JLG 450A-AJ Operator Manual
Operation and Safety Manual
®
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
450A Series II
450AJ Series II
S/N 0300160835S/N E0300001114
to Present
ANSI
3121289
October 1, 2014
NOTE: This manual also applies to machines with the following
Serial Numbers: 0300159794, 0300159795,
0300160088, 0300160456, and E300001067.
FOREWORD
FOREWORD
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating
procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without
prior notification. Contact JLG Industries, Inc. for updated information.
3121289 – JLG Lift – a
FOREWORD
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
This is the Safety Alert Symbol. It is used to alert you to the potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury or
death
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL RESULT IN
SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD RESULT IN
SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACKGROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT IN
MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES. THIS
DECAL WILL HAVE A YELLOW BACKGROUND.
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
b – JLG Lift – 3121289
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG
INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION
REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS
PRODUCT.
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF
THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE CURRENT OWNER
RECORDS ARE UPDATED AND ACCURATE.
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG
PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH
OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.
For:
• Accident Reporting
• Product Safety Publications
• Current Owner Updates
• Questions Regarding
Product Safety
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
or Your Local JLG Office
(See addresses on inside of manual cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: 240-420-2661
Fax: 301-745-3713
E-mail: ProductSafety@JLG.com
FOREWORD
• Standards and Regulations
Compliance Information
• Questions Regarding Special
Product Applications
• Questions Regarding Product Modifications
3121289 – JLG Lift – c
FOREWORD
Original Issue - June 19, 2012
Revised - June 29, 2012
Revised - April 1, 2013
Revised - October 1, 2014
REVISION LOG
d – JLG Lift – 3121289
TABLE OF CONTENTS
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 . . . . . . . . . . . . . . . . . . 1-10
1.4 TOWING, LIFTING, AND HAULING. . . . . . . . . . . . . . . . . . . . 1-11
1.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Maintenance Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION,
AND INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED). . . . 2-11
SECTION - 3 - MACHINE CONTROLS AND INDICATORS
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . 3-6
Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-13
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 OPERATING CHARACTERISTICS AND LIMITATIONS . . . . 4-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Fuel Reserve / Shut-Off System. . . . . . . . . . . . . . . . . . . . . 4-4
4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . . 4-7
3121289 – JLG Lift – i
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Raising and Lowering the Tower Boom. . . . . . . . . . . . 4-10
Raising and Lowering the Main Boom . . . . . . . . . . . . . 4-10
Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-10
4.8 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.9 AUXILIARY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.10 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . 4-11
4.11 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.12 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.13 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Prior to Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.14 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . . . . . . . . . 4-15
Changing From Gasoline to LP Gas. . . . . . . . . . . . . . . . 4-15
Changing From LP Gas to Gasoline. . . . . . . . . . . . . . . . 4-15
SECTION - 5 - EMERGENCY PROCEDURES
5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Operator Unable to Control Machine. . . . . . . . . . . . . . . 5-2
Platform or Boom Caught Overhead . . . . . . . . . . . . . . . 5-2
5.4 EMERGENCY TOWING PROCEDURES. . . . . . . . . . . . . . . . . . 5-2
SECTION - 6 - GENERAL SPECIFICATIONS
AND OPERATOR MAINTENANCE
6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 OPERATING SPECIFICATIONS AND PERFORMANCE DATA. .
