Typical on oppo-

site side of machine)

2. Rotary Angle Switch

Page 29

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION & INSPECTION

2-10 – JLG Lift – 3121165

NOTES:

Page 30

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3121165 – JLG Lift – 3-1

SECTION 3. USER RESPONSIBILITIES AND MACHINE CONTROLS

3.1 GENERAL

NOTICE

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 PERSONNEL.

This section provides the necessary information needed to understand control functions. Included in this section are the operating characteristics and limitations, and functions and purposes of controls and indicators. It is important that the user read and understand the proper procedures before operating the machine. These procedures 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 personnel who have demonstrated that they understand the proper use and maintenance of the machine. It is important that all personnel who are assigned to and responsible for the operation and maintenance of the machine undergo a thorough

training program and check out period in order to become familiar with the characteristics prior to operating the machine.

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

Operator Training

Operator training must include instruction in the following:

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 performed.

4. Proper use of all required personnel safety equipment.

5. Sufficient knowledge of the mechanical operation of

the machine to recognize a malfunction or potential malfunction.

Page 31

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3-2 – JLG Lift – 3121165

6. The safest means to operate near overhead obstruc-

tions, other moving equipment, obstacles, depressions, holes, drop-offs, 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

Train ing must be don e under the s upervision o f a qualifi ed operator or supervisor in an open area free of obstructions 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 responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site and to request further information from his supervisor or JLG Distributor before proceeding.

NOTE: Manufacturer or Dealer will provide qualified persons for

training assistance with first unit(s) delivered 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 requirement for any user, regardless of user’s experience with similar types of equipment.

Placards

Important points to remember during operation are provided at the control stations by DANGER, WARNING, CAUTION, IMPORTA NT an d IN STR U CT IO N pl ac a rd s. Th i s i n fo rm at io n i s p la ce d a t various locations for the express purpose of alerting personnel of potential hazards constituted by the operating characteristics and load limitations of the machine. See foreword for definitions of the above placards.

Capacities

Raising platform above horizontal with or without any load in platform, is based on the following criteria:

1. Machine is positioned on a smooth, firm and level surface.

2. Load is within manufacturer’s rated capacity.

3. All machine systems are functioning properly.

Page 32

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3121165 – JLG Lift – 3-3

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

Ground Control Station

DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN THE PLATFORM EXCEPT IN AN EMERGENCY. PERFORM AS MANY PRE-OPERATIONAL CHECKS AND INSPECTIONS FROM THE GROUND CONTROL STATION AS POSSIBLE.

NOTE: When the machine is shut down for overnight parking or

battery charging, the emergency stop and power select switches must be positioned to off to prevent draining the batteries.

1. Platform/Ground Control Switch A three position, key-operated power select 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 ground control. The

ground control emergency stop switch provides power to the key switch. With the power select switch in the center off position, power is shut off to both platform and ground controls.

2. Platform Lift/Lower Switch - A three position, momentary contact Lift control switch provides raising and lowering of the platform when positioned to up or down.

3. Emergency Stop Switch - A two-position, red, mushroom-shaped emergency stop switch, when positioned to ON with the power selector switch positioned to ground, furnishes operating power to the ground control station. 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 depressing switch.

Page 33

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3-4 – JLG Lift – 3121165

4. Battery Charger Status - This panel, located to the right of the ground control box, is designed to give the operator an accurate read on the status of the battery charger.

a. Green = Charge complete b. Ye l lo w = C ha r gi ng in p r oc es s c. Red = Charging abnormal

Figure 3-1. Ground Control Station

GREEN

YELLOW

RED

Figure 3-2. Battery Charger Status

Page 34

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3121165 – JLG Lift – 3-5

3.5 PLATFORM CONTROL STATION

NOTE: *There is no light equipped on a single

capacity ANSI machine.

1. Indoor (CE) / Zone A Capacity (ANSI)*

2. Outdoor (CE) / Zone B Capacity (ANSI)

3. System Distress

4. Battery Discharge Indicator

5. Tilt Indicator

6. Overload Indicator

7. Capacity Selec t Switch

8. Lift/Drive Select Switch

9. Horn

10. Steer Switch

11. Contro ller

12. Emergency Stop Switch

13. Tr ig ge r Sw it ch

Figure 3-3. Platform Control Station

Page 35

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3-6 – JLG Lift – 3121165

NOTE: The platform control indicator panel uses different shaped

symbols to alert the operator to different types of operational situations that could arise. The meaning of those symbols are explained below.

1. Indoor (CE) / Zone A Capacity (ANSI/AUS) - This indicator light will be illuminated when the Indoor (CE) or Zone A (ANSI/AUS) capacity is selected.

2. Outdoor (CE) / Zone B Capacity (ANSI/AUS) - This indicator light will be illuminated when the Outdoor (CE) or Zone B (ANSI/AUS) capacity is selected.

3. System Distress Indicator - This indicator will light up with a fault flash code that will determine where a problem, within the system, exists.

4. Battery Discharge Indicator (BDI) - This set of lights is designed to let the operator know the condition of the batteries.

5. Tilt Indicator Warning Light - A red warning light on the control panel that illuminates when the chassis is on a slope greater than what the machine is programmed for.

6. Overload Indicator (If Equipped) - Indicates the platform has been overloaded. An audible alarm will also signal when the platform is overloaded.

NOTE: If the Overload Indicator is illuminated, all functions will

be prevented from the platform controls. Using the ground controls or manual descent, fully lower the machine and reduce the weight in the platform so as to not exceed the rated workload indicated on the capacity decal.

7. Capacity Select Switch - On model 2630ES/3246ES machines this switch is used to choose allowable capacity zone. On all CE machines, except the 2630ES, this switch is used to select either indoor or outdoor capacity zone.

Indicates a potentially hazardous situation, which if not corrected, could result in serious injury or death. This indicator will be red.

Indicates an abnormal operating condition, which if not corrected, may result in machine interruption or damage. This indicator will be yellow.

Indicates important information regarding the operating condition, i.e. procedures essential for safe operation. This indicator will be green with the exception of the capacity indicator which will be green or yellow depending upon platform position.

Page 36

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3121165 – JLG Lift – 3-7

8. Lift/Drive Select - This toggle switch is used to select

either drive or lift. After selecting a function, the controller must be moved in the proper direction in order to activate that function. The function must be selected with the joystick in the neutral position. Otherwise, the function select will not occur.

9. Horn - This push-button switch, when activated, permits the operator to warn jobsite personnel when the machine is operating in the area.

10. Steer Switch - The steer switch is a thumb operated switch located at the top of the control handle. Depressing the switch to the right will steer the wheels to the right. Depressing the switch to the left will steer the wheels to the left.

11. Controller - The control handle controls three functions: drive, lift, and steer. The drive and lift switch must be selected prior to moving the control handle. After selecting the drive function, moving the control handle forward will drive the machine forward and moving the control handle backwards will drive the machine backward. After selecting the lift function, moving the control handle backward will raise the platform and moving the control handle forward will lower the platform. The speed on all selected functions is proportionally controlled by the distance of travel of the hand controller. The thumb-operated

steer switch on top of the hand controller activates the steer wheels in the direction activated (right or left).

12. Emergency Stop Switch - A two-position, red, mushroom-shaped emergency stop switch functions to provide power to the platform control station and also to turn off power to the platform function controls in the event of an emergency. 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).

13. Trigg er Switch - This switch is loc ated on t he front of the controller. The trigger switch acts as an enable and must be depressed when operating the drive, steer and lift functions. When released, the function being operated will stop.

IF THE TILT INDICATOR WARNING LIGHT OR HORN IS ON WHEN PLATFORM IS RAISED, LOWER PLATFORM COMPLETELY, THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE RAISING PLATFORM.

14. Tilt Alarm Warning Horn - The Tilt Alarm Warning Horn is activated when the chassis is on a slope greater than what the machine is programmed for and the platform is elevated.

Page 37

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3-8 – JLG Lift – 3121165

NOTE: ANSI/CSA/AUS machines are equipped with a tilt interlock

which cuts out drive and lift up functions when chassis is on a slope greater than what is allowable for the machine and the platform is elevated.

DO NOT “LOWER” WITHOUT COMPLETELY RETRACTING THE PLATFORM EXTENSION.

DO NOT OPERATE MACHINE IF HIGH DRIVE SPEED OPERATES WHEN PLATFORM IS RAISED ABOVE THE STOWED POSITION.

Page 38

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3121165 – JLG Lift – 3-9

3.6 MDI (MULTIFUNCTION DIGITAL INDICATOR)

1. Battery Compartment

2. Diagnostic Trouble Code LCD

3. Wrench Icon ( Fault)

4. Faul t LE D

5. Battery Discharge Indicator (BDI)

Figure 3-3. MDI Indicator - Location and Description

Page 39

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3-10 – JLG Lift – 3121165

MDI Description

Located in the battery compartment on the left side of the machine (See Figure 3-3.) is a Multifunction Digital Indicator (MDI). The purpose of the MDI is to display Diagnostic Trouble Codes (DTC) when a functional problem occurs with the machine. The MDI is plugged into the diagnostic connector in the battery compartment.

When a problem occurs:

1. A Wrench Icon will display on the Diagnostic Trouble Code LCD display.

2. A three to five digit DTC will display on the Diagnostic Trouble Code LC D display, belo w the w rench ico n.

NOTE: When more than one DTC exists, each DTC will be dis-

played on the LCD for 3 seconds before changing to the next DTC. Once the last active DTC is displayed, the display will recycle indefinitely until the DTC’s are corrected.

3. The red Fault LED will illuminate (this does not apply to 00x

DTC’s; the Fault LED will not illuminate for these

DTC’s).

NOTE: For DTC’s and desc ription s, r efer to Sect ion 4.13, Diagnos-

tic Trouble Codes (DTC) Check Tables.

Also located on the MDI are Battery Discharge Indicators (BDI). These green LEDs indicate the level of charge in the batteries.

NOTE: When the batteries are completely discharged, the LED in

the 0-25% range "red area" will flash.

• The BDI will convey the same information as the BDI on the platform control station. (see Figure 3-3., Platform Control Station)

• Under normal driving conditions the BDI’s will be illuminated. When a DTC exists (other than 00x

DTC’s) the BDI

LEDs will not be illuminated.

100%

75%

50%

0-25%

Battery Charge/Discharge Indicator

Page 40

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3121165 – JLG Lift – 3-11

18 36

22 12

Both Sides

Figure 3-3. Decal Location - 1930ES- Sheet 1 of 2

Page 41

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3-12 – JLG Lift – 3121165

4127

45 19

2630

Both Sides

Figure 3-4. Decal Location - 1930ES - Sheet 2 of 2

Page 42

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3121165 – JLG Lift – 3-13

41 22

Both Sides

Figure 3-5. Decal Location - 2030ES & 2630ES - Sheet 1 of 2

Page 43

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3-14 – JLG Lift – 3121165

41 22

134317

Figure 3-6. Decal Location - 2030ES & 2630ES - Sheet 2 of 2

Page 44

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3121165 – JLG Lift – 3-15

24 24

Both Sides

12 38

21 41

Both Sides

Figure 3-7. Decal Location - 2646ES & 3246ES - Sheet 1 of 2

Page 45

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3-16 – JLG Lift – 3121165

Both Sides

40 21

41 22

Figure 3-8. Decal Location - 2646ES & 3246ES - Sheet 2 of 2

Page 46

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3121165 – JLG Lift – 3-17

Tabl e 3- 1. De ca l Lo ca ti on L eg en d

Item

ANSI

0275220-3

0275221-3

Australian

0275222-3

English/French

0275223-3

English/ Spanish

0275224-3

Portuguese/

Spanish

0275225-3

English/ Chinese

0275226-3

Korean

0275227-3

1 - 3 N/A N/A N/A N/A N/A N/A N/A N/A

417005841700584170058417005841700584170058417005841700584

5 - 6 N/A N/A N/A N/A N/A N/A N/A N/A

717026311702631170263117026311702631170263117026311702631

8N/A N/A N/A N/A N/A N/A N/A N/A

917044121704412170441217044121704412170441217044121704412

10 1705693 1705693 1705693 1705693 1705693 1705693 1705693 1705693

11 1704016 1704016 1704016 1704016 1703817 1703817 1704016 1704016

12 1702155 1702155 1702155 1702155 1702155 1702155 1702155 1702155

13 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

14 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811

15 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814

16 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

17 1703819 1703819 1703819 1703819 1703819 1703819 1703819 1703819

18 1703822 1703822 1703822 1703822 1703822 1703822 1703822 1703822

Page 47

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3-18 – JLG Lift – 3121165

19 1705692 1705692 1705692 1705692 1705692 1705692 1705692 1705692

20 N/A N/A N/A N/A N/A N/A N/A N/A

21 1705694 1705673 1705673 1705694 1705694 1705722 1705694 1705694

22 1705695 1705671 1705671 1705695 1705695 1703834 1705695 1705695

23 1705686 N/A N/A 1705723 1705720 17057 26 1705946 1706057

24 1705680 N/A N/A 1705680 1705680 17058 94 1705680 1705680

25 1705679 N/A N/A 1705679 1705679 17057 27 1705679 1705679

26 1705681 N/A N/A 1705681 1705681 17057 21 1705681 1705681

27 1703813 1705670 1705670 1704340 1704339 1704341 1704344 1707022

28 N/A N/A N/A N/A N/A N/A N/A N/A

29 (1930ES) (2030ES) (2630ES) (2646ES) (3246ES)

1705642 1705643 1705644 1705645 1705646

Tabl e 3- 1. De ca l Lo ca ti on L eg en d

Item

ANSI

0275220-3

0275221-3

Australian

0275222-3

English/French

0275223-3

English/ Spanish

0275224-3

Portuguese/

Spanish

0275225-3

English/ Chinese

0275226-3

Korean

0275227-3

Page 48

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3121165 – JLG Lift – 3-19

30 (1930ES) (2030ES) (2630ES) (2646ES) (3246ES)

1705638 1705639 1705941 1705640 1705641

1705666 1705667 1705942 1705668 1705704

1705666 1705667 1705887 1705668 1705819

1705638 1705639 1705941 1705640 1705641

31 1705699 N/A N/A N/A N/A N/A 1705699 N/A

32 0272870 0272870 0272870 0272870 0272870 0272870 0272870 0272870

33 - 34 N/A N/A N/A N/A N/A N/A N/A N/A

35 0272870 0272870 0272870 0272870 0272870 0272870 0272870 0272870

36 (1930ES) (2030ES) (2630ES) (2646ES) (3246ES)

1705647 1704134 1706310 1706311 1706311

1705648 1706310 1706310 1706312 1706312

1705647 1704134 1706310 1706311 1706311

37 N/A N/A N/A N/A N/A N/A N/A N/A

38 N/A N/A N/A 1705303 N/A 1705303 N/A N/A

Tabl e 3- 1. De ca l Lo ca ti on L eg en d

Item

ANSI

0275220-3

0275221-3

Australian

0275222-3

English/French

0275223-3

English/ Spanish

0275224-3

Portuguese/

Spanish

0275225-3

English/ Chinese

0275226-3

Korean

0275227-3

Page 49

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROLS

3-20 – JLG Lift – 3121165

39 N/A N/A N/A N/A N/A N/A N/A 3251243

40 N/A N/A N/A 1705717 1705725 1705725 1705943 1706052

41 N/A N/A N/A 1705718 1705724 1705724 1705944 1706056

42 (1930ES) (2030ES) (2630ES) (2646ES) (3246ES)

1705850 1705850 1705850 1705851 1705851

43 N/A N/A N/A 3252098 1705719 1705719 1705945 1706053

44 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

45 (1930ES) 1001092071 1001092497 1001092071 1001092580 1001092071 1001092071 1001092071 1001092071

46 1001094359 1001094359 1001094359 1001094359 1001094359 1001094359 1001094359 1001094359

47 1001146794 1001146795 1001146795 1001146794 1001146794 1001146794 1001146794 1001146794

Tabl e 3- 1. De ca l Lo ca ti on L eg en d

Item

ANSI

0275220-3

0275221-3

Australian

0275222-3

English/French

0275223-3

English/ Spanish

0275224-3

Portuguese/

Spanish

0275225-3

English/ Chinese

0275226-3

Korean

0275227-3

Page 50

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-1

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 Station in the platform. From this Control Station, the operator can drive and steer the machine in both forward and reverse directions, raise and lower the platform and, if equipped, operate the powered deck extension. 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 in an emergency to lower the platform to the ground should the operator in the platform be unable to do so.

NOTE: All platform extension capacities are 250 lb (120 kg).

4.2 OPERATION

Platform/Ground Select Switch

The power selector switch functions to direct electrical power to the desired control station. With the switch in the ground position, power is supplied to the emergency stop switch at the ground control station. When the switch is in the platform position, power is supplied to the emergency stop switch at the platform control station. The switch should be in the off position when parking the machine overnight.

Emergency Stop Switch

This switch, when in the on (out) position, provides electrical 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.

Page 51

SECTION 4 - MACHINE OPERATION

4-2 – JLG Lift – 3121165

4.3 PLATFORM OPERATION

ONLY RAISE PLATFORM ON A FIRM, LEVEL AND SMOOTH SURFACE FREE OF OBSTRUCTIONS AND HOLES.

NOTE: When selecting between the Lift/Drive functions, the con-

troller must be in the neutral position for 3 seconds before

the function change is effective. The machine is inopera-

ble at this point.

Raising

1. If the machine is shut down, place the power selector switch to the desired position (platform or ground).

2. Position the applicable emergency stop switch to the "ON" position.

NOTE: If the machine is equipped with a footswitch (Japanese

Specification Only), the footswitch must be depressed in conjunction with the red trigger switch, located on the controller. 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, select lift function, squeeze and hold the red trigger switch, move the controller backward (up) and hold

until desired elevation is reached. The lift switch works in conjunction with the enable switch. Releasing the trigger switch will stop the function being operated.

Lowering

ENSURE SCISSOR ARM AREA IS FREE OF PERSONNEL PRIOR TO LOWERING PLATFORM.

NOTE: The machine is equipped with a descent alarm which will

sound as the platform is being lowered (CE Optional).