6-1
Reach Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
ii – JLG Lift – 3121289
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
6.4 TIRES & WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34
Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Tire Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Wheel and Tire Replacement. . . . . . . . . . . . . . . . . . . . . 6-35
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
6.5 PROPANE FUEL FILTER REPLACEMENT . . . . . . . . . . . . . . . 6-37
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
6.6 PROPANE FUEL SYSTEM PRESSURE RELIEF . . . . . . . . . . . 6-38
6.7 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . .6-39
SECTION - 7 - INSPECTION AND REPAIR LOG
LIST OF FIGURES
2-1. Basic Nomenclature - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . 2-6
2-2. Basic Nomenclature - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . 2-7
2-3. Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . . . . . . 2-8
2-4. Daily Walk-Around Inspection - Sheet 2 of 3 . . . . . . . . . . 2-9
2-5. Daily Walk-Around Inspection - Sheet 3 of 3 . . . . . . . . . 2-10
3-1. Ground Control Station - A Models . . . . . . . . . . . . . . . . . . . 3-3
3-1. Ground Control Station - AJ Models . . . . . . . . . . . . . . . . . . 3-4
3-2. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . . 3-7
3-3. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-4. Platform Control Indicator Panel . . . . . . . . . . . . . . . . . . . . 3-14
4-1. Position of Least Forward Stability. . . . . . . . . . . . . . . . . . . . 4-5
4-2. Position of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-6
4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-4. Lifting and Tie Down Chart. . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4-5. Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-6. Decal Installation - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . 4-16
4-7. Decal Installation - Sheet 2 of 6 . . . . . . . . . . . . . . . . . . . . . . 4-17
4-8. Decal Installation - Sheet 3 of 6 . . . . . . . . . . . . . . . . . . . . . . 4-18
4-9. Decal Installation - Sheet 4 of 6 . . . . . . . . . . . . . . . . . . . . . . 4-19
4-10. Decal Installation - Sheet 5 of 6 . . . . . . . . . . . . . . . . . . . . . . 4-20
4-11. Decal Installation - Sheet 6 of 6 . . . . . . . . . . . . . . . . . . . . . . 4-21
6-1. Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
3121289 – JLG Lift – iii
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
6-2. Engine Operating Temperature Specifications - Caterpillar
- Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6-3. Engine Operating Temperature Specifications - Caterpillar
Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-4. Engine Operating Temperature Specifications - Deutz
Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6-5. Engine Operating Temperature Specifications - Deutz
Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6-6. Engine Operating Temperature Specifications - GM
Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-7. Engine Operating Temperature Specifications - GM
Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6-8. Operator Maintenance and Lubrication Diagram -
Deutz D2.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6-9. Operator Maintenance and Lubrication Diagram -
Deutz D2011 and CAT C2.2 . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6-10. Operator Maintenance and Lubrication Diagram -
GM Dual-Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6-11. Deutz D2011 Engine Dipsticks . . . . . . . . . . . . . . . . . . . . . . 6-27
6-12. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6
1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . . . . . . . . . 1-9
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3
4-1 Decal Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
6-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 Reach Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-3 Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-4 Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-5 Component Weights - 450 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-6 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-7 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-8 Caterpillar C2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-9 Deutz TCD2.9L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-10 Deutz D2011L03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-11 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-12 Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-13 Mobilfluid 424 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-14 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-15 UCon Hydrolube HP-5046. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-16 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-17 Exxon Univis HVI 26 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-18 Quintolubric 888-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-19 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6-20 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
LIST OF TABLES
iv – JLG Lift – 3121289
1.1 GENERAL
SECTION 1 - SAFETY PRECAUTIONS
SECTION 1. SAFETY PRECAUTIONS
This section outlines the necessary precautions for proper and
safe machine usage and maintenance. It is mandatory that a daily
routine is established based on the content of this manual to promote proper machine usage. A maintenance program, using the
information provided in this manual and the Service and Maintenance Manual, must also be established by a qualified person and
must be followed to ensure that the machine is safe to operate.
The owner/user/operator/lessor/lessee of the machine must not
accept operating responsibility until this manual has been read,
training is accomplished, and operation of the machine has been
completed under the supervision of an experienced and qualified operator.
This section contains the responsibilities of the owner, user, operator, lessor, and lessee concerning safety, training, inspection,
maintenance, application, and operation. If there are any questions with regard to safety, training, inspection, maintenance,
application, and operation, please contact JLG Industries, Inc.
(“JLG”).
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD
RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
1.2 PRE-OPERATION
Operator Training and Knowledge
• The Operation and Safety Manual must be read and understood in its entirety before operating the machine. For clarification, questions, or additional information regarding any
portions of this manual, contact JLG Industries, Inc.
3121618 – JLG Lift – 1-1
SECTION 1 - SAFETY PRECAUTIONS
• An operator must not accept operating responsibilities until
adequate training has been given by competent and authorized persons.
• Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and maintenance of the
unit.
• Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine and in this
manual.
• Ensure that the machine is to be used in a manner which is
within the scope of its intended application as determined by
JLG.
• All operating personnel must be familiar with the emergency
controls and emergency operation of the machine as specified
in this manual.
• Read, understand, and obey all applicable employer, local, and
governmental regulations as they pertain to your utilization
and application of the machine.
Workplace Inspection
• Precautions to avoid all hazards in the work area must be
taken by the user before and during operation of the machine.
• Do not operate or raise the platform from a position on trucks,
trailers, railway cars, floating vessels, scaffolds or other equipment unless the application is approved in writing by JLG.
• Before operation, check work area for overhead hazards such
as electric lines, bridge cranes, and other potential overhead
obstructions.
• Check operating surfaces for holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards.
• Check the work area for hazardous locations. Do not operate
the machine in hazardous environments unless approved for
that purpose by JLG.
• Ensure that the ground conditions are adequate to support
the maximum tire load indicated on the tire load decals
located on the chassis adjacent to each wheel. Do not travel
on unsupported surfaces.
1-2 – JLG Lift – 3121618
SECTION 1 - SAFETY PRECAUTIONS
Machine Inspection
• Do not operate this machine until the inspections and functional checks as specified in Section 2 of this manual have
been performed.
• Do not operate this machine until it has been serviced and
maintained according to the maintenance and inspection
requirements as specified in the machine’s Service and Maintenance Manual.
• Ensure all safety devices are operating properly. Modification
of these devices is a safety violation.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY
WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
• Do not operate any machine on which the safety or instruction
placards or decals are missing or illegible.
• Check the machine for modifications to original components.
Ensure that any modifications have been approved by JLG.
• Avoid accumulation of debris on platform floor. Keep mud, oil,
grease, and other slippery substances from footwear and platform floor.
1.3 OPERATION
General
• Machine operation requires your full attention. Bring the
machine to a full stop before using any device, i.e. cell phones,
two-way radios, etc. that will distract your attention from
safely operating the machine.
• Do not use the machine for any purpose other than positioning personnel, their tools, and equipment.
• Before operation, the user must be familiar with the machine
capabilities and operating characteristics of all functions.
• Never operate a malfunctioning machine. If a malfunction
occurs, shut down the machine. Remove the unit from service
and notify the proper authorities.
• Do not remove, modify, or disable any safety devices.
• Never slam a control switch or lever through neutral to an
opposite direction. Always return switch to neutral and stop
before moving the switch to the next function. Operate controls with slow and even pressure.
• Do not allow personnel to tamper with or operate the
machine from the ground with personnel in the platform,
except in an emergency.
3121618 – JLG Lift – 1-3
SECTION 1 - SAFETY PRECAUTIONS
• Do not carry materials directly on platform railing unless
approved by JLG.
• When two or more persons are in the platform, the operator
shall be responsible for all machine operations.
• Always ensure that power tools are properly stowed and never
left hanging by their cord from the platform work area.
• When driving, always position boom over rear axle in line with
the direction of travel. Remember, if boom is over the front
axle, steer and drive functions will be reversed.
• Do not assist a stuck or disabled machine by pushing or pulling except by pulling at the chassis tie-down lugs.
• Fully lower platform and shut off all power before leaving
machine.
• Remove all rings, watches, and jewelry when operating
machine. Do not wear loose fitting clothing or long hair unrestrained which may become caught or entangled in equipment.
• Persons under the influence of drugs or alcohol or who are
subject to seizures, dizziness or loss of physical control must
not operate this machine.
Trip and Fall Hazards
• During operation, occupants in the platform must wear a full
body harness with a lanyard attached to an authorized lanyard
anchorage point. Attach only one (1) lanyard per lanyard
anchorage point..
• Enter and exit only through gate area. Use extreme caution
when entering or leaving platform. Ensure that the platform
assembly is fully lowered. Face the machine when entering or
leaving the platform. Always maintain “three point contact”
with the machine, using two hands and one foot or two feet
and one hand at all times during entry and exit.