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, select lift function squeeze the red trigger switch and push the controller forward (down) and hold until desired elevation is reached or until platform is fully lowered. The lift switch works in conjunction with the enable switch. Releasing the trigger switch will stop the function being operated.

Page 52

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-3

Arm Guards (If equipped)

If the machine is equipped with arm guards, the platform will stop lowering and an alarm will sound once it has reached a preset height. At this point, the trigger switch and controller must be released before the lowering function can begin again.

DO NOT ‘LOWER’ WITHOUT COMPLETELY RETRACTING THE PLATFORM EXTENSION.

Platform Extension

The machine is equipped with a mechanically extendable deck, giving the operator better access to worksites. On the 1930ES/ 2030ES/2630ES this extension adds 3 ft (0.9 m) and on the 2646ES and 3246ES the extension adds 4 ft (1.2 m) to the front of the platform. To extend the deck, pull out handles from latch and swing up, then use the handles and handrail to push the extendable deck out. To retract the deck, pull out the handles from latch and swing up, use the handles and handrail to pull and retract the deck. Be sure the handles are in place after the deck is retracted. Maximum capacity of the deck extension is 250 lbs (120 kg).

Page 53

SECTION 4 - MACHINE OPERATION

4-4 – JLG Lift – 3121165

Fold-Down Rails

DO NOT RAISE PLATFORM WITH RAILS FOLDED DOWN. THE RAILS MUST BE IN THE UPRIGHT POSITION AND PROPERLY PINNED WHEN RAISING THE PLATFORM.

NOTE: The rails must only be folded down when the machine is in

the stowed (fully lowered) position.

NOTE: Ensure that the drywall gate at the rear of the machine is

up and locked in position. Platform control box should be removed and placed on the platform with rails folded down.

1. To f ol d do wn t he r ai ls , rem ov e th e fo ur ( 4) b ai l pi ns a t the two front corners and center of the rails.

2. Tak in g a firm h ol d o n th e to p rail s, car ef ully p ush fo rward and lower until the top rail rests on the middle rail.

3. To r ai se t he r ai ls b ac k to the upright position, firmly pull the rails toward the back of the machine and replace the bail pins into the rails. Return drywall gate to the lowered position.

AFTER THE RAILS HAVE BEEN FOLDED DOWN, USE EXTREME CAUTION WHEN EXITING AND ENTERING THE PLATFORM.

BAIL PI NS

Page 54

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-5

4.4 STEERING

To st ee r t he ma ch in e, the th um b operated steer control switch on the controller handle 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.

4.5 DRIVING

DO NOT DRIVE WITH PLATFORM RAISED EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE FREE OF OBSTRUCTIONS AND HOLES.

TO AVOID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES AND SIDESLOPES, DO NOT DRIVE MACHINE ON GRADES OR SIDESLOPES EXCEEDING THOSE SPECIFIED. REFERENCE FIGURE 4-1., GRADE AND SIDESLOPE.

Driving Forward

1. Place power selector switch at ground control station to "Platform."

2. Position emergency stop switch at platform control station to "On" position.

3. Select "Drive" on the drive/lift select switch.

4. Squeeze controller (joystick), depressing red trigger

on front of joystick, and move joystick forward for duration of travel. The drive system is proportional so for additional drive speed, push the joystick further in the direction of travel. Releasing the trigger will stop the function being operated.

Driving in Reverse

1. Position power selector switch at ground control station 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. The drive system is proportional so for additional drive speed, push the joystick further in the direction of travel. Releasing the trigger will stop the function being operated.

Page 55

SECTION 4 - MACHINE OPERATION

4-6 – JLG Lift – 3121165

HORIZONTAL

Figure 4-1. Grade and Sideslope

Page 56

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-7

4.6 PARKING AND STOWING

Park and stow the machine as follows:

1. Drive the machine to a reasonably well-protected and well-ventilated area.

2. Ensure the platform is fully lowered.

3. Position the emergency stop switch to the "Off " posi-

tion.

4. If necessary, cover the instruction placards, caution and warning decals so that they will be protected from hostile environment.

5. Chock at least two wheels when parking the machine for an extended period of time.

6. Turn the p ower selector switch to "Off " and remove the key to disable the machine and prevent unauthorized use. The platform control station can also be secured to it’s mounting plate, see Figure 4-2.

7. If equipped with the optional anti-vandal package, the platform and ground control box assemblies may be covered and locked to prevent access.

NOTICE

DO NOT OPERATE MACHINE FROM THE PLATFORM OR GROUND CONTROLS WITH THE ANTI-VANDAL COVERS CLOSED AND LOCKED IN PLACE.

NOTE: If machine is not equipped with the anti-vandal covers

option to prevent unauthorized removal, the platform control station can be secured to it’s mount by placing a lock through one or more of the holes located on it’s upper mounting tabs.

Figure 4-2. Securing Control Station to Platform

Page 57

SECTION 4 - MACHINE OPERATION

4-8 – JLG Lift – 3121165

4.7 BATTERY CHARGING

Operation

NOTE: Be sure that machine is parked in a well ventilated area

before charging begins.

ONLY PLUG THE CHARGER INTO A PROPERLY INSTALLED AND GROUNDED OUTLET. DO NOT USE GROUND ADAPTORS OR MODIFY PLUG. DO NOT TOUCH NON-INSULATED PORTION OF OUTPUT CONNECTOR OR NON-INSULATED BATTERY TERMINAL.

ALWAYS DISCONNECT THE AC SUPPLY BEFORE MAKING OR BREAKING THE CONNECTIONS TO THE BATTERY BEFORE CHARGING.

DO NOT OPEN OR DISASSEMBLE CHARGER.

DO NOT OPERATE CHARGER IF THE AC SUPPLY CORD IS DAMAGED OR IF THE CHARGER HAS RECEIVED A SHARP BLOW, BEEN DROPPED, OR OTHERWISE DAMAGED IN ANY WAY.

The battery charger receptacle is located at the right rear of the machine near the ground control panel.

1. Connect the charger to a grounded outlet.

2. On the Battery Charger, the charger will automatically

turn on and go through a short LED indicator self-test. All LED’s will flash in an up and down sequence for two seconds.

3. The batteries are fully charged when green light on the battery charger status panel is illuminated.

Page 58

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-9

NOTE: If the charger is left plugged in, the charger will automati-

cally restart a complete charge cycle if the batteries voltage drops below a minimum voltage or 30 days has elapsed.

Battery Charger Fault Codes

If a fault occurred during charging, the red "Fault" LED will flash with a code. The number of flashes corresponds to the error. Refer to Table 4-1, Battery Charger Flash Codes.

Tabl e 4- 1. Ba tt er y Ch ar ge r Fl as h Co de s

Flash(s) Fault Faul t Remo val

1Battery voltage highAuto-recover - Indicates a high battery pack voltage

2Battery voltage lowAuto-recover - Indicates either a battery pack failure, battery pack not connected to charger or battery volts per cell is less than 0.5 VDC.

Check the battery pack and connections

3Charge time-out Indicates the batteries did not charge in the allowed time. This could occur if the batteries are a larger capacity than the algorithm is

intended for or if the batteries are damaged old or in poor condition.

4Check battery Indicates the batteries could not be trickle charged up to the minimum voltage per cell level required for the charge to be started.

5Over-temperatureAuto-recover - Indicates charger has shut down due to high internal temperature

6QuiQ fault Indicates that the battery will not accept charge current, or an internal fault has been detected in the charger. This fault will nearly always

be set within the first 30 seconds of operation. Once it has been determined that the batteries and connections are not faulty and fault 6 is again displayed after interrupting AC power for at least 10 seconds, the charger must be brought to a qualified service depot.

Page 59

SECTION 4 - MACHINE OPERATION

4-10 – JLG Lift – 3121165

4.8 PLATFORM LOADING

The platform maximum rated load capacity is shown on a placard located on the platform and is based upon the following criteria:

1. The machine is positioned on a firm, uniform surface.

2. All braking devices are engaged.

3. Refer to Section 6 for the maximum platform capacity.

NOTE: It is important to remember that the load should be

evenly distributed on the platform. The load should be placed near the center of the platform when possible.

4.9 SAFETY PROP

THE SAFETY PROP MUST BE USED WHENEVER MAINTENANCE PERFORMED ON THE MACHINE REQUIRES THE SCISSOR ARMS TO BE RAISED AND ONLY WITH NO LOAD IN THE PLATFORM.

To en ga ge th e s af et y p ro p, rais e t he pl at fo rm , s wi ng th e s af et y prop from it’s stowed position located on the right side of the machine. Lower the platform until the safety prop rests on the designated safety prop rest.

To s to re t he s af et y pro p, r ai se t he p la tform , sw in g th e sa fety prop around and restore it back to its stowed position.

Page 60

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-11

4.10 TIE DOWN/LIFT LUGS

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 two tie-down/lift lugs located at the rear of the machine for lifting and tieing down. There is a single tiedown lug at the front of the machine. This lug is designed for tieing down only. Do not attempt to lift machine from the front lug.

LIFTING THE MACHINE FROM THE SIDES USING A FORK TRUCK IS NOT RECOMMENDED BY JLG. IN THE EVENT THAT THE MACHINE NEEDS TO BE LIFTED FROM THE SIDES CAUTION MUST BE USED TO AVOID JAMMING THE POT HOLE PROTECTION BARS UP AGAINST THE FRAME. EVERY TIME THE MACHINE IS LIFTED FORM THE SIDE, BE SURE AND TEST THE POT HOLE PROTECTION SYSTEM BEFORE THE MACHINE IS PUT BACK INTO OPERATION.