1-4 – JLG Lift – 3121618
SECTION 1 - SAFETY PRECAUTIONS
• Before operating the machine, make sure all gates are closed
and fastened in their proper position.
• Keep both feet firmly positioned on the platform floor at all
times. Never position ladders, boxes, steps, planks, or similar
items on unit to provide additional reach for any purpose.
• Keep oil, mud, and slippery substances cleaned from footwear
and the platform floor.
Electrocution Hazards
• This machine is not insulated and does not provide protection
from contact or proximity to electrical current.
3121618 – JLG Lift – 1-5
SECTION 1 - SAFETY PRECAUTIONS
Table 1-1. Minimum Approach Distances (M.A.D.)
• Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum
Approach Distance (MAD) as shown in Table 1-1.
• Allow for machine movement and electrical line swaying.
Voltage R ange
(Phase to Phase)
0 to 50 KV 10 (3)
Over 50KV to 200 KV 15 (5)
Over 200 KV to 350 KV 20 (6)
Over 350 KV to 500 KV 25 (8)
Over 500 KV to 750 KV 35 (11)
Over 750 KV to 1000 KV 45 (14)
NOTE: This requirement shall apply except where
employer, local or governmental regulations are
more stringent.
• Maintain a clearance of at least 10 ft. (3m) between any part of
the machine and its occupants, their tools, and their equipment from any electrical line or apparatus carrying up to
50,000 volts. One foot additional clearance is required for
every additional 30,000 volts or less.
MINIMUM APPROACH DISTANCE
in Feet (Meters)
1-6 – JLG Lift – 3121618
SECTION 1 - SAFETY PRECAUTIONS
• The minimum approach distance may be reduced if insulating
barriers are installed to prevent contact, and the barriers are
rated for the voltage of the line being guarded. These barriers
shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within
the designed working dimensions of the insulating barrier.
This determination shall be made by a qualified person in
accordance with the employer, local, or governmental requirements for work practices near energized equipment
DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD). ASSUME
ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE.
Tipping Hazards
• The user must be familiar with the surface before driving. Do
not exceed the allowable sideslope and grade while driving.
• Do not elevate platform or drive with platform elevated while
on or near a sloping, uneven, or soft surface. Ensure machine is
positioned on a firm, level and smooth surface before elevating platform or driving with the platform in the elevated position.
• Before driving on floors, bridges, trucks, and other surfaces,
check allowable capacity of the surfaces.
3121618 – JLG Lift – 1-7
SECTION 1 - SAFETY PRECAUTIONS
• Never exceed the maximum work load as specified on the
platform. Keep all loads within the confines of the platform,
unless authorized by JLG.
• Keep the chassis of the machine a minimum of 2 ft. (0.6m)
from holes, bumps, drop-offs, obstructions, debris, concealed
holes, and other potential hazards at the ground level.
• Do not push or pull any object with the boom.
• Never attempt to use the machine as a crane. Do not tie-off
machine to any adjacent structure. Never attach wire, cable, or
any similar items to platform.
• Do not operate the machine when wind conditions exceed 28
mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Reference Only).
• Do not increase the surface area of the platform or the load.
Increase of the area exposed to the wind will decrease stability.
• Do not increase the platform size with unauthorized deck
extensions or attachments.
• If boom assembly or platform is in a position that one or more
wheels are off the ground, all persons must be removed before
attempting to stabilize the machine. Use cranes, forklift trucks,
or other appropriate equipment to stabilize machine.
1-8 – JLG Lift – 3121618
DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/S).
Table 1-2. Beaufort Scale (For Reference Only)
SECTION 1 - SAFETY PRECAUTIONS
Beaufort
Number
0 0 0-0.2 Calm Calm. Smoke rises vertically
1 1-3 0.3-1.5 Light air Wind motion visible in smoke
2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle
3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion
4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move.
5 19-24 8.0-10.7 Fresh breeze Smaller trees sway.
6 25-31 10.8-13.8 Strong breeze Large branches in motion. Flags waving near horizontal. Umbrella use
7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind.
8 39-46 17.2-20.7 Fresh Gale Twigs broken fro m trees. Cars veer on road.
9 47-54 20.8-24.4 Strong Gale Light structure damage.
Wind Speed
mph m/s
Description Land Conditions
becomes difficult.
3121618 – JLG Lift – 1-9
SECTION 1 - SAFETY PRECAUTIONS
Crushing and Collision Hazards
• Approved head gear must be worn by all operating and
ground personnel.
• Check work area for clearances overhead, on sides, and bottom of platform when lifting or lowering platform, and driving.
• During operation, keep all body parts inside platform railing.
• Use the boom functions, not the drive function, to position the
platform close to obstacles.
• Always post a lookout when driving in areas where vision is
obstructed.
• Keep non-operating personnel at least 6 ft. (1.8m) away from
machine during all driving and swing operations.
• Under all travel conditions, the operator must limit travel
speed according to conditions of ground surface, congestion,
visibility, slope, location of personnel, and other factors which
may cause collision or injury to personnel.
• Be aware of stopping distances in all drive speeds. When driving in high speed, switch to low speed before stopping. Travel
grades in low speed only.
• Do not use high speed drive in restricted or close quarters or
when driving in reverse.
• Exercise extreme caution at all times to prevent obstacles from
striking or interfering with operating controls and persons in
the platform.
• Be sure that operators of other overhead and floor level
machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes.
• Warn personnel not to work, stand, or walk under a raised
boom or platform. Position barricades on floor if necessary.
1-10 – JLG Lift – 3121618
SECTION 1 - SAFETY PRECAUTIONS
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 the Emergency Procedures section of this manual for
emergency towing procedures.
• Ensure boom is in the stowed position and the turntable
locked prior to towing, lifting or hauling. The platform must be
completely empty of tools.
• When lifting machine, lift only at designated areas of the
machine. Lift the unit with equipment of adequate capacity.
• Refer to the Machine Operation section of this manual for lifting information.
1.5 MAINTENANCE
This sub-section contains general safety precautions which must
be observed during maintenance of this machine. Additional precautions to be observed during machine maintenance are
inserted at the appropriate points in this manual and in the Service and Maintenance Manual. It is of utmost importance that
maintenance personnel pay strict attention to these precautions
to avoid possible injury to personnel or damage to the machine
or property. A maintenance program must be established by a
qualified person and must be followed to ensure that the
machine is safe.
Maintenance Hazards
• Shut off power to all controls and ensure that all moving parts
are secured from inadvertent motion prior to performing any
adjustments or repairs.
• Never work under an elevated platform until it has been fully
lowered to the full down position, if possible, or otherwise
supported and restrained from movement with appropriate
safety props, blocking, or overhead supports.
• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the machine is powered on or when the hydraulic
system is under pressure.
• Always relieve hydraulic pressure from all hydraulic circuits
before loosening or removing hydraulic components.
3121618 – JLG Lift – 1-11
SECTION 1 - SAFETY PRECAUTIONS
• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help protect
hands from spraying fluid.
• 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.
• Do not use machine as a ground for welding.
• When performing welding or metal cutting operations, precautions must be taken to protect the chassis from direct
exposure to weld and metal cutting spatter.
• Do not refuel the machine with the engine running.
• Use only approved non-flammable cleaning solvents.
• Do not replace items critical to stability, such as batteries or
solid tires, with items of different weight or specification. Do
not modify unit in any way to affect stability.
• Refer to the Service and Maintenance Manual for the weights
of critical stability items.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY
WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
1-12 – JLG Lift – 3121618
Battery Hazards
SECTION 1 - SAFETY PRECAUTIONS
• 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.
3121618 – JLG Lift – 1-13
SECTION 1 - SAFETY PRECAUTIONS
NOTES:
1-14 – JLG Lift – 3121618
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
2.1 PERSONNEL TRAINING
The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.
Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical control must not
operate this machine.
Operator Training
Operator training must cover:
1. Use and limitations of the controls in the platform and at the
ground, emergency controls and safety systems.