4.11 LIFTING

In the event that the machine must be lifted, there is a forktruck pocket located at the rear of the machine. The machine can also be lifted using a proper spreader bar and straps/chains. Reference Figure 4-3., Lifting and Tie Down Diagram.

Page 61

SECTION 4 - MACHINE OPERATION

4-12 – JLG Lift – 3121165

FRONT

(JAPAN - AUS)

(ANSI - CSA - CE)

FRONT

REAR

Figure 4-3. Lifting and Tie Down Diagram

Page 62

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-13

4.12 TOWING

It is not recommended that this machine be towed, except in the event of an emergency such as a machine malfunction or a total machine power failure.

NOTE: The machine may be equipped with a remote electric

brake release, a push button electric brake release, or both styles of electric brake release.

RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES, TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ONHIGHWAY TOWING NOT PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH.

MAXIMUM TOWING SPEED 5 MPH (8 KPH) FOR NO FURTHER THAN 60 FEET (18 M).

MAXIMUM TOWING GRADE 25%.

Remote Electric Brake Release

1. Chock wheels or secure machine with tow vehicle.

2. Pull the emergency stop switch out and position the

keyswitch to ground mode.

3. The brake release cable hangs on a hook in the battery compartment on the opposite side of the ground control panel.

4. Locate brake release plug near the analyzer plug at the left front corner of the machine and plug the release cable into the plug.

5. Depress switch to release brakes.

6. When finished towing; release switch, unplug release

switch and return brake switch to the proper storage area in the battery compartment.

Push Button Electric Brake Release

NOTE: The push button electric brake release is located on the

right side of the machine just forward of the ground control box.

1. Chock wheels or secure machine with tow vehicle.

2. Pull the emergency stop switch out and position the

keyswitch to ground mode.

3. Push the button once to release the brakes.

4. To re se t th e br ak es , pu sh t he button again, or push in

the emergency stop switch, or take the ground control keyswitch out of the ground mode position.

Page 63

SECTION 4 - MACHINE OPERATION

4-14 – JLG Lift – 3121165

Mechanical Brake Release

Machines, USA built prior to s/n 0200118041: Machines, Belgium built prior to s/n 1200001487:

1. Chock wheels or secure machine with tow vehicle.

2. Power machine in ground mode.

3. Remove the three cover bolts (1), from the back of drive

motor unit.

4. Remove brake cover (2).

5. Locate the 2 disengage bolts (3) that are stored in the motor end cap. Remove bolts and insert them into the two disengage holes (4) in the brake housing, see Item 4 in

Figure 4-4., Manual Disengage.

6. Tighten down the bolts and the brake on that drive motor will disengage.

7. Repeat this procedure on opposite wheel drive. With both drive motor brakes now disengaged, the machine can be moved manually.

8. After towing is complete, chock wheels and remove 2 disengage bolts (3) from disengage holes (4). Insert bolts

back into original holes in motor end cap.

9. Reinstall cover (2).

AFTER THE MACHINE IS TOWED, THE DISENGAGE BOLTS MUST BE REMOVED FROM THE BRAKE DISENGAGE HOLES. THE BRAKES CANNOT BE ENGAGED WITH THE DISENGAGE BOLTS IN THE BRAKE DISENGAGE HOLES. THIS WILL CAUSE THE MACHINE TO ROLL WHEN PARKED ON AN INCLINE.

Figure 4-4. Manual Disengage

Page 64

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-15

Mechanical Brake Release

Machines, USA built s/n 0200152825 to s/n 0200170585: Machines, Belgium built s/n 1200008481 to s/n 1200015159:

1. Chock wheels or secure machine with tow vehicle.

2. Power machine in ground mode.

3. Remove the two cover bolts (1), cover (2), and cover o- ring seal (3) from the back of drive motor unit.

4. Insert the cover bolts (1) into the two disengage holes in the brake housing (4), see Item 4 in Figure 4-5., Manual

Disengage.

5. Tighten down the bolts and the brake on that drive motor will disengage.

6. Repeat this procedure on opposite wheel drive. With both drive motor brakes now disengaged, the machine can be moved manually.

7. After towing is complete, chock wheels and remove cover bolts (1) from disengage holes (4).

8. Reinstall cover (2). Before installation, check the cover oring seal (3) for damage, replace if necessary.

AFTER THE MACHINE IS TOWED, THE DISENGAGE BOLTS MUST BE REMOVED FROM THE BRAKE DISENGAGE HOLES. THE BRAKES CANNOT BE ENGAGED

WITH THE DISENGAGE BOLTS IN THE BRAKE DISENGAGE HOLES. THIS WILL CAUSE THE MACHINE TO ROLL WHEN PARKED ON AN INCLINE.

Mechanical Brake Release

Machines, USA built s/n 0200170585 to Present: Machines, Belgium built s/n 1200015159 to Present:

Figure 4-5. Manual Disengage

Page 65

SECTION 4 - MACHINE OPERATION

4-16 – JLG Lift – 3121165

1. Chock wheels or secure machine with tow vehicle.

2. Ensure E-stop button is pushed in to the "OFF" posi-

tion.

3. Remove the two cover bolts (2) and brake cover (1).

4. Insert the cover bolts (2) into the two disengage holes (3) in the brake housing, see item 3 in Figure 4-

6., Manual Disengage.

5. Tighten down the cover bolts (2) and the brake on that drive motor will disengage.

6. Repeat this procedure on opposite wheel drive. With both drive motor brakes now disengaged, the machine can be moved manually.

7. After towing is complete, chock wheels and remove cover bolts (2) from disengage holes (3).

8. Reinstall brake cover (1).

Figure 4-6. Manual Disengage

Page 66

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-17

MODEL

1930ES

2030ES

2630ES

2646ES

3246ES

WHEELBASE

(in.)X(in.)Z(in.)

MODEL

2030ES

2630ES

2646ES

3246ES

WHEELBASE

(cm.)X(cm.)Z(cm.)

1930ES

83.7

160

108.6

108.4

209.1

187.7

98.9

38.5

33.5 63

20.5

43.8

82.32

20.5

43.8

82.32

73.9

38.5

97.8

Figure 4-7. Lifting and Tie Down Chart

Page 67

SECTION 4 - MACHINE OPERATION

4-18 – JLG Lift – 3121165

4.13 DIAGNOSTIC TROUBLE CODES (DTC)

Introduction

This sub-section provides a reference for Diagnostic Trouble Codes (DTC) read from the Multifunction Digital Indicator (MDI). For more information on the MDI, refer to Section 3. For information on the locations of any limit switches/sensors, refer to Section 2. DTCs are sorted in groups by the first two digits, which is also the system distress lamp flash code. To troubleshoot multiple DTCs, start with the DTC with the higher first two digits. If a correction is made during a check, conclude the check by cycling the

machine power, using the emergency stop switch.

Page 68

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-19

4.14 DIAGNOSTIC TROUBLE CODES (DTC) CHECK TABLES

0-0 Help Comments

DTC FAULT ME SSAG E DESCRIPTION CHECK

Error (Displayed on MDI) The MDI is powered, but cannot communi-

cate with the control system.

• Check the MDI connector.

• Check the diagnostic connector.

Refer problem to a qualified JLG mechanic.

001 EVERYTHING OK The normal help message in platform

mode. Displays on the analyzer only.

002 GROUND MODE OK The normal help message in ground mode.

Displays on the analyzer only.

003 ALARM SOUNDING - TILTED & ABOVE

ELEVATION

Control sys tem sens es that the platform is elevated and the vehicle is tilted, and the machine not configured to cutout.

• Check that the machine is tilted. If so, lower the platform and reposition the machine to a level surface.

• Fully stow the platform.

• The tilt sensor is par t of the ground control box. Check that the ground

control box is secured to the machine.

• Check that the pothole protection switches are securely mounted.

• Check that the elevation angle sensor is securely mounted.

Refer problem to a qualified JLG mechanic.

Page 69

SECTION 4 - MACHINE OPERATION

4-20 – JLG Lift – 3121165

004 DRIVING AT CUTBACK - ABOVE ELEVA-

TION

The platform is elevated and the machine is driving.

• Fully stow the platform.

• Check that the elevation angle sensor is securely mounted.

• Check that the pothole protection switches are securely mounted.

Refer problem to a qualified JLG mechanic.

005 DRIVE & LIFT UP PREVENTED - TILTED

& ELEVATED

Driving is not possible since the platform is elevated and the chassis is not level.

• Check that the machine is tilted. If so, lower the platform and reposition the machine to a level surface.

• Fully stow the platform.

• The tilt sensor is part of the ground control box. Check that the ground

control box is secured to the machine.

• Check that the pothole protection switches are securely mounted.

• Check that the elevation angle sensor is securely mounted.

Refer problem to a qualified JLG mechanic.

006 LIFT UP PREVENTED - MAX HEIGHT

ZONE A

The vehicle has reached the maximum height and further lift up motion is not possible. Applicable to 2630ES or 3246ES.