2. Control labels, instructions, and warnings on the machine.
3. Rules of the employer and government regulations.
4. Use of approved fall protection device.
5. Enough knowledge of the mechanical operation of the
machine to recognize a malfunction or potential malfunction.
6. The safest means to operate the machine where overhead
obstructions, other moving equipment, and obstacles,
depressions, holes, dropoffs.
7. Means to avoid the hazards of unprotected electrical conductors.
8. Specific job requirements or machine application.
Training Supervision
Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has
developed the ability to safely control and operate the machine.
Operator Responsibility
The operator must be instructed that he/she has the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job
site.
3121289 – JLG Lift – 2-1
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
2.2 PREPARATION, INSPECTION, AND MAINTENANCE
The following table covers the periodic machine inspections and
maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as
necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the
machine is used in a severe manner.
JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE
SPECIFIC JLG PRODUCT MODEL.
2-2 – JLG Lift – 3121289
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Table 2-1.Inspection and Maintenance Table
Type F requen cy
Pre-Start Inspection Before using each day; or
whenever there’s an Operator change.
Pre-Delivery Inspection (See
Note)
Frequent Inspection
(See Note)
Annual Machine Inspection
(See Note)
Preventative Maintenance At intervals as specified in the Service and Maintenance
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.
Before each sale, lease, or rental delivery. Owner, Dealer, or User Quali fied JLG Mechanic Service and Maintenance Manual
In service for 3 months or 150 hours, whichever comes first;
or
Out of service for a peri od of more than 3 months; or
Purchase d used.
An n ua l ly , n o la t er t ha n 13 m on t hs f ro m th e da te o f p r i or
inspection.
Manual.
Primary
Responsibility
User or Operator User or Operator Operator and Safety Manual
Owner, Dealer, or User Q ualified JLG Mechanic Service a nd Maintenance Manual
Owner, Dealer, or User Factory Trained
Owner, Dealer, or User Q ualified JLG Mechanic Service a nd Maintenance Manual
Service
Qualification
Service Technician
(Recommended)
Reference
and applicable JLG inspection form
and applicable JLG inspection form
Service and Maintenance Manual
and applicable JLG inspection form
3121289 – JLG Lift – 2-3
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Parent Metal Crack Weld Crack
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 Responsibilities (ANSI markets only) is enclosed in the weather resistant storage
container.
5. “Walk-Around” Inspection – Refer to Figure 2-3. and
Figure 2-4.
6. Battery – Charge as required.
7. Fuel (Combustion Engine Powered Machines) – Add the
proper fuel as necessary.
8. Engine Oil Supply - Ensure the engine oil level is at the Full
mark on the dipstick and the filler cap is secure.
9. Hydraulic Oil – Check the hydraulic oil level. Ensure hydraulic oil is added as required.
10. Accessories/Attachments - Reference the Operator and
Safety Manual of each attachment for accessory installed
upon the machine for specific inspection, operation, and
maintenance instructions.
2-4 – JLG Lift – 3121289
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
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 instructions.
IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDIATELY!
REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT OPERATE
THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION.
Function Check
Perform the Function Check as follows:
1. From the ground control panel with no load in the platform:
a. Check that all guards protecting the switches or locks
are in place;
b. Operate all functions and check boom limit switches;
drive speed should switch to creep mode if lower boom
is elevated or main boom is above horizontal.
c. Check auxiliary power (or manual descent);
d. Ensure that all machine functions are disabled when
the Emergency Stop Button is activated.
e. Ensure all boom functions stop when the function
enable switch is released.
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 switches or locks
are in place;
c. Operate all functions and check all limiting and cut-out
switches;
d. Ensure that all machine functions are disabled when
the Emergency Stop Button is pushed in.
e. Ensure that all machine functions stop when the foot-
switch is released.
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 that the tilt indicator is illuminated to ensure
proper operation.
3121289 – JLG Lift – 2-5
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
4
3
16
1
18
2
17
11
10
12
9
8137
6145
15
Figure 2-1. Basic Nomenclature - Sheet 1 of 2
2-6 – JLG Lift – 3121289
Loading...