• Check that the zone is set appropriately for the platform load.

• Check that the platform height is at the rated maximum height specifica-

tion (20’ for 2630 or 26’ for the 3246).

• Check that the elevation angle sensor is securely mounted.

• If there are any elevation sensor faults (DTC 251, 252, 2511, or 2512),

troubleshoot those first.

Refer problem to a qualified JLG mechanic.

0-0 Help Comments

DTC FAULT ME SSAG E DESCRIPTION CHECK

Page 70

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-21

007 DRIVING AT CUTBACK - POTHOLE STILL

ENGAGED

While stowed, drive speed is reduced since the control system detected that the pothole protection mechanism failed to retract.

• Check for obstructions around the pot-hole protection mechanisms.

• Check that the PHP switches are securely mounted.

Refer problem to a qualified JLG mechanic.

008 FUNCTIONS LOCKED OUT - SYSTEM

POWERED DOWN

After 2 hours with out activity, the control system enters a low-power state to preserve battery charge.

• Normal operation should resume after power is cycled off then back on.

• Check batteries charge, condition, etc.

Refer problem to a qualified JLG mechanic.

009 DRIVE PREVENTED - ELEVATED ABOVE

DRIVE CUTOUT HEIGHT

The platform is elevated above the calibrated cutout height.

• Check that the elevation angle sensor is securely mounted.

Refer problem to a qualified JLG mechanic.

2-1 Power-Up

DTC FAULT ME SSAG E DESCRIPTION CHECK

211 POWER CYCLE This help message is issued at each power

cycle. Displays on the analyzer only.

Normal operation. No check necessary.

212 KEYSWITCH FAULTY Both platform and ground modes are

selected simultaneously. Defaults to ground mode.

Refer problem to a qualified JLG mechanic.

0-0 Help Comments

DTC FAULT ME SSAG E DESCRIPTION CHECK

Page 71

SECTION 4 - MACHINE OPERATION

4-22 – JLG Lift – 3121165

2-2 Platform Controls

DTC FAULT ME SSAG E DESCRIPTION CHECK

221 FUNCTION PROBLEM - HORN PERMA-

NENTLY SELECTED

The horn switch was closed during power up in platform mode.

• Check if the horn switch is damaged, obstructed or jammed.

Refer problem to a qualified JLG mechanic.

222 FUNCTION PROBLEM - INDOOR / OUT-

DOOR PERMANENTLY SELECTED

The indoor / outdoor (zone A / zone B) switch was closed during power-up in platform mode.

• Check if the indoor/outdoor (zone A / zone B) capacity switch is damaged, obstructed or jammed.

Refer problem to a qualified JLG mechanic.

223 FUNCTION PROBLEM - DRIVE & LIFT

ACTI VE TOGETHER

The drive and lift inputs are closed simultaneously in platform mode.

• Check drive/lift switch for visible damage.

Refer problem to a qualified JLG mechanic.

224 FUNCTION PROBLEM - STEER LEFT

PERMANENTLY SELECTED

The steer left switch was closed during power-up in platform mode.

• Check if the steer left switch is obstructed or jammed.

Refer problem to a qualified JLG mechanic.

225 FUNCTION PROBLEM - STEER RIGHT

PERMANENTLY SELECTED

The steer right switch was closed during power-up in platform mode.

• Check if the steer right switch is obstructed or jammed.

Refer problem to a qualified JLG mechanic.

226 ACCELERATOR FAULTY - WIPER OUT OF

RANGE

There is a problem with the joystick. • Cent er joyst ick and check to see if a power cycle will c lear DTC.

Refer problem to a qualified JLG mechanic.

227 STEER SWITCHES FAULTY The steer left and steer right inputs were

closed simultaneously.

• Check if the steer switches are damaged, obstructed or jammed.

Refer problem to a qualified JLG mechanic.

228 FUNCTION LOCKED OUT - ACCELERA-

TOR NOT C ENTE RED

The joystick was not centered at power-up. • Release joystick and allow to center.

• Check if the joystick is obstructed or jammed.

Refer problem to a qualified JLG mechanic.

229 FUNCTION PROBLEM - TRIGGER PER-

MANENTLY CLOSED

The trigger switch was closed during power-up in platform mode.

• Check if the trigger switch is obstructed or jammed.

Refer problem to a qualified JLG mechanic.

Page 72

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-23

2210 TRIGGER CLOSED TOO LONG WHILE IN

NEUTRAL

The trigger switch was closed for more than five seconds while the joystick was centered.

• Check if the trigger switch is obstructed or jammed.

Refer problem to a qualified JLG mechanic.

2232 FUNCTION PROBLEM - DRIVE & LIFT

BOTH OPEN

The drive and li ft inputs are both de-energized in platform mode.

• Check if either function is active, if Yes; Refer problem to a qualified JLG mechanic.

2-3 Ground Controls

DTC FAULT ME SSAG E DESCRIPTION CHECK

231 FUNCTION PROBLEM - LIFT PERMA-

NENTLY SELECTED

The ground control box lift switch was closed up or down, during power-up in ground mode.

• Check if the lift switch is obstructed or jammed.

Refer problem to a qualified JLG mechanic.

232 GROUND LIFT UP / DOWN ACTIVE

TOGE THER

The lift up / down inputs are closed simultaneously.

• Check if the lift switch is obstructed or jammed.

Refer problem to a qualified JLG mechanic.

233 FUNCTION PROBLEM - BRAKE RELEASE

PERMANENTLY SELECTED

The manual brake release switch was closed during power-up.

• Check if the brake release switch is obstructed or jammed.

Refer problem to a qualified JLG mechanic.

2-2 Platform Controls

DTC FAULT ME SSAG E DESCRIPTION CHECK

Page 73

SECTION 4 - MACHINE OPERATION

4-24 – JLG Lift – 3121165

2-5 Function Prevented

DTC FAULT ME SSAG E DESCRIPTION CHECK

251 ELEV ANGLE SENSOR FAULTY - VOLT-

AGE O UT OF RANG E

There is a problem with the elevation angle sensor input.

• Check that the platform elevation sensor is securely mounted and undamaged.

Refer problem to a qualified JLG mechanic.

252 ELEV ANGLE SENSOR HAS NOT BEEN

CALIBRATED

The elevation angle sensor has not been calibrated.

Refer problem to a qualified JLG mechanic.

253 DRIVE PREVENTED - CHARGER CON-

NECTED

Driving is not possible while the vehicle is charging.

• Check if the charger is connected to off board power source and disconnect if desired.

Refer problem to a qualified JLG mechanic.

254 DRIVE & LIFT UP PREVENTED - CHAR-

GER CONNECTED

Drive or lift is not possible while the vehicle is charging AND is configured to prevent all motion.

• Check if the charger is connected to off board power source and disconnect if desired.

Refer problem to a qualified JLG mechanic.

255 PLATFORM OVERLOADED The load sensing system measured plat-

form load is excessive.

• Remove excess weight from the platform.

• Check that the platform is not caught on something, preventing up or

down movement.

Refer problem to a qualified JLG mechanic.

256 DRIVE PREVENTED - POTHOLE NOT

ENGAGED

Driving is not possible while elevated since the pot-hole protection system failed to deploy.

• Check for obstructions or mechanical problems around the pot-hole protection mechanisms.

• Check that the PHP switches are securely mounted.

Refer problem to a qualified JLG mechanic.

Page 74

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-25

257 ELEV PROX PERMANENTLY CLOSED -

CHECK PROX AND ANGLE ADJUSTMENT

The elevation proximity switch shows the platform to be stowed, while the elevation angle sensor shows the platform to be raised. The elevation proximity switch is only found on certain older lifts. This switch is not used on current machines so this DTC should not occur.

Refer problem to a qualified JLG mechanic.

258 DRIVE & LIFT PREVENTED - BRAKES

ELECTRICALLY RELEASED FOR TOWING

Manual brake release mode is activated with the switch in the battery box near the ground control box. Drive or lift is not possible.

• Push manual brake release switch again or cycle power to clear manual brake release mode.

• Check if the brake release switch is obstructed or jammed.

Refer problem to a qualified JLG mechanic.

259 MODEL CHANGED - HYDRAULICS SUS-

PENDED - CYCLE EMS

The model selection has been changed. Refer problem to a qualified JLG mechanic.

2510 DRIVE PREVENTED - BRAKES NOT

RELEASING

There is a problem with the drive or brake system.

• Ensure vehicle is not stuck on something preventing movement.

Refer problem to a qualified JLG mechanic.

2511 ELEV ANGLE SENSOR FAULTY - NOT

MOUNTED

The input voltage from the elevation angle sensor indicates the elevation angle sensor is not mounted.

• Check that the elevation angle sensor is securely mounted.

Refer problem to a qualified JLG mechanic.

2512 ELEV ANGLE SENSOR NOT DETECTING

CHANGE

The input voltage from the elevation angle sensor did not change while vehicle was lifting up.

• Check that the elevation angle sensor is securely mounted.

Refer problem to a qualified JLG mechanic.

2-5 Function Prevented

DTC FAULT ME SSAG E DESCRIPTION CHECK

Page 75

SECTION 4 - MACHINE OPERATION

4-26 – JLG Lift – 3121165

3-1 Line Contactor Open Circuit

DTC FAULT ME SSAG E DESCRIPTION CHECK

311 OPEN CIRCUIT LINE CONTACTOR There is a problem with the line contactor. Refer problem to a qualified JLG mechanic.

312 CONTACTOR DRIVER PERMANENTLY

OFF

There is a problem with the power module line contactor control.

Refer problem to a qualified JLG mechanic.

3-2 Line Contactor Short Circuit

DTC FAULT ME SSAG E DESCRIPTION CHECK

321 LINE CONTACTOR MISWIRED ON OR

WELDED

There is a problem with the line contac tor. Refer problem to a qualified JLG mechanic.

322 CONTACTOR DRIVER PERMANENTLY ONThere is a problem with the power module

line contactor control.

Refer problem to a qualified JLG mechanic.

326 AUXILIARY RELAY - SHORT TO BAT-

TERY

There is a problem with the auxiliar y relay contacts or wiring.

Refer problem to a qualified JLG mechanic.

Page 76

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-27

3-3 Ground Output Driver

DTC FAULT ME SSAG E DESCRIPTION CHECK

331 BRAKE SHORT TO BATTERY A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

332 BRAKE OPEN CIRCUIT A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

333 LIFT UP SHORT TO BATTERY A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

334 LIFT UP OPEN CIRCUIT A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

335 LIFT DN SHORT TO BATTERY A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

336 LIFT DN OPEN CIRCUIT A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

337 STEER LEFT SHORT TO BATTERY A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

338 STEER LEFT OPEN CIRCUIT A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

339 STEER RIGHT SHORT TO BATTERY A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

Page 77

SECTION 4 - MACHINE OPERATION

4-28 – JLG Lift – 3121165

3310 STEER RIGHT OPEN CIRCUIT A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

3311 GROUND ALARM SHORT TO BATTERY A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

3312 LEFT BRAKE SHORT TO BATTERY A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

3313 RIGHT BRAKE SHORT TO BATTERY A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

3314 LEFT BRAKE OPEN CIRCUIT A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

3315 RIGHT BRAKE OPEN CIRCUIT A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

33297 LEFT BRAKE - SHORT TO GROUND A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

33298 STEER LEFT VALVE - SHORT TO

GROUND

A problem has been detected in this function.

Refer problem to a qualified JLG mechanic.

33299 LINE CONTACTOR COIL - SHORT TO

BATTERY

A problem has been detected in this function.

Refer problem to a qualified JLG mechanic.

33302 NEGATIVE SUPPLY - SHORT TO BAT-

TERY

A problem has been detected in this function.

Refer problem to a qualified JLG mechanic.

3-3 Ground Output Driver

DTC FAULT ME SSAG E DESCRIPTION CHECK

Page 78

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-29

33303 NEGATIVE SUPPLY - SHORT TO

GROUND

A problem has been detected in this function.

Refer problem to a qualified JLG mechanic.

33304 RIGHT BRAKE - SHORT TO GROUND A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

33305 STEER RIGHT VALVE - SHORT TO

GROUND

A problem has been detected in this function.

Refer problem to a qualified JLG mechanic.

33406 LIFT UP VALVE - SHORT TO GROUND A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

33407 LIFT DN VALVE - SHORT TO GROUND A problem has been detected in this func-

tion.

Refer problem to a qualified JLG mechanic.

4-2 Thermal Limit (SOA)

DTC FAULT ME SSAG E DESCRIPTION CHECK

421 POWER MODULE TOO HOT - PLEASE

WAI T

The power module has reached thermal cutout.

• Power down and allow to cool.

• Do not operate in ambients over 140° F (60° C).

Refer problem to a qualified JLG mechanic.

422 DRIVING AT CUTBACK - POWER MOD-

ULE CURRENT LIMIT

The drive portion of the power module has reached thermal li mit.

Refer problem to a qualified JLG mechanic.

3-3 Ground Output Driver

DTC FAULT ME SSAG E DESCRIPTION CHECK

Page 79

SECTION 4 - MACHINE OPERATION

4-30 – JLG Lift – 3121165

423 LIFT UP AT CUTBACK - POWER MOD-

ULE CURRENT LIMIT

The lift up portion of the power module has reached thermal limit.

Refer problem to a qualified JLG mechanic.

4-4 Battery Supply

DTC FAULT ME SSAG E DESCRIPTION CHECK

441 BATTERY VOLTAGE TOO LOW - SYSTEM

SHUTDOWN

A problem has been detected with the batteries or power module.

• Recharge batteries or check for damaged batteries.

• Check battery charger function.

Refer problem to a qualified JLG mechanic.

442 BATTERY VOLTAGE TOO HIGH - SYSTEM

SHUTDOWN

A problem has been detected with the batteries or power module.

• May be due to improper battery charging or incorrect voltage batteries being used.

Refer problem to a qualified JLG mechanic.

443 LSS BATTERY VOLTAGE TOO HIGH A problem has been detected with the load

sense system.

• May be due to improper battery charging or incorrect voltage batteries being used.

Refer problem to a qualified JLG mechanic.

444 LSS BATTERY VOLTAGE TOO LOW A problem has been detected with the load

sense system.

• Recharge batteries or check for damaged batteries.

Refer problem to a qualified JLG mechanic.

446 4421 4422

LOG IC SU PPLY VO LTAG E O UT OF RA NGE The Sy ste m Mod ule l ogi c sup pl y v olt ag e

was measured to be out of normal operating range.

• Check for severely discharged battery, l oos e c ab les or fo r da ma ged ba ttery; otherwise;

• Refer problem to a qualified JLG mechanic.

4-2 Thermal Limit (SOA)

DTC FAULT ME SSAG E DESCRIPTION CHECK

Page 80

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-31

6-6 Communication

DTC FAULT ME SSAG E DESCRIPTION CHECK

661 CANBUS FAILURE - POWER MODULE The control system failed to receive mes-

sages from the power module.

Refer problem to a qualified JLG mechanic.

662 CANBUS FAILURE - PLATFORM MOD-

ULE

In platform mode, the control system failed to receive messages from the platform board.

Refer problem to a qualified JLG mechanic.

663 CANBUS FAILURE - LOAD SENSING

SYSTEM MODULE

With load s ensing syste m enab led, the control system failed to receive messages from the load sensing system module.

Refer problem to a qualified JLG mechanic.

664 CANBUS FAILURE - ACCESSORY MOD-

ULE

An accessory module has stopped communication.

• See accessory module documentation for troubleshooting.

Refer problem to a qualified JLG mechanic.

6635 CANBUS FAILURE - CHASSIS TILT SEN-

SOR

Machine control system lost communication with the machines’ tilt sensor.

Refer problem to a qualified JLG mechanic.

6-7 Accessory

DTC FAULT ME SSAG E DESCRIPTION CHECK

671 ACCESSORY FAULT An accessory module is reporting a fault. • See accessory module documentation for troubleshooting.

Refer problem to a qualified JLG mechanic.

Page 81

SECTION 4 - MACHINE OPERATION

4-32 – JLG Lift – 3121165

7-7 Electric Motor

DTC FAULT ME SSAG E DESCRIPTION CHECK

771 OPEN CIRCUIT DRIVE MOTOR WIRING The power module detected a problem in

the drive motors' power circuit wiring.

Refer problem to a qualified JLG mechanic.

772 STALLED TRACTION MOTOR OR POWER

WIRING ERROR

The power module detected a problem in the drive motors' power circuit wiring.

Refer problem to a qualified JLG mechanic.

773 CAPACITOR BANK FAULT - CHECK

POWER CIRCUITS

The power module detected a problem in the pump or drive motors' power circuit wiring.

Refer problem to a qualified JLG mechanic.

774 SHORT CIRCUIT FIELD WIRING The power module detected a problem in

the drive motors' power circuit wiring.

Refer problem to a qualified JLG mechanic.

775 OPEN CIRCUIT FIELD WIRING The power module detected a problem in

the drive motors' power circuit wiring.

Refer problem to a qualified JLG mechanic.

776 STALLED PUMP MOTOR OR POWER

WIRING ERROR

The power module detected a problem in the drive motors' power circuit wiring.

Refer problem to a qualified JLG mechanic.

777 OPEN CIRCUIT PUMP MOTOR WIRING The power module detected a problem in

the drive motors' power circuit wiring.

Refer problem to a qualified JLG mechanic.

778 TRACTION T HIGH - CHECK POWER CIR-

CUITS

The power module detected a problem in the drive motors' power circuit wiring.

Refer problem to a qualified JLG mechanic.

779 TRACTION T LOW - CHECK POWER CIR-

CUITS

The power module detected a problem in the drive motors' power circuit wiring.

Refer problem to a qualified JLG mechanic.

Page 82

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-33

7710 PUMP P HIGH - CHECK POWER CIR-

CUITS

The power module detected a problem in the drive motors' power circuit wiring.

Refer problem to a qualified JLG mechanic.

7711 PUMP P LOW - CHECK POWER CIR-

CUITS

The power module detected a problem in the drive motors' power circuit wiring.

Refer problem to a qualified JLG mechanic.

7741 ARMATURE BRAKING CURRENT TOO

HIGH

The power module has detected excessive braking current .

This can be caused by transpor ting an excessive load on a steep grade.

7742 FIELD VOLTAGE IMPROPER The power module detected a problem in

the drive motors' power circuit wiring.

Recycle power on/off, if problem persists; Refer problem to a qualified JLG mechanic.

7-7 Electric Motor

DTC FAULT ME SSAG E DESCRIPTION CHECK

8-1 Tilt Sensor

DTC FAULT ME SSAG E DESCRIPTION CHECK

811 TILT SENSOR NOT CALIBRATED The tilt sensor calibration has not been

performed.

Refer problem to a qualified JLG mechanic.

812 NO DATA FROM TILT SENSOR - NOT

CONNE CTED OR FAULTY

No signal from tilt sensor. Refer problem to a qualified JLG mechanic.

Page 83

SECTION 4 - MACHINE OPERATION

4-34 – JLG Lift – 3121165

8-2 Platform Load Sense

DTC FAULT ME SSAG E DESCRIPTION CHECK

821 LSS CELL #1 ERROR A problem has been detected with the load

sense system.

Refer problem to a qualified JLG mechanic.

822 LSS CELL #2 ERROR A problem has been detected with the load

sense system.

Refer problem to a qualified JLG mechanic.

823 LSS CELL #3 ERROR A problem has been detected with the load

sense system.

Refer problem to a qualified JLG mechanic.

824 LSS CELL #4 ERROR A problem has been detected with the load

sense system.

Refer problem to a qualified JLG mechanic.

825 LSS HAS NOT BEEN CALIBRATED The load sensing system module has not

been calibrated

Refer problem to a qualified JLG mechanic.

9-9 Hardware

DTC FAULT ME SSAG E DESCRIPTION CHECK

991 LSS WATCHDOG RESET A problem has been detected with the load

sense system.

Refer problem to a qualified JLG mechanic.

992 LSS EEPROM ERROR A problem has been detected with the load

sense system.

Refer problem to a qualified JLG mechanic.

993 LSS INTERNAL ERROR - PIN EXCITA-

TION

A problem has been detected with the load sense system.

Refer problem to a qualified JLG mechanic.

Page 84

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-35

994 LSS INTERNAL ERROR - DRDY MISSING

FROM A/D

A problem has been detected with the load sense system.

Refer problem to a qualified JLG mechanic.

995 POWER MODULE FAILURE - PERSON-

ALITY RANGE ERROR

A problem has been detected with the power module.

Refer problem to a qualified JLG mechanic.

996 POWER MODULE FAILURE - INTERNAL

ERROR

A problem has been detected with the power module.

Refer problem to a qualified JLG mechanic.

997 POWER MODULE FAILURE - CHECK

POWER CIRCUITS OR MOSFET SHORT CIRCUIT

A problem has been detected with the power module.

Refer problem to a qualified JLG mechanic.

998 EEPROM FAILURE - CHECK ALL SET-

TINGS

A problem has been detected with the ground board.

Refer problem to a qualified JLG mechanic.

999 FUNCTION LOCKED OUT - POWER

MODULE SOFTWARE VERSION IMPROPER

The power module software version is not compatible with the rest of the system.

Refer problem to a qualified JLG mechanic.

9910 FUNCTION LOCKED OUT - PLATFORM

MODULE SOFTWARE VERSION IMPROPER

The platform board software version is not compatible with the rest of the system.

Refer problem to a qualified JLG mechanic.

9911 FUNCTION LOCKED OUT - LSS MODULE

SOFTWARE VERSION IMPROPER

The load sensing system module software version is not compat ible with the rest of the system.

Refer problem to a qualified JLG mechanic.

9912 POWER MODULE FAILURE - SYSTEM

MONITOR

A problem has been detected with the power module.

Refer problem to a qualified JLG mechanic.

9-9 Hardware

DTC FAULT ME SSAG E DESCRIPTION CHECK

Page 85

SECTION 4 - MACHINE OPERATION

4-36 – JLG Lift – 3121165

9924 FUNCTIONS LOCKED OUT - MACHINE

NOT CONFIGURED

A new ground board was installed but not configured.

Refer problem to a qualified JLG mechanic.

9-9 Hardware

DTC FAULT ME SSAG E DESCRIPTION CHECK

Page 86

SECTION 4 - MACHINE OPERATION

3121165 – JLG Lift – 4-37

9950 9951 9952 9953 9954 9955 9956 9957 9958 9960 9962 9963 9964 9969 9971

9970 99143 99144 99145 99146 99147 99148 99149

POWER MODULE FAILURE - INTERNAL ERROR

A problem has been detected with the power module.

Cycl e m ach ine powe r o n / off a f ew tim es if t his doe sn’t cl ear the DTC, refer problem to a qualif ied JLG mecha nic.

9-9 Hardware

DTC FAULT ME SSAG E DESCRIPTION CHECK

Page 87

SECTION 4 - MACHINE OPERATION

4-38 – JLG Lift – 3121165

NOTES:

Page 88

SECTION 5 - EMERGENCY PROCEDURES

3121165 – JLG Lift – 5-1

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 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 personnel whose responsibilities include any work or contact with the machine.

Emergency Stop Switch

These large red buttons, one located at the Ground Control Station and one at the Platform Control Station, will immediately stop the machine when depressed.

CHECK MACHINE DAILY TO MAKE SURE EMERGENCY STOP BUTTON IS IN PLACE AND THAT GROUND CONTROL INSTRUCTIONS ARE IN PLACE AND LEGIBLE.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 controlling the platform lift up and down functions from the ground. Place the power select switch in the ground position 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, above the left rear wheel. The handle is connected, by a cable, to the manual descent valve on the lift cylinder. Pulling the manual descent handle opens the valve spool, lowering the platform.

Page 89

SECTION 5 - EMERGENCY PROCEDURES

5-2 – JLG Lift – 3121165

5.2 EMERGENCY OPERATION

Use of Ground Controls

NOTICE

KNOW HOW TO USE THE GROUND CONTROLS IN AN EMERGENCY SITUATION.

Ground personnel must be thoroughly familiar with the machine operating characteristics and the ground control functions. Training should include operation of the machine, review and understanding of this section and hands-on operation of the controls in simulated emergencies.

Operator Unable to Control Machine

1. Operate the machine from ground controls ONLY with the assistance of other personnel and equipment (cranes, overhead hoists, etc.) as may be required to safely remove the danger or emergency condition.

2. Other qualified personnel on the platform may use the platform controls. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION NORMALLY.

3. Cranes, forklift trucks or other equipment which may be available are to be used to remove platform occupants and stabilize motion of the machine in case machine controls are inadequate or malfunction when used.

Page 90

SECTION 5 - EMERGENCY PROCEDURES

3121165 – JLG Lift – 5-3

Platform Caught Overhead

If the platform becomes jammed or snagged in overhead 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

Following any incident, thoroughly inspect the machine and test all functions first from the ground controls, then from the platform controls. Do not lift above 10 feet (3 meters) until you are secure that all damage has been repaired, if required, and that all controls are operating correctly.

5.3 INCIDENT NOTIFICATION

It is imperative that JLG Industries, Inc. be notified immediately 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 contacted by telephone and provided with all necessary details.

Contact at 1-877-JLG-SAFE (554-7233) between the hours of 8:00 AM - 4:45 PM Eastern Standard time.

It should be noted that failure to notify the Manufacturer of an incident involving a JLG Industries product within 48 hours of such an occurrence may void any warranty consideration on that particular machine.

Page 91

SECTION 5 - EMERGENCY PROCEDURES

5-4 – JLG Lift – 3121165

NOTES:

Page 92

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

3121165 – JLG Lift – 6-1

SECTION 6. GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

6.1 INTRODUCTION

This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine.

The maintenance portion of this section is intended as information to assist the machine operator to perform daily maintenance tasks only, and does not replace the more thorough Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual.

Other Publications Available Specific to this Machine:

Service and Maintenance Manual................ 3121166

Illustrated Parts Manual ................................... 3121167

Page 93

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

6-2 – JLG Lift – 3121165

6.1 OPERATING SPECIFICATIONS

Tabl e 6- 1. Op er at in g Sp ec if ic at io ns

Model 1930ES 2030ES 2630ES 2646ES 3246ES

Maximum Stowed Travel Grade (Gradeability)

- Re f e r t o Fi g u re 4- 1. o n pa g e 4 - 6

25% 25% 25% 25% 25%

Maximum Stowed Travel Grade (Sideslope)

- Refer to Figure 4-1. on page 4-6

5° 5° 5° 5° 5°

Maximum Platform Height 18.75 ft

5.7 m

20 ft

6 m

25.5 ft

7.75 m

26 ft

7.9 m

32 ft

9.8 m

Maximum Tire Load: A NS I C E

1365 lb (620 kg) 1540 lb (699 kg)

1660 (755)

1835 lb (832 kg)

1885 lb (832 kg) 1835 lb (832 kg)

2070 lb (939 kg)

2320 lb (1052 kg)

2070 lb (939 kg)

2320 lb (1052 kg)

Ground Bearing Pressure (ANSI) 109 psi

(7.7 kg/cm

)

81 psi

(5.7 kg/cm2 )

90 psi

(6.3 kg/cm2 )

87 psi

(6.1 kg/cm2 )

87 psi

(6.1 kg/cm2 )

Ground Bearing Pressure (CE) 8.7 kg/cm

(123 psi)

6.3 kg/cm

(90 psi)

6.3 kg/cm

(90 psi)

6.9 kg/cm

(98 psi)

6.9 kg/cm

(98 psi)

Maximum Drive Speed 3 mph

(4.8 kmh)

3 mph

(4.8 kmh)

2.75 mph (4.4 kmh)

2.5 mph (4 kmh)

Maximum Wind Speed 28 mph (12.5 m/s)

(Depending on model, market, and indoor/outdoor selection, see Table 6-2, Platform Capacities on page 6-5)

Page 94

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

3121165 – JLG Lift – 6-3

Maximum Horizontal Manual Side Force: A NS I / CS A A NS I / CS A ( In d o or ) A NS I / CS A (O u t do o r ) A NS I / CS A ( Zo n e A) A NS I / CS A ( Zo n e B) CE (Indoor) C E ( O u td o or ) AU S ( I nd o or ) AU S ( In d o or Z o ne A ) AU S ( I nd o or Z o ne B ) AU S ( Ou t d oo r ) AU S ( Ou t d oo r Zo n e A) AU S ( Ou t d oo r Zo n e B)

100 lb force (445 N)

N/A N/A N/A

N/A 90 lb force (400 N) 45 lb force (200 N) 90 lb force (400 N)

N/A

N/A 45 lb force (200 N)

N/A

120 lb force (533 N)

N/A N/A N/A

N/A 90 lb force (400 N) 45 lb force (200 N) 90 lb force (400 N)

N/A

N/A 45 lb force (200 N)

N/A

N/A N/A

N/A 120 lb force (533 N) 100 lb force (445 N)

90 lb force (400 N)

N/A

90 lb force (400 N) 90 lb force (400 N)

N/A

150 lb force (667 N)

N/A N/A N/A

N/A 90 lb force (400 N) 90 lb force (400 N) 90 lb force (400 N)

N/A

N/A 90 lb force (400 N)

N/A

N/A N/A

N/A 150 lb force (667 N) 105 lb force (467 N)

90 lb force (400 N) 45 lb force (200 N)

N/A

90 lb force (400 N) 90 lb force (400 N)

N/A

45 lb force (200 N)

Maximum Hydraulic Pressure 1800 psi 1800 psi

1700 psi (single)

1950 psi (dual)

2000 psi 2000 psi

Inside Steer Angle 90° 90° 90° 90° 90°

Outside Steer Angle 69° 73° 73° 67° 67°

Electrical System Voltage (DC) 24V 24V 24V 24V 24V

Approximate Gross Machine Weight ANSI/CSA

2685 lbs 3830 lbs

4815 lbs (single)

4750 lbs (dual)

4945 lbs 4945 lbs

Tabl e 6- 1. Op er at in g Sp ec if ic at io ns

Model 1930ES 2030ES 2630ES 2646ES 3246ES

Page 95

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

6-4 – JLG Lift – 3121165

Approximate Gross Machine Weight CE/Australia

1495 kg 2064 kg

2198 kg (single)

2155 kg (dual)

2706 kg 2871 kg

Approximate Gross Machine Weight - Japan 1297 kg 1755 kg

2198 kg (single)

2155 kg (dual)

2257 kg 2257 kg

Ground Clearance with pot hole protection system up 3.5 in (8.9 cm)

Ground Clearance with pot hole protection system down 1 in (2.5 cm) .75 in (1.9 cm)

Tabl e 6- 1. Op er at in g Sp ec if ic at io ns

Model 1930ES 2030ES 2630ES 2646ES 3246ES

Page 96

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

3121165 – JLG Lift – 6-5

Tab le 6 -2. P lat fo rm C ap acit ie s

MODEL

ANSI/CSA/JPN

CE AUSTR ALIAN

INDOOR OUTDOOR INDOOR OUTDOOR

Max

Capacity

Max

Persons

Max

Capacity

Max

Pers ons

Max

Capacity

Max

Persons

Max

Capacity

Max

Persons

Max

Capacity

Max

Persons

1930ES

500 lb

(227 kg)

2230 kg2120 kg1230 kg2120 kg1

2030ES

800 lb

( 36 3 kg )

2360 kg2160 kg1360 kg2160 kg1

2630ES

single cap

500 lb

( 22 7 kg )

2230 kg2

N/A N/A 230 kg 2 N/A N/A

2630ES

dual cap.to 20 ft

800 lb

( 36 3 kg )

2360 kg2

N/A N/A 360 kg 2 N/A N/A

2630ES

dual cap.to 26 ft

500 lb

( 22 7 kg )

2230 kg2

N/A N/A 230 kg 2 N/A N/A

2646ES

1000 lb

(454 kg)

2450 kg2230 kg2450 kg2230 kg2

3246ES to 26 ft.

Zone A

1000 lb

(454 kg)

2 450kg2320 kg1450 kg2320 kg1

3246ES to 32 ft.

Zone B

700 lb

(317 kg)

2 320kg2320 kg1320 kg2320 kg1

Page 97

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

6-6 – JLG Lift – 3121165

Dimensional Data

Tabl e 6- 3. D im en si on s

Model 1930ES 2030ES 2630ES 2646ES 3246ES

Unit of Measure feet meter feet meter feet meter feet meter feet meter

Platform Height - Elevated 18.75 5.7 20 6 25.5 7.77 26 7.9 31.8 9.7

Platform Height - Stowed 2.9 0.9 3.6 1.1 4 1.2 4 1.2 4 1.2

Wor kin g Hei ght 25 7 .6 26 7.9 3 2 9.8 3 2 9.8 38 11 .6

Overall Stowed Machine Height - Rails Up 6.5 2 7.2 2.2 7.7 2.3 7.7 2.3 7.7 2.3

Overall Stowed Machine Height - Rails Collapsed N/A N/A 6 1.8 6.4 1.9 6.4 1.9 6.4 1.9

Rail Height (From platform floor) 3.6 1.1 3.6 1.1 3.6 1.1 3.6 1.1 3.6 1.1

Overall Machine Width 2.5 0.8 2.5 0.8 2.5 0.8 3.7 1.2 3.7 1.2

Overall Machine Length - Deck Retracted 6 1.9 7.5 2.3 7.5 2.3 8.2 2.5 8.2 2.5

Overall Machine Length - Deck Extended 9 2.8 10.5 3.2 10.5 3.2 12.4 3.8 12.4 3.8

Platform Size - Length 6.1 1.9 7.5 2.3 7.5 2.3 8.2 2.5 8.2 2.5

Platform Size - Width 2.5 0.8 2.5 0.8 2.5 0.76 3.7 1.1 3.7 1.1

Platform Extension Length 3 0.9 3 0.9 3 0.9 4.2 1.3 4.2 1.3

Wheelbase 63 1.6 73.9 1.9 73.9 1.9 82.3 2 82.3 2

Page 98

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

3121165 – JLG Lift – 6-7

Motors

Drive Motor

Type: Shunt Wound, Sepex 24V DC

Power: 0.65 Horsepower @ 3750 rpm

Hydraulic Pump/Electric Motor Assembly (All Models)

Type: Series Wound Permanent Magnet 24V DC

Power: 3kW

Batteries

Tabl e 6- 4. Ba tt er y Sp ec if ic at io ns

Vol tage 6V per batt ery

Amp Hour (Standard Battery) 220 Amp

Amp Hour (Optional High Output Battery) 245 Amp

Page 99

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

6-8 – JLG Lift – 3121165

Capacities

Tires

Tabl e 6- 5. Fl ui d Ca pa ci ti es

Model 1930ES/ 2030ES/2630ES 2646ES/3246ES

Hydraulic Tank

2 Gal.

(7.6 L)

2 Gal.

(7.6 L)

3 Gal.

(11.3 L)

Hydraulic System (Including Tank)

2.2 Gal (8 . 3 L )

2.8 Gal

(10.6 L)

5.3 Gal

(19.9 L)

Tabl e 6- 6. T ir e Sp ec if ic at io ns

Model

1930ES 2030ES 2630ES 2646ES 3246ES

Size

323mm x 100mm 406 mm x 125 mm

Max Tire Load 2500 lbs (1134 kg) 4000 lbs (1814 kg)

Wheel Bolt Torque 105 - 120 ft lb (142-163 Nm)

Page 100

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

3121165 – JLG Lift – 6-9

6.1 CRITICAL STABILITY WEIGHTS

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.

Tabl e 6- 7. C ri ti ca l St ab il it y Wei gh ts

Component 1930 ES 2030ES 2630ES 2646ES 3246ES

Wheel and Tire Assembly (each) 22 lbs (9.8 kg) 42 lbs (19 kg)

Wheel/Tire and Drive Assembly (each) 117 lbs (53 kg) 162 lbs (73.4 kg)

Lift Cylinder 176 lbs(80 kg) 205 lbs (93 kg) 263 lbs (119 kg) 283 lbs (128 kg)

Batteries: (each) 22 0 Am p 22 0 Am p (u s ed w it h I n ve r te r/ C ha rg e r) 24 5 Am p

60 lbs (27 kg) 66 lbs (30 kg)

N/A

60 lbs (27 kg) 66 lbs (30 kg) 70 lbs (32 kg